Boiler Book 2005

The Boiler Book
Produced by the Employees of
Performance Proven Worldwide
Cleaver-Brooks Division, Aqua-Chem, Inc. 2002
The Boiler Book is protected by copyright and is to be used solely by consulting and specifying engineers for the purpose of selecting and specifying Cleaver-Brooks equipment. Any other use of The Boiler Book is strictly prohibited without written permission from Cleaver-Brooks.
Cleaver-Brooks P.O. Box 421 Milwaukee, WI 53201
(414) 359-0600 email: Iinfo@Cleaver-Brooks.com www.cleaver-brooks.com Printed in the U.S.A.
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The Boiler Book is intended for use by qualied engineering professionals. All information contained herein is subject to change without notice. Cleaver-Brooks is only responsible for the accuracy of the information and data presented at time of publication. Cleaver-Brooks shall not be responsible for the use of this data or information nor for any systems, designs, or engineering in which the data or information is utilized.
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TABLE OF CONTENTS
Firetube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
A1 General A2 Model CB Boilers A3 Model CB (LE) Boilers A4 Model CBW Boilers A5 Discontinued A6 Model CB Ohio Special Boilers A7 Model CBE Boilers A8 Model CEW Boilers A9 Model CEW-LN Boilers A10 Model CEW Ohio Special Boilers A11 Model CBL Boilers A12 Model ICB Boilers A13 Model ICB-LN Boilers
Commercial Boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B

B1 Model FLX Boilers B2 Model 4 Boilers B3 Model 5 Boilers B4 Electric Boilers B5 - TrueFire Boilers B6 - ClearFire Boilers
Industrial Watertube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E Stacks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F Economizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G Feedwater Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section H
H1 Spraymaster Deaerators (Single Tank) H2 Spraymaster Deaerators (Duo Tank) H3 Boilermate Deaerators H4 Surge Tanks H5 Boiler Feed Systems H6 Chemical Feed Systems and Metering Pumps H7 Filters H8 Softeners H9 Dealkalizers H10 Blowdown Separators H11 Blowdown Heat Recovery Systems H12 Flash Tank Heat Exchangers H13 Sample Coolers
System Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section I

I1 Boiler Selection Considerations I2 Hot Water Systems I3 Steam Systems I4 General Engineering Data
Glossary/Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section J
Section A1
GENERAL
Model CB Boilers Model CB-LE Boilers Model CBW Boilers Model CBH Boiler (discontinued) Model CB Ohio Special Boilers Model CBE Boilers Model CEW Boilers Model CEW-LN Boilers Model CEW Ohio Special Boilers Model CBL Boilers Model ICB Boilers Model ICB-LN Boilers A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13
A1-1
12-02
General
Firetube Boilers
Heavy duty motor with direct drive, maintenance free, caseless fan. Integral forced draft fan eliminates the need for: Large diameter breeching. High chimneys. Induced draft fans. Barometric dampers. Sequencing draft controls. Thick Fiberglass Insulation: 2" insulation covered with sturdy sheet metal lagging provides maximum efciency and durable construction. All units nished with hard enamel paint coating. Customer Service and Support:
FEATURES AND BENEFITS

The following Cleaver-Brooks retube boiler models (CB, CB-LE, CBW, CB Ohio Special) include the following features and benets. Packaged Design with Integral Front Head: Integral front head provides proper burner/boiler compatibility for maximum efciency and ease of maintenance. Packaged boiler is factory assembled, wired, and tested for guaranteed performance and reliability. Packaged design allows for easy connection of utilities, minimum start-up requirements, and lower long-term maintenance requirements. Built and tested to ASME standards. Single Point Positioning Combustion Control Package: Accurate, repeatable combustion control for responsiveness to load swings. Single point linkage assembly for air and fuel simplies adjustments and reduces start-up and maintenance costs. Unique variable contour.cam assembly allows accurate adjustment and enhances safe operation of the boiler. Computerized burner control provides accurate sequencing and continuous monitoring for optimum safety, efciency, and reliability. Low Stack Temperatures: Guaranteed efciency veried by low stack temperatures. Reduced fuel and operating costs. Low Excess Air: Operates at 3% O2 with less than 200 ppm CO for maximum combustion efciency. High efciency and low maintenance requirements. High Steam Quality: Large steam space and liberal surface area ensure high steam quality, free from entrained particles of moisture. Provides reliable, high quality (98.5% dry) source of steam. Quiet Operation: Integral front head with vibration free combustion air fan provides quiet operation. Ideal for sound critical applications, like hospitals and schools.
Boiler start-up, nal adjustment, and operator training provided with all retube boilers. Emergency service response 24 hours a day, 7 days a week, from the industrys most advanced worldwide computerized parts/service distribution network. Largest network of factory trained technicians provide: System trouble shooting. Operator training. Customized factory-backed planned maintenance programs. Emergency boiler rental. Total after-sale support.
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Firetube Boilers
General
The Model CB Ohio Special Boiler (standard offering) design is based on operator requirements of the state of Ohio, under the rules and regulations for unattended units. 100 hp through 225 hp. Four-pass dryback design (100 hp). Two-pass dryback design (125-225 hp). 150, 200 and 250 psig high pressure steam. 15 psig low pressure steam. Natural gas or light oil ring. The Model CBE Boiler (standard offering) provides high quality steam or hot water, utilizing a baseline boiler/burner design. Three-pass dryback design. 60-350 hp. 15 psig low pressure steam. 150-300 psig high pressure steam. 30 and 125 psig hot water. Natural gas or light oil. The Model CEW Boiler (standard offering) provides high quality steam or hot water, utilizing a baseline boiler/burner design. Three-pass wetback design. 125-800 hp. 15 psig low pressure steam. 150-250 psig high pressure steam. 30 and 125 psig hot water. Natural gas or light oil. The Model CEW-LN Boiler is the baseline retube product offering with a low emission package. Three-pass wetback design. 125-800 hp. 30 ppm package (natural gas). 15 psig low pressure steam. 150-250 psig high pressure steam. 30 and 125 psig hot water. Natural gas or light oil.
PRODUCT OFFERING
Cleaver-Brooks retube boilers are available in low pressure steam, high pressure steam, and hot water designs. Burners are available to re natural gas, light oil, heavy oil, or a combination of oil and gas. Optional alternate fuel (propane, mixed gas, digester gas, etc.) burners are also available. The retube product offering is available in the following models. The Model CB Boiler (standard offering) is the premium retube product offering providing maximum boiler efciency, the widest range of size and pressures, and premium control packages. Four-pass dryback design. 15 hp through 800 hp. 150-350 psig high pressure steam. 15 psig low pressure steam. 30 or 125 psig hot water. Natural gas, light oil, or heavy oil ring. The Model CB (LE) Boiler is the premium retube product offering with a low emission package. Four-pass dryback design. 125-800 hp. 20-60 ppm packages (natural gas). 15 psig low pressure steam. 150-300 psig high pressure steam. 30 and 125 psig hot water. Natural gas or light oil. The Model CBW Boiler (standard offering) provides the advantages of the Cleaver-Brooks integral front head in a three-pass wetback design. Three-pass wetback design. 100 hp through 800 hp. 150-250 psig high pressure steam. 15 psig low pressure steam. 30 or 125 psig hot water. Natural gas, light oil, or heavy oil ring.
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General
The Model CEW Ohio Special Boiler (standard offering) baseline design is based on operator requirements of the state of Ohio, under the rules and regulations of unattended units. Three-pass wetback design. 100-225 hp. 15 psig low pressure steam. 150-200 psig high pressure steam. Natural gas or light oil. The Model CBL Boiler (standard offering) line provides high quality steam utilizing a boiler/burner package. Three or four-pass wetback design. 800-1500 hp. 150-250 psig high pressure steam. Natural gas, light oil, or heavy oil ring. The Model ICB Boiler is a baseline retube product, designed to provide high quality steam or hot water. Its revolutionary design incorporates the key features and benets of both the wetback and dry back retube boilers. Three or four-pass Intercooled design. 100 800 hp. 15 psig low pressure steam. 150 300 psig high pressure steam. 30 and 125 psig hot water. Natural gas or light oil ring. The Model ICB-LN Boiler is a baseline retube product, designed to provide high quality steam or hot water with a low emission package. Its revolutionary design incorporates the key features and benets of both the wetback and dry back retube boilers. Three or four-pass Intercooled design. 100 800 hp. 30 ppm package (natural gas). 15 psig low pressure steam. 150 300 psig high pressure steam. 30 and 125 psig hot water. Natural gas or light oil ring.
Firetube Boilers
MODEL NUMBER, FUEL SERIES NUMBER, HORSEPOWER, AND DESIGN PRESSURE

The model designation for Cleaver-Brooks retube boilers includes the following: Light Oil: Series 100 Natural Gas: Series 700 Heavy Oil: Series 600 Light Oil and Natural Gas: Series 200 Heavy Oil and Natural Gas: Series 400 For example, a model CB700-350-150ST would represent a model CB boiler, natural gas red, 350 hp, 150 psig steam design pressure. All Cleaver-Brooks retube boilers are built in accordance with ASME Codes and, with the exception of the Ohio Special Boilers and CBL Boilers, UL/ULC standards. Insurance requirements (e.g., Industrial Risk Insurance IRI, Factory Mutual FM, etc.) or special local code requirements may dictate additional controls or equipment to be included. Please contact your local Cleaver-Brooks authorized representative for assistance in completing your specication or for additional information and optional equipment. Refer to Table A1-1 for information on the standard product offering for each retube boiler model.
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12-02
Table A1-1. Quick Comparison of Standard Features for Cleaver-Brooks FIretube Boilers
MODEL Rated Capacity Design PressureA
CB 15-800 HP (SECTION A2) 15-800 hp Steam 15-300 psig Hot Water 30 & 125 psig
CBLE 125-800 HP (SECTION A3) 125-800 hp Steam 15-300 psig Hot Water 30 & 125 psig 4-Pass Dry Back 60" 125-200 hp 78" 250-350 hp 96" 400-800 hp
CBW 100-800 HP (SECTION A4) 100-800 hp Steam 15-250 psig Hot Water 30 & 125 psig 3-Pass Wet Back 60" 100-200 hp 78" 250-400 hp 96" 500-800 hp
CB OHIO SPECIAL 100-225 HP (SECTION A6) 100-225 hp Steam Only 15-250 psig
CBE 60-350 HP (SECTION A7) 60-350 hp Steam 15-300 psig Hot Water 30 & 125 psig
CEW 125-800 HP (SECTION A8) 125-800 hp Steam 15-250 psig Hot Water 30 & 125 psig 3-Pass Wet Back 60" 125-200 hp 78" 250-400 hp 96" 500-800 hp
CEW-LN 125-800 HP (SECTION A9) 125-800 hp Steam 15-250 psig Hot Water 30 & 125 psig 3-Pass Wet Back 60" 125-200 hp 78" 250-400 hp 96" 500-800 hp
CEW OHIO SPECIAL 100-225 HP (SECTION A10) 100-225 hp Steam 15-250 psig
CBL 800-1500 HP (SECTION A11) 800-1500 hp Steam 150-250 psig
ICB 100-800 HP (SECTION A12) 100-800 hp Steam 15-300 psig Hot Water 30 & 125 psig
ICB-LN 100-800 HP (SECTION A13) 100-800 hp Steam 15-300 psig Hot Water 30 & 125 psig
Boiler Type Shell Size
4-Pass Dry Back 36" 15-40 hp 48" 50-100 hp 60" 125-200 hp 78" 250-350 hp 96" 400-800 hp 15-800 hp No. 2 Oil, Gas, Combination Oil/Gas 50-800 hp No. 6 OilB, Gas, Combination Oil/Gas
Passes VaryC 48" 100 hp 60"125-225 hp
3-Pass Dry Back 48" 60-100 hp 60" 125-200 hp 78" 250-350 hp
3 Pass Wet Back 60" 100-225 hp
3 or 4-Pass Wet Back 114" or 126"E
4-Pass Intercooled 4-Pass Intercooled 3-Pass Option 3-Pass Option 55" 100-125 hp 60" 150-200 hp 72" 250-300 hp 78" 350-400 hp 92" 500-600 hp 106" 700-800 hp No. 2 Oil, Natural Gas Combination Oil/ Gas 55" 100-125 hp 60" 150-200 hp 72" 250-300 hp 78" 350-400 hp 92" 500-600 hp 106" 700-800 hp No. 2 Oil, Natural Gas Combination Oil/ Gas
Fuel
No. 2 Oil, Gas, Combination Oil/Gas
No. 2 Oil, Gas, Combination Oil/Gas No. 6 OilB, Gas, Combination Oil/Gas
100-225 hp No. 2 Oil, Gas, Combination Oil/Gas 100 hp No. 6 Oil, Gas, Combination Oil/Gas Full Modulation
800-1300 hp No. 2 Oil, Gas, Combination Oil/Gas 800-1500 hp Gas 800-1000 hp No. 6 Oil, Gas, Combination Oil/Gas
12-02
Firing Method
15-20 hp On-off 30-40 hp Low-High-Low-Off 50-800 hp Full Modulation
Full Modulation
Full Modulation
Full Modulation
Full Modulation
Full Modulation
Full Modulation
Full Modulation
Full Modulation
Full Modulation
Air Damper Type
Single Blade 15-40 hp Rotary 50-800 hp Blue UL & ULC Boiler/Burner McD&M 157 Warrick 3C-2 McD&M PS 750-MT-120
Rotary
Rotary
Rotary
Multi-Blade
Multi-Blade 125-350 hp, Rotary 400-800 hp Blue UL & cUL Boiler/ Burner McD&M 157 Warrick 3C-2 McD&M PS 750-MT-120
Rotary
Multi-Blade
Rotary & Louvers
Multiblade 100-250 hp Rotary 300-800 hpF Blue UL & cUL Boiler/Burner McD&M 157, McD&M 193 Warrick 3C-2 McD&M PS 750-MT-120
Rotary
Paint Color Approvals
Blue UL & ULC Boiler/Burner McD&M 157 Warrick 3C-2 McD&M PS 750-MT-120
Blue UL & ULC Boiler/Burner McD&M 157 Warrick 3C-2 McD&M PS 750-MT-120
Blue N/A
Blue UL & cUL Boiler/Burner McD&M 157 Warrick 3C-2 McD&M PS 750-MT-120
Blue UL & cUL Boiler/Burner McD&M 157 Warrick 3C-2 McD&M PS 750-MT-120
Blue N/A
Blue 800-1000 hp UL & CSA (Burner Only) McD&M 193-7 Warrick 3C-2 N/A
Blue UL & cUL Boiler/Burner McD&M 157, McD&M 193 Warrick 3C-2 McD&M PS 750-MT-120
Steam Trim-Low Water Control Steam Trim Aux Low Water Control Water Trim-Low Water Control
McD&M 157 Warrick 3C-2 N/A
McD&M 157 Warrick 3C-2 N/A
A Consult your local Cleaver-Brooks authorized representative for higher design pressures. B Consult your local Cleaver-Brooks authorized representative for No. 4 & No. 5 oil applications. C Ohio Special-Model CB 100 hp 4-pass dryback, 125-225 hp 2-pass dryback. E Shell varies by square foot of pressure vessel and boiler horsepower. F ICB Three-Pass Boiler utilizes multiblade 100-350 and Rotary 400-800.
Table A1-1. Quick Comparison of Standard Features for Cleaver-Brooks FIretube Boilers (Continued)
MODEL Controls Steam & Hot Water Controls Surface Blowoff Conn. & Dip Tube on top C/L Air Vent Connection Stack Thermometer Drain Valve-HW & 15 psig-Steam Front Door
CB 15-800 HP (SECTION A2) Hi Limit (MR), Oper. Limit, Firing Rate 30-800 hp HPS-Std LPS-Conn. Only HW-Std. Yes No Hinge 15-200 hp Davit/Hinge 250-800 hp Hinge 15-100 hp Davit 125-800 hp 2 inch 3 Phase
CBLE 125-800 HP (SECTION A3) Hi Limit (MR), Oper. Limit, Firing Rate HPS-Std LPS-Conn. Only HW-Std. Yes No Hinge 125-200 hp Davit /Hinge 250-800 hp Davit 2 inch 3 Phase
CBW 100-800 HP (SECTION A4) Hi Limit (MR), Oper. Limit, Firing Rate HPS-Std LPS-Conn. Only HW-Std. Yes No Hinge 100-200 hp Davit/Hinge 250-800 hp Davit 2 inch 3 Phase
CB OHIO SPECIAL 100-225 HP (SECTION A6) Hi Limit (MR), Oper. Limit, Firing Rate HPS-Std LPS-Conn. Only N/A Yes No Hinge
CBE 60-350 HP (SECTION A7) Hi Limit (MR), Oper.Limit, Firing Rate HPS-Std LPS-Conn. Only HW-Std. No No Davit
CEW 125-800 HP (SECTION A8) Hi Limit (MR), Oper. Limit, Firing Rate HPS-Std LPS-Conn. Only HW-Std. No No Davit
CEW-LN 125-800 HP (SECTION A9) Hi Limit (MR), Oper. Limit, Firing Rate HPS-Std LPS-Conn. Only HW-Std. No No Davit
CEW OHIO SPECIAL 100-225 HP (SECTION A10) Hi Limit (MR), Oper. Limit, Firing Rate HPS-Std LPS-Conn. Only N/A No No Davit
CBL 800-1500 HP (SECTION A11) Hi Limit (MR), Oper. Limit, Firing Rate HPS-Std
ICB 100-800 HP (SECTION A12) Hi Limit (MR), Oper. Limit, Firing Rate HPS-Std LPS-Conn. Only HW-Std No No Davit
ICB-LN 100-800 HP (SECTION A13) Hi Limit (MR), Oper. Limit, Firing Rate HPS-Std LPS-Conn. Only HW-Std No No Davit
N/A Yes N/A Davit
Rear Door Insulation Standard Voltage Requirements 12-02 Fuse Protection
Hinge 100 hp Davit 125-225 hp 2 inch 3 Phase
Davit 2 inch 60-80 hp1 Phase 100-350 hp3 Phase Control Circuit & All 3 Phase Loads Except Remote Oil Pump Yes-3 Phase Only Cleaver-Brooks CB110 Ultraviolet
Davit 2 Inch 3 Phase
Davit 2 inch 3 Phase
Davit 2 inch 3 Phase
Control Circuit & All 3 Phase Loads Except Remote Oil Pump Yes Cleaver-Brooks CB780 Infrared
Control Circuit & All 3 Phase Loads Except Remote Oil Pump Yes Cleaver-Brooks CB110 Ultraviolet
Control Circuit & All 3 Phase Loads Except Remote Oil Pump Yes Cleaver-Brooks CB110 Ultraviolet (Gas & No. 2 Oil) Infrared (No. 6 Oil) Burner without Key Lock LD, FV, LW, FF
Control Circuit Transformer Flame Safeguard Control Scanner Type
Control Panel Location Indicating Lights Type of Pilot
Front Head with Key Lock 50-800 hp LD, FV, LW, FF Interrupted Gas Pilot-Gas, No. 6 Oil & All Combination 15-800 hp Direct Spark Ignition-No. 2 Oil 15-40 hp Spark Ignited Oil Pilot-No. 2 Oil 50-800 hp
Front Head with Key Lock LD, FV, LW, FF Interrupted Gas Pilot-Gas & All Combination
Front Head with Key Lock LD, FV, LW, FF Interrupted Gas Pilot-Gas, No. 6 Oil & All Combination Spark Ignited Oil Pilot No. 2 Oil
Front Head with Key Lock LD, FV, LW, FF Interrupted Gas Pilot-Gas, No. 6 Oil & All Combination Spark Ignited Oil Pilot No. 2 Oil
Burner without Key Lock LD, FV, LW, FF Interrupted Gas Pilot-Gas & All Combination
Burner without Key Lock LD, FV, LW, FF
On Burner without Key Lock LD, FV, LW, FF
Remote-Right Side without Key Lock LD, FV, LW, FF
Interrupted Gas Interrupted Gas Interrupted Gas Interrupted Gas Interrupted Gas Interrupted Gas Pilot-Gas, No. 2 Oil Pilot-Gas, No. 2 Oil Pilot-Gas, No. 2 Oil Pilot-Gas, No. 2 Oil, Pilot-Gas, No. 2 Oil Pilot-Gas, No. 2 Oil All Combination All Combination No. 6 Oil & & & All Combination & All Combination All Combination All Combination
Spark Ignited Oil Pilot No. 2 Oil
No. 2 Oil Direct Spark Ignition 60-100 hp Gas Pilot 125-350 hp
Table A1-1. Quick Comparison of Standard Features for Cleaver-Brooks FIretube Boilers (Continued)
MODEL Gas Burner Type
CB 15-800 HP (SECTION A2) High Radiant Multi-PortAll Except 125-200 hpAnnular Entry Motorized Buttery Valve Required, Not Included Yes No-15-50 hp Yes-60-800 hp Air Atomizing
CBLE 125-800 HP (SECTION A3) High Radiant Multi-PortAll Except 125-200 hpAnnular Entry Motorized Buttery Valve Required, Not Included Yes Yes
CBW 100-800 HP (SECTION A4) High Radiant Multi-PortAll Except 125-200 hpAnnular Entry Motorized Buttery Valve Required, Not Included Yes Yes
CB OHIO SPECIAL 100-225 HP (SECTION A6) High Radiant Multi-Port 100 hp Annular 125-225 hp
CBE 60-350 HP (SECTION A7) High Radiant Multi-Port
CEW 125-800 HP (SECTION A8) High Radiant Multi-Port
CEW-LN 125-800 HP (SECTION A9) High Radiant Multi-Port
CEW OHIO SPECIAL 100-225 HP (SECTION A10) High Radiant Multi-Port
CBL 800-1500 HP (SECTION A11) High Radiant Multi-Port
ICB 100-800 HP (SECTION A12) High Radiant Multi-Port
ICB-LN 100-800 HP (SECTION A13) High Radiant Multi-Port
Main Gas Valve Main Gas Control System Gas Pressure Regulator Gas Pilot Regulator High & Low Gas Pressure Switches Oil Burner Type
Motorized Buttery Valve Required, Not Included Yes Yes
Solenoid, Motorized Solenoid, Motorized Solenoid, Motorized Solenoid, Motorized Buttery Valve Included Yes Yes Buttery Valve Included Yes Yes Buttery Valve Included Yes Yes Buttery Valve Included Yes Yes
Motorized Buttery Valve Included Yes Yes
Solenoid, Motorized Solenoid, Motorized Buttery Valve Included Yes Yes Buttery Valve Included Yes Yes
Air Atomizing
Air Atomizing
Air Atomizing
Pressure Atomizing Pressure Atomizing 125-200 hp 60-200 hp Air Atomizing Air Atomizing 250-800 hp 250-350 hp Air Compressor Air CompressorShipped loose Shipped Loose Solenoid Metering System Included No. 2 Oil 60-200 hp Burner Mounted No. 2 Oil 250-350 hp Remote Solenoid Metering System Included No. 2 Oil 125-200 hp Burner Mounted No. 2 Oil 250-800 hp Remote No-Use CEW-LN
Air Atomizing Air Compressor 125-300 hpMounted 350-800 hpShipped Loose Solenoid Metering System Included No. 2 Oil 125-800 hp Remote
Air Atomizing
Air Atomizing
Pressure Atomizing 100-150 hp Air Atomizing 200-800 hp Solenoid Metering System Included No. 2 Oil 100-150 hp Burner Mounted No. 2 Oil 200-800 hp Remote No-Use ICB-LN
Air Atomizing
Main Oil Valves Oil Control System Oil Pump Location of Oil Pump 12-02
Solenoid Metering Valve Included No. 2 Oil 15-40 hp on Front Head; 50-800 hp Remote No. 6 Oil 50-800 hp, Remote
Solenoid Metering Valve Included No. 2 Oil 125-800 hp Remote
Solenoid Metering Valve Included No. 2 Oil 100-800 hp Remote
Solenoid Metering Valve Included No. 2 Oil 100-225 hp Remote No. 6 Oil 100-225 hp Remote N/A
Solenoid Metering System Included No. 2 Oil 100-225 hp Remote
Motorized Metering System Included No. 2 Oil Remote
Solenoid Metering System Included No. 2 Oil 100-800 hp Remote
No. 6 Oil 100-800 hp Remote Induced FGRD (LE Option) 125-800 hp 20-60 ppm (Natural Gas) + or-0.25" W.C. No-Use CEW-LN
No. 6 Oil Mounted on Oil Pump/Oil Heater Skid Induced FGR 30 ppm(Natural Gas) N/A Optional-Induced FGR 30 ppm (Natural Gas) up to 1300 hp. + or-0.50" W.C. + or-0.25" W.C. With FGR
NOx Control
No-Use CBLE
N/A
Induced FGR 30 ppm (Natural Gas)
Maximum Stack Pressure Variation Start-Up Included
15-40 hp + or-0.25" W.C. 50-800 hp + or-0.50" W.C. Yes
+ or-0.50" W.C.
+ or-0.25" W.C.
+ or-0.25" W.C.
+ or-0.25" W.C.
+ or-0.25" W.C.
+ or-0.25" W.C.
+ or-0.25" W.C.
+ or-0.25" W.C.
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
D Altitude, size, and fuel series limitations may apply.
General
Firetube Boilers
Notes
A1-8
12-02
Section A2
MODEL CB BOILERS
CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-3 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-3 DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-4 PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-21 Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-21 Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-21 ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-24 Blowdown Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-24 Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-27 Gas-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-30 Gas Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-31 Oil-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-36 No. 6 Oil Piping, Storage Tank Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-36 Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-44 Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-44 Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-44 Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-44 SAMPLE SPECIFICATION (MODEL CB BOILER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-47 ILLUSTRATIONS Figure A2-1. Model CB Steam Boiler Dimensions and Weights (15 and 150 psig Design Pressure 15 to 100 hp) Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A2-2. Model CB Steam Boiler Dimensions and Weights (15 and 150 psig Design Pressure 125 to 800 hp) Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A2-3. Model CB Hot Water Boiler Dimensions (30 psig and 125 psig Design Pressure 15 to 100 hp) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A2-4. Model CB Hot Water Boiler Dimensions (30 psig and 125 psig Design Pressure 15 to 100 hp) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A2-5. Space Required to Open Rear Head on Model CB Boilers Equipped with Davits . . . . . . . . . . . . . . . . . . . Figure A2-6. Lifting Lug Location, Model CB Boilers - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A2-7. Model CB Boiler Mounting Piers 20 Figure A2-8. Predicted Stack Temperature Increase for Pressure Greater Than 125 psig . . . . . . . . . . . . . . . . . . . . . . . . Figure A2-9. Standard Gas Train Connection Size and Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-10 A2-12 A2-14 A2-16 A2-18 A2-18 A2-23 A2-34 A2-1
07-02
Model CB Boilers
Firetube Boilers
A2-35 A2-36 A2-37 A2-37 A2-38 A2-38 A2-39 A2-39 A2-40 A2-40 A2-41 A2-41 A2-42 A2-42 A2-43 A2-43 A2-45 A2-45 A2-46
Figure A2-10. Typical Gas Piping Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A2-11. Model CB Gas Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A2-12. No. 2 Oil Connection Size, Location and Recommended Line Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A2-13. No. 6 Oil Connection Size, Location and Recommended Line Sizes, Model CB Boiler . . . . . . . . . . . . . . Figure A2-14. No. 2 Oil Piping, Single Boiler Installation, Remote Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A2-15. No.2 Oil Piping, Single Boiler Installation Oil Pump Integral with Boiler . . . . . . . . . . . . . . . . . . . . . . . . Figure A2-16. No. 2 Oil Piping, Multiple Boiler Installation, Remote Oil Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A2-17. No. 2 Oil Piping, Multiple Boiler Installation, Oil Pump Integral with Boiler . . . . . . . . . . . . . . . . . . . . . Figure A2-18. No. 2 Oil Piping, Multiple Boiler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A2-19. No. 6 Oil Piping, Single Boiler Installation, Remote Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A2-20. No. 6 Oil Piping, Multiple Boiler Installation, Remote Oil Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A2-21. No. 6 Oil Piping, Multiple Boiler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A2-22. No. 2 Oil Transfer Tank Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A2-23. Typical Fuel Storage Tank Arrangement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A2-24. Typical Cross Section of Bundled Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A2-25. Schematic of Standard Alstrom Hot Water Safety-Type Preheating System . . . . . . . . . . . . . . . . . . . . . . . Figure A2-26. Boiler Room Length (Typical Layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A2-27. Boiler Room Width (Typical Layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A2-28. Breeching Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TABLES
Table A2-1. Model CB Steam Boiler Ratings (15 - 100 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-5 Table A2-2. Model CB Steam Boiler Ratings (125 - 800 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-5 Table A2-3. Model CB Hot Water Boiler Ratings (15 - 100 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-6 Table A2-4. Model CB Hot Water Boiler Ratings (125 - 800 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-6 Table A2-5. Steam Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-7 Table A2-6. Hot Water Boiler Relief Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-8 Table A2-7. Predicted Fuel-to-Steam Efficiencies (%), Model CB Boilers - 10 psig, Natural Gas . . . . . . . . . . . . . . . . . A2-22 Table A2-8. Predicted Fuel-to-Steam Efficiencies (%), Model CB Boilers - 125 psig, Natural Gas . . . . . . . . . . . . . . . . A2-22 Table A2-9. Predicted Fuel-to-Steam Efficiencies (%), Model CB Boilers - 10 psig, No. 6 Oil . . . . . . . . . . . . . . . . . . . A2-22 Table A2-10. Predicted Fuel-to-Steam Efficiencies (%), Model CB Boilers - 125 psig, No 6 Oil . . . . . . . . . . . . . . . . . . A2-22 Table A2-11. Predicted Fuel-to-Steam Efficiencies (%), Model CB Boilers - 10 psig, No. 2 Oil . . . . . . . . . . . . . . . . . . A2-23 Table A2-12. Predicted Fuel-to-Steam Efficiencies (%), Model CB Boilers - 125 psig, No. 2 Oil . . . . . . . . . . . . . . . . . A2-23 Table A2-13. Model CB Boiler Emission Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-24 Table A2-14. Heating Surface, Model CB Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-24 Table A2-15. Steam Volume and Disengaging Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-25 Table A2-16. Water Circulation Rate and Temperature Drop for Hot Water Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-25 Table A2-17. Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity) . . . . . . . . . . . . . . . A2-26 Table A2-18. Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-26 Table A2-19. Model CB Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-27 Table A2-20. Sound Pressure Level Summary (50 - 800 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-27 Table A2-21. Model CB Boiler Sound Pressure Level Details (40 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-27 Table A2-22. Model CB Boiler Sound Pressure Level Details (50 - 125 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-28 Table A2-23. Model CB Boiler Sound Pressure Level Details (125 - 200 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-29 Table A2-24. Model CB Boiler Sound Pressure Level Details (250 - 350 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-29 Table A2-25. Model CB Boiler Sound Pressure Level Details (400 - 800 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-30 Table A2-26. Minimum Required Gas Pressure at Entrance to Standard and FM Gas Trains (Downstream of Gas Pressure Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-31 Table A2-27. Minimum Gas Pressure at Entrance to Gas Trains Equipped with Industrial Risk Insurers (IRI) Requirements (Downstream of Gas Pressure Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-31 Table A2-28. Under and Oversized Standard and FM Gas Trains, Model CB Boilers (50 - 800 hp) . . . . . . . . . . . . . . . . A2-32 Table A2-29. Under and Oversized IRI Gas Trains, Model CB Boilers (50 - 800 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-33 Table A2-30. Minimum Required Gas Pressure Altitude Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-33 Table A2-31. Maximum Gas Consumption (CFH) for Natural Gas and Propane Vapor & Gas Pilot Data. . . . . . . . . . . . A2-34
A2-2
07-02
Firetube Boilers
Model CB Boilers
Air atomizing oil burner available for proper oil atomization, maximum combustion efciency, and low maintenance requirements. Air atomizing compressor provided with the boiler package for clean oil burning and ease of maintenance. Combination gas/oil burners provide quick fuel changeover without re-adjustment of the burner. Fuel oil controller eliminates the need for over 40 connections, combining gauges, valves, and regulators into a single casting. Retractable oil nozzle provides easy access and cleaning and eliminates coking of oil and nozzle tip when ring gas. Low NOx Capability Available:

In addition to the features provided on all Cleaver-Brooks Firetube Boilers, the following features apply specically to Model CB Firetube Boilers. The CB four-pass dryback boiler is the premium retube boiler design available. Four-Pass Dryback Design: Four-pass design provides high ue gas velocities and low stack temperature for guaranteed maximum efciency. Dryback design provides full access to boiler tubes, tube sheet, and furnace for ease of maintenance. Dryback design includes single rear tube sheet construction, providing reduced tube sheet stresses. Five Square Feet of Heating Surface per Boiler hp: Maximum heat transfer with minimum thermal stresses provide guaranteed efciency and long boiler life. Highest guaranteed fuel-to-steam efciencies. Low Furnace Location Furnace located well below water level with generous clearance from bottom of boiler, allowing proper circulation. Low furnace provides additional safety margin between furnace and water level. Reduces water carryover, producing drier steam. Hinged or Davited Front and Rear Doors: Provides full access to front and rear tube sheet and furnace. Reduces maintenance costs. High Turndown Burner: 4:1 turndown (gas and oil) is standard on boilers up to 250 hp. Guaranteed 10:1 turndown (gas red) 8:1 (No. 2 oil red) standard on 250 hp through 800 hp. Advanced burner design provides maximum combustion efciencies and high turndown. Reduced boiler cycling and maintenance. Boiler stays on line during low load conditions for optimum efciency and performance. Gas, No. 2 Oil, No. 6 Oil, and Combination Gas and Oil Burners Available: High radiant multi-port gas burner designed for high gas velocities and complete fuel/air mixing, providing maximum combustion efciencies.
20 ppm NOx guarantee available on Model CB (LE) Boilers.
PRODUCT OFFERING
Model CB Firetube Boilers are available in low pressure steam, high pressure steam, and hot water designs. Burners are available to re natural gas, light oil, heavy oil, or a combination of oil and gas. Optional alternate fuel burners are also available. Model CB Boilers include: Four-pass dryback design. 15 hp through 800 hp. 150 psig - 350 psig high pressure steam. 15 psig low pressure steam. 30 psig or 125 psig hot water. Natural gas, light oil, or heavy oil ring. The Model CBBoiler is the premium retube product offering providing maximum boiler efciency, the widest range of size and pressures, and premium control packages. Available options: For option details, contact your CleaverBrooks authorized representative. Options include the following: Boiler Options Auxiliary low water cut-off (standard on steam boilers). Drain valves. Additional screwed or anged tappings. Special design pressures. Surge load bafes. Seismic design.
A2-3
07-02
Model CB Boilers
Internal hot water coils. Blowdown valves. Non-return valves. Feedwater valves and regulators. Special doors, davited, hinged, left swing. Special base rails. Surface blowdown systems. Combustion relief door. Weather-proong. Blend pump. Burner/Control Options Special modulation controls. Low NOx equipment. Optional ame safeguard controller. Lead/lag system. High altitude design, up to 12,000 ft. Special insurance and code requirements (e.g., IRI, FM, ASME CSD-1). Alarm bell/silence switch. Special motor requirements (TEFC, high efciency). Remote contacts. Special purpose indicator lights. Main disconnect. Elapsed time meter. Voltmeter/micro-ammeter. NEMA enclosures. Low re hold controls. Remote emergency shut-off (115V). Circuit breaker. Day/night controls. Special power requirements. Fuel Options Automatic fuel changeover. Special gas pressure regulator. Oversized/undersized gas trains. Gas strainer. Special fuel shut-off valves. Special pilot.
Firetube Boilers
Alternate fuel ring (propane, digester gas, etc.). Special oil pumps.
DIMENSIONS AND RATINGS

Dimensions and ratings for the Model CB boilers are shown in the following tables and illustrations: Table A2-1. Model CB Steam Boiler Ratings (15 thru 100 hp) Table A2-2. Model CB Steam Boiler Ratings (125 thru 800 hp) Table A2-3. Model CB Hot Water Boiler Ratings (15 thru 100 hp) Table A2-4. Model CB Hot Water Boiler Ratings (125 thru 800 hp) Table A2-5. Safety Valve Openings Table A2-6. Relief Valve Openings Figure A2-1. Model CB Steam Boiler Dimensions (15 and 150 lb design pressure) (15 thru 100 hp) Figure A2-2. Model CB Steam Boiler Dimensions (15 and 150 lb design pressure) (125 thru 800 hp) Figure A2-3. Model CB Hot Water Boiler Dimensions (30 lb design pressure) (15 thru 100 hp) Figure A2-4. Model CB Hot Water Boiler Dimensions (20 lb design pressure) (125-800 hp) Figure A2-5. Space Required to Open Rear Head on Model CB Boilers Equipped with Davits Figure A2-6. Lifting Lug Locations, Model CB Boilers Figure A2-7. Model CB Boiler Mounting Piers
A2-4
07-02
Firetube Boilers
Table A2-1. Model CB Steam Boiler Ratings (15 - 100 hp)
BOILER HP 15C 20C 30C 40C 50 60
Model CB Boilers
70
80
100
RATINGS - SEA LEVEL TO 3000 FT Rated Cap. (lbs steam/hr @212F) Btu Output (1000 Btu/hr) 518 502 690 670 1035 1004 1380 1339 1725 1674 2070 2009 2415 2343 2760 2678 3450 3348
APPROXIMATE FUEL CONSUMPTION AT RATED CAPACITY Light Oil (gph)

A
4.5 625 6.3
6.0 835 8.4
9.0 1255 12.6
12.0 1675 16.8
15.0 14.0 2095 21.0
18.0 16.5 2510 25.1
21.0 19.5 2930 29.3
24.0 22.5 3350 33.5
30.0 28.0 4185 41.9
Heavy Oil (gph)B Gas (cfh) 1000 Btu-Nat Gas (Therm/hr)
POWER REQUIREMENTS - SEA LEVEL TO 3000 FT, 60 HZ Blower Motor hp (except gas) Gas Models (only) Oil Pump Motor, hp No. 2 Oil Oil Pump Motor, hp No. 6 Oil Oil Heater kW No. 6 Oil Air Compressor Motor hp (Oil firing Only) 1 1 1 1 1-1/2 1-1/2 2 2 2 2 1/3 1/3 5 2 2 2 1/3 1/3 5 2 2 2 1/3 1/3 5 2 2D 2D 1/3 1/3 5 2 3 3 1/3 1/3 5 2
Belt-Driven From Blower -
Air Compressor Belt-Driven from Blower Motor
NOTES: 1. For altitudes above 3000 ft, contact your local Cleaver-Brooks authorized representative for verification of blower motor hp. A. Based on 140,000 Btu/gal. B. Based on 150,000 Btu/gal. C. No. 6 Oil not available in 15-40 hp range. D. 3 hp above 2000 ft.
Table A2-2. Model CB Steam Boiler Ratings (125 - 800 hp)

BOILER HP 125 150 200 250 300 350 400 500 600 700 750 800 RATINGS SEA LEVEL TO 3000 FT J Rated Cap. (lbs steam/hr @ 212F) Btu Output (1000 Btu/hr) 4313 4184 5175 5021 6900 6695 8625 8369 10350 10043 12075 11716 13800 13390 17250 16738 20700 20085 24150 23432 25875 25106 27600 26779
APPROXIMATE FUEL CONSUMPTION AT RATED CAPACITY Light Oil (gph)A Heavy Oil (gph)B Gas (cfh) MBTU-nat Gas (Therm/hr) 37.5 35.0 5230 52.3 45.0 42.0 6280 62.8 60.0 56.0 8370 83.7 74.5 69.5 10460 104.6 89.5 83.5 12555 125.5 104.5 97.5 14650 146.5 119.5 111.5 16750 167.5 149.5 139.5 20925 209.3 179.5 167.5 25100 251.0 209.0 195.5 29300 293.0 224.2 209.2 31385 313.8 239.3 223.4 33480 334.8
POWER REQUIREMENTS - SEA LEVEL TO 3000 FT, 60 HZ Blower Motor hp (except gas) Gas Models (only) Oil Pump Motor, hp No. 2 Oil Oil Pump Motor, hp No. 6 Oil Oil Heater kW No. 6 Oil Air Compressor Motor hp (Oil firing Only) 5 5 1/2 1/2 5 7-1/2 5 1/2 1/2 5 15 10 1/2 1/2 5 7-1/2 7-1/2 1/2 1/2 7-1/2 10C 7-1/2I 3/4 1/2 7-1/2 15D 15 3/4 3/4 7-1/2 10C 10C 3/4 3/4 7-1/2 7-1/2 15E 15E 3/4 3/4 7-1/2
K
20F 20F 3/4 3/4 7-1/2K 7-1/2
30G 30G 1 3/4 7-1/2K 7-1/2
40L 40L 1 3/4 7-1/2K 7-1/2
50H 50H 1 3/4 7-1/2K 7-1/2
Air Compressor Belt-Driven From Blower Motor
7-1/2
NOTES: 1. For altitudes above 3000 ft, contact your local Cleaver-Brooks authorized representative for verification of blower motor hp. A. Based on 140,000 Btu/gal. B. Based on 150,000 Btu/gal. C.15 hp above 2500 ft. D. 20 hp above 2500 ft. E. 20 hp above 2000 ft.
F. 30 hp above 2500 ft. G. 40 hp above 2000 ft. H. 60 hp above 3000 ft. I. 10 hp above 2500 ft. J. Sea level to 2,500 ft for 300 and 350 Hp sizes. K. 10 kW on low pressure. L. 50 hp above 2500 ft.
A2-5
07-02
Model CB Boilers
Table A2-3. Model CB Hot Water Boiler Ratings (15 - 100 hp)
BOILER HP 15c 20c 30c 40c 50 60 70 80
Firetube Boilers
100A
100
125A
RATINGS - SEA LEVEL TO 3000 FT Rated Cap Btu Output (1000 Btu/hr) 502 670 1004 1339 1674 2009 2343 2678 3348 3348 4184
APPROXIMATE FUEL CONSUMPTION AT RATED CAPCITY Light Oil (gph)A Heavy Oil (gph)B Gas (cfh) MBtu- nat Gas (Therm/hr) 4.5 625 6.3 6.0 835 8.4 9.0 1255 12.6 12.0 1675 16.8 15.0 14.0 2095 21.0 18.0 16.5 2510 25.1 21.0 19.5 2930 29.3 24.0 22.5 3350 33.5 30.0 28.0 4185 41.9 30.0 28.0 4185 41.9 37.5 35.0 5230 52.3
POWER REQUIREMENTS - SEA LEVEL TO 3000 FT, 60 HZ Blower Motor hp (except gas) Gas Models (only) Oil Pump Motor, hp No. 2 Oil Oil Pump Motor, hp No. 6 Oil Oil Heater kW No. 6 Oil Air Compressor Motor hp (Oil firing Only) 1 1 1 1 1-1/2 1-1/2 2 2 2 2 1/3 1/3 5 2 2 2 1/3 1/3 5 2 2 2 1/3 1/3 5 2 2D 2D 1/3 1/3 5 2 3 3 1/3 1/3 5 2 3 3 1/3 1/3 5 2 3 3 1/2 1/2 5 2
Belt-Driven From Blower -
Air Compressor Belt-Driven from Blower Motor
NOTES: 1. For altitudes above 3000 ft, contact your local Cleaver-Brooks authorized representative for verification of blower motor hp. A. Based on 140,000 Btu/gal. B. Based on 150,000 Btu/gal. C. No. 6 Oil not available in 15-40 hp range. D. 3 hp above 2000 ft.
Table A2-4. Model CB Hot Water Boiler Ratings (125 - 800 hp)
BOILER HP 150 175A 200 250 300 350 400 500 600 700
J
750
800
RATINGS - SEA LEVEL TO 3000 FT Rated Cap. Btu Output (1000 Btu/hr) 5021 5858 6695 8369 10043 11716 13390 16738 20085
23432
25106
26779
APPROXIMATE FUEL CONSUMPTON AT RATED CAPCITY Light Oil (gph)A 45.0 42.0 6280 62.8 52.5 49.0 7320 73.2 60.0 56.0 8370 83.7 74.5 69.5 10460 104.6 89.5 83.5 12555 125.5 104.5 97.5 14650 146.5 119.5 111.5 16750 167.5 149.5 139.5 20925 209.3 179.5 167.5 25100 251.0 209.0 195.5 29300 293.0 224.2 209.3 31385 313.8 239.3 223.4 33480 334.8
Heavy Oil (gph)B Gas (cfh) MBtu-Natural Gas (Therm/hr)
POWER REQUIREMENTS - SEA LEVEL TO 3000 FT, 60 HZ Blower Motor hp (except gas) Gas Models (only) Oil Pump Motor, hp No. 2 Oil Oil Pump Motor, hp No. 6 Oil Oil Heater kW No. 6 Oil Air Compressor Motor hp (Oil firing Only) NOTES: 1. For altitudes above 3000 ft, contact your local Cleaver-Brooks authorized representative for verification of blower motor hp. A. Based on 140,000 Btu/gal. B. Based on 150,000 Btu/gal. C. 15 hp above 2500 ft. D. 20 hp above 2500 ft. E. 20 hp above 2000 ft. 7-1/2 5 1/2 1/2 5 7-1/2 5 1/2 1/2 5 15 10 1/2 1/2 5 7-1/2 7-1/2 1/2 1/2 7-1/2 10C 7-1/2I 3/4 1/2 7-1/2 15D 15 3/4 3/4 7-1/2 10C 10C 3/4 3/4 10 7-1/2 15E 15E 3/4 3/4 10 7-1/2 20F 20F 3/4 3/4 10 7-1/2 30G 30G 1 3/4 10 7-1/2 40K 40K 1 3/4 10 7-1/2 50H 50H 1 3/4 10 7-1/2
F. 30 hp above 2500 ft. G. 40 hp above 2000 ft. H. 60 hp above 3000 ft. I. 10 hp above 2500 ft. J. Sea level to 2,500 ft for 300 and 350 hp sizes. K. 50 hp above 2500 ft.
A2-6
07-02
Firetube Boilers
Model CB Boilers
Table A2-5. Steam Boiler Safety Valve Openings

VALVE SETTING BOILER HP 15 PSIG STEAM NO. OF VALVES REQ'D OUTLET SIZE (IN.) 100 PSIG STEAM NO. OF VALVES REQ'D OUTLET SIZE (IN.) 125 PSIG STEAM NO. OF VALVES REQ'D OUTLET SIZE (IN.) 150 PSIG STEAM NO. OF VALVES REQ'D OUTLET SIZE (IN.) 200 PSIG STEAM NO. OF VALVES REQ'D OUTLET SIZE (IN.) 250 PSIG STEAM NO. OF VALVES REQ'D OUTLET SIZE (IN.)
15 20 25 30 40 50 60 70 80 100 125 150 200 250 300 350 400 500 600 700
1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 3 3 3 4 5
1-1/2 1-1/2 2 2 2-1/2 2-1/2 2 2 2-1/2 2-1/2 3 3 2-1/2 (1) 2-1/2 (1) 3 3 (1) 2 (2) 3 (2) 3 (1) 2-1/2 3 (1) 2-1/2 (3) 3 (3) 3 (2)2-1/2 (3) 3 (2)2-1/2 (3) 3 (2)2-1/2
1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 3 3 3 4 5
1 1 1 1-1/4 1-1/4 1-1/2 1-1/2 2 2 2 1-1/2 (1) 2 (1) 1-1/2 2 (1) 2-1/2 (1) 2 2-1/2 (1) 2-1/2 (2) 2 (1) 2 (2) 2-1/2 2-1/2 (3) 2-1/2 (1) 2 (3) 2-1/2 (2) 2 (3) 2-1/2 (2) 2 (3) 2-1/2 (2) 2
1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 3 3 4
3/4 1 1 1 1-1/4 1-1/2 1-1/2 1-1/2 1-1/2 2 (1) 1-1/2 (1) 1-1/4 1-1/2 (2) 1-1/2 2 (1) 2-1/2 (1) 2 2-1/2 2-1/2 (2) 2-1/2 (1) 2 2-1/2 (3) 2-1/2 (1) 2 (3) 2-1/2 (1) 2 (3) 2-1/2 (1) 2
1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 3 3
3/4 3/4 1 1 1 1-1/4 1-1/4 1-1/4 1-1/2 1-1/2 (1) 1-1/2 (1) 1-1/4 (1) 1-1/2 (1) 1-1/4 2) 1-1/2 (1) 2 (1) 1-1/2 2 (1) 2-1/2 (1) 2 (1) 2-1/2 (1) 2 2-1/2 2-1/2 (1) 2 (2) 2-1/2 (1) 2 (2) 2-1/2 (1) 2 (2) 2-1/2 (1)2
1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2
3/4 3/4 3/4 3/4 1 1 1-1/4 1-1/4 1-1/4 1-1/2 (1) 1-1/4 (1) 1 1-1/4 (1) 1-1/2 (1) 1-1/4 1-1/2 (1) 2 (1) 1-1/2 2 2 (1) 2-1/2 (1) 2 2-1/2 2-1/2
1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2
3/4 3/4 3/4 3/4 1 1 1 1-1/4 1-1/4 1-1/4 1 (1) 1 (1) 1-1/4 (2) 1-1/4 (1) 1-1/2 (1) 1-1/4 1-1/2 (1) 1-1/2 (1)2 (1) 2 (1) 1-1/2 2 (1) 2 (1) 2-1/2 2-1/2
750
2-1/2
2-1/2
800
2-1/2
2-1/2
NOTE: Valve manufacturers are Kunkle, Consolidated or Conbraco, depending on availability.
A2-7
07-02
Model CB Boilers
Table A2-6. Hot Water Boiler Relief Valve Openings
VALVE SETTING BOILER HP 15 20 25 30 40 50 & 50A 60 70 80 100 100A 125 125A 150 175A 200 250 300 350 400 500 600 700 750 800 30 PSIG HW NO. OF VALVES REQ'D 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 3 3 4 4 5 5 5 OUTLET SIZE (IN.) 1 1 1-1/4 1-1/4 1-1/4 2 2 2 2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 (1) 1 (1) 2-1/2 (1) 2-1/2 (1) 1-1/4 (1) 2 (1) 2-1/2 2-1/2 (2) 2-1/2 (1) 1 (1) 2 (2) 2-1/2 (1) 1 (3) 2-1/2 (3) 2-1/2 (1) 2 (1) 1 (4) 2-1/2 (1) 1 (4) 2-1/2 (1) 1 (4) 2-1/2 60 PSIG HW NO. OF VALVES REQ'D 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 3 3 3 3 OUTLET SIZE (IN.) 1 1 1 1 1 1-1/4 1-1/4 2 2 2 2 2 2 2-1/2 2-1/2 2-1/2 2-1/2 (1) 1 (1) 2-1/2 (1) 2-1/2 (1) 2 (1) 2 (1) 2-1/2 (2) 2-1/2 (1) 1-1/4 (2) 2-1/2 (1) 2 (2) 2-1/2 (1) 2 (2) 2-1/2 (1) 2 (2) 2-1/2 100 PSIG HW NO. OF VALVES REQ'D 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 OUTLET SIZE (IN.) 1 1 1 1 1 1 1 1-1/4 1-1/4 1-1/4 1-1/4 2 2 2 2 2 2-1/2 2-1/2 2-1/2 (1) 1 (1) 2-1/2 (1) 2-1/2 (1) 1-1/4 (1) 2 (1) 2-1/2 (2) 2-1/2 (2) 2-1/2 (2) 2-1/2
Firetube Boilers
125 PSIG HW NO. OF VALVES REQ'D 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 OUTLET SIZE (IN.) 1 1 1 1 1 1 1 1 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 2 2 2 2 2-1/2 2-1/2 2-1/2 (1) 1 (1) 2-1/2 (1) 2-1/2 (1) 1-1/4 (1) 2-1/2 (1) 2 (1) 2-1/2 (1) 2 (1) 2-1/2 (1) 2
NOTES: 1.Hot water relief valves are Kunkle #537. 2. BHP followed by A designates hot water boilers furnished in a smaller vessel size with additional tubes in the upper portion of the vessel.
A2-8
07-02
Firetube Boilers
Model CB Boilers
NOTES
A2-9
07-02
Model CB Boilers
Firetube Boilers
NOTE: ALLOW 3 FEET FOR DOOR SWING PER NEC
BOILER HP
DIM
15
20
30 LENGTHS
40
50
60
70
80
100
Overall Shell Base Frame Front Head Extension Rear Head Extension Front Ring Flange to Nozzle - 15 psig Front Ring Flange to Nozzle - 150 psig Ring Flange to Base
A B C D E F F G
96-5/8 62-5/8 59 18-1/2 15-1/2 36 36 1-13/16
96-5/8 62-5/8 59 18-1/2 15-1/2 36 36 1-13/16
114-5/8 80-5/8 77 18-1/2 15-1/2 45 45 1-13/16
140-5/8 106-5/8 103 18-1/2 15-1/2 57 57 1-13/16
129 92 91 18-1/2 18-1/2 46 46 5/8
129 92 91 18-1/2 18-1/2 46 46 1/2
168 131 130 18-1/2 18-1/2 65-1/2 72-1/2 1/2
168 131 130 18-1/2 18-1/2 65-1/2 72-1/2 1/2
187 150 148 18-1/2 18-1/2 75 82 1/2
WIDTHS Overall ID, Boiler Center to Water Column Center to Outside Hinge Center to Lagging Center to Auxiliary LWCO Base, Outside Base, Inside I J K KK L LL M N 61 36 33 22 20 28 28 22 61 36 33 22 20 28 28 22 61 36 33 22 20 28 28 22 61 36 33 22 20 28 28 22 73 48 39 29 27 34 37-5/8 29-5/8 73 48 39 29 27 34 37-3/8 29-5/8 73 48 39 29 27 34 37-3/8 29-5/8 73 48 39 29 27 34 37-3/8 29-5/8 73 48 39 29 27 34 37-3/8 29-5/8
Figure A2-1. Model CB Steam Boiler Dimensions and Weights (15 and 150 psig Design Pressure 15 to 100 hp) Sheet 1 of 2
A2-10
07-02
Firetube Boilers
BOILER HP DIM 15 20 30 HEIGHTS Base to Steam Outlet (15 psig only) Overall Base to Vent Outlet Base to Steam Outlet (150 psig only) Height of Base Base to Bottom of Boiler PL OO O PH Q R 50-1/4 66 53-1/2 50-1/4 8 12 50-1/4 66 53-1/2 50-1/4 8 12 50-1/4 66 53-1/2 50-1/4 8 12 50-1/4 66 53-1/2 50-1/4 8 12 64-3/4 78-3/4 70 66-31/2 12 16 64-3/4 78-3/4 70 66-1/2 12 16 40 50 60
Model CB Boilers
70 80 100
64-3/4 78-3/4 70 66-1/2 12 16
64-3/4 78-3/4 70 66-1/2 12 16
64-3/4 78-3/4 70 64-3/4 12 16
BOILER CONNECTIONS Chemical Feed Feedwater, Right and Left Low Pressure (15 psig only) Steam Nozzle Drain, Front and Rear High Pressure (150 psig only) Surface Blowoff, Top CL Steam Nozzle Blowdown, Front and Rear H S U W T Y W 1 1 4 1 1 1-1/2 1 1 1 4 1 1 1-1/2 1 1 1 4 1 1 2 1 1 1 6A 1-1/4 1 2 1 1 1-1/4 6A 1-1/4 1 3 1-1/4 1 1-1/4 6A 1-1/4 1 3 1-1/4 1 1-1/4 6A 1-1/2 1 3 1-1/4 1 1-1/4 6A 1-1/2 1 3 1-1/4 1 1-1/4 8A 1-1/2 1 4B 1-1/4
VENT STACK Diameter (flgd connection) Front Ring Flange to Vent CL BB CC 6 4 6 4 8 5 8 5 10 6 10 6 12 7 12 7 12 7
MINIMUM CLEARANCES Rear Door Swing

C
DD EE FF GG
44 44 56 46
44 44 56 46
44 44 74 64
44 44 100 90
55 55 84 74
55 55 84 74
55 55 123 113
55 55 123 113
55 55 142 132
Front Door SwingC Tube Removal, Rear Tube Removal, Front
MINIMUM BOILER ROOM LENGTH ALLOWING FOR DOOR SWING AND TUBE REMOVAL FROM: Rear of Boiler Front of Boiler Thru Window or Doorway RR RF RD 163 153 151 163 153 151 199 189 169 251 241 195 231 221 202 231 221 202 309 299 241 309 299 241 347 337 260
WEIGHT IN LBS Normal Water Capacity Approx. Ship Wgt - 15 psig Approx. Ship Wgt - 150 psig Approx. Ship Wgt - 200 psig 1340 3000 3100 3300 1300 3100 3200 3400 1710 3650 3800 4100 2290 4350 4500 4700 3130 6900 7000 7400 2920 7000 7200 7600 4620 8100 8800 9300 4460 8200 9000 9500 5088 9000 9500 10000
NOTES: 1. Air compressor belt driven from blower motor on sizes 15 thru 40 2. Air compressor module on sizes 50 thru 100 hp. 3. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension prints. A. ANSI 150 psig flange. B. ANSI 300 psig flange. C. 15 thru 100 hp standard hinged door.
A2-11
07-02
Model CB Boilers
Firetube Boilers
BOILER HP
DIM
125
150
200
250
300
350
400
500
600
700
750
800
LENGTHS Overall Shell Base Frame Front Head Extension Rear Head Extension Front Ring Flange to Nozzle 15 psig Front Ring Flange to Nozzle 150 psig Ring Flange to Base A B C D E F F G 174-1/2 125 124 30 19-1/2 62-1/2 55 1/2 199-/12 149 148 31 19-1/2 74-1/2 66 1/2 232-1/2 180 179 33 19-1/2 90 78 1/2 197 144 143 29 24 72 59-1/2 1/2 WIDTHS Overall ID, Boiler Center to Water Column Center to Outside Hinge Center to Lagging Center to Auxiliary LWCO Base, Outside Base, Inside I J K KK L LL M N 85 60 45 35 33 40 52-1/2 44-1/2 85 60 45 35 33 40 52-1/2 44-1/2 85 60 45 35 33 40 52-1/2 44-1/2 103 78 54 51 42 49 64-3/8 52-3/8 103 78 54 51 42 49 64-3/8 52-3/8 103 78 54 51 42 49 64-3/8 52-3/8 123 96 64 62 51 59 72 56 123 96 64 62 51 59 72 56 123 96 64 62 51 59 72 56 123 96 64 62 51 59 72 56 123 96 64 62 51 59 72 56 123 96 64 62 51 59 72 56 227 171 170 32 24 85-1/2 73 1/2 257 201 200 32 24 100-1/2 88 1/2 210 152 151 26 32 76 62 1/2 244 186 185 26 32 93 79 1/2 284 222 221 30 32 111 97 1/2 317 255 254 30 32 127-1/2 127-1/2 1/2 319 255 254 32 32 127-1/2 127-1/2 1/2 319 255 254 32 32 127-1/2 127-1/2 1/2
A2-12
07-02
Firetube Boilers
Model CB Boilers
BOILER HP
DIM
125
150
200
250 HEIGHTS
300
350
400
500
600
700
750
800
Base to Steam Outlet (15 psig only) Overall Base to Vent Outlet Base to Steam Outlet (150 psig only) Davit (Front) Davit (Rear) Height of Base Base to Bottom of Boiler
PL OO O PH DF DR Q R
77 88 85 77 84-3/4 12 16
77 88 85 77 84-3/4 12 16
77 88 85 77 84-3/4 12 16
96 106 106 96 104 104 10 17
96 106 106 96 104 104 10 17
96 106 106 96 104 104 10 17
116 126 126 116 125 126 12 19
116 126 126 116 125 126 12 19
116 126 126 116 125 126 12 19
116 126 126 116 125 126 12 19
116 126 126 116 125 126 12 19
116 126 126 116 125 126 12 19
BOILER CONNECTIONS Chemical Feed Feedwater, Right and Left Low Pressure (15 psig only) Steam Nozzle (Note A) Drain, Front and Rear High Pressure (150 psig only) Surface Blowoff, Top CL Steam Nozzle (Note B) Blowdown, Front and Rear H S U W T Y W 1 1-1/2 8 1-1/2 1 4 1-1/2 1 1-1/2 8 1-1/2 1 4 1-1/2 1 2 10 2 1 4 1-1/2 1 2 10 2 1 6 1-1/2 1 2 12 2 1 6 1-1/2 1 2-1/2 12 2 1 6 1-1/2 1 2-1/2 12 2 1 6 2 1 2-1/2 12 2 1 8 2 1 2-1/2 12 2 1 8 2 1 2-1/2 12 2 1 8 2 1 2-1/2 12 2 1 8 2 1 2-1/2 12 2 1 8 2
VENT STACK Diameter (flgd. connection) Front Ring Flange to Vent CL BB CC 16 9 16 9 16 9 20 10-1/2 20 10-1/2 20 10-1/2 24 12-1/2 24 12-1/2 24 12-1/2 24 12-1/2 24 12-1/2 24 12-1/2
MINIMUM CLEARANCES Rear Door Swing Front Door Swing Tube Removal, Rear Tube Removal, Front DD EE FF GG 32C 67 115 103 32C 67 139 127 32C 67 170 158 43C 89C 131 116 43C 89C 157 142 43C 89C 187 172 53C 108C 135 116 53C 108C 169 151 53C 108C 205 187 53C 108C 238 220 53C 108C 238 220 53C 108C 238 220
MINIMUM BOILER ROOM LENGTH ALLOWING FOR DOOR SWING AND TUBE REMOVAL FROM: Rear of Boiler Front of Boiler Thru Window or Doorway RR RF RD 307 260 224 355 308 248 417 370 279 364 303 275 417 356 302 477 416 332 395 322 313 463 390 347 535 462 383 601 528 416 601 528 416 601 528 416
WEIGHT IN LBS Normal Water Capacity Approx. Ship Wgt - 15 psig Approx. Ship Wgt - 150 psig Approx. Ship Wgt - 200 psig 5750 12200 12800 13400 7250 12900 13800 14500 8625 15200 16300 17100 10670 21800 23400 25200 13000 24000 26000 28000 15465 27300 28500 30000 15340 33500 36500 38300 19300 38400 41400 44000 23425 44000 47000 50500 27790 51400 54100 57700 27790 51400 54100 57700 27790 51400 54100 57700
NOTES: 1. Air compressor belt driven from blower motor on sizes 125 thru 350 hp. 2. Control Panel relocation on boilers 250 hp and up. 3. Air compressor module on sizes 400 thru 800 hp. 4. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension prints. A. ANSI 150 psig flange. B. ANSI 300 psig flange. C. Davit equipped, standard, 125 - 800 hp (rear door). D. Davit equipped, standard, 250- 800 hp (front door)
A2-13
07-02
Model CB Boilers
Firetube Boilers
LWCO
BOILER HP
DIM
15
20
30 LENGTHS
40
50
60
70
80/ 100A
100/ 125A
Overall Shell Base Frame Front Head Ext. Rear Head Ext. Front Ring Flange to Return Front Ring Flange to Outlet Ring Flange to Base
A B C D E F G H
97 62-5/8 59 18-1/2 15-1/2 43-5/8 55-1/8 1-13/16
97 62-5/8 59 18-1/2 15-1/2 43-5/8 55-1/8 1-13/16
114-5/8 80-5/8 77 18-1/2 15-1/2 62 73-1/8 1-13/16
140-5/8 106-5/8 103 18-1/2 15-1/2 81 98-1/2 1-13/16
129 92 91 18-1/2 18-1/2 69 84-5/8 5/8
129 92 91 18-1/2 18-1/2 69 84-5/8 5/8
168 131 130 18-1/2 18-1/2 108 123-5/8 5/8
168 131 130 18-1/2 18-1/2 108 123-5/8 5/8
187 150 148 18-1/2 18-1/2 127 142-5/8 1
WIDTHS Overall ID, Boiler Center to Entrance Box Center to Outside Hinge Center to Lagging Base, Outside Base, Inside I J K KK L M N 48-3/4 36 28-3/4 22 20 28 22 48-3/4 36 28-3/4 22 20 28 22 48-3/4 36 28-3/4 22 20 28 22 48-3/4 36 28-3/4 22 20 28 22 63 48 36 29 27 37-5/8 29-5/8 63 48 36 29 27 37-5/8 29-5/8 63 48 36 29 27 37-5/8 29-5/8 63 48 36 29 27 37-5/8 29-5/8 63 48 36 29 27 37-5/8 29-5/8
Figure A2-3. Model CB Hot Water Boiler Dimensions (30 psig and 125 psig Design Pressure 15 to 100 hp) - Sheet 1 of 2
A2-14
07-02
Firetube Boilers
Model CB Boilers
BOILER HP
DIM
15
20
30 HEIGHTS
40
50
60
70
80/ 100A
100/ 125A
Overall Base to Vent Outlet Base to Return and outlet Davit (Front) Davit (Rear) Height of Base Base to bottom of boiler
OO O P DF DR Q R
66 53-1/2 50 8 12
66 53-1/2 50 8 12
66 53-1/2 50 8 12
66 53-1/2 50 8 12
72-5/8 70 67 12 16
72-5/8 70 67 12 16
72-5/8 70 67 12 16
72-5/8 70 67 12 16
72-5/8 70 67 12 16
BOILER CONNECTION Waterfill Conn. Right & Left Water Return - Threaded Water Outlet - ThreadedA Air Vent Drain, Front and Rear Auxiliary Connection S T U v W X 1 2-1/2 2-1/2 1 1 1 1 2-1/2 2-1/2 1 1 1 1 3 3 1 1 1 1 3 3 1 1-1/4 1 1-1/4 4 4 1-1/4 1-1/4 1 1-1/4 4 4 1-1/4 1-1/4 1 1-1/4 4 4 1-1/4 1-1/2 1 1-1/4 4 4 1-1/4 1-1/2 1 1-1/4 4 4 1-1/4 1-1/2 1
VENT STACK Diameter (flgd. connection) Front Ring Flange to vent CL BB CC 6 4 6 4 8 5 8 5 10 6 10 6 12 7 12 7 12 7
MINIMUM CLEARANCES Rear Door Swing Front Door Swing Tube Removal, Rear Tube, Removal, Front DD EE FF GG 44 44 56 46 44 44 56 46 44 44 74 64 44 44 100 90 55 55 84 74 55 55 84 74 55 55 123 113 55 55 123 113 55 55 142 132
MINIMUM BOLER ROOM LENGTH ALLOWING FOR DOOR SWING AND TUBE REMOVAL FROM: Rear of Boiler Front of Boiler Thru Window or Doorway RR RF RD 163 153 151 163 153 151 199 189 169 251 241 195 231 221 202 231 221 202 309 299 241 309 299 241 347 337 260
WEIGHT IN LBS Water Capacity Flooded Approx. Ship. Wgt. 30 psig Approx. Ship. Wgt. 125 psig 1500 3000 3300 1460 3100 3400 1915 3650 3880 2585 4350 4580 3665 6800 7100 3500 7000 7300 5420 8000 8350 5250 8100 8450 5960 8800 9150
NOTES: 1. Accompanying dimensions and ratings while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension prints. 2. Air compressor belt driven from blower motor on sizes 15 thru 40 hp. 3. Air compressor module on sizes 50 thru 100 hp. 4. 15 - 100 hp, hinged door standard. 5. Add 370lbs to the 80 hp ship weight for 100A and 485 lbs to the 100 hp ship weight for the 125A. A. Dip Tube included.
Figure A2-3. Model CB Hot Water Boiler Dimensions (30 psig Design Pressure 15 to 100 hp) - Sheet 2 of 2 A2-15
07-02
Model CB Boilers
Firetube Boilers
LWCO
BOILER HP
DIM
125
150/ 175A
200
250
300
350
400
500
600
700
750
800
LENGTHS Overall Shell Base Frame Front Head Extension Rear Head Extension Front Ring Flange to Return Front Ring Flange to Outlet Ring Flange to Base A B C D E F G H 174-1/2 199-1/2 232-1/2 125 124 30 19-1/2 91 114 1/2 149 148 31 19-1/2 102 136 1/2 180 179 33 19-1/2 131 167 1/2 197 144 143 29 24 227 171 170 32 24 257 201 200 32 24 210 152 151 26 32 244 186 185 26 32 139 170 1/2 284 222 221 30 32 175 206 1/2 317 255 254 30 32 207 239 1/2 319 255 254 32 32 207 239 1/2 319 255 254 32 32 207 239 1/2
104-1/2 131-1/2 161-1/2 111-1/2 131 1/2 WIDTHS 158 1/2 188 1/2 146 1/2
Overall ID, Boiler Center to Entrance Box Center to Outside Hinge Center to Lagging Base, Outside Base, Inside
I J K KK L M N
75-1/2 60 42-1/2 35 33 52-1/2 44-1/2
75-1/2 60 42-1/2 35 33 52-1/2 44-1/2
75-1/2 60 42-1/2 35 33 52-1/2 44-1/2
93 78 51 51 42 64-3/8 52-3/8
93 78 51 51 42 64-3/8 52-3/8
93 78 51 51 42 64-3/8 52-3/8
113 96 62 62 51 72 56
113 96 62 62 51 72 56
113 96 62 62 51 72 56
113 96 62 62 51 72 56
113 96 62 62 51 72 56
113 96 62 62 51 72 56
Figure A2-4. Model CB Hot Water Boiler Dimensions (30 psig Design Pressure - 125 - 800 hp) - Sheet 1 of 2
A2-16
07-02
Firetube Boilers
Model CB Boilers
BOILER HP
DIM
125
150/ 175A
200
250 HEIGHTS
300
350
400
500
600
700
750
800
Overall Base to Vent Outlet Base to Return and Outlet Davit (Front) Davit (Rear) Height of Base Base to Bottom of Boiler
OO O P DF DR Q R
88 85 77 84-3/4 12 16
88 85 77 84-3/4 12 16
88 85 77 84-3/4 12 16
106 106 96 104 104 10 17
106 106 96 104 104 10 17
106 106 96 104 104 10 17
126 126 116 125 126 12 19
126 126 116 125 126 12 19
126 126 116 125 126 12 19
126 126 116 125 126 12 19
126 126 116 125 126 12 19
126 126 116 125 126 12 19
BOILER CONNECTION Waterfill Conn. Right & Left Water Return FlangeA Water Outlet Flange Air Vent Drain, Front and Rear Auxiliary Connection S T U V W X 1-1/2 6 6 1-1/2 1-1/2 1 1-1/2 6 6 1-1/2 1-1/2 1 2 6 6 1-1/2 2 1 2 8 8 1-1/2 2 1-1/4 VENT STACK Diameter (flgd. connection) Front Ring Flange to vent CL BB CC 16 9 16 9 16 9 20 10-1/2 20 10-1/2 20 10-1/2 24 12-1/2 24 12-1/2 24 12-1/2 24 12-1/2 24 12-1/2 24 12-1/2 2 8 8 1-1/2 2 1-1/4 2-1/2 8 8 1-1/2 2 1-1/4 2-1/2 10 10 2 2 1-1/4 2-1/2 10 10 2 2 1-1/4 2-1/2 12 12 2 2 1-1/4 2-1/2 12 12 2 2 1-1/4 2-1/2 12 12 2 2 1-1/4 2-1/2 12 12 2 2 1-1/4
MINIMUM CLEARANCES Rear Door Swing Front Door Swing Tube Removal, Rear Tube, Removal, Front DD EE FF GG 32B 67 115 103 32B 67 139 127 32B 67 170 158 43B 89B 131 116 43B 89B 157 142 43B 89B 187 172 53B 108B 135 117 53B 108B 169 151 53B 108B 205 187 53B 108B 238 220 53B 108B 238 220 53B 108B 238 220
MINIMUM BOILER ROOM LENGTH ALLOWING FOR DOOR SWING AND TUBE REMOVAL FROM: Rear of Boiler Front of Boiler Thru Window or Doorway RR RF RD 307 260 224 355 308 248 417 370 279 364 303 275 417 356 302 477 416 332 395 322 313 463 390 347 535 462 383 601 528 416 601 528 416 601 528 416
WEIGHT IN LBS Water Capacity Flooded Approx. Ship. Wgt. 30 psig Approx. Ship. Wgt. 125 psig 7670 12100 12500 9295 12800 13200 11130 15100 15500 13880 21700 22500 16840 23900 24700 20090 27200 28000 20630 33400 34400 25925 38300 39300 31510 43900 44900 36600 51300 52300 36600 51300 52300 36600 51300 52300
NOTES: 1. Accompanying dimensions and ratings while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension prints. 2. Control panel relocated on boilers 250 hp and up. 3. Air compressor belt driven from blower motor on sizes 125 thru 350 hp. 4. Air compressor module on sizes 400 thru 800 hp. 5. Davited front doors are standard on 250 - 800 hp. 6. Add 480 lbs to the 150 hp ship weight for 175A. A. Dip Tube included. B. Davited rear doors are standard on 125 - 800 hp units.
Figure A2-4. Model CB Hot Water Boiler Dimensions (30 psig Design Pressure - 125 - 800 hp) - Sheet 2 of 2
A2-17
07-02
Model CB Boilers
Firetube Boilers
DIMENSION (INCHES) BOILER HP A 15 - 40, 50A 50 - 100, 100A, 125A 125 - 200, 175A 250 - 350 400 - 800 20 27 33 42 51 B 36 48 55 69 88 C 28 38 45 58 71 D 45 60 68 86 109 E 20 26 32 43 53 PLAN VIEW
NOTE: 1. Dimensions in inches. 2. 15 - 100 hp (100A & 125A) boilers are standardly equipped with hinges. Davit available as an option.
Figure A2-5. Space Required to Open Rear Head on Model CB Boilers Equipped with Davits
Figure A2-6. Lifting Lug Location, Model CB Boilers - Sheet 1 of 2
A2-18
07-02
Firetube Boilers
BOILER HP 15 Steam Hot Water 20 Steam Hot Water 25 Steam Hot Water 30 Steam Hot Water 40 Steam Hot Water 50A Water 50 60 70 80 100 100A 125A 125 150 175A 200 250 All All All All All Hot Water Hot Water All All Hot Water All Steam Hot Water 300 Steam Hot Water 350 Steam Hot Water 400 Steam Hot Water 500 Steam Hot Water 600 Steam Hot Water 700 Steam Hot Water 750 Steam Hot Water 800 Steam Hot Water B B B B B B B B B A B B B B B B B B B B B B B B B B B B B B 50-1/2 68 68 68 68 68 68 68 80-1/4 80-1/4 80-1/4 80-1/4 99 99 99 99 99 99 119 119 119 119 119 119 119 119 119 119 119 119 12 18 18 27 27 27 27 27 29-3/4 29-3/4 29-3/4 29-3/4 36 36 36 36 36 36 34-1/2 34-1/2 34-1/2 34-1/2 34-1/2 34-1/2 34-1/2 34-1/2 34-1/2 34-1/2 34-1/2 34-1/2 82-3/4 57 57 67 67 86 67 100 70-1/2 83-1/2 83-1/2 114-1/2 72 72 99 99 129 129 83 83 117 117 153 153 186 186 186 186 186 186 VIEW A B A B A B A B A B ALL DIMENSIONS IN INCHES A 51-3/4 50-1/2 51-3/4 50-1/2 51-3/4 50-1/2 51-3/4 50-1/2 51-3/4 50-1/2 B 12 12 12 12 12 12 12 12 12 12 C 38-3/4 38-3/4 38-3/4 38-3/4 56-3/4 56-3/4 56-3/4 56-3/4 82-3/4 82-3/4
Model CB Boilers
D 6 6 6 6 6
E 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2
6 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 11 11 11 11 11 11 11 11 11 11 11
2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
NOTE: 1. A, B and C Dimensions may vary by 1/2 inch. 2. BHP followed by A designates hot water boilers furnished in a smaller vessel size with additional tubes in upper portion of vessel.
Figure A2-6. Lifting Lug Location, Model CB Boilers - Sheet 2 of 2
A2-19
07-02
Model CB Boilers
Firetube Boilers
BOILER HP 15-20 25-30 40-50A 50-60 70-80, 100A 100, 125A 125 150, 175A 200 250 300 350 400 500 600 700-750-800
A 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6
B 8 8 8 8 8 8 9 9 9 12 12 12 14 14 14 14
C 59 77 103 91 130 148 124 148 179 143 170 200 151 185 221 254
D 17 17 17 26 26 26 39-1/2 39-1/2 39-1/2 46 46 46 50 50 50 50
E 33 33 33 42 42 42 57-1/2 57-1/2 57-1/2 70 70 70 78 78 78 78
F 3 3 3 4 4 4 4 4 4 6 6 6 8 8 8 8
G 22 22 22 29-5/8 29-5/8 29-5/8 44-1/2 44-1/2 44-1/2 52-3/8 52-3/8 52-3/8 56 56 56 56
X 9-3/4 9-3/4 9-3/4 8-1/4 8-1/4 8-1/4 10-1/4 10-1/4 10-1/4 22-1/2 22-1/2 22-1/2 24-1/2 24-1/2 24-1/2 24-1/2
NOTE: 1. All numbers in table are in inches. 2. 6-inch high mounting piers recommended for use beneath the boiler base frame. The use of these piers provides increased inspection accessibility to the piping beneath the boiler and added height for washing down the area beneath the boiler.
Figure A2-7. Model CB Boiler Mounting Piers
A2-20
07-02
Firetube Boilers
Model CB Boilers
4. Any efciency verication testing will be based on the stack loss method. When specifying the efciencies in the tables, be sure to include the specic guarantee conditions to maximize the effectiveness of your efciency specication. If you have any questions regarding the efciency specications, please contact your local Cleaver-Brooks authorized representative. For efciencies and stack temperatures at operating pressures not listed, follow these procedures: When the operating steam pressure is between 10 psig and 125 psig, interpolate the values from the efciency tables. When the operating steam pressure is above 125 psig, estimated efciency can be calculated as follows: Example: Boiler: 350 hp. Fuel: natural gas. Operating steam pressure: 200 psig. Find the fuel-to-steam efciency at 100% ring rate. From Table A2-8 for a 350 hp boiler operating at 100% ring rate and an operating steam pressure of 125 psig, the efciency is 82.5%. Using Figure A2-8, note that the stack temperature increases 36 F at the higher operating pressure. To estimate boiler efciency, use this rule of thumb: For every 40 F increase in stack temperature, efciency decreases by 1%. Since the stack temperature rise is 36 F, the decrease in the boiler efciency at 200 psig operating pressure is calculated as follows: 36/40 = .9%. Therefore, the boiler efciency at 200 psig operating pressure is 82.5 - .9 = 81.6%.
PERFORMANCE DATA
Efficiency
Tables A2-7, A2-8, A2-9, A2-10, A2-11, and A2-12 show predicted fuel-to-steam efciencies (including radiation and convection losses) for Cleaver-Brooks Model CB Firetube boilers. For specic efciencies on retube boiler offerings not listed here, contact your local Cleaver-Brooks authorized representative. Cleaver-Brooks offers an industry leading fuel-to-steam boiler efciency guarantee for Model CB Firetube Boilers. The guarantee is based on the fuel-to-steam efciencies shown in the efciency tables and the following conditions. The efciency percent number is only meaningful if the specic conditions of the efciency calculations are clearly stated in the specication (see Cleaver-Brooks publication CB-7768 for a detailed description of efciency calculations). The boiler manufacturer shall guarantee that, at the time of startup, the boiler will achieve fuel-to-steam efciency (as shown in the tables listed above) at 100% ring rate (add efciency guarantees at 25%, 50%, and 75% of rating, if required). If the boiler(s) fail to achieve the corresponding guaranteed efciency as published, the boiler manufacturer will rebate, to the ultimate boiler owner, ve thousand dollars ($5,000) for every full efciency point (1.0%) that the actual efciency is below the guaranteed level. The specied boiler efciency is based on the following conditions. 1. Fuel specication used to determine boiler efciency: Natural Gas Carbon, % (wt) = 69.98 Hydrogen, % (wt) = 22.31 Sulfur, % (wt) = 0.0 Heating value, Btu/lb = 21,830 No. 2 Oil Carbon, % (wt) = 85.8 Hydrogen, % (wt) = 12.7 Sulfur, % (wt) = 0.2 Heating value, Btu/lb = 19,420 No. 6 Oil Carbon, % (wt) = 86.6 Hydrogen, % (wt) = 10.9 Sulfur, % (wt) = 2.09 Heating value, Btu/lb = 18,830 2. Efciencies are based on ambient air temperature of 80 F, relative humidity of 30%, and 15% excess air in the exhaust ue gas. 3. Efciencies are based on manufacturers published radiation and convection losses. (For Cleaver-Brooks radiation and convection losses, see Boiler Efciency Facts Guide, publication number CB-7767).
Emissions
The emission data included in this section consists of typical uncontrolled emission levels for Cleaver-Brooks Model CB Firetube Boilers. Cleaver-Brooks Firetube boilers are available with the standard burner package for Model CB, or optional internal ue gas recirculation on Model CB (LE) (refer to Section A3). The Cleaver-Brooks IFGR packages are integrated boiler/ burner/control packages designed specically for CleaverBrooks boilers. For detailed information on Cleaver-Brooks IFGR packages, refer to Model CB (LE) in Section A3.
NOTICE
The data in Table A2-13 represents typical emission levels only. Guaranteed emission levels are available from your local Cleaver-Brooks authorized representative.
A2-21
07-02
Model CB Boilers
Table A2-7. Predicted Fuel-to-Steam Efciencies (%), Model CB Boilers - 10 psig, Natural Gas
BOILER HP 50 60 70 80 100 125 150 200 250 300 350 400 500 600 700 750 800 FIRING RATE (%) 25 83.0 82.9 84.5 84.6 84.4 83.3 84.4 85.0 85.0 85.3 85.3 84.5 85.5 85.7 85.7 85.8 85.8 50 83.2 83.1 84.7 84.8 85.0 83.6 84.6 85.3 84.7 85.3 85.7 84.7 85.7 86.0 86.2 86.1 86.1 75 82.9 82.7 84.3 84.5 84.8 83.4 84.5 85.1 84.0 84.6 85.2 84.6 85.5 85.8 86.0 85.9 85.9 100 82.4 82.3 83.9 84.0 84.4 83.2 84.3 84.9 83.3 83.9 84.5 84.4 85.2 85.6 85.7 85.6 85.6
Firetube Boilers
Table A2-9. Predicted Fuel-to-Steam Efciencies (%), Model CB Boilers - 10 psig, No. 6 Oil
Table A2-8. Predicted Fuel-to-Steam Efciencies (%), Model CB Boilers - 125 psig, Natural Gas
Table A2-10. Predicted Fuel-to-Steam Efciencies (%), Model CB Boilers - 125 psig, No 6 Oil
A2-22
07-02
Firetube Boilers
Model CB Boilers
Figure A2-8. Predicted Stack Temperature Increase for Pressure Greater Than 125 psig
A2-23
07-02
Model CB Boilers
Table A2-13. Model CB Boiler Emission Data
Firetube Boilers
ESTIMATED LEVELS - UNCONTROLLED POLLUTANT NATURAL GAS CO ppmA Lb/MMBtu ppmA Lb/MMBtu ppmA Lb/MMbtu ppmA Lb/MMBtu ppmA Lb/MMBtu 200 0.15 100 0.12 1 0.001 40 0.016 0.01 NO. 2 OILB 90 0.07 185 0.25 278 0.52 50 0.025 0.025 NO. 6 OILC 95 0.075 502 0.67 278 0.52 70 0.035 0.160
NOx
SOx
HC/VOCs
PM
NOTES: Refer to Section E for detailed emission information. A. ppm levels corrected to 3% O2, dry basis. B. Based on fuel constituent levels of: Fuel-bound nitrogen content = 0.05% by weight Sulfur content = 0.5% by weight Ash content = 0.01% by weight C. Based on fuel constituent levels of: Fuel-bound nitrogen content = 0.7% by weight Sulfur content = 0.5% by weight Ash content = 0.1% by weight Conradson carbon residue = 16% by weight
ENGINEERING DATA
The following engineering information is provided for Model CB Firetube Boilers. Additional detail is available from your local Cleaver-Brooks authorized representative. Refer to Tables A2-14 through A2-18.
Table A2-14. Heating Surface, Model CB Boilers

BOILER HP 15 20 25 HEATING SURFACE (SQ-FT) FIRESIDE 75 100 125 150 200 250 300 350 400 500 625 750 1000 1250 1500 1750 2000 2500 3000 3500 3500 3500 WATERSIDE 85 109 144 162 219 266 323 388 441 544 679 820 1092 1346 1623 1932 2151 2691 3262 3810 3810 3810
Blowdown Water Requirements

Some local codes require blowdown tanks to be constructed in accordance with recommendations of the National Board of Boiler and Pressure Vessel Inspectors. The National Boards recommendations base the size of the blowdown tank on the removal of at least 4 inches of water from the boiler. Table A2-19 lists the approximate quantity of water represented by 4 inches of water at normal operating level for Cleaver-Brooks Model CB Boilers.
30 40 50 60 70 80 100 125 150 200 250 300 350 400 500 600 700 750 800
A2-24
07-02
Firetube Boilers
Table A2-15. Steam Volume and Disengaging Area
STEAM VOLUME CU-FT BOILER HP 15 20 25 & 30 40 50 60 70 80 100 125 150 200 250 300 350 400 500 600 700-750-800 NOTE: Based on normal water level. A. Based on 150 psig design pressure. B. Based on 15 psig design pressure. 2.9 2.9 3.9 5.3 9.7 9.7 14.3 14.3 16.6 25.4 30.7 37.7 49.2 59.5 70.9 75.8 95.0 115.4 134.0 HIGH PRESSURE
A
Model CB Boilers
STEAM RELIEVING AREA, SQ-IN
B
LOW PRESSURE 5.9 5.9 7.9 10.8 16.0 16.0 23.7 23.7 27.4 36.6 44.3 54.4 70.6 85.3 101.7 102.5 128.5 156.1 181.3
HIGH PRESSUREA 1356 1356 1817 2485 2959 2959 4367 4367 5053 5371 6511 7985 7980 9651 11507 10148 12722 15448 17948
LOW PRESSUREB 1637 1637 2195 2999 3372 3372 4975 4975 5757 5887 7138 8752 8695 10516 12538 10960 13740 16685 19385
Table A2-16. Water Circulation Rate and Temperature Drop for Hot Water Boiler
BOILER HP 15 20 30 40 50 60 70 80 100 & 100A 125 &125A 150 175A 200 250 300 350 400 500 600 700 750 800 BOILER OUTPUT (1000) BTU/HR 500 670 1005 1340 1675 2010 2345 2680 3350 4185 5025 5858 6695 8370 10045 11720 13400 16740 20080 23450 25106 26780 SYSTEM TEMPERATURE DROP - DEGREES F 10 20 30 40 50 60 70 80 90 100
MAXIMUM CIRCULATING RATE - GPM 100 134 200 268 335 402 470 536 670 836 1005 1172 1340 1675 2010 2350 2680 3350 4020 4690 5025 5360 50 67 100 134 168 201 235 268 335 418 503 586 670 838 1005 1175 1340 1675 2010 2345 2510 2680 33 45 67 89 112 134 157 179 223 279 335 391 447 558 670 784 895 1120 1340 1565 1675 1785 25 33 50 67 84 101 118 134 168 209 251 293 335 419 503 587 670 838 1005 1175 1255 1340 20 27 40 54 67 80 94 107 134 168 201 234 268 335 402 470 535 670 805 940 955 1075 17 22 33 45 56 67 78 90 112 140 168 195 224 280 335 392 447 558 670 785 840 895 14 19 29 38 48 58 67 77 96 120 144 167 192 240 287 336 383 479 575 670 720 765 12 17 25 33 42 50 59 67 84 105 126 147 168 210 251 294 335 419 502 585 625 670 11 15 22 30 37 45 52 60 75 93 112 130 149 186 223 261 298 372 448 520 555 595 10 13 20 27 33 40 47 54 67 84 100 117 134 167 201 236 268 335 402 470 500 535
NOTES: 1. Minimum recommended return water temperature is 150 F. Minimum recommended outlet temperature for Model CB Hot Water Boilers is 170 F. Contact your local Cleaver-Brooks authorized representative for special hot water application information. 2. See Section H2 for over-pressure requirements.
A2-25
07-02
Model CB Boilers
Firetube Boilers
Table A2-17. Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity)
BOILER HP OPERATING PRESSURE PSIG 15 30 40 50 75 100 125 150 200 250 15 4 2 2 1.5 1.5 1.5 1.5 1.5 1.5 1.5 20 4 2 2 2 2 1.5 1.5 1.5 1.5 1.5 25 4 2.5 2.5 2 2 2 2 2 2 2 30 4 2.5 2.5 2.5 2 2 2 2 2 2 40 6 3 3 2.5 2.5 2 2 2 2 2 50 6 4 3 3 3 3 3 2.5 2.5 2 60 6 4 4 3 3 3 3 2.5 2.5 2 70 6 4 4 4 3 3 3 2.5 2.5 2 80 6 4 4 4 4 3 3 2.5 2.5 2 100 8 6 6 4 4 4 4 2.5 2.5 2 125 8 6 6 6 4 4 4 3 2.5 2.5 150 8 6 6 6 4 4 4 3 3 2.5 200 10 8 6 6 6 6 4 4 4 3 250 10 8 8 6 6 6 6 4 4 4 300 12 8 8 8 6 6 6 6 4 4 350 12 10 8 8 8 6 6 6 4 4 400 12 10 10 8 8 6 6 6 6 4 500 12 10 10 8 8 8 8 6 6 6 600 12 12 10 10 8 8 8 6 6 6 700 12 12 12 10 10 8 8 8 6 6 750 12 12 12 12 10 8 8 8 6 6 800 12 12 12 12 10 10 8 8 6 6
NOTES: 1. Steam nozzle sizes given in inches. 2. Recommended steam nozzle sizes based on 4000 to 5000 fpm steam velocity. Spool pieces (300 lb flanges) are available in the following sizes (in inches): 3x21/2x30, 4x3x30, 6x4x36, 8x6x48, 10x8x48, and 12x8x48. 3. All standard steam nozzle sizes for 150 psig design pressure or greater are the same as 125 psig operating pressure on the above table. To increase or decrease the standard size, request the change with your local Cleaver-Brooks authorized representative.
Table A2-18. Recommended Non-Return Valve Size

BOILER HP 100 125 150 200 250 300 350 400 500 600 700 750 800 BOILER CAPACITY (LBS/HR) 3450 4313 5175 6900 8625 10350 12025 13800 17210 20700 24150 25875 27600 OPERATING PRESSURES (PSIG) 50 3 4 4 4 4 6 6 6 6 8 8 8 8 75 2-1/2 3 4 4 4 4 6 6 6 8 8 8 8 100 2-1/2 3 3 4 4 4 4 4 6 6 6 6 6 125 2-1/2 3 3 3 4 4 4 4 6 6 6 6 6 150 2-1/2 3 3 3 3 4 4 4 4 6 6 6 6 175 2-1/2 2-1/2 3 3 3 4 4 4 4 4 6 6 6 200 2-1/2 2-1/2 2-1/2 3 3 4 4 4 4 4 6 6 6 250 2-1/2 2-1/2 2-1/2 3 3 3 3 4 4 4 6 6 6
Note: Valve sizes (300 psig flanges) given in inches.
A2-26
07-02
Firetube Boilers
Table A2-19. Model CB Blowdown Tank Sizing Information
BOILER HP 15-20 25-30 40 50-60 70-80 100 125 150 200 250 300 350 400 500 600 700-750 800 WATER (GAL.) 26 34 47 55 80 93 97 118 145 146 176 210 183 230 280 325 325
Model CB Boilers
Sound Level
Table A2-20 summarizes predicted sound pressure levels for Model CB Boilers. Tables A2-21 through A2-25 give detailed octave band sound pressure levels for each boiler. These values are based on standard motors. Optional motor types and altitude conditions can increase sound levels. Units The units for the sound level tables are dBA (decibels, measured on the A-weighted scale) in reference to 0.0002 microbars (20 micro-Newtons per square meter). They are standardly referenced in specifying and reporting sound pressure levels on industrial equipment. Test Method The sound pressure levels in the above tables were obtained from tests in accordance with the "ABMA Test Code for the Measurement of Sound from Packages Boilers." In accordance with this code, the sound pressure levels reported were measured on the boiler centerline 4-1/2 feet vertically above the bottom of the base rails and 3 feet horizontally in front of the end of the blower motor or front surface of the electrical cabinet. Sound Level Meter The sound level meter used complies with ANSI S1.4, Type 1 (Precision). The readings are taken with the meter set for slow response.
NOTE: Quantity of water removed from boiler by lowering normal water line 4".
Table A2-20. Sound Pressure Level Summary (50 - 800 hp)

BOILER HP HFO, dBA LFO, dBA HFG, dBA LFG, dBA 50 79 78 77 72 60 79 78 77 73 70 79 78 78 74 80 79 78 78 75 100 81 79 78 75 125A 82 79 79 75 125 83 81 81 78 150 83 82 80 77 200 83 81 82 78 250 88 86 84 81 300 88 86 86 82 350 89 85 86 83 400 83 80 82 80 500 83 82 82 81 600 83 82 82 81 700 85 82 85 82 750 87 83 86 83 800 88 84 87 84
NOTES: 1. Boiler No. followed by an a designates hot water boilers furnished in a smaller vessel size with additional tubes in the upper portion of the vessel. 2. Sound Pressure levels measured on boilers operating in various locations and expressed in dBA are as follows:
ABBREVIATIONS: HF = High Fire LF = Low Fire O = Oil G = Gas
Table A2-21. Model CB Boiler Sound Pressure Level Details (40 hp)
FIRING RATE FUEL SOUND LEVEL dBA OCTAVE BAND SOUND PRESSURE LEVELS IN dB RE .0002 MICROBAR 31Hz 63Hz 125Hz 250Hz A 40HP LFG LFO HFG HFO NOTE: ABBREVIATIONS: HF = High Fire 76 77 79 79 73 73 81 72 LF = Low Fire O = Oil G = Gas 75 75 78 77 72 75 74 77 74 76 80 81 76 75 78 78 70 72 71 73 67 67 69 69 68 66 68 66 64 66 64 66 57 58 58 58 500Hz 1kHz 2kHz 4kHz 8kHz 16kHz
A. The data shown above was taken on the 40 hp. Since the highest Sound Level is below 80 dBA, no additional 36" diameter Firetubes were tested. If Sound Level predictions are required for the 15 thru 30 hp, use the values shown for the 40 hp.
A2-27
07-02
Model CB Boilers
Firetube Boilers
Table A2-22. Model CB Boiler Sound Pressure Level Details (50 - 125 hp)
FIRING RATE FUEL SOUND LEVEL dBA OCTAVE BAND SOUND PRESSURE LEVELS IN dB RE .0002 MICROBAR 31Hz 63Hz 125Hz 250Hz 50 HP LFG LFO HFG HFO 72 78 77 79 71 71 72 72 65 76 68 70 71 78 75 75 71 73 76 75 60 HP LFG LFO HFG HFO 73 78 77 79 70 68 73 75 75 77 75 75 72 74 72 75 72 74 72 75 70 HP LFG LFO HFG HFO 74 78 78 79 70 70 72 73 70 73 72 73 75 77 77 80 74 74 78 77 80 HP LFG LFO HFG HFO 75 78 78 79 70 69 72 75 75 77 74 75 75 76 78 75 73 74 75 74 75 76 75 76 76 74 76 75 66 73 57 69 62 63 61 62 62 62 59 59 53 57 52 54 73 75 75 77 71 74 76 76 62 70 68 70 56 59 58 60 51 53 52 54 46 57 57 48 73 75 75 77 68 74 76 77 61 71 63 72 56 58 55 59 50 53 50 52 45 48 44 45 70 72 74 77 68 72 74 77 63 76 66 70 60 61 61 63 53 56 54 56 46 54 47 54 500Hz 1kHz 2kHz 4kHz 8kHz 16kHz
100 & 100A HP LFG LFO HFG HFO 75 79 78 81 69 68 69 68 69 73 70 70 75 78 77 77 76 78 77 78 125A HP LFG LFO HFG HFO 75 79 79 82 69 68 70 70 70 73 70 71 76 78 77 78 78 78 79 80 73 75 75 79 71 74 75 78 65 76 69 71 63 63 63 64 59 59 59 59 50 54 50 57 73 75 74 78 71 79 74 77 65 76 69 71 63 63 63 64 59 59 59 59 50 54 50 57
NOTES: 1. ABBREVIATIONS: HF = High Fire LF = Low Fire O = Oil G = Gas 2. Boiler HP followed by an A designates hot water boilers furnished in a smaller vessel size with additional tubes in the upper portion of the vessel.
A2-28
07-02
Firetube Boilers
FIRING RATE FUEL SOUND LEVEL dBA
Model CB Boilers
OCTAVE BAND SOUND PRESSURE LEVELS IN dB RE .0002 MICROBAR 31Hz 63Hz 125Hz 250Hz 125 HP 500Hz 1kHz 2kHz 4kHz 8kHz 16kHz
LFG LFO HFG HFO
78 81 81 83
76 80 79 78
70 75 73 78
78 82 87 89
80 82 78 79
80 81 80 82
73 77 76 81
65 74 71 77
58 67 64 64
56 63 57 70
51 60 51 58
150 & 175A HP LFG LFO HFG HFO 77 82 80 83 75 76 71 70 70 68 72 71 78 80 82 83 76 78 76 79 200 HP LFG LFO HFG HFO 78 81 82 83 74 76 77 76 74 74 76 76 78 79 82 81 79 77 79 78 79 81 81 82 72 75 78 79 65 71 72 73 58 62 62 66 54 60 55 59 50 55 50 53 77 79 80 82 72 75 76 77 67 71 71 73 63 66 64 65 58 60 58 60 55 58 52 55
NOTES: 1. ABBREVIATIONS: HF = HighFire LF = Low Fire O = Oil G = Gas 2. Boiler HP followed by an A designates hot water boilers furnished in a smaller vessel size with additional tubes in the upper portion of the vessel.
FIRING RATE FUEL
SOUND LEVEL dBA
OCTAVE BAND SOUND PRESSURE LEVELS IN dB RE .0002 MICROBAR 31Hz 63Hz 125Hz 250Hz 250 HP 500Hz 1kHz 2kHz 4kHz 8kHz 16kHz
LFG LFO HFG HFO
81 86 84 88
72 76 78 79
81 87 85 84
85 87 84 84
84 85 84 84 300 HP
82 84 84 85
75 82 79 86
68 73 72 74
60 70 62 68
56 76 55 67
53 68 50 65
LFG LFO HFG HFO
82 86 86 88
75 80 77 82
74 77 78 80
80 80 84 84
83 84 87 85 350 HP
83 82 85 85
78 81 82 83
71 75 77 79
65 75 67 72
58 77 60 67
53 72 53 69
LFG LFO HFG HFO NOTE: ABREVIATIONS: HF = High Fire LF = Low Fire O = Oil G = Gas
83 85 86 89
75 82 78 82
78 79 79 82
87 84 87 85
86 84 85 85
83 84 84 86
78 84 84 86
70 70 72 79
58 66 65 68
55 66 61 68
A2-29
07-02
Model CB Boilers
FIRING RATE FUEL LFG LFO HFG HFO LFG LFO HFG HFO LFG LFO HFG HFO LFG LFO HFG HFO LFG LFO HFG HFO LFG LFO HFG HFO NOTE: ABBREVIATIONS: HF = High Fire LF = Low Fire O = Oil G = Gas SOUND LEVEL dBA 80 80 82 83 81 82 82 83 81 82 82 83 82 82 85 85 83 83 86 87 84 84 87 88
Firetube Boilers
OCTAVE BAND SOUND PRESSURE LEVELS IN dB RE .0002 MICROBAR
31Hz
63Hz
125Hz
250Hz
500Hz 400 HP
1kHz
2kHz
4kHz
8kHz
16kHz
70 74 73 75 78 77 79 77 78 77 79 77 80 79 80 81 82 80 81 82 83 82 82 83
79 83 84 85 83 83 87 87 83 83 87 87 87 88 90 90 89 90 91 91 90 91 92 92
85 86 87 87 87 87 87 87 87 87 87 87 91 90 89 91 93 92 90 92 94 93 91 92
87 87 89 89 87 87 84 84 87 87 84 84 87 87 89 89 87 87 89 89 87 87 89 89
78 78 80 80 500 HP 78 81 79 81 600 HP 79 81 79 81 700 HP 80 81 82 82 750 HP 81 82 83 83 800 HP 82 82 83 83
70 71 74 75 73 75 76 77 73 75 76 77 75 76 77 80 76 77 79 81 77 78 81 82
66 67 70 71 66 70 70 71 66 70 70 71 70 72 76 77 71 73 89 80 73 74 82 83
61 63 64 73 62 63 63 62 62 63 63 62 66 67 66 68 67 68 68 70 68 68 70 71
55 58 57 58 58 59 57 58 58 59 57 58 62 63 64 65 63 64 66 68 64 65 68 70
50 50 50 52 54 55 55 55 54 55 55 55 56 57 57 57
Sound Pressure On large size boilers, the need for auxiliary equipment, and the necessary interconnecting piping, make it impractical (and sometimes impossible) to provide a boiler testing environment that is suitable for obtaining the data needed to develop Sound Pressure Power levels. Typical Values Sound pressure levels (dBA) for identical boilers will vary between boiler rooms. In addition, variations will occur between different people using different sound meters on the same boiler. And nally, no two boilers can be expected to give precisely the same sound levels. For these reasons, we can only predict, but not guarantee, sound levels (dBA). Octave Band When predicting sound pressures in octave bands (e.g., dB at 125 Hz), even greater variations between boilers, between sound meters, and between operators can be expected. These larger variations in the low and high frequencies make octave band levels a less reliable method of reporting than A-scale A2-30
07-02
sound levels. (Since A-scale sound levels are dominated by mid-frequency sounds, the A-scale sound levels between two boilers can be in reasonable agreement even though the low and high frequencies of octave band measurement do not closely correspond).
Gas-Fired Burners NOTICE

A gas pressure regulator must be installed in the gas piping to each boiler. Gas pressure regulators for Model CB Firetube Boilers are sized and selected on a job-by-job basis. Therefore, gas pressure requirements shown in Tables A2-26, A2-27, A2-28, A2-29, and A2-30 list "regulated" gas pressure. Regulated gas pressure is the pressure downstream of the gas pressure regulator. Total gas pressure required for the boiler equals regulated gas pressure plus the pressure drop of the selected gas pressure regulator.
Firetube Boilers
Table A2-26. Minimum Required Gas Pressure at Entrance to Standard and FM Gas Trains (Downstream of Gas Pressure Regulator)
MODEL CB BOILER HP 15 20 25 30 40 50A 50 60 70 80 100A 100 125A 125 150 175A 200 250 300 350 400 500 600 700 750 800 CONN SIZE (IN.) 1-1/4 1-1/4 2 2 2 2 2 2 2 2 2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 3 3 3 4 4 4 4 4 4 NET REGD PRESS. REQ'D (IN. WC) 3.5 6.0 7.0 7.5 6.5 4.5 5.5 8.0 9.5 8.5 9.5 11.5 7.5 8.5 11.5 15.5 17.5 23.0 32.5 16.5 25.5 36.0 50.0 57.0 64.0 HTBB MIN GAS PRESS. REQ'D 22.0 31.0 42.5 21.0 35.0 41.5 57.5 66.0 75.5 BOILER HP 15 20 25 30 40 50A 50 60 70 80 100A 100 125A 125 150 175A 200 250 300 350 400 500 600 700 750 800 CONN SIZE (IN) 1-1/4 1-1/4 2 2 2 2 2 2 2 2 2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 3 3 3 4 4 4 4 4 4
Model CB Boilers
Table A2-27. Minimum Gas Pressure at Entrance to Gas Trains Equipped with Industrial Risk Insurers (IRI) Requirements (Downstream of Gas Pressure Regulator)
MODEL CB MIN PRESS REQ'D (IN WC) 4.0 6.5 7.0 8.0 7.5 5.5 6.5 9.0 10.5 11.0 11.0 11.5 7.5 9.5 12.5 15.5 17.5 23.0 32.5 16.5 25.5 36.0 50.0 57.0 64.0 HTBB MIN GAS PRESS. REQD 22.0 31.0 42.5 21.0 35.0 41.5 57.5 66.0 75.5
NOTES: 1.These gas pressure requirements effective on all boiler shipped after July 1,1992 for 15 - 350 hp and Sept. 1, 1993 for 400 - 800 hp. 2. BHP followed by A designates hot water boilers furnished in a smaller vessel size with additional tubes in the upper portion of the vessel. 3. For standard and FM gas pressure requirements for Canada, refer to Table A2-27, IRI Trains. A. Based on 1000 Btu/cu-ft natural gas and elevations up to 700 feet. B. HTB is for high turndown (10:1) burners.
NOTES: 1.These gas pressure requirements effective on all boilers shipped after July 1,1992 for 15 - 350 hp and Sept. 1, 1993 for 400 - 800 hp. 2. BHP followed by A designates hot water boiler furnished in a smaller vessel size with additional tubes in the upper portion of the vessel. 3. Pressures shown also apply to standard and FM gas trains for Canada. A. Based on 1000 Btu/cu-ft natural gas and elevation up to 700 feet. B. HTB is for high turndown (10:1) burners.
Table A2-26 shows regulated gas pressure requirements for Model CB Boilers with standard or FM gas trains. Table A2-27 shows regulated gas pressure requirements for Model CB Boilers with IRI gas trains. Table A2-28 and A2-29 show regulated gas pressure with over and undersized gas trains. Table A2-30 shows minimum required gas pressure altitude conversion.
Capacity: The capacity can be determined by multiplying the maximum burning rate (CFH) by 1.15, see Table A2-31. This 15 percent over-capacity rating of the regulator provides for proper regulation. Spring Adjustment: The spring should be suitable for a range of adjustment from 50 percent under the desired regulated pressure to 50 percent over. Sharp Lock-Up: The regulator should include this feature to prevent the downstream pressure (between the regulator and the boiler) from climbing when there is no gas ow. Regulators in Parallel: This type of installation can be used if the required gas volume is very large and if the pressure drop must be kept to a minimum. Regulators in Series: This type of installation can be used if the available gas pressure is over 5, 10, or 20 psig.
Gas Pressure Regulator

The following items should be considered when selecting a regulator: Pressure Rating: The regulator must have a pressure rating at least equivalent to that of the gas distribution system.
A2-31
07-02
Model CB Boilers
Firetube Boilers
Table A2-28. Under and Oversized Standard and FM Gas Trains, Model CB Boilers (50 - 800 hp)
50 PIPE SIZE 1-1/2 2 2-1/2 3 125 PIPE SIZE 2 2-1/2 3 4 400 PIPE SIZE 3 4 4A PRESS REQD 35.5 21.0 17.0 PIPE SIZE 3 4 4A PRESS REQD 11.0 7.5 5.5 4.5 PIPE SIZE 2 2-1/2 3 4 500 PRESS REQD 59.0 35.0 27.5 PIPE SIZE 3 4 4A PRESS REQD 8.0 4.5 4.0 3.75 PIPE SIZE 1-1/2 2 2-1/2 3 150 PRESS REQD 14.5 8.5 6.5 5.0 60 PRESS REQD 11.0 5.5 5.0 4.5 PIPE SIZE 1-1/2 2 2-1/2 3 175A PIPE SIZE 2 2-1/2 3 4 600 PRESS REQD 75.5 41.5 30.0 PIPE SIZE 3 4 4A PRESS REQD 20.0 11.5 9.5 7.0 PIPE SIZE 2 2-1/2 3 4 700 PRESS REQD NA 57.5 42.0 PIPE SIZE 3 4 4A 70 PRESS REQD 15.0 8.0 7.5 7.0 PIPE SIZE 1-1/2 2 2-1/2 3 200 PRESS REQD 26.0 15.5 12.5 9.0 PIPE SIZE 2-1/2 3 4 4A 750 PRESS REQD NA 66.0 48.0 PIPE SIZE 3 4 4A 80 PRESS REQD 18.5 9.5 9.0 8.0 PIPE SIZE 1-1/2 2 2-1/2 3 250 PRESS REQD 29.5 22.0 15.5 13.5 PIPE SIZE 2-1/2 3 4 4A 800 PRESS REQD NA 75.5 55.1 100 PRESS REQD 22.5 9.5 8.5 7.5 100A PIPE SIZE 1-1/2 2 2-1/2 3 300 PRESS REQD 44.5 31.0 22.5 20.0 PIPE SIZE 2-1/2 3 4 4A PRESS REQD 22.5 9.5 8.5 7.5 350 PRESS REQD 62.0 42.5 31.0 27.5 125A PIPE SIZE 2 2-1/2 3 PRESS REQD 15.0 11.5 9.5
NOTES: 1.Pipe size in inches, and pressure required in inches of WC. 2. Models followed by A designates hot water boilers furnished in a smaller vessel size with additional tubes in upper portion of vessel. 3. Pressure requirement is downstream of gas pressure regulator.
A. Low pressure drop Maxon valves (replaces 6" trains). B. Standard gas train shown by shaded area. C. Charts for 250 - 800 hp are for high turndown burners.
Depending on the regulator characteristics, one regulator would reduce the pressure to 2 to 3 psig, and a second regulator would reduce the pressure to the burner requirements. Regulator Location: A straight run of gas line piping should be used on both sides of the regulator to ensure proper regulator operation. This is particularly important when pilot-operated regulators are used. The regulator can be located close to the gas train connection, but 2 to 3 feet of straight run piping should be used on the upstream side of the regulator. When oxygen trim is used, the regulator selection must be consistent with details shown in Section D.
Gas pressure regulator selction for high turndown (10:1) burners is critical at minimum ow rates. Contact your local Cleaver-Brooks authorized representative for proper selection. Table A2-31 shows maximum gas consumption for natural gas and propane vapor. Figure A2-9 shows standard gas train sizes and locations for Model CB Firetube Boilers. Figure A2-10 shows typical gas train piping layouts for multiple boiler applications. Figure A2-11 shows gas train components.
A2-32
07-02
Firetube Boilers
Model CB Boilers
Table A2-29. Under and Oversized IRI Gas Trains, Model CB Boilers (50 - 800 hp)
50 PIPE SIZE 1-1/2 2 2-1/2 3 125 PIPE SIZE 2 2-1/2 3 4 400 PIPE SIZE 3 4 4A NOTES: PRESS REQD 35.5 21.0 17.0 PIPE SIZE 3 4 4A PRESS REQD 11.0 7.5 5.5 4.5 PIPE SIZE 2 2-1/2 3 4 PRESS REQD 9.0 5.0 4.5 4.0 PIPE SIZE 1-1/2 2 2-1/2 3
60 PRESS REQD 12.5 6.5 5.5 5.0 150 PRESS REQD 14.5 9.5 6.5 5.0 500 PRESS REQD 59.0 35.0 27.5 PIPE SIZE 3 4 4A PIPE SIZE 1-1/2 2 2-1/2 3
70 PRESS REQD 17.5 9.0 8.0 7.5 175A PIPE SIZE 2 2-1/2 3 4 600 PRESS REQD 75.5 41.5 30.0 PIPE SIZE 3 4 4A PRESS REQD 20.0 12.5 9.5 7.0 PIPE SIZE 2 2-1/2 3 4 PIPE SIZE 1-1/2 2 2-1/2 3
80 PRESS REQD 22.0 10.5 9.5 8.5 200 PRESS REQD 26.0 15.5 12.5 9.0 700 PRESS REQD NA 57.5 42.0 PIPE SIZE 3 4 4A PIPE SIZE 2-1/2 3 4 4A PIPE SIZE 1-1/2 2 2-1/2 3
100 PRESS REQD 28.0 11.0 9.0 8.0 250 PRESS REQD 29.5 22.0 15.5 13.5 750 PRESS REQD NA 66.0 48.0
100A PIPE SIZE 1-1/2 2 2-1/2 3 300 PIPE SIZE 2-1/2 3 4 4A 800 PIPE SIZE 3 4 4A PRESS REQD NA 75.5 55.5 PRESS REQD 44.5 31.0 22.5 20.0 PRESS REQD 28.0 11.0 9.0 8.0
125A PIPE SIZE 2 2-1/2 3 PRESS REQD 15.0 11.5 9.5
350 PIPE SIZE 2-1/2 3 4 4A PRESS REQD 62.0 42.5 31.0 27.5
1. Pipe size in inches, and pressure required in inches WC. 2. Models followed by A designate hot water boilers furnished in a smaller vessel size with additional tubes in upper portion of vessel. 3. Pressure requirement is downstream of gas pressure regulator. A. Low pressure drop Maxon valves (replaces 6" trains). B. Standard gas train shown by shaded areas.
Table A2-30. Minimum Required Gas Pressure Altitude Conversion

ALTITUDE (FT) 1000 2000 3000 4000 5000 CORRECTION FACTOR 1.04 1.07 1.11 1.16 1.21 ALTITUDE (FT) 6000 7000 8000 9000 CORRECTION FACTOR 1.25 1.30 1.35 1.40 -
To obtain minimum required gas pressure at altitudes above 700 feet, multiply the pressure by the listed factors: Inches WC x 0.577 = oz/sq-in. Oz/sq-in x 1.732 = Inches WC. Inches WC x 0.0361= psig. Oz/sq-in x 0.0625 = psig. Psig x 27.71 = Inches WC. Psig x 16.0 = Oz/sq-in.
A2-33
07-02
Model CB Boilers
Table A2-31. Maximum Gas Consumption (CFH) for Natural Gas and Propane Vapor (1 of 2)
BOILER HP 15 20 25 30 40 50A 50 60 70 80 100A 100 125A 125 150 175A 200 250 300 350 400 500 600 700 750 800 TYPE OF GAS AND HEAT CONTENT NATURAL GAS 1000 (Btu/cu-ft) 625 835 1045 1255 1675 2095 2095 2510 2930 3350 4185 4185 5230 5230 6280 7350 8370 10460 12555 14650 16750 20925 25100 29300 31385 33500 PROPANE GAS 2550 (Btu/cu-ft) 245 330 410 490 655 820 820 985 1150 1315 1640 1640 2050 2050 2465 2880 3280 4105 4925 5745 6570 8205 9845 11480 12305 13140
Firetube Boilers
Table A2-31. Gas Pilot Data (2 of 2)
Connection Size (inches) NPT Minimum Required Gas Pressure (Up to 700 ) Inches WC 4 5 Natural 1000 Btu/ Cu. Ft 60 100 150 200 Maximum Permissible Gas Pressure (psig)
BHP
50-100 125-800
1/2 1/2 Manufactured 500 Btu/ Cu. Ft 120 200 300 400
5 5 Propane 2500 Btu/Cu Ft 25 40 60 80
BHP
50-100 125-200 250-350 400-800
Approximate Gas Usage: 1. Multiply the CFH rate by 0.007 to obtain the number of cu.ft of gas used in 25 sec. (Length of (1) light off). 2. Multiply the number of cu. ft/light (item 1) by the estimated number of lights/hour or per day to obtain the approximate usage in cu.ft/hour or cu.ft/day.
NOTES: BHP followed by A designates hot water boilers furnished in a smaller vessel size with additional tubes in upper portion of vessel.
MODEL CB BOILER HP 15,20 25 30 40,50A 50 60, 70, 80 100A, 100 125A 125 150, 200 250 300, 350 400, 500, 600, 700, 750, 800 CONNECTION SIZE (IN.) (NPT) 1-1/4 2 2 2 2 2 2-1/2 2-1/2 2-1/2 3 3 4 LOCATION DIMENSION "A" (IN.) 61 63 63 44 51 61 61 67-1/2 67-1/2 70-1/2 70-1/2 109-1/2
NOTE: BHP followed by A designates hot water boiler furnished in a smaller vessel size with additional tubes in upper portion of vessel. Dimensions are for IRI gas trains.
Figure A2-9. Standard Gas Train Connection Size and Location A2-34
07-02
Firetube Boilers
Model CB Boilers
This figure illustrates the basic gas valve arrangement on Cleaver-Brooks Model CB Boiler and shows the contractor's connection point. The valves and controls between the contractor connection point and the gas main in the street are representative of a typical installation. Actual requirements may vary depending on local codes or local gas company requirements which should be investigated prior to preparation of specifications and prior to construction.
A. Utilities service valve. B. Utilities service regulator. C. Gas meter. D. Piping from meter to boiler. E. Gas pressure regulator at burner. The size of the gas line from the meter to the gas pressure regulator at the boiler can be very important if gas pressures are marginal. The gas line sizing is dependent on: 1. Gas pressure at outlet of gas meter (C) 2. Rate of gas flow required, CFH 3. Length of pipe run (D) 4. Pressure required at contractor connection point. The local gas utility will advise the pressure that is available at the outlet of their meter.
Figure A2-10. Typical Gas Piping Layout
A2-35
07-02
Model CB Boilers
Firetube Boilers
INS ITEM DESCRIPTION BOILER HP 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Pilot Shut Off Cock Pilot Shut Off Cock Shut Off Cock Shut Off Cock Pilot Pressure Regulator Pilot Pressure Gauge Gas Pilot Valve High Gas Pressure Switch Low Gas Pressure Switch Main Gas Valve with POC Main Gas Valve without POC Main Gas Valve with POC Main Gas Valve without POC Vent Valve Buttery Valve x x x x x x x x x x x x x 15-20 x 3050 x
UL 60100 x 125250 x
FM 3003015-20 800 100 x x x 125250 x
IRI 30015-20 30-100 800 x x x x x x x x x x x x 125800 x x x x x x x x x x x x x x x x x x x x x x x
FM & IRI 15-20 30-100 x x x x x x x x x x x x x x x x x x 125250 x x x x x x x x x x x x x x x x x x x x 300800 x x x x x x x x x x
x x x x x x x x
x x x x x x x x x
x x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x x
x x x x x x x x
x x x x x x x
x x x x x x
x x
Figure A2-11. Model CB Gas Train Components
Oil-Fired Burners
Fuel oil consumption information is shown on the boiler rating sheets in the Dimensions and Rating Section. Figure A2-12 shows the oil connection sizes and locations for Model CB Boilers ring No. 2 oil. Figure A2-13 shows the oil connection sizes and locations for Model CB Boilers ring No. 5 and No. 6 oil. Figures A2-14 through A2-21 show typical oil systems and layouts. Figure A2-22 shows the detail of an oil transfer tank (day tank) typically utilized to provide a storage reservoir between the oil system supply pump and the boiler oil pump.
for the particular oil at this pumping temperature can be determined. It is recommended to provide for tank and/or line heating on all No. 6 oil installations to ensure against high viscosities at decreased pumping temperatures. The following are two common methods: 1. 2. Provide a tank suction heater and bundling the steam or water lines to the heater with the oil lines. Provide electric heating equipment on the oil lines and/or in the storage tank.
NOTICE
The temperature in the oil suction line should not exceed 130 F as higher temperatures could cause vapor binding of the oil pump and decreased oil flow. See Figures A2-23 and A2-24 for an example of (No. 1 above) tank heating method. See Figure A2-25 for examples of preheat-
No. 6 Oil Piping, Storage Tank Heating

If the oil viscosity exceeds 4,000 SSU at the pumping temperature, tank preheating is required. Based on the climate conditions for the job location, the minimum pumping temperature can be predicted, and the viscosity A2-36
07-02
Firetube Boilers
Model CB Boilers
MODEL CB SUPPLY AND RETURN CONN SIZES (IN.) (NPT) 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 1 RECOMMENDED OIL LINEA SIZES (STANDARD PIPE) (IN.) (IN.) STORAGE TANK TO BOILER OR PUMP CONNECT 3/4 3/4 3/4 3/4 1 1 1 1 1 PUMP TO BOILER NONE NONE 1 1 1 1 1 1 1 RETURN LINE TO TANK 3/4 3/4 3/4 3/4 1 1 1 1 1
BOILER HP
15,20 25 30, 40 50, 60 70 ,80 100 125, 150, 200 250, 300, 350 400, 500, 600 700, 750, 800
8-1/4 8-1/4 11-1/2 11-1/2 11-1/2 12-1/2 34 34 34
NOTE: See No. 2 Oil Line Sizing Instruction for systems with other conditions. A. For suction line condition with a maximum of 10 Feet of lift and a total of 100 equivalent feet of suction line. B. This table is based on a single boiler installation.
Figure A2-12. No. 2 Oil Connection Size, Location and Recommended Line Sizes
SUPPLY CONNECTION BOILER HP SIZE (IN.) (NPT) 50, 60, 70, 80, 100 125, 150 200 250, 300, 350 400, 500, 600,700, 750, 800 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 A (IN.) 27-3/4 49-1/2 65-1/2 89-3/4 63
RETURN CONNECTION SIZE (IN.) (NPT) 3/4 1-1/4 1-1/4 1-1/4 1-1/4
GAS PILOT CONNECTION 4-5" WC PRESS. REQD SIZE (IN.) (NPT) 1/2 1/2 1/2 1/2 1/2 C (IN.) 28 38 38 56 54
RECOMMENDED OIL LINE SIZES (STANDARD PIPE) (IN.) STORAGE TANK TO PUMP 2 2-1/2 2-1/2 2-1/2 3 PUMP TO BOILER 1-1/4 1-1/2 1-1/2 1-1/2 2 RETURN LINE TO TANK 1-1/4 2 2 2 2
B (IN.) 19-3/4 39 39 59-3/4 48
NOTES: 1. All dimensions in inches. 2.For suction lines with a maximum of 10 feet of lift and a total of 100 equivalent feet of suction line. 3. This table is based on a single boiler installation.
Figure A2-13. No. 6 Oil Connection Size, Location and Recommended Line Sizes, Model CB Boiler A2-37
07-02
Model CB Boilers
Firetube Boilers
Figure A2-14. No. 2 Oil Piping, Single Boiler Installation, Remote Oil Pump
Figure A2-15. No.2 Oil Piping, Single Boiler Installation Oil Pump Integral with Boiler
A2-38
07-02
Firetube Boilers
Model CB Boilers
Figure A2-16. No. 2 Oil Piping, Multiple Boiler Installation, Remote Oil Pumps
Figure A2-17. No. 2 Oil Piping, Multiple Boiler Installation, Oil Pump Integral with Boiler
A2-39
07-02
Model CB Boilers
STRAINER
Firetube Boilers
CHECK VALVE
VACUUM GAUGE GATE VALVE
GATE VALVE F.O.S. F.O.R. ADJUSTABLE PRESSURE RELIEF VALVE (75 PSIG)
STANDBY OIL PUMP UNION GATE VALVE RELIEF VALVE (100 PSIG) PRESSURE GAUGE
GATE VALVE CHECK VALVE
USE LAYOUT FOR: MODEL CB . . . . . . . 50 THRU 800 HP

Relief valve on the boiler must be set at 100 psig so that adjustable pressure relief valve in the loop system is in control. BOILER BASE FRAME BOILER FRONT CONTACTOR CONNECTIONS AT THIS POINT F.O.S. F.O.R.
Figure A2-18. No. 2 Oil Piping, Multiple Boiler Installation
A2-40
07-02
Firetube Boilers
Model CB Boilers
CHECK VALVE VACUUM GAUGE GATE VALVE STANDBY OIL PUMP TEMPERATURE GAUGE UNION GATE VALVE RELIEF VALVE (100 PSIG) PRESSURE GAUGE STRAINER GATE VALVE F.O.S. F.O.R. ADJUSTABLE PRESSURE RELIEF VALVE (75 PSIG)
GATE VALVES

Relief valve on the boiler must be set at 100 psig so that adjustable pressure relief valve in the loop system is in control. OIL HEATER BOILER BASE FRAME F.O.S. F.O.R.
BOILER FRONT
CONTACTOR CONNECTIONS AT THIS POINT
A2-41
07-02
Model CB Boilers
Firetube Boilers
Figure A2-22. No. 2 Oil Transfer Tank Detail
Figure A2-23. Typical Fuel Storage Tank Arrangement
A2-42
07-02
Firetube Boilers
Model CB Boilers
Note 1: The outer jacket of the four line bundle should be protected by a waterproof covering to protect the lines and insulation from moisture damage. Tar paper and hot asphalt sealer have been successfully used as a waterproof covering. Note 2: When the bundle runs under driveways or other traffic areas, a heavy duty outer jacket of reinforced concrete, vitrified tile, or corrugated steel is recommended.
Figure A2-24. Typical Cross Section of Bundled Lines
In order to properly preheat No. 6 oil, the minimum recommended boiler water temperature is 200 F. Some No. 6 oils must be preheated up to 210 F, and higher boiler water temperatures are then desirable. Although lower boiler water temperatures can be used, this condition means that the electric preheater will be doing more of the work. It is more economical to use higher temperature boiler water for preheating than to use lower temperature water which increases the electric preheating load. To ensure the most trouble-free, dependable preheating system, a boiler water-to-water-to-oil preheating system is furnished as standard equipment and is mounted, piped and wired on the boiler. This safety type system or double heat exchanger eliminates the possibility of an oil leak fouling the boiler, oil heater, piping, control valves, and circulating pumps. Insurance companies recognize this as the best system for the application. The standard system does not have provisions for a hot water line to a storage tank heater.
Figure A2-25. Schematic of Standard Alstrom Hot Water Safety-Type Preheating System
A2-43
07-02
Model CB Boilers
Boiler Room Information
Figure A2-26 shows typical boiler room length requirements. Figure A2-27 shows typical boiler room width requirements. Figure A2-28 shows typical breeching arrangements.
Firetube Boilers
C. A vent fan in the boiler room is not recommended, as it could create a slight vacuum under certain conditions and cause variations in the quantity of combustion air. This can result in unsatisfactory burner performance. D. Under no condition should the total area of the air supply openings be less than (1) square foot. E. Size the openings by using the formula: Area (sq-ft) = cfm/fpm 2. Amount of air required (cfm). A. Combustion Air = Rated bhp x 8 cfm/bhp. B. Ventilation Air = Maximum bhp x 2 cfm/bhp C. Total recommended air, 10 cfm/bhp - up to 1000 feet elevation. Add 3 percent more per 1000 feet of added elevation. 3. Acceptable air velocity in boiler room (fpm). A. From oor to (7) foot height - 250 fpm. B. Above (7) foot height - 500 fpm. Example: Determine the area of the boiler room air supply openings for (1) 300 hp boiler at 800 feet altitude. The air openings are to be 5 feet above oor level. Air required: 300 x 10 = 3000 cfm (from 2B above). Air velocity: Up to 7 feet = 250 fpm (from 3 above). Area Required: Area = cfm = 3000/250 = 12 Sq-ft total. Area/Opening: 12/2 = 6 sq-ft/opening (2 required).
Stack Support Capabilities

Cleaver-Brooks Firetube Boilers 15 hp through 100 hp can support up to 1,000 lbs without additional support. Firetube boilers 125 hp through 800 hp can support up to 2,000 lbs without additional support. Firetube sizes 250 hp through 800 hp can be reinforced to support 3,000 lbs.
Stack/Breeching Size Criteria

The design of the stack and breeching must provide the required draft at each boiler ue gas outlet. Proper draft is critical to burner performance. Although constant pressure at the ue gas outlet of the Model CB is not required, it is necessary to size the stack/breeching to limit ue gas pressure variation. For boiler sizes 50 800 horsepower, the allowable pressure range is 0.5" W.C. to +0.5" W.C. The maximum pressure variation at any ring rate for the boiler is 0.5" W.C. For boiler sizes 15 40 horsepower, the allowable pressure range is 0.25" W.C. to +0.25" W.C. For additional information, please review Section I4, General Engineering Data (Stacks) and Section F, Stacks. Stack and breeching sizes should always be provided by a reputable stack supplier who will design the stack and breeching system based on the above criteria. Your local Cleaver-Brooks authorized representative is capable of assisting in your evaluation of the stack/breeching design.
NOTICE
Consult local codes, which may supersede these requirements.
Boiler Room Combustion Air

When determining boiler room air requirements, the size of the room, air ow, and velocity of air must be reviewed as follows: 1. Size (area) and location of air supply openings in boiler room. A. Two (2) permanent air supply openings in the outer walls of the boiler room are recommended. Locate one at each end of the boiler room, preferably below a height of 7 feet. This allows air to sweep the length of the boiler. B. Air supply openings can be louvered for weather protection, but they should not be covered with ne mesh wire, as this type of covering has poor air ow qualities and is subject to clogging by dust or dirt.
A2-44
07-02
Firetube Boilers
Model CB Boilers
1. Shortest boiler room length (Dwg A) is obtained by allowing for possible future tube replacement (from front or rear of boiler) through a window or doorway. Allowance is only made for minimum door swing at each end of the boiler. This arrangement provides sufficient aisle space at the front of the boiler but a "tight" space condition at the rear. If space permits, approximately 1.5 additional feet should be allowed at the rear for additional aisle and working space. 2. Next shortest boiler room length (Dwg B) is obtained by allowing for possible future tube replacement from the front of the boiler. Allowance is only made for minimum door swing at the rear. If space permits, approximately 1.5 additional feet should be allowed at the rear for additional aisle and working space. 3. A slightly longer boiler room (Dwg C) is obtained by allowing for possible future tube replacement from the rear of the boiler. Allowance for door swing at the front provides sufficient aisle and working space at the front.
Figure A2-26. Boiler Room Length (Typical Layout)
BOILER HP Dimension A Dimension B
15-40 75" 103"
50-100 81" 115"
125-200 87" 127"
250-350 96" 151"
400-800 106" 183"
NOTES: 1. Recommended Minimum Distance Between Boiler and Wall. Dimension "A" allows for a "clear" 42" aisle between the water column on the boiler and the wall. If space permits, this aisle should be widened. 2. Recommended Minimum Distance Between Boilers. Dimension "B" between boilers allows for a "clear" aisle of: 42" - 15-200 hp 48" - 250-350 hp 60" - 400-800 hp If space permits, this aisle should be widened.
Figure A2-27. Boiler Room Width (Typical Layout)
A2-45
07-02
Model CB Boilers
Firetube Boilers
MULTIPLE BOILERS WITH A COMMON STACK NOTE: These stack breeching arrangements for multiple boilers are typical and not intended for your specic design requirements. For additional information, review Section F, Stacks. Stack and breeching sizes should always be provided by a reputable stack supplier who will design the stack and breeching system based on your specic criteria. Your local CLeaver-Brooks authorized representative is capable of assisting in your evaluation of stack and breeching design.
MULTIPLE BOILERS WITH INDIVIDUAL STACKS
Figure A2-28. Breeching Arrangement
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Firetube Boilers
Model CB Boilers
SAMPLE SPECIFICATION (MODEL CB BOILER)

The following sample specication is provided by Cleaver-Brooks to assist you in meeting your customers specic needs and application. A separate specication for steam boilers and hot water boilers is provided. Burner specications and detailed control specications for CB 780 Flame Safeguard control and the CB-HAWK Flame Safeguard control are included. See Section D, Controls, for additional information on control options. The Sample Specications are typically utilized as the base template for the complete boiler specication. Contact your local Cleaver-Brooks authorized representative for information on special insurance requirements, special code requirements, optional equipment, or general assistance in completing the specication. Model CB Steam Boiler (15-800 hp, Steam 15-350 psig) 1.0 Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model CB Hot Water Boiler (15-800 hp, 30 psig, 125 psig) 1.0 Boiler Characteristics (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Hot Water Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model CB Steam Boiler (15-800 hp, Steam 15-350 psig) 1.0 Boiler Characteristics (Steam) 1.1 The Steam Boiler shall be Cleaver-Brooks Model CB, Fuel Series ______ (100, 200, 400, 600, 700), _____ hp designed for _____ psig (15, 150, 200, or other psig steam). The maximum operating pressure shall be _____ psig. 1.2 The boiler shall have a maximum output of _____ Btu/hr, or _____ horsepower when red with CS 12-48 _____ oil and/or natural gas, _____ Btu/cu-ft. Electrical power available will be _____ Volt _____ Phase _____ Cycle. 2.0 General Boiler Design 2.1 The boiler shall be a four pass horizontal retube updraft boiler with ve (5) square feet of heating surface per rated boiler horsepower (except 750 or 800 hp). It shall be mounted on a heavy steel frame with integral forced draft burner and burner controls. A2-57 A2-57 A2-58 A2-58 A2-64 A2-65 A2-65 A2-47 A2-47 A2-48 A2-49 A2-55 A2-56 A2-56
NOTICE
The complete package boiler shall be approved as a unit by Underwriters Laboratories and shall bear the UL/ ULC label, except in the case where 50 Hz has been selected.
2.1.1 The boiler shall be completely preassembled and re tested at the factory. The unit shall be ready for immediate mounting on oor or simple foundation and ready for attachment of water, steam, fuel, electrical, vent and blowdown connections.
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Model CB Boilers
Firetube Boilers
2.1.2 The boiler shall be built to comply with the following insurance and codes ____________________ (Factory Mutual, Industrial Risk Insurance, ASME CSD-1). 2.2 Boiler Shell (Steam) 2.2.1 The boiler shell must be constructed in accordance with ASME Boiler Code and must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser. 2.2.2 Two lifting eyes shall be located on top of the boiler. 2.2.3 Front and rear doors on the boiler shall be hinged or davited. Doors are to be sealed with berglass tadpole gaskets and fastened tightly using heavy capscrews that thread into replaceable brass nuts. 2.2.4 Rear refractory and insulation shall be contained in the formed door, which must swing open for inspection of brick work. 2.2.5 The boiler tubes shall not include turbulators, swirlers or other add-on appurtenances. 2.2.6 Front and rear tube sheets and all ues must be fully accessible for inspection and cleaning when the doors are swung open. The boiler shall be furnished with adequate handholes to facilitate boiler inspection and cleaning. 2.2.7 For boilers 125 horsepower and over, a manhole shall be provided. 2.2.8 The exhaust gas vent shall be located near the front of the boiler on the top center line and shall be capable of supporting: 15-100 hp. 1000 lbs and shall contain a stack thermometer 125-800 hp. 2000 lbs and shall contain a stack thermometer 2.2.9 The boiler shell shall contain a chemical feed connection. 2.3 Observation ports for the inspection of ame conditions shall be provided at each end of the boiler. 2.4 The boiler insulation shall consist of a 2 inch blanket under a sectional preformed sheet metal lagging. This insulation must be readily removable and capable of being reinstalled, if required. 2.5 The entire boiler base frame and other components shall be factory painted before shipment using a hard nish enamel coating. 3.0 Steam Boiler Trim 3.1 Water Column A water column shall be located on the right hand side of the boiler complete with gauge glass set and water column blowdown valves. 3.1.1 Feedwater Pump Control The boiler feedwater pump control shall be included as an integral part of the water column to automatically actuate a motor driven feed water pump maintaining the boiler water level within normal limits. 3.1.2 Low Water Cutoff The low water cutoff shall be included as an integral part of the boiler feedwater control wired into the burner control circuit to prevent burner operation if the boiler water level falls below a safe level. 3.2 Auxiliary Low Water Cutoff Auxiliary low water cutoff manual reset shall be included, piped to the vessel, and wired to the burner control circuit. A manual reset device shall be used on this control. 3.3 Steam Pressure Gauge The steam pressure gauge shall be located at the front of the boiler and include cock and test connection. 3.4 Safety Valves
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Firetube Boilers
Safety valves of a type and size to comply with ASME Code requirements shall be shipped loose. 3.5 Steam Pressure Controls
Model CB Boilers
The steam pressure controls to regulate burner operation shall be mounted near the water column. Controls shall be a high limit (manual reset), operating limit (auto reset), and ring rate control (30-800 hp). 4.0 Burner and Controls 4.1 Mode of Operation Select one of the following: A. 15 and 20 hp. Burner operation shall be on-off principle. B. 30 and 40 hp. Burner operation shall be high-low-off principle. The burner shall always return to low re position for ignition. C. 50 - 800 hp. Burner operation shall be full modulation principle. The burner shall always return to low re position for ignition. 4.2 Blower 4.2.1 Air for combustion shall be supplied by a forced draft blower mounted in the front boiler door, above the burner, to eliminate vibration and reduce noise level. 4.2.2 Maximum sound level of the boiler/burner package shall not exceed _____ dbA (when measured in accordance with ABMA Sound Test Standards). 4.2.3 The impeller shall be cast aluminum, radial blade, carefully balanced, and directly connected to the blower motor shaft. 4.3 Combustion Air Control Select one of the following: A. 15 and 20 hp. Combustion air damper shall be manually set for proper air-fuel ratios. B. 30 and 40 hp. Combustion air damper shall be linked to damper motor. Auxiliary switch on the damper motor shall control high or low ring rate. C. 50 - 800 hp. Combustion air damper and cam operated fuel metering valves shall be operated by a single damper control motor that regulates the re according to load demand. Potentiometer type position controls shall be provided to regulate operation of the damper control motor. 4.4 Fuel Specication and Piping Select one of the following fuel types: Fuel series 700 - Gas red (4.4.1). Fuel series 100 - Light oil (No. 2) red (4.4.2). Fuel series 200 - Light oil or gas red (4.4.3). Fuel series 600 - No. 6 oil red (4.4.4). Fuel series 400 - No. oil or gas red (4.4.5). 4.4.1 Fuel Series 700 - Gas Fired 4.4.1.1 Burner Type - The burner shall be integral with the front head of the boiler and of high radiant multi-port type for gas. The burner shall be approved for operation on natural gas fuel. 4.4.1.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include two manual shutoff valves, solenoid valve, pressure regulator and pressure gauge. 4.4.1.3 Gas Burner Piping - Gas burner piping on all units shall include primary gas shutoff valve, motor operated with proof of closure switch and plugged leakage test connection. The main gas valve(s) shall be wired to close automatically in the event of A2-49
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Model CB Boilers
Firetube Boilers
power failure, ame failure, low water or any safety shutdown condition. A lubricating plug cock or buttery shutoff valve shall be provided as a means for a tightness check of the primary shut off valve. An additional plug cock on buttery valve shall be furnished at entrance to gas train. Select one of the following: A. 15-50 hp. Burners equipped as shown above. B. 60-100 hp. High and low gas pressure switches shall be provided. C. 125-250 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided. D. 300-800 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided. A vent valve shall be located between the safety shutoff valves. 4.4.1.4 Burner Turndown - Select one of the following: A. 15 and 20 hp. Burner shall operate on the on/off principle. B. 30 and 40 hp. Burner shall operate on the high-low-off principle with a turndown of 3:1 when ring natural gas. C. 50-200 hp. Turndown range of burner shall be 4:1 when ring natural gas. D. 250-800 hp. Turndown range of the burner shall be 10:1 when ring natural gas. (Consult with your local Cleaver-Brooks authorized representative regarding high turndown capability based on available gas pressure.) 4.4.2 Fuel Series 100 - Light Oil Fired 4.4.2.1 Burner Type - The burner shall be integral with the front head of the boiler, and shall be a low pressure air atomizing type approved for operation with CS12-48, Commercial No. 2 oil. 4.4.2.2 Oil Pilot - The oil pilot shall be air atomizing type with automatic electric ignition and include oil solenoid valve. An electronic detector shall monitor the pilot so that the primary oil valve cannot open until ame has been established. 4.4.2.3 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Select one of the following: A. 15 hp through 40 hp. The oil pump shall be integral with the burner and belt driven from the blower motor. B. 50 hp through 800 hp. Separate motor driven pump set, shipped loose to be installed in a location favorable to the oil storage tank, shall be provided. 4.4.2.4 Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, solenoid shutoff valves, pressure gauges and fuel strainer, all integrally mounted on the unit. Select one of the following: A. 50 hp through 800 hp. A fuel oil controller shall be provided to combine all of the fuel oil controls into a single casting which is mounted on the front door of the unit. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. B. 70 hp through 800 hp. A low oil pressure switch shall be included in the oil piping. 4.4.2.5 Low Pressure Air Atomizing - Select one of the following: A. 15 hp through 40 hp. Belt driven air compressor, lubricating oil tank, oil level indicator, inlet air lter, air pressure gauge, and low atomizing air pressure switch. B. 50 hp through 100 hp. Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch. C. 125 hp through 350 hp. Belt driven air compressor, lubricating air tank, oil level indicator, inlet air lter, air pressure gauge, and low atomizing air pressure switch. D. 400 hp through 800 hp. Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch. 4.4.2.6 Burner Turndown - Select one of the following: A. 15 and 20 hp. Burner shall operate on the on/off principle. B. 30 and 40 hp. Burner shall operate on the high-low-off principle with a turndown of 3:1 when ring No. 2 oil. C. 50 hp through 200 hp. Turndown range shall be 4:1 when ring No. 2 oil. A2-50
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Firetube Boilers
D. 250 hp through 800 hp. Turndown range shall be 8:1 when ring No. 2 oil. 4.4.3 Fuel Series 200 - Light Oil or Gas Fired
Model CB Boilers
4.4.3.1 Burner Type - The burner, integral with the front head of the boiler, shall be a combination of the low pressure air atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 Oil or natural gas. 4.4.3.2 Gas Pilot - The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary fuel valve cannot open until ame has been established. The pilot train shall include two manual shut-off valves, solenoid valve, pressure regulator and pressure gauge. 4.4.3.3 Oil Burner 4.4.3.3.1 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Select one of the following: A. 15 hp through 40 hp. The oil pump shall be integral with the burner and belt driven from the blower motor. B. 50 hp through 800 hp. Separate motor driven pump set, shipped loose, to be installed in a location favorable to the oil storage tank, shall be provided. 4.4.3.3.2 Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, solenoid shutoff valves, pressure gauges and fuel strainer, all integrally mounted on the unit. Select one of the following: A. 50 hp through 800 hp. A fuel oil controller shall be provided to combine all of the fuel oil controls into a single casting which is mounted on the front door of the unit. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. B. 70 hp through 800 hp. A low oil pressure switch shall be included in the oil piping. 4.4.3.3.3 Low pressure air atomizing. Select one of the following: A. 15 hp through 40 hp. Belt driven air compressor, lubricating oil tank, oil level indicator, inlet air lter, air pressure gauge and low atomizing air pressure switch. B. 50 hp through 100 hp. Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch. C. 125 hp through 350 hp. Belt driven air compressor, lubricating air tank, oil level indicator, inlet air lter, air pressure gauge and low atomizing air pressure switch. D. 400 hp through 800 hp. Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch. 4.4.3.4 Gas Burner 4.4.3.4.1 Gas Burner Piping - gas burner piping on all units shall include primary gas shutoff valve, motor operated with proof of closure switch and plugged leakage test connection. The main gas valve(s) shall be wired to close automatically in the event of power failure, ame failure, low water or any safety shutdown condition. A lubricating plug cock or buttery shutoff valve shall be provided as a means for a tightness check of the primary shut off valve. An additional plug cock or buttery valve shall be furnished at entrance to gas train. Select one of the following: A. 15-50 hp. Burners equipped as shown above. B. 60-100 hp. High and low gas pressure switches shall be provided. C. 125-250 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided. D. 300-800 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided. A vent valve shall be located between the safety shutoff valves. 4.4.3.5 Burner Turndown Select one of the following: A. 15 and 20 hp. Burner shall operate on the on/off principle.
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Model CB Boilers
B. 30 and 40 hp. Burner shall operate on the high-low-off principle with a turndown of 3:1 C. 50-200 hp. Turndown range of the burner shall be 4:1.
Firetube Boilers
D. 250-800 hp. Turndown range of the burner shall be 10:1 when ring natural gas and 8:1 on No. 2 oil. (Consult your local Cleaver-Brooks authorized representative regarding high turndown capability based on available gas pressure.) 4.4.4 Fuel Series 600 - No. 6 Oil Fired 4.4.4.1 Burner Type - The burner shall be integral with the front head of the boiler and low pressure air atomizing type approved for operation with CS12-48, Commercial No. 6 Oil. 4.4.4.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary oil valve cannot open until pilot ame has been established. The pilot train shall include two manual shutoff valves, solenoid valve, pressure regulator and pressure gauge. 4.4.4.3 Oil Pump - An oil pump set with a capacity of approximately twice the maximum burning rate shall be included. A separate motor driven pump set shall be included shipped loose for location favorable to the oil storage tank. 4.4.4.4 Oil Burner Piping - A fuel oil controller combining all of the fuel oil controls into a single casing shall be provided. Oil pressure regulating devices, oil metering controls, solenoid shutoff valves, high and low oil temperature switches and necessary pressure and temperature gauges shall be included in this packaged assembly mounted on the front door of the boiler. A fuel strainer shall also be provided, mounted to the boiler. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. Flexible hoses shall be provided to allow easy removal of the nozzle for inspection when it is placed in the vice jaws located on the front door of the boiler. The metering valve shall permit circulation of hot oil to the burner at all times. The burner drawer oil piping and nozzle shall be purged of oil on each shutdown. For 70 through 800 hp, a low oil pressure switch shall be included in the oil piping. 4.4.4.5 Low Pressure Air Atomizing - Select one of the following: A. 50 through 100 hp. Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch. B. 125 through 350 hp. Belt driven air compressor, lubricating oil tank, oil level indicator, inlet air lter, air pressure gauge and low atomizing air pressure switch. C. 400 through 800 hp. Separate air compressor modules mounted on boiler base rail with low atomizing air pressure switch. 4.4.4.6 Oil Preheat The oil shall be preheated by a steam heater and electric heater, each with thermostatic control. Both heaters shall be installed in a single compact shell mounted, piped, and wired on the boiler. The thermostatic controls shall be set to cut-out the electric heater when steam is available. Select one of the following: A. 50 through 200 hp. Electric preheater size shall be 5 kW. B. 250 through 800 hp. Electric preheater size shall be 7-1/2 kW.
NOTICE
15 psig only - 500 through 800 hp. Electric preheater size 10 kW.
4.4.5 Fuel Series 400 - No. 6 Oil or Gas Fired 4.4.5.1 Burner Type - The burner shall be integral with the front head of the boiler and shall be a combination of the low pressure atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 6 oil or natural gas. 4.4.5.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the
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Firetube Boilers
Model CB Boilers
pilot so that the primary oil valve cannot open until pilot ame has been established. The pilot train shall include two manual shutoff valves, solenoid valve, pressure regulator and pressure gauge. 4.4.5.3 Oil Burner 4.4.5.3.1 Oil Pump - An oil pump set with a capacity of approximately twice the maximum burning rate shall be included. 4.4.5.3.2 Oil Burner Piping - A fuel oil controller combining all of the fuel oil controls into a single casing shall be provided. Oil pressure regulating devices, oil metering controls, solenoid shutoff valves, high and low oil temperature switches, and the necessary pressure and temperature gauges shall be included in this packaged assembly mounted on the front door of the boiler. A fuel strainer shall also be provided, mounted to the boiler. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. Flexible hoses shall be provided to allow easy removal of the nozzle for inspection when it is placed in the vice jaws located on the front door of the boiler. The metering valve shall permit circulation of hot oil to the burner at all times. The burner drawer oil piping and nozzle shall be purged of oil at each shutdown. For 70 through 800 hp, a low oil pressure switch shall be included in the oil piping. 4.4.5.4 Low Pressure Air Atomizing - Select one of the following: A. 50 through 100 hp. Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch. B. 125 through 350 hp. Belt driven air compressor, lubricating oil tank, oil level indicator, inlet air lter, air pressure gauge and low atomizing air pressure switch. C. 400 through 800 hp. Separate air compressor modules mounted on boiler base rail with low atomizing air pressure switch. 4.4.5.6 Oil Preheat The oil shall be preheated by a steam heater and electric heater, each with thermostatic control. Both heaters shall be installed in a single compact shell mounted, piped, and wired on the boiler. The thermostatic controls shall be set to cut-out the electric heater when steam is available. Select one of the following: A. 50 through 200 hp. Electric preheater size shall be 5 kW. B. 250 through 800 hp. Electric preheater size shall be 7-1/2 kW.
NOTICE
15 psig only - 500 through 800 hp Electric preheater size 10 kw.
4.4.5.7 Gas Burner 4.4.5.7.1 Gas Burner Piping - Gas burner piping on all units shall include primary gas shutoff valve, motor operated with proof of closure switch and plugged leakage test connection. The main gas valve(s) shall be wired to close automatically in the event of power failure, ame failure, low water or any safety shutdown condition. A lubricating plug cock or buttery shutoff valve shall be provided as means for a tightness check of the primary shutoff valve. An additional plug cock or buttery valve shall be furnished at entrance to gas train. Select one of the following: A. 50 hp. Burner equipped as shown above. B. 60 through 100 hp. High and low gas pressure switches shall be provided. C. 125 through 250 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided. D. 300 through 800 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional leakage test connection shall be provided. A vent valve shall be located between the safety shutoff valves. 4.4.5.7.2 Burner Turndown - Turndown shall be 4:1. 4.5 Boiler Flame Safeguard Controller and Control Panel 4.5.1 CB780 Flame Safeguard A2-53
07-02
Model CB Boilers
Firetube Boilers
4.5.1.1 Boilers with CB780 Control - Each boiler shall be factory equipped with ame safeguard controller providing technology and functions equal to the Cleaver-Brooks Model CB780. Controller shall be computerized solid state having sequence and ame-on lights and alpha-numeric rst out fault indications of ame safeguard trip functions. It shall include dynamic self-check logic. The controller shall have a xed operating sequence incapable of being manually altered. The sequence shall include start, pre-purge, pilot and main fuel ignition run and post-purge cycles. Controller shall be the non-recycle type for maximum safety that shall shutdown the burner and indicate as a minimum the following trip functions: pilot and main ame failure, high and low re proving switch faults, locking interlocks open, false ame signal and fuel valve open (when proof of closure switch is furnished). The controller shall have a run/test switch. It shall allow interruptions to sequence just after pre-purge, during pilot ignition trial and run cycles for adjustments to ring rate motor, damper linkages and pilot ame for minimum turndown tests. 4.5.1.2 Control Panel - The control panel shall be mounted on the front door of the boiler in a location convenient to the operator. The hinged metal cabinet will have NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet key type lock. The panel shall contain the boiler ame safeguard controller, blower motor starter, indicating lights and selector switches. The panel shall have a removable sub-base for mounting the ame safeguard controller, blower motor starter, and terminal blocks. For combination gas-oil and heavy oil red boilers the panel will contain the fuel selector and/or oil heater selector switch. The panel shall contain the following lights and switches: 4.5.1.3 Lights White - load demanded. White - fuel valve open. Red - low water. Red - ame failure. 4.5.1.4 Control Switches Burner On-Off. Manual-Automatic. Manual Firing Rate Control. 4.5.1.5 Oil, heat and moisture resistant wire shall be used and identied with circuit numbers corresponding to the electrical wiring diagram. 4.5.1.6 All electrical equipment and wiring shall be in conformance with Underwriters Laboratories requirements. 4.5.1.7 Boiler to be supplied with a control circuit transformer and fuse protection for the control circuit. 4.5.2 CB-HAWK Flame Safeguard Each boiler shall be factory equipped with a Boiler Management Control System providing technology and functions equal to the Cleaver-Brooks Model CB-HAWK. The system shall consist of a computer based boiler controller and solid state sensors totally integrated to provide automatic burner sequencing, ame supervision, and indications of system status, faults, and self-diagnostics. The boiler controller shall consist of chassis, program module, keyboard display, and ame signal amplier. It shall be the nonrecycle type and have a xed operating sequence incapable of being manually altered. The sequence shall include standby, prepurge, pilot, main fuel ignition, and run, and post-purge periods. The system shall incorporate full modulating control of fuel and combustion air as well as ring rate control based on system demand. The boiler controller shall have a non-volatile memory that retains history les and sequence status after interruptions.
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Firetube Boilers
Model CB Boilers
An 80 character, 2 line liquid crystal (LCD) display and keyboard shall be provided to adjust control settings and display 73 fault messages, 12 diagnostic messages, 38 historical messages as well as system status messages and operating pressures and temperatures. Boiler ring rate shall also be displayed in addition to the last 6 lockouts and boiler operating information when the lockout occurred. Provisions for a security access code shall be provided. Separate status indicators will show: Ready: HAWK operational. Demand: call for heat. Main Valve: fuel valve open. Low Water: low water condition. Alarm: safety shutdowns. The boiler controller shall incorporate a ve function run/test switch. The system shall be characterized for each individual model boiler. The system shall also incorporate a tailored pre-purge cycle that minimizes pre-purge energy losses, while maintaining the maximum required air changes. It shall permit the user to select a specic rate control program for precise load tracking that reduces on-off cycling due to load swings. The system shall also provide an integrated thermal stress protection program to prolong boiler life. An assured low re cutoff feature shall also be provided. The system shall monitor inputs from solid state sensor for gas pressure, oil pressure, and temperature. A single solid state sensor shall be used for both on-off and proportioning control of the burner. The high/low limits and operating set points of all sensors will be programmable from the keyboard display. The system shall be capable of detecting a jumpered or defective sensor. A dynamic check of the gas pressure sensor shall be made prior to the main ame establishing period to ensure it is fully operational. An optional 2 way communications module to allow for remote control of non-safety settings and monitoring of up to 6 boilers shall also be available. Up to 3 pre-programmed telephone numbers shall be called in the event of a fault condition. Options such as Lead/Lag, Boiler Efciency, and Heating Boiler packages can be interfaced to this module without any change to the existing system structure. The communications module shall be able to interface with an IBMTM PC or compatible system. 4.5.2.1 Control Panel: The control panel shall be mounted on the front door of the boiler in a location convenient to the operator. The hinged metal cabinet will have NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet key type lock. The panel shall contain the boiler ame safeguard controller, indicating lights and selector switches. Panel shall have a removable sub-base for mounting the ame safeguard controller, and terminal blocks. For combination gas-oil and heavy oil red boilers the panel will contain the fuel selector and/or oil heater selector switch. 4.5.2.2 Oil, heat, and moisture resistant wire shall be used and identied with circuit numbers corresponding to the electrical wiring diagram. 4.5.2.3 All electrical equipment and wiring shall be in conformance with Underwriters Laboratories requirements. 4.5.2.4 Boiler to be supplied with a control circuit transformer and fuse protection for the control circuit. 5.0 Efciency Guarantee The boiler manufacturer shall guarantee that, at the time of startup, the boiler will achieve ________ fuel-to-steam efciency at 100% ring rate when burning natural gas and ________ fuel-to-steam efciency at 100% ring rate when burning oil (add efciency guarantees at 25%, 50%, and 75% of rating, if required). If the boiler(s) fail to achieve the corresponding guaranteed efciency as published, the boiler manufacturer will rebate, to the ultimate boiler owner, ve thousand dollars ($5,000) for every full efciency point (1.0%) that the actual efciency is below the guaranteed level. The specied boiler efciency is based on the following conditions. 5.1 Fuel specication used to determine boiler efciency: 5.1.1 Natural Gas
A2-55
07-02
Model CB Boilers
Carbon, % (wt) = 69.98 Hydrogen, % (wt) = 22.31 Sulfur, % (wt) = 0.0 Heating value, Btu/lb = 21,830 5.1.2 No. 2 Oil Carbon, % (wt) = 85.8 Hydrogen, % (wt) = 12.7 Sulfur, % (wt) = 0.2 Heating value, Btu/lb = 19,420 5.1.3 No. 6 Oil Carbon, % (wt) = 86.6 Hydrogen, % (wt) = 10.9 Sulfur, % (wt) = 2.09 Heating value, Btu/lb = 18,830
Firetube Boilers
5.2 Efciencies are based on ambient air temperature of 80 F, relative humidity of 30%, and 15% excess air in the exhaust ue gas. 5.3 Efciencies are based on manufacturers published radiation and convection losses. (For Cleaver-Brooks radiation and convection losses, see Boiler Efciency Facts Guide, publication number CB-7767). 5.4 Any efciency verication testing will be based on the stack loss method. 6.0 Warranty 6.1 All equipment is to be guaranteed against defects in materials and/or workmanship for a period of 12 months from date of start-up or 18 months from date of shipment, whichever comes rst. 7.0 Execution 7.1 Shop Tests 7.1.1 The packaged boiler must receive factory tests to check the construction, controls, and operation of the unit. All tests may be witnessed by the purchaser, if desired. 7.2 Start-up Service 7.2.1 After boiler installation is completed, the manufacturer shall provide the services of a eld representative for starting the unit and training the operator at no additional costs. 7.2.1.1 A factory approved and authorized start-up report shall be submitted to the customer/user at the time of start-up.
A2-56
07-02
Firetube Boilers
Model CB Boilers
Model CB Hot Water Boiler (15-800 hp, 30 psig, 125 psig) 1.0 Boiler Characteristics (Hot Water) 1.1 The Hot Water Boiler shall be Cleaver-Brooks Model CB, Fuel Series ______ (100, 200, 400, 600, 700), _____ hp designed for _____ psig (30, 125, or other psig hot water). The maximum water temperature will be _____ degree F, and the maximum system temperature drop will be _____ degree F. 1.2 The boiler shall have a maximum output of _____ Btu/hr, or _____ horsepower when red with CS 12-48 _____ oil and/or natural gas, _____ Btu/cu-ft. Electrical power available will be _____Volt _____ Phase _____ Cycle. 2.0 General Boiler Design 2.1 The boiler shall be a four pass horizontal retube updraft boiler with ve (5) square feet of heating surface per rated boiler horsepower (except 750 or 800 hp). It shall be mounted on a heavy steel frame with integral forced draft burner and burner controls. The complete package boiler shall be approved as a unit by Underwriters Laboratories and shall bear the UL/ULC label. 2.1.1 The boiler shall be completely preassembled and re tested at the factory. The unit shall be ready for immediate mounting on oor or simple foundation and ready for attachment of water, steam, fuel, electrical, vent and blowdown connections. 2.1.2 The boiler shall be built to comply with the following insurance and codes ____________________ (Factory Mutual, Industrial Risk Insurance, ASME CSD-1). 2.2 Boiler Shell (Hot Water) 2.2.1 The boiler shell must be constructed in accordance with ASME Boiler Code and must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser. 2.2.2 The hot water return and outlet connections shall be located on the top center line of the boiler. The boiler shall be designated to rapidly mix the return water with the boiler water. Forced internal circulation shall be used. 2.2.3 A dip tube shall be included as an integral part of the water outlet. 2.2.4 Two lifting eyes shall be located on top of the boiler. 2.2.5 Front and rear doors on the boiler shall be hinged or davited. Doors are to be sealed with berglass tadpole gaskets and fastened tightly using heavy capscrews that thread into replaceable brass nuts. 2.2.6 Rear refractory and insulation shall be contained in the formed door, which must swing open for inspection of brick work. 2.2.7 The boiler tubes shall not include turbulators, swirlers or other add-on appurtenances. 2.2.8 Front and rear tube sheets and all ues must be fully accessible for inspection and cleaning when the doors are swung open. The shell must be furnished with adequate handholes to facilitate boiler inspection and cleaning. 2.2.9 For boilers 125 horsepower and over, a manhole shall be provided. 2.2.10 The exhaust gas vent shall be located near the front of the boiler on the top center line and shall be capable of supporting: 15-100 hp. 1000 lbs and shall contain a stack thermometer 125-800 hp. 2000 lbs and shall contain a stack thermometer 2.3 Observation ports for the inspection of ame conditions shall be provided at each end of the boiler. 2.4 The boiler insulation shall consist of a 2 inch blanket under a sectional preformed sheet metal lagging. This insulation must be readily removable and capable of being reinstalled, if required. 2.5 The entire boiler based frame and other components shall be factory painted before shipment using a hard nish enamel coating.
A2-57
07-02
Model CB Boilers
3.0 Hot Water Boiler Trim 3.1 Low Water Cutoff
Firetube Boilers
A low water cutoff control (manual reset) shall be mounted on the top centerline of the boiler wired into the burner control circuit to prevent burner operation if boiler water falls below a safe level. 3.2 Pressure and Temperature Gauges Pressure and temperature gauges shall be mounted on the boiler with temperature sensing element located adjacent to the hot water outlet. 3.3 Relief Valves Water relief valves of a type and size to comply with ASME Code requirements shall be shipped loose. 3.4 Temperature Controls Temperature controls to regulate burner operation shall be mounted on the unit with temperature sensing elements located adjacent to the hot water outlet. Controls shall be high limit (manual reset), operating limit (auto reset), and ring rate control (30-800 hp). 4.0 Burner and Controls 4.1 Mode of Operation Select one of the following: A. 15 and 20 hp. Burner operation shall be on-off principle. B. 30 and 40 hp. Burner operation shall be high-low-off principle. The burner shall always return to low re position for ignition. C. 50 - 800 hp. Burner operation shall be full modulation principle. The burner shall always return to low re position for ignition. 4.2 Blower 4.2.1 Air for combustion shall be supplied by a forced draft blower mounted in the front boiler door, above the burner, to eliminate vibration and reduce noise level. 4.2.2 Maximum sound level of the boiler/burner package shall not exceed _____ dbA (when measured in accordance with ABMA Sound Test Standards). 4.2.3 The impeller shall be cast aluminum, radial blade, carefully balanced, and directly connected to the blower motor shaft. 4.3 Combustion Air Control Select one of the following: A. 15 and 20 hp. Combustion air damper shall be manually set for proper air-fuel ratios. B. 30 and 40 hp. Combustion air damper shall be linked to damper motor. Auxiliary switch on the damper motor shall control high or low ring rate. C. 50 - 800 hp. Combustion air damper and cam operated fuel metering valves shall be operated by a single damper control motor that regulates the re according to load demand. Potentiometer type position controls shall be provided to regulate operation of the damper control motor (remove this sentence when a CB-HAWK Flame Safeguard is used). 4.4 Fuel Specication and Piping Select one of the following fuel types: Fuel series 700 - Gas red (4.4.1). Fuel series 100 - Light oil (No. 2) red (4.4.2). Fuel series 200 - Light oil or gas red (4.4.3).
A2-58
07-02
Firetube Boilers
Fuel series 600 - No. 6 oil red (4.4.4). Fuel series 400 - No. oil or gas red (4.4.5). 4.4.1 Fuel Series 700 - Gas Fired
Model CB Boilers
4.4.1.1 Burner Type - The burner shall be integral with the front head of the boiler and of high radiant multi-port type for gas. The burner shall be approved for operation on natural gas fuel. 4.4.1.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include two manual shutoff valves, solenoid valve, pressure regulator and pressure gauge. 4.4.1.3 Gas Burner Piping - Gas burner piping on all units shall include primary gas shutoff valve, motor operated with proof of closure switch and plugged leakage test connection. The main gas valve(s) shall be wired to close automatically in the event of power failure, ame failure, low water or any safety shutdown condition. A lubricating plug cock or buttery shutoff valve shall be provided as a means for a tightness check of the primary shut off valve. An additional plug cock on buttery valve shall be furnished at entrance to gas train. Select one of the following: A. 15-50 hp. Burners equipped as shown above. B. 60-100 hp. High and low gas pressure switches shall be provided. 125-250 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided. C. 300-800 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided. A vent valve shall be located between the safety shutoff valves. 4.4.1.4 Burner Turndown - Select one of the following: A. 15 and 20 hp. Burner shall operate on the on/off principle. B. 30 and 40 hp. Burner shall operate on the high-low-off principle with a turndown of 3:1 when ring natural gas. C. 50-200 hp. Turndown range of burner shall be 4:1 when ring natural gas. D. 250-800 hp. Turndown range of the burner shall be 10:1 when ring natural gas. (Consult with your local Cleaver-Brooks authorized representative regarding high turndown capability based on available gas pressure.) 4.4.2 Fuel Series 100 - Light Oil Fired 4.4.2.1 Burner Type - The burner shall be integral with the front head of the boiler, and shall be a low pressure air atomizing type approved for operation with CS12-48, Commercial No. 2 oil. 4.4.2.2 Oil Pilot - The oil pilot shall be air atomizing type with automatic electric ignition and include oil solenoid valve. An electronic detector shall monitor the pilot so that the primary oil valve cannot open until ame has been established. 4.4.2.3 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Select one of the following: A. 15 hp through 40 hp. The oil pump shall be integral with the burner and belt driven from the blower motor. B. 50 hp through 800 hp. Separate motor driven pump set, shipped loose to be installed in a location favorable to the oil storage tank, shall be provided. 4.4.2.4 Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, solenoid shutoff valves, pressure gauges and fuel strainer, all integrally mounted on the unit. Select one of the following: A. 50 hp through 800 hp. A fuel oil controller shall be provided to combine all of the fuel oil controls into a single casting which is mounted on the front door of the unit. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. B. 70 hp through 800 hp. A low oil pressure switch shall be included in the oil piping. 4.4.2.5 Low Pressure Air Atomizing - Select one of the following:
A2-59
07-02
Model CB Boilers
Firetube Boilers
A. 15 hp through 40 hp. Belt driven air compressor, lubricating oil tank, oil level indicator, inlet air lter, air pressure gauge, and low atomizing air pressure switch. B. 50 hp through 100 hp. Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch. C. 125 hp through 350 hp. Belt driven air compressor, lubricating air tank, oil level indicator, inlet air lter, air pressure gauge, and low atomizing air pressure switch. D. 400 hp through 800 hp. Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch. 4.4.2.6 Burner Turndown - Turndown range of the burner shall be 4:1 when ring No. 2 oil. Select one of the following: A. 15 and 20 hp. Burner shall operate on the on/off principle. B. 30 and 40 hp. Burner shall operate on the high-low-off principle with a turndown of 3:1 when ring No. 2 oil. C. 50 hp through 200 hp. Turndown range shall be 4:1 when ring No. 2 oil. D. 250 hp through 800 hp. Turndown range shall be 8:1 when ring No. 2 oil. 4.4.3 Fuel Series 200 - Light Oil or Gas Fired 4.4.3.1 Burner Type - The burner, integral with the front head of the boiler, shall be a combination of the low pressure air atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 Oil or natural gas. 4.4.3.2 Gas Pilot - The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary fuel valve cannot open until ame has been established. The pilot train shall include two manual shut-off valves, solenoid valve, pressure regulator and pressure gauge. 4.4.3.3 Oil Burner 4.4.3.3.1 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Select one of the following: A. 15 hp through 40 hp. The oil pump shall be integral with the burner and belt driven from the blower motor. B. 50 hp through 800 hp. Separate motor driven pump set, shipped loose, to be installed in a location favorable to the oil storage tank, shall be provided. 4.4.3.3.2 Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, solenoid shutoff valves, pressure gauges and fuel strainer, all integrally mounted on the unit. Select one of the following: A. 50 hp through 800 hp. A fuel oil controller shall be provided to combine all of the fuel oil controls into a single casting which is mounted on the front door of the unit. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. B. 70 hp through 800 hp. A low oil pressure switch shall be included in the oil piping. 4.4.3.3.3 Low pressure air atomizing - Select one of the following: A. 15 hp through 40 hp. Belt driven air compressor, lubricating oil tank, oil level indicator, inlet air lter, air pressure gauge and low atomizing air pressure switch. B. 50 hp through 100 hp. Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch. C. 125 hp through 350 hp. Belt driven air compressor, lubricating air tank, oil level indicator, inlet air lter, air pressure gauge and low atomizing air pressure switch. D. 400 hp through 800 hp. Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch. 4.4.3.4 Gas Burner 4.4.3.4.1 Gas Burner Piping - gas burner piping on all units shall include primary gas shutoff valve, motor operated with proof of closure switch and plugged leakage test connection. The main gas valve(s) shall be wired to close automatically in the event of power failure, ame failure, low water or any safety shutdown condition. A lubricating plug cock or buttery shutoff valve shall be
A2-60
07-02
Firetube Boilers
Model CB Boilers
provided as a means for a tightness check of the primary shut off valve. An additional plug cock or buttery valve shall be furnished at entrance to gas train. Select one of the following: A. 15-50 hp. Burners equipped as shown above. B. 60-100 hp. High and low gas pressure switches shall be provided. C. 125-250 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided. D. 300-800 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus and additional plugged leakage test connection shall be provided. A vent valve shall be located between the safety shutoff valves. 4.4.3.5 Burner Turndown - Select one of the following: A. 15 and 20 hp. Burner shall operate on the on/off principle. B. 30 and 40 hp. Burner shall operate on the high-low-off principle with a turndown of 3:1 C. 50-200 hp. Turndown range of the burner shall be 4:1. D. 250-800 hp. Turndown range of the burner shall be 10:1 when ring natural gas and 8:1 on No. 2 oil. (Consult with your local Cleaver-Brooks authorized representative regarding high turndown capability based on available gas pressure.) 4.4.4 Fuel Series 600 - No. 6 Oil Fired 4.4.4.1 Burner Type - The burner shall be integral with the front head of the boiler and low pressure air atomizing type approved for operation with CS12-48, Commercial No. 6 Oil. 4.4.4.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary oil valve cannot open until pilot ame has been established. The pilot train shall include two manual shutoff valves, solenoid valve, pressure regulator and pressure gauge. 4.4.4.3 Oil Pump - An oil pump set with a capacity of approximately twice the maximum burning rate shall be included. A separate motor driven pump set shall be included shipped loose for location favorable to the oil storage tank. 4.4.4.4 Oil Burner Piping - A fuel oil controller combining all of the fuel oil controls into a single casing shall be provided. Oil pressure regulating devices, oil metering controls, solenoid shutoff valves, high and low oil temperature switches and necessary pressure and temperature gauges shall be included in this packaged assembly mounted on the front door of the boiler. A fuel strainer shall also be provided, mounted to the boiler. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. Flexible hoses shall be provided to allow easy removal of the nozzle for inspection when it is placed in the vice jaws located on the front door of the boiler. The metering valve shall permit circulation of hot oil to the burner at all times. The burner drawer oil piping and nozzle shall be purged of oil on each shutdown. For 70 through 800 hp, a low oil pressure switch shall be included in the oil piping. 4.4.4.5 Low Pressure Air Atomizing - Select one of the following: A. 50 through 100 hp. Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch. B. 125 through 350 hp. Belt driven air compressor, lubricating oil tank, oil level indicator, inlet air lter, air pressure gauge and low atomizing air pressure switch. C. 400 through 800 hp. Separate air compressor modules mounted on boiler base rail with low atomizing air pressure switch. 4.4.4.6 Oil Preheat The oil shall be preheated by a safety type water-to-water-to-oil preheating system in conjunction with an electric preheater, each with thermostatic control. Both heaters shall be mounted, piped, and wired on the boiler. Select one of the following: A. 50 through 200 hp. Electric preheater size shall be 5 kW. B. 250 through 350 hp. Electric preheater size shall be 7-1/2 kW. C. 400 through 800 hp. Electric preheater size shall be 10 kW. A2-61
07-02
Model CB Boilers
4.4.5 Fuel Series 400 - No. 6 Oil or Gas Fired
Firetube Boilers
4.4.5.1 Burner Type - The burner shall be integral with the front head of the boiler and shall be a combination of the low pressure atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 6 oil or natural gas. 4.4.5.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary oil valve cannot open until pilot ame has been established. The pilot train shall include two manual shut-off valves, solenoid valve, pressure regulator and pressure gauge. 4.4.5.3 Oil Burner 4.4.5.3.1 Oil Pump - An oil pump set with a capacity of approximately twice the maximum burning rate shall be included. 4.4.5.3.2 Oil Burner Piping - A fuel oil controller combining all of the fuel oil controls into a single casing shall be provided. Oil pressure regulating devices, oil metering controls, solenoid shutoff valves, high and low oil temperature switches, and the necessary pressure and temperature gauges shall be included in this packaged assembly mounted on the front door of the boiler. A fuel strainer shall also be provided, mounted to the boiler. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. Flexible hoses shall be provided to allow easy removal of the nozzle for inspection when it is placed in the vice jaws located on the front door of the boiler. The metering valve shall permit circulation of hot oil to the burner at all times. The burner drawer oil piping and nozzle shall be purged of oil at each shutdown. For 70 through 800 hp, a low oil pressure switch shall be included in the oil piping. 4.4.5.4 Low Pressure Air Atomizing - Select one of the following: A. 50 through 100 hp. Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch. B. 125 through 350 hp. Belt driven air compressor, lubricating oil tank, oil level indicator, inlet air lter, air pressure gauge and low atomizing air pressure switch. C. 400 through 800 hp. Separate air compressor modules mounted on boiler base rail with low atomizing air pressure switch. 4.4.5.6 Oil Preheat The oil shall be preheated by a safety type water-to-water-to-oil preheating system in conjunction with an electric preheater, each with thermostatic control. Both heaters shall be mounted, piped, and wired on the boiler. Select one of the following: A. 50 through 200 hp. Electric preheater size shall be 5 kW. B. 250 through 350 hp. Electric preheater size shall be 7-1/2 kW. 4.4.5.7 Gas Burner 4.4.5.7.1 Gas Burner Piping - Gas burner piping on all units shall include primary gas shutoff valve, motor operated with proof of closure switch and plugged leakage test connection. The main gas valve(s) shall be wired to close automatically in the event of power failure, ame failure, low water or any safety shutdown condition. A lubricating plug cock or buttery shutoff valve shall be provided as means for a tightness check of the primary shutoff valve. An additional plug cock or buttery valve shall be furnished at entrance to gas train. Select one of the following: A. 50 hp. Burner equipped as shown above. B. 60 through 100 hp. High and low gas pressure switches shall be provided. 125 through 250 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided. C. 300 through 800 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional leakage test connection shall be provided. A vent valve shall be located between the safety shutoff valves. 4.4.5.7.2 Burner Turndown - Turndown shall be 4:1. 4.5 Boiler Flame Safeguard Controller and Control Panel 4.5.1 CB780 Flame Safeguard
A2-62
07-02
Firetube Boilers
Model CB Boilers
4.5.1.1 Boilers with CB780 Control - Each boiler shall be factory equipped with ame safeguard controller providing technology and functions equal to the Cleaver-Brooks Model CB780. Controller shall be computerized solid state having sequence and ame-on lights and digital rst out fault code indications of ame safeguard trip functions. It shall include dynamic self-check logic. The controller shall have a xed operating sequence incapable of being manually altered. The sequence shall include start, pre-purge, pilot and main fuel ignition run and post-purge cycles. Controller shall be the non-recycle type for maximum safety that shall shutdown the burner and indicate as a minimum the following trip functions: pilot and main ame failure, high and low re proving switch faults, running interlocks open, false ame signal and fuel valve open (when proof of closure switch is furnished). The controller shall have a run/test switch. It shall allow interruptions to sequence just after pre-purge, during pilot ignition trial and run cycles for adjustments to ring rate motor, damper linkages and pilot ame for minimum turndown tests. 4.5.1.2 Control Panel: The control panel shall be mounted on the front door of the boiler in a location convenient to the operator. The hinged metal cabinet will have NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet key type lock. The panel shall contain the boiler ame safeguard controller, blower motor starter, indicating lights and selector switches. The panel shall have a removable sub-base for mounting the ame safeguard controller, blower motor starter, and terminal blocks. For combination gas-oil and heavy oil red boilers the panel will contain the fuel selector and/or oil heater selector switch. The panel shall contain the following lights and switches: 4.5.1.3 Lights White - load demanded. White - fuel valve open. Red - low water. Red - ame failure. 4.5.1.4 Control Switches Burner On-Off. Manual-Automatic. Manual Firing Rate Control. 4.5.1.5 Oil, heat and moisture resistant wire shall be used and identied with circuit numbers corresponding to the electrical wiring diagram. 4.5.1.6 All electrical equipment and wiring shall be in conformance with Underwriters Laboratories requirements. 4.5.1.7 Boiler to be supplied with a control circuit transformer and fuse protection for the control circuit. 4.5.2 CB-HAWK Flame Safeguard Each boiler shall be factory equipped with a Boiler Management Control System providing technology and functions equal to the Cleaver-Brooks Model CB-HAWK. The system shall consist of a computer based boiler controller and solid state sensors totally integrated to provide automatic burner sequencing, ame supervision, and indications of system status, faults, and self-diagnostics. The boiler controller shall consist of chassis, program module, keyboard display, and ame signal amplier. It shall be the nonrecycle type and have a xed operating sequence incapable of being manually altered. The sequence shall include standby, prepurge, pilot, main fuel ignition, and run, and post-purge periods. The system shall incorporate full modulating control of fuel and combustion air as well as ring rate control based on system demand.
A2-63
07-02
Model CB Boilers
Firetube Boilers
The boiler controller shall have a non-volatile memory that retains history les and sequence status after interruptions. An 80 character, 2 line liquid crystal (LCD) display and keyboard shall be provided to adjust control settings and display 73 fault messages, 12 diagnostic messages, 38 historical messages as well as system status messages and operating pressures and temperatures. Boiler ring rate shall also be displayed in addition to the last 6 lockouts and boiler operating information when the lockout occurred. Provisions for a security access code shall be provided. Separate status indicators will show: Ready: HAWK operational. Demand: call for heat. Main Valve: fuel valve open. Low Water: low water condition. Alarm: safety shutdowns. The boiler controller shall incorporate a ve function run/test switch. The system shall be characterized for each individual model boiler. The system shall also incorporate a tailored pre-purge cycle that minimizes pre-purge energy losses, while maintaining the maximum required air changes. It shall permit the user to select a specic rate control program for precise load tracking that reduces on-off cycling due to load swings. The system shall also provide an integrated thermal stress protection program to prolong boiler life. An assured low re cutoff feature shall also be provided. The system shall monitor inputs from solid state sensor for gas pressure, oil pressure, and temperature. A single solid state sensor shall be used for both on-off and proportioning control of the burner. The high/low limits and operating set points of all sensors will be programmable from the keyboard display. The system shall be capable of detecting a jumpered or defective sensor. A dynamic check of the gas pressure sensor shall be made prior to the main ame establishing period to ensure it is fully operational. An optional 2 way communications module with built-in modem to allow for remote control of non-safety settings and monitoring of up to 6 boilers shall also be available. Up to 3 pre-programmed telephone numbers shall be called in the event of a fault condition. Options such as Lead/Lag, Boiler Efciency, and Heating Boiler packages can be interfaced to this module without any change to the existing system structure. The communications module shall be able to interface with an IBMTM PC or compatible system. 4.5.2.1 Control Panel: The control panel shall be mounted on the front door of the boiler in a location convenient to the operator. The hinged metal cabinet will have NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet key type lock. The panel shall contain the boiler ame safeguard controller, indicating lights and selector switches. Panel shall have a removable sub-base for mounting the ame safeguard controller, and terminal blocks. For combination gas-oil and heavy oil red boilers the panel will contain the fuel selector and/or oil heater selector switch. 4.5.2.2 Oil, heat, and moisture resistant wire shall be used and identied with circuit numbers corresponding to the electrical wiring diagram. 4.5.2.3 All electrical equipment and wiring shall be in conformance with Underwriters Laboratories requirements. 4.5.2.4 Boiler to be supplied with a control circuit transformer and fuse protection for the control circuit. 5.0 Efciency Guarantee The boiler manufacturer shall guarantee that, at the time of startup, the boiler will achieve ________ fuel-to-steam efciency at 100% ring rate when burning natural gas and ________ fuel-to-steam efciency at 100% ring rate when burning oil (add efciency guarantees at 25%, 50%, and 75% of rating, if required). If the boiler(s) fail to achieve the corresponding guaranteed efciency as published, the boiler manufacturer will rebate, to the ultimate boiler owner, ve thousand dollars ($5,000) for every full efciency point (1.0%) that the actual efciency is below the guaranteed level. The specied boiler efciency is based on the following conditions.
A2-64
07-02
Firetube Boilers
5.1 Fuel specication used to determine boiler efciency: 5.1.1 Natural Gas Carbon, % (wt) = 69.98 Hydrogen, % (wt) = 22.31 Sulfur, % (wt) = 0.0 Heating value, Btu/lb = 21,830 5.1.2 No. 2 Oil Carbon, % (wt) = 85.8 Hydrogen, % (wt) = 12.7 Sulfur, % (wt) = 0.2 Heating value, Btu/lb = 19,420 5.1.3 No. 6 Oil Carbon, % (wt) = 86.6 Hydrogen, % (wt) = 10.9 Sulfur, % (wt) = 2.09 Heating value, Btu/lb = 18,830
Model CB Boilers
5.2 Efciencies are based on ambient air temperature of 80 F, relative humidity of 30%, and 15% excess air in the exhaust ue gas. 5.3 Efciencies are based on manufacturers published radiation and convection losses. (For Cleaver-Brooks radiation and convection losses, see Boiler Efciency Facts Guide, publication number CB-7767). 5.4 Any efciency verication testing will be based on the stack loss method. 6.0 Warranty 6.1 All equipment is to be guaranteed against defects in materials and/or workmanship for a period of 12 months from date of startup or 18 months from date of shipment, whichever comes rst. 7.0 Execution 7.1 Shop Tests 7.1.1 The packaged boiler must receive factory tests to check the construction, controls, and operation of the unit. All tests may be witnessed by the purchaser, if desired. 7.2 Start-up Service 7.2.1 After boiler installation is completed, the manufacturer shall provide the services of a eld representative for starting the unit and training the operator at no additional costs. 7.2.1.1 A factory approved and authorized start-up report shall be submitted to the customer/user at the time of start-up.
A2-65
07-02
Model CB Boilers
Firetube Boilers
NOTES
A2-66
07-02
Section A3
MODEL CB-LE BOILERS
CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3 Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3 Available Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3 DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3 PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-23 Specifying Boiler Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-23 Efficiency Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-23 Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-23 ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-26 Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-26 Gas-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-26 Oil-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-27 General Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-33 Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-33 Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-33 Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-33 Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-33 SAMPLE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-38
ILLUSTRATIONS Figure A3-1. Model CB-LE Steam Boiler Dimensions, 60 (15 - 150 psig Design Pressure) - Sheet 1 of 2 . . . . . . . . . . A3-8 Figure A3-2. Model CB-LE Steam Boiler Dimensions, 78 (15 - 150 psig Design Pressure) - Sheet 1 of 2 . . . . . . . . . . A3-10 Figure A3-3. Model CB-LE Steam Boiler Dimensions, 96 (15 - 150 psig Design Pressure) - Sheet 1 of 2 . . . . . . . . . . A3-12 Figure A3-4. Model CB-LE Hot Water Boiler Dimensions, 60 (30 and 125 psig Design Pressure) - Sheet 1 of 2 . . . . A3-14 Figure A3-5. Model CB-LE Hot Water Boiler Dimensions, 78 (30 and 125 psig Design Pressure) - Sheet 1 of 2 . . . . A3-16 Figure A3-6. Model CB-LE Hot Water Boiler Dimensions, 96 (30 and 125 psig Design Pressure) - Sheet 1 of 2 . . . . A3-18 Figure A3-7. Space Required to Open Rear Head on Model CB-LE Boilers Equipped with Davits . . . . . . . . . . . . . . . . A3-20 A3-1
02-02
Model CB-LE Boilers
Firetube Boilers
Figure A3-8. Model CB-LE Boiler Mounting Piers (60 and 78) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-20 Figure A3-9. Model CB-LE Boiler Mounting Piers (96). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-21 Figure A3-10. Lifting Lug Location, Model CB-LE Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-22 Figure A3-11. Predicted Stack Temperature Increase for Pressure Greater Than 125 psig . . . . . . . . . . . . . . . . . . . . . . . A3-24 Figure A3-12. Standard Gas Train Connection Size and Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-28 Figure A3-13. Typical Gas Piping Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-29 Figure A3-14. Model CB-LE Gas Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-30 Figure A3-15. No. 2 Oil Connection Size, Location, and Recommended Line Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-30 Figure A3-16. No. 2 Oil Piping, Single Boiler Installation, Remote Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-31 Figure A3-17. No. 2 Oil Piping, Multiple Boiler Installation, Remote Oil Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-31 Figure A3-18. No. 2 Oil Piping, Multiple Boiler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-32 Figure A3-19. No. 2 Oil Transfer Tank Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-32 Figure A3-20. Typical Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-33 Figure A3-21. Boiler Room Length (Typical Layouts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-36 Figure A3-22. Boiler Room Width (Typical Layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-36 Figure A3-23. Breeching Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-37 TABLES Table A3-1. Model CB-LE Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4 Table A3-2. Model CB-LE Hot Water Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4 Table A3-3. Model CB-LE Combustion Air Fan Motor Horsepower Requirements Operating Pressures 125 psig and Less, and All Hot Water Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5 Table A3-4. Model CB-LE Combustion Air Fan Motor Horsepower Requirements Operating Pressures Greater Than 125 psig (Steam Boilers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5 Table A3-5. Model CB-LE Boiler Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6 Table A3-6. Steam Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7 Table A3-7. Hot Water Boiler Relief Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7 Table A3-8. Predicted Fuel-to-Steam Efficiencies - Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-24 Table A3-9. Predicted Fuel-to-Steam Efficiencies - No. 2 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-25 Table A3-10. CB-LE Boilers - Natural Gas, Emission Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-25 Table A3-11. CB-LE Boilers - No. 2 Oil, Emission Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-25 Table A3-12. Model CB-LE Predicted Sound Levels30 ppm NOx Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-26 Table A3-13. Under and Oversized Standard, FM, and IRI Gas Trains, Model CB-LE Boilers . . . . . . . . . . . . . . . . . . . . A3-27 Table A3-14. Minimum Required Regulated Gas Pressure at the Entrance to Standard, FM, and IRI Gas Trains . . . . . . A3-27 Table A3-15. Minimum Required Gas Pressure Altitude Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-28 Table A3-16. Maximum Gas Consumption (CFH) for Natural Gas and Propane Vapor . . . . . . . . . . . . . . . . . . . . . . . . . . A3-28 Table A3-17. Model CB-LE Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-34 Table A3-18. Heating Surface, Model CB-LE Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-34 Table A3-19. Steam Volume and Disengaging Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-35 Table A3-20. Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity) . . . . . . . . . . . . . . . . A3-35 Table A3-21. Recommended Non-Return Valve Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-35 Available as an option to the Model CB Firetube Dryback Boiler (125 - 800 hp), the Low Emission Option provides NOx control, top performance, and reliable Cleaver-Brooks efciency. The Low Emission Option combines the packaging of induced ue gas recirculation with the Cleaver-Brooks integral front head. The front head routes the ue gases from the fourth pass to the fan and burner assembly for reliable low NOx performance. The enhanced burner design assures maximum NOx reduction at all ring rates while maintaining top of the line boiler performance. Standard Low Emission Options include 60, 30, 25, or 20 ppm packages (all NOx emission levels are given on a dry volume basis and corrected to 3% O2): NOx performance for 60 ppm (natural gas corrected to 3% O2) uses a standard size combustion air fan for induced ue gas recirculation. NOx performance for 30, 25, or 20 ppm (natural gas corrected to 3% O2) includes a larger combustion air fan/motor assembly and a larger internal NOx reduction system. Cleaver-Brooks' commitment to lowering emissions is based on more than 400 low NOx installations - all passing guaranteed emission performance levels. A3-2
02-02
Firetube Boilers
Model CB-LE Boilers

Full line of Model CB Firetube options. Additional NOx reduction packages.

The Cleaver-Brooks Model CB Boiler - the premium retube on the market today - includes the four-pass dryback design, ve square feet of heating surface per boiler horsepower, and maximum boiler efciency. In addition to the features of the Model CB Boiler, the Low Emission Option provides the following Integral Front Head Design Single-piece front door. Fan cassette assembly for easy access to fan and motor. Guaranteed low nitrogen oxide (NOx) performance. Enhanced burner performance. Improved ame stability and combustion control. Intimate mixing of air and fuel assures minimum CO levels at low NOx levels. True Boiler/Burner/Low NOx Package. UL/ULC approved package. Assures highest fuel-to-steam efciency. Eliminates the need for eld installation of burner, controls, or NOx equipment. Single point positioning of fuel and air ensures ease of startup and provides reliable operation.

The Model CB-LE dimensions and ratings are provided in Tables A3-1 through A3-7, and in Figures A3-1 through A310.
PRODUCT OFFERING
The Low Emission Option currently is available on: 125 - 800 hp Model CB Firetube Dryback Boilers. High-pressure and low-pressure steam and hot water designs. Natural Gas, No. 2 oil, or combination red. Retrot capability.
Standard Equipment
Model CB Firetube Boiler. New integral front head with internal low NOx system. Enhanced burner design.
Available Options
For option details, contact your local Cleaver-Brooks authorized representative.
A3-3
02-02
Model CB-LE Boilers
Firetube Boilers
Table A3-1. Model CB-LE Steam Boiler Ratings

BOILER HP 125 150 200 250 300 350 400 500 600 700 750 800
RATINGS SEA LEVEL TO 700 FT Rated Steam Cap. (lbs/hr from and @ 212 F) Btu Output (1000 Btu/hr) Light Oil (gph)A Natural Gas (cfh) MBtu Gas (Therm/hr) Blower Motor hp Oil Pump Motor, hp No. 2 Oil Air Compressor Motor hp (Oil ring Only) NOTES: A. Based on 140,000 Btu/gal. 1/2 3 1/2 3 1/2 3 1/2 3 3/4 3 4313 4184 36.4 5103 51.0 5175 5021 43.7 6124 61.2 6900 6695 58.3 8165 81.7 8625 8369 72.9 10206 102.1 10350 10043 87.5 12247 122.5 12075 11716 102.1 14288 142.8 13800 13390 116.6 16329 163.3 17250 16738 145.8 20412 204.2 20700 20085 175.0 24494 245.0 24150 23432 204.1 28576 285.8 25875 25106 218.7 30618 306.2 27600 26779 233.3 32659 326.6
APPROXIMATE FUEL CONSUMPTION AT RATED CAPACITY
POWER REQUIREMENTS - SEA LEVEL TO 700 FT, 60 HZ Refer to Tables A3-3 and A3-4 3/4 3 3/4 7-1/2 3/4 7-1/2 3/4 7-1/2 1 7-1/2 1 7-1/2 1 7-1/2
Table A3-2. Model CB-LE Hot Water Boiler Ratings

BOILER HP 125 150 200 250 300 350 400 500 600 700 750 800
POWER REQUIREMENTS - SEA LEVEL TO 700 FT, 60 HZ Rated Cap. Btu Output (1000 Btu/hr) 4184 5021 6695 8369 10043 11716 13390 16738 20085 23432 25106 26779
APPROXIMATE FUEL CONSUMPTON AT RATED CAPACITY Light Oil (gph)A Natural Gas (cfh) MBtu Gas (Therm/hr) 36.4 5103 51.0 43.7 6124 61.2 58.3 8165 81.7 72.9 10206 102.1 87.5 12247 122.5 102.1 14288 142.9 116.6 16329 163.3 145.8 20415 204.2 175.0 24494 245.0 204.1 28576 285.8 218.7 30618 306.2 233.3 32659 326.6
POWER REQUIREMENTS - SEA LEVEL TO 700 FT, 60 HZ Blower Motor hp Oil Pump Motor, hp No. 2 Oil Air Compressor Motor hp (Oil firing Only) NOTES: A. Based on 140,000 Btu/gal. 1/2 3 1/2 3 1/2 3 1/2 3 Refer to Tables A3-3 and A3-4 3/4 3 3/4 3 3/4 7-1/2 3/4 7-1/2 3/4 7-1/2 1 7-1/2 1 7-1/2 1 7-1/2
A3-4
02-02
Firetube Boilers
Model CB-LE Boilers
Table A3-3. Model CB-LE Combustion Air Fan Motor Horsepower Requirements - Operating Pressures 125 psig and Less, and All Hot Water Boilers
MOTOR HP BOILER HP 60 PPM 125 150 200 250 300 350 400 500 600 700 750 800 5 7.5 15 7.5 10 15 10 15 20 30 50 50 30 PPM 10 10 15 10 15 25 15 20 30 50 60 75 25 PPM 5 10 20 15 20 40 20 25 50 75 75 NA 20 PPM 10 10 NA 15 25 40 20 30 60 75 NA NA 125 150 200 250 300 350 400 500 600 700 750 800 BOILER HP 60 PPM 5 10 15 7.5 10 20 10 20 25 40 50 60 30 PPM 10 10 20 10 20 30 15 25 40 60 75 75A 25 PPM 10 10 20 15 30 40 20 30 60 75B NA NA 20 PPM 10 15 NA 20 40 50 25 40 60 75C NA NA
Table A3-4. Model CB-LE Combustion Air Fan Motor Horsepower Requirements - Operating Pressures Greater Than 125 psig (Steam Boilers)
MOTOR HP
NOTES: For elevations above 700 - contact your local CleaverBrooks authorized representative.
NOTES: For elevation above 700 - contact your local CleaverBrooks authorized representative. A. Downrate to 770 hp. B. Downrate to 675 hp. C. Downrate to 660 hp.
A3-5
02-02
Model CB-LE Boilers
Firetube Boilers
Table A3-5. Model CB-LE Boiler Weights

BOILER HP FUEL SERIES 100 125 200 700 100 150 200 700 100 200 200 700 100 250 200 700 100 300 200 700 100 350 200 700 100 400 200 700 100 500 200 700 100 600 200 700 100 700 800 200 700 HOT WATER 30 PSIG 11200 11400 11300 12300 12500 12300 14400 14500 14500 20700 21400 20900 23100 23500 23400 26200 26700 26400 33000 33300 33200 36600 36900 36800 41850 42150 42050 49450 49750 49650 125 PSIG 11600 11800 11700 12700 12900 12700 14800 14900 14900 21500 22200 21700 23900 24300 24200 27000 27500 27200 36970 37270 37170 40470 40780 40680 45905 46005 45915 53000 53300 53200 15 PSIG 11300 11500 11400 12400 12600 12400 14500 14600 14600 20800 21500 21000 23200 23600 23500 26300 26800 26500 33200 33500 33400 36810 37110 37010 42000 42300 42200 49300 49600 49500 STEAM 150 PSIG 12000 12400 12300 13200 13500 13300 15500 15600 15600 22000 22800 22500 24800 25200 25000 27600 27800 27700 36270 36570 36470 39670 39970 39870 44725 45025 44925 51850 52150 52050 200 PSIG 12600 13000 12900 13900 14200 14000 16300 16400 16400 23800 24600 24300 26800 27200 27000 29100 29300 29200 39380 39680 39580 43480 43580 43280 49100 49400 49300 57015 57315 57215
NOTES: 1. Weights shown are based on standard product offering for current listed boilers. If units are of special design and construction, actual weight will be determined at time of shipment. Shipment will then be made on shippers weight and count. All weights are in US pounds.
A3-6
02-02
Firetube Boilers
Model CB-LE Boilers
Table A3-6. Steam Boiler Safety Valve Openings

VALVE SETTING BOILER HP 125 150 200 250 300 350 400 500 600 700, 750 & 800 15 PSIG STEAM NO. OF VALVES REQ'D 1 1 2 2 2 3 3 3 4 5 OUTLET SIZE (IN.) 3 3 2-1/2 (1) 2-1/2 (1) 3 3 (1) 2 (2) 3 (2) 3 (1) 2-1/2 (3) 3 3 (3) 3 (2) 2-1/2 100 PSIG STEAM NO. OF VALVES REQ'D 2 2 2 2 2 3 3 3 4 5 OUTLET SIZE (IN.) 1-1/2 (1) 2 (1) 1-1/2 2 (1) 2-1/2 (1) 2 2-1/2 (1) 2-1/2 (2) 2 (1) 2 (2) 2-1/2 2-1/2 (3) 2-1/2 (1) 2 (3) 2-1/2 (2) 2 125 PSIG STEAM NO. OF VALVES REQ'D 2 2 2 2 2 2 2 3 3 4 OUTLET SIZE (IN.) (1) 1-1/2 (1) 1-1/4 1-1/2 (1) 2 (1) 1-1/2 2 (1) 2-1/2 (1) 2 2-1/2 2-1/2 (2) 2-1/2 (1) 2 2-1/2 (3) 2-1/2 (1) 2 150 PSIG STEAM NO. OF VALVES REQ'D 2 2 2 2 2 2 2 2 3 3 OUTLET SIZE (IN.) (1) 1-1/2 (1) 1-1/4 (1) 1-1/2 (1) 1-1/4 1-1/2 (1) 2 (1) 1-1/2 (2) 2 (1) 2-1/2 (1) 2 (1) 2-1/2 (1) 2 (2) 2-1/2 (2) 2-1/2 (1) 2 (2) 2-1/2 (1) 2 200 PSIG STEAM NO. OF VALVES REQ'D 2 2 2 2 2 2 2 2 2 2 OUTLET SIZE (IN.) (1) 1-1/4 (1) 1 1-1/4 (1) 1-1/2 (1) 1-1/4 1-1/2 (1) 2 (1) 1-1/2 2 2 (1) 2-1/2 (1) 2 2-1/2 2-1/2 250 PSIG STEAM NO. OF VALVES REQ'D 2 2 2 2 2 2 2 2 2 2 OUTLET SIZE (IN.) 1 (1) 1 (1) 1-1/4 1-1/4 (1) 1-1/2 (1) 1-1/4 1-1/2 (1) 1-1/2 (1) 2 (1) 2 (1) 1-1/2 (2) 2 (1) 2 (1) 2-1/2 2-1/2
NOTES: Valve manufacturers are Kunkle, Consolidated or Conbraco, depending on availability.
Table A3-7. Hot Water Boiler Relief Valve Openings

VALVE SETTING BOILER HP 125 150 200 250 300 350 400 500 600 700, 750 & 800 30 PSIG HW NO. OF VALVES REQ'D 1 1 2 2 2 3 3 4 4 5 OUTLET SIZE (IN.) 2-1/2 2-1/2 (1) 2-1/2 (1) 1-1/4 (1) 2 (1) 2-1/2 2-1/2 (2) 2-1/2 (1) 1 (1) 2 (2) 2-1/2 (1) 1 (3) 2-1/2 (3) 2-1/2 (1) 2 (1) 1 (4) 2-1/2 60 PSIG HW NO. OF VALVES REQ'D 1 1 1 1 2 2 2 2 3 3 OUTLET SIZE (IN.) 2 2-1/2 2-1/2 2-1/2 (1) 1 (1) 2-1/2 (1) 2-1/2 (1) 2 (1) 2 (2) 2-1/2 2-1/2 (1) 1-1 (2) 2-1/2 (1) 2 (2) 2-1/2 100 PSIG HW NO. OF VALVES REQ'D 1 1 1 1 1 1 2 2 2 2 OUTLET SIZE (IN.) 2 2 2 2-1/2 2-1/2 2-1/2 (1) 1 (1) 2-1/2 (1) 2-1/2 (1) 1-1/4 (1) 2 1) 2-1/2 2-1/2 125 PSIG HW NO. OF VALVES REQ'D 1 1 1 1 1 1 1 2 2 2 OUTLET SIZE (IN.) 1-1/4 2 2 2 2-1/2 2-1/2 2-1/2 (1) 1 (1) 2-1/2 (1) 2-1/2 (1) 1-1/4 (1) 2-1/2 (1) 2
NOTES: Hot water relief valves are Kunkle #537.
A3-7
02-02
Model CB-LE Boilers
Firetube Boilers
BOILER HP LENGTHS Overall (60 ppm System) Shell Base Frame Front Head Extension (60 ppm System) Rear Head Extension Front Ring Flange to Nozzle - 15 lb Front Ring Flange to Nozzle -150 lb Ring Flange to Base Over Tubesheets Shell Extension
DIM
125
150
200
A B C D E H H F&G V P
171-1/2 125 124 27 19-1/2 56 55 1/2 113 12
196-1/2 149 148 28 19-1/2 70-1/2 66 1/2 137 12
228-1/2 180 179 29 19-1/2 90 78 1/2 168 12
Figure A3-1. Model CB-LE Steam Boiler Dimensions, 60 (15 - 150 psig Design Pressure) - Sheet 1 of 2
A3-8
02-02
Firetube Boilers
Model CB-LE Boilers
BOILER HP WIDTHS Overall I.D. Boiler Center to Water Column Center to Outside Hinge Center to Lagging Center to Auxiliary LWCO Base, Outside Base, Inside HEIGHTS Base to Steam Outlet Overall Base to Vent Outlet Height of Base Base to Bottom of Boiler BOILER CONNECTIONS Feedwater, Right and Left Chemical Feed Low Pressure (15 lb only) Steam Nozzle Drain, Front and Rear High Pressure (150 lb only) Surface Blowoff, Top CL Steam Nozzle Blowdown, Front and Rear VENT STACK Diameter (flgd. connection) MINIMUM CLEARANCES Rear Door Swing (Davit Equipped) Front Door Swing Tube Removal, Rear Tube Removal, Front
DIM
125
150
200
I J K KK L LL M N
85 60 45 35 33 40 52-1/2 44-1/2
85 60 45 35 33 40 52-1/2 44-1/2
85 60 45 35 33 40 52-1/2 44-1/2
X OO O Q R
77 86 85 12 16
77 86 85 12 16
77 86 85 12 16
S Z U W T Y W
1-1/2 1 8A 1-1/2 1 4B 1-1/2
1-1/2 1 8A 1-1/2 1 4B 1-1/2
2 1 10A 2 1 4B 1-1/2
BB
16
16
16
DD EE FF GG
32 67 115 103
32 67 139 127
32 67 170 158
MINIMUM BOILER ROOM LENGTH ALLOWING FOR DOOR SWING AND TUBE REMOVAL FROM: Rear of Boiler Front of Boiler Thru Window or Doorway WEIGHT IN LBS Normal Water Capacity Approx. Ship Wgt - 15 psig Approx. Ship Wgt - 150 psig Approx. Ship Wgt - 200 psig NOTES: All connections are threaded unless indicated. A. ANSI 150 psig flange. B. ANSI 300 psig flange. 5750 11300 12400 13000 7250 12600 13500 14200 8625 14600 15600 16400 RR RF RD 307 260 224 355 308 248 417 370 279
A3-9
02-02
Model CB-LE Boilers
Firetube Boilers
BOILER HP LENGTHS Overall (60 ppm System) Shell Base Frame Front Head Extension (60 ppm System) Rear Head Extension Front Ring Flange to Nozzle - 15 lb Front Ring Flange to Nozzle - 150 lb Ring Flange to Base Over Tubesheets Shell Extension
DIM
250
300
350
A B C D E H H F&G V P
191-1/2 144 143 23-1/2 24 72 59-1/2 1/2 129 15
220 171 170 25 24 85-1/2 73 1/2 156 15
252 201 200 28 24 100-1/2 88 1/2 186 15
A3-10
02-02
Firetube Boilers
Model CB-LE Boilers
BOILER HP WIDTHS Overall I.D. Boiler Center to Water Column Center to Outside Hinge Center to Lagging Center to Auxiliary LWCO Base, Outside Base, Inside HEIGHTS Base to Steam Outlet Overall Base to Vent Outlet Height of Base Base to Bottom of Boiler BOILER CONNECTIONS Feedwater, Right and Left Chemical Feed Low Pressure (15 lb only) Steam Nozzle Drain, Front and Rear High Pressure (150 lb only) Surface Blowoff, Top CL Steam Nozzle Blowdown, Front and Rear VENT STACK Diameter (flgd. connection) MINIMUM CLEARANCES Rear Door Swing Front Door Swing Tube Removal, Rear Tube Removal, Front
DIM
250
300
350
I J K KK L LL M N
103 78 54 51 42 49 64 52
103 78 54 51 42 49 64 52
103 78 54 51 42 49 64 52
X OO O Q R
96 115 106 10 17
96 115 106 10 17
96 115 106 10 17
S Z U W T Y W
2 1 10A 2 1 6B 1-1/2
2 1 12A 2 1 6B 1-1/2
2-1/2 1 12A 2 1 6B 1-1/2
BB
20
20
20
DD EE FF GG
43 89 131 116
43 89 157 142
43 89 187 172
MINIMUM BOILER ROOM LENGTH ALLOWING FOR DOOR SWING AND TUBE REMOVAL FROM: Rear of Boiler Front of Boiler Thru Window or Doorway WEIGHT IN LBS Normal Water Capacity Approx. Ship Wgt - 15 psig Approx. Ship Wgt - 150 psig Approx. Ship Wgt - 200 psig NOTES: All connections are threaded unless indicated. A. ANSI 150 psig flange. B. ANSI 300 psig flange. 10670 21500 22800 24600 13000 23600 25200 27200 15465 26800 27800 29300 RR RF RD 364 303 275 417 356 302 477 416 332
A3-11
02-02
Model CB-LE Boilers
Firetube Boilers
BOILER HP
DIM
400
500
600
700
750
800
LENGTHS Overall (60 ppm System) Shell Base Frame Front Head Extension (60 ppm System) Rear Head Extension Shell Ring Flange to Base Rear Ring Flange to Base Shell Flange to Nozzle 15 lb Shell Flange to Nozzle 150 lb Over Tubesheets Shell Extension A B C D E F G H H V P 206 147 112 27 32 23 12 62 60 130 17 228 168 133 28 32 23 12 77 78 151 17 262 200 165 30 32 23 12 96 96 183 17 299 233 198 34 32 23 12 112 112 216 17 300 233 198 35 32 23 12 112 112 216 17 300 233 198 35 32 23 12 112 112 216 17
A3-12
02-02
Firetube Boilers
Model CB-LE Boilers
BOILER HP
DIM
400 WIDTHS
500
600
700
750
800
Overall I.D. Boiler Center to Water Column Center to Outside Hinge
I J K KK L
123 96 64 62 51 59 72 56
123 96 64 62 51 59 72 56
123 96 64 62 51 59 72 56
123 96 64 62 51 59 72 56
123 96 64 62 51 59 72 56
123 96 64 62 51 59 72 56
Center to Auxiliary LWCO Base, Outside Base, Inside
LL M N
HEIGHTS Overall Base to Vent Outlet Height of Base Base to Steam Outlet Base to Bottom of Boiler OO O Q X R 134 126 12 116 19 134 126 12 116 19 134 126 12 116 19 134 126 12 116 19 134 126 12 116 19 134 126 12 116 19
BOILER CONNECTIONS Feedwater, Right and Left Chemical Feed Surface Blowoff, Top CL (150 lb only) Blowdown, Front and Rear Low Pressure (15 psig Only) High Pressure (150 psig Only) S Z T W U Y 2-1/2 1 1 2 12A 6B 2-1/2 1 1 2 12A 8B 2-1/2 1 1 2 12A 8B 2-1/2 1 1 2 12A 8B 2-1/2 1 1 2 12A 8B 2-1/2 1 1 2 12A 8B
VENT STACK Diameter (Flanged Connection) BB 24 24 24 24 24 24
MINIMUM CLEARANCES Rear Door Swing Front Door Swing Tube Removal, Rear Tube Removal, Front DD EE FF GG 53 108 131 114 53 108 152 135 53 108 184 167 53 108 217 200 53 108 217 200 53 108 217 200
MINIMUM BOILER ROOM LENGTH ALLOWING FOR DOOR SWING AND TUBE REMOVAL FROM: Rear of Boiler Front of Boiler Thru Window or Doorway RR RF RD 386 314 308 428 356 329 492 420 361 558 486 394 558 486 394 558 486 394
WEIGHT IN LBS Normal Water Capacity Approx. Ship. Wgt. 15 psig Approx. Ship. Wgt. - 150 psig Approx. Ship. Wgt. - 200 psig 14810 33500 36570 39680 15950 37110 39970 43580 19270 42300 45025 49400 23000 49500 52050 57315 23000 49600 52150 57415 23000 49600 52150 57415
NOTES: All connections are threaded unless indicated: A. ANSI 150 psig ange. B. ANSI 300 psig ange.
A3-13
02-02
Model CB-LE Boilers
Firetube Boilers
LWCO
BOILER HP LENGTHS Overall (60 ppm System) Shell Base Frame Front Head Extension (60 ppm System) Rear Head Extension Front Ring Flange to Outlet Front Ring Flange to Return Ring Flange to Base Over Tubesheets Shell Extension
DIM
125
150
200
A B C D E HH H F&G V P
171-1/2 125 124 27 19-1/2 114 89 1/2 113 12
196-1/2 149 148 28 19-1/2 136 102 1/2 137 12
228-1/2 180 179 29 19-1/2 167 131 1/2 168 12
Figure A3-4. Model CB-LE Hot Water Boiler Dimensions, 60 (30 and 125 psig Design Pressure) - Sheet 1 of 2
A3-14
02-02
Firetube Boilers
Model CB-LE Boilers
BOILER HP WIDTHS Overall I.D. Boiler Center to Entrance Box Center to Outside Hinge Center to Lagging Base, Outside Base, Inside HEIGHTS Overall Base to Vent Outlet Base to Return and Outlet Height of Base Base to Bottom of Boiler
DIM
125
150
200
I J K KK L M N
75-1/2 60 42-1/2 35 33 52-1/2 44-1/2
75-1/2 60 42-1/2 35 33 52-1/2 44-1/2
75-1/2 60 42-1/2 35 33 52-1/2 44-1/2
OO O X Q R BOILER CONNECTION
86 85 77 12 16
86 85 77 12 16
86 85 77 12 16
Waterfill Conn. Right & Left Auxiliary Connection Water Return Flange Water Outlet Flange (2" Dip Tube Included) Drain, Front and Rear Air Vent VENT STACK Diameter (flgd. connection)
S Z T U W Y
1-1/2 1 6A 6A 1-1/2 1-1/2
1-1/2 1 6A 6A 1-1/2 1-1/2
2 1 6A 6A 2 1-1/2
BB MINIMUM CLEARANCES
16
16
16
Rear Door Swing Front Door Swing Tube Removal, Rear Tube, Removal, Front
DD EE FF GG
32 67 115 103
32 67 139 127
32 67 170 158
MINIMUM BOILER ROOM LENGTH ALLOWING FOR DOOR SWING AND TUBE REMOVAL FROM: Rear of Boiler Front of Boiler Thru Window or Doorway WEIGHT IN LBS Water Capacity Flooded Approx. Ship. Wgt. 30 psig Approx. Ship. Wgt. 125 psig NOTES: All connections are threaded unless indicated. A. ANSI 150 psig flange. 7670 11400 11800 9295 12500 12900 11130 14500 14900 RR RF RD 307 260 224 355 308 248 417 370 279
A3-15
02-02
Model CB-LE Boilers
Firetube Boilers
LWCO
BOILER HP LENGTHS Overall (60 ppm System) Shell Base Frame Front Head Extension (60 ppm System) Rear Head Extension Front Ring Flange to Return Front Ring Flange to Outlet Ring Flange to Base Over Tubesheets Shell Extension
DIM
250
300
350
A B C D E H HH F&G V P
191-1/2 144 143 23-1/2 24 103-1/2 131 1/2 129 15
220 171 170 25 24 130 158 1/2 156 15
252 201 200 27 24 160 188 1/2 186 15
A3-16
02-02
Firetube Boilers
Model CB-LE Boilers
BOILER HP WIDTHS Overall I.D. Boiler Center to Entrance Box Center to Outside Hinge Center to Lagging Base, Outside Base, Inside HEIGHTS Overall Base to Vent Outlet Base to Return and Outlet Height of Base Base to Bottom of Boiler
DIM
250
300
350
I J K KK L M N
93 78 51 51 42 64 52
93 78 51 51 42 64 52
93 78 51 51 42 64 52
OO O X Q R BOILER CONNECTION
115 106 96 10 17
115 106 96 10 17
115 106 96 10 17
Waterfill Conn. Right & Left Auxiliary Connection Water Return Flange (2" Dip Tube included) Water Outlet Flange (2" Dip Tube Included) Air Vent Drain, Front and Rear VENT STACK Diameter (flgd. connection)
S Z T U Y W
2 1-1/4 8A 8A 1-1/2 2
2 1-1/4 8A 8
A
2-1/2 1-1/4 8A 8A 1-1/2 2
1-1/2 2
BB MINIMUM CLEARANCES
20
20
20
Rear Door Swing Front Door Swing Tube Removal, Rear Tube, Removal, Front
DD EE FF GG
43 89 131 116
43 89 157 142
43 89 187 172
MINIMUM BOILER ROOM LENGTH ALLOWING FOR DOOR SWING AND TUBE REMOVAL FROM: Rear of Boiler Front of Boiler Thru Window or Doorway WEIGHT IN LBS Water Capacity Flooded Approx. Ship. Wgt. 30 psig Approx. Ship. Wgt. 125 psig NOTES: All connections are threaded unless indicted. A. ANSI 150 psig flange. 13880 21400 22200 16840 23500 24300 20090 26700 27500 RR RF RD 364 303 275 417 356 302 477 416 332
A3-17
02-02
Model CB-LE Boilers
Firetube Boilers
LWCO
BOILER HP
DIM
400
500
600
700
750
800
LENGTHS Overall (60 ppm System) Shell Base Frame Front Head Extension (60 ppm System) Rear Head Extension Shell Ring Flange to Base Rear Ring Flange to Base Shell Flange to Outlet Shell Flange to Return Over Tubesheets Shell Extension A B C D E F G HH H V P 206 147 112 27 32 23 12 139-1/2 107 130 17 228 168 133 28 32 23 12 156-1/2 125 151 17 262 200 165 30 32 23 12 182-1/2 151-1/2 183 17 299 233 198 34 32 23 12 216-1/2 185 216 17 300 233 198 35 32 23 12 216-1/2 185 216 17 300 233 198 35 32 23 12 216-1/2 185 216 17
A3-18
02-02
Firetube Boilers
Model CB-LE Boilers
BOILER HP
DIM
400
500 WIDTHS
600
700
750
800
Overall I.D. Boiler Center to Entrance Box Center to Outside Hinge Center to Lagging Base, Outside Base, Inside
I J K KK L M N
113 96 62 62 51 72 56
113 96 62 62 51 72 56 HEIGHTS
113 96 62 62 51 72 56
113 96 62 62 51 72 56
115 96 64 62 51 72 56
115 96 64 62 51 72 56
Overall Base to Vent Outlet Height of Base Base to Bottom of Boiler Base to Return and Outlet
OO O Q R X
134 126 12 19 116
134 126 12 19 116
134 126 12 19 116
134 126 12 19 116
134 126 12 19 116
134 126 12 19 116
BOILER CONNECTIONS Waterll Connection, Right and Left Auxiliary Connection Drain, Front and Rear Water Return Water Outlet (2 Dip Tube Included) Air Vent S Z W T U Y 2-1/2 1-1/4 2 10A 10A 2 2-1/2 1-1/4 2 10A 10A 2 2-1/2 1-1/4 2 12A 12A 2 2-1/2 1-1/4 2 12A 12A 2 2-1/2 1-1/4 2 12A 12A 2 2-1/2 1-1/4 2 12A 12A 2
VENT STACK Diameter (Flanged Connection) BB 24 24 24 24 24 24
MINIMUM CLEARANCES Rear Door Swing Front Door Swing Tube Removal, Rear Tube Removal, Front DD EE FF GG 53 108 131 114 53 108 152 135 53 108 184 167 53 108 217 200 53 108 217 200 53 108 217 200
MINIMUM BOILER ROOM LENGTH ALLOWING FOR DOOR SWING AND TUBE REMOVAL FROM: Rear of Boiler Front of Boiler Thru Window or Doorway RR RF RD 386 314 308 428 356 329 492 420 361 558 486 394 558 486 394 558 486 394
WEIGHT IN LBS Normal Water Capacity Approx. Ship. Wgt. 30 psig Approx. Ship. Wgt. 125 psig 20015 33300 37270 23300 36900 40780 28260 42150 46005 33360 49650 53300 33360 49750 53400 33360 49750 53400
NOTES: All connections are threaded unless indicated: A. ANSI 150 psig ange.
A3-19
02-02
Model CB-LE Boilers
Firetube Boilers
DIMENSIONS (INCHES) BOILER HP A CB-125 THRU CB-200 CB-250 THRU CB-350 CB-400 THRU CB-800 33 42 51 B 55 69 88 C 45 58 71 D 68 86 109 E 32 43 53
Figure A3-7. Space Required to Open Rear Head on Model CB-LE Boilers Equipped with Davits
BOILER HP 125 150 200 250 300 350
A 6 6 6 6 6 6
B 9 9 9 12 12 12
C 124 148 179 143 170 200
D 39-1/2 39-1/2 39-1/2 46 46 46
E 57-1/2 57-1/2 57-1/2 70 70 70
F 4 4 4 6 6 6
G 44-1/2 44-1/2 44-1/2 52 52 52
X 9-3/4 9-3/4 9-3/4 22 22 22
Figure A3-8. Model CB-LE Boiler Mounting Piers (60 and 78)
A3-20
02-02
Firetube Boilers
Model CB-LE Boilers
BOILER HP 400 500 600 700-750-800
A 6 6 6 6
B 14 14 14 14
C 112 133 165 198
D 50 50 50 50
E 78 78 78 78
F 8 8 8 8
G 56 56 56 56
Figure A3-9. Model CB-LE Boiler Mounting Piers (96)
A3-21
02-02
Model CB-LE Boilers
Firetube Boilers
BOILER HP 125 150 200 250 All All All Steam Hot Water Steam Hot Water Steam Hot Water Steam Hot Water Steam Hot Water Steam Hot Water Steam Hot Water
VIEW B B B B B B B B B B B B B B B B B
ALL DIMENSIONS IN INCHES A 80-1/4 80-1/4 80-1/4 99 99 99 99 99 99 119 119 119 119 119 119 119 119 B 29-3/4 29-3/4 29-3/4 36 36 36 36 36 36 35-3/4 35-3/4 35-3/4 35-3/4 35-3/4 35-3/4 35-3/4 35-3/4 C 70-1/2 83-1/2 114-1/2 72 81 99 108 129 138 78 78 99 99 131 131 164 164 D 10 10 10 10 10 10 10 10 10 11 11 11 11 11 11 11 11 E 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
300
350
400
500
600 700, 750 & 800
NOTE: A, B and C dimensions may vary by 1/2 inch.
Figure A3-10. Lifting Lug Location, Model CB-LE Boilers
A3-22
02-02
Firetube Boilers
Model CB-LE Boilers

2. Efciencies are based on ambient air temperature of 80 F, relative humidity of 30%, and 15% excess air in the exhaust ue gas. 3. Efciencies are based on manufacturers published radiation and convection losses. (For Cleaver-Brooks radiation and convection losses, see Boiler Efciency Facts Guide, publication number CB-7767). 4. Any efciency verication testing will be based on the stack loss method. For efciencies and stack temperatures at operating pressures not listed, follow these procedures: When the operating steam pressure is between 10 psig and 125 psig, interpolate the values from the efciency tables. When the operating steam pressure is above 125 psig, estimated efciency can be calculated as follows: Example: Boiler: 350 hp. Fuel: natural gas.
PERFORMANCE DATA
The Low Emission Option provides NOx reduction at current published and predicted fuel-to-steam efciencies. Refer to Tables A3-8 and A3-9.
Specifying Boiler Efficiency

Cleaver-Brooks offers an industry leading fuel-to-steam boiler efciency guarantee for Model CB-LE Firetube Boilers. The guarantee is based on the fuel-to-steam efciencies shown in the efciency tables and the following conditions. The efciency percent number is only meaningful if the specic conditions of the efciency calculations are clearly stated in the specication (see Cleaver-Brooks publication CB-7768 for a detailed description of efciency calculations). When specifying the efciencies in the tables, be sure to include the specic guarantee conditions to maximize the effectiveness of your efciency specication. If you have any questions regarding the efciency specications, please contact your local Cleaver-Brooks authorized representative.
Efficiency Specification
The boiler manufacturer shall guarantee that, at the time of startup, the boiler will achieve fuel-to-steam efciency (as shown in Tables A3-8 and A3-9) at 100% ring rate (add efciency guarantees at 25%, 50%, and 75% of rating, if required). If the boiler(s) fail to achieve the corresponding guaranteed efciency as published, the boiler manufacturer will rebate, to the ultimate boiler owner, ve thousand dollars ($5,000) for every full efciency point (1.0%) that the actual efciency is below the guaranteed level. The specied boiler efciency is based on the following conditions. 1. Fuel specication used to determine boiler efciency: Natural Gas Carbon, % (wt) = 69.98 Hydrogen, % (wt) = 22.31 Sulfur, % (wt) = 0.0 Heating value, Btu/lb = 21,830 No. 2 Oil Carbon, % (wt) = 85.8 Hydrogen, % (wt) = 12.7 Sulfur, % (wt) = 0.2 Heating value, Btu/lb = 19,420 No. 6 Oil Carbon, % (wt) = 86.6 Hydrogen, % (wt) = 10.9 Sulfur, % (wt) = 2.09 Heating value, Btu/lb = 18,830
Operating steam pressure: 200 psig. Find the fuel-to-steam efciency at 100% ring rate. From Table A3-8 for a 350 hp boiler operating at 100% ring rate and an operating steam pressure of 125 psig, the efciency is 82.5%. Using Figure A3-11, note that the stack temperature increases 36 F at the higher operating pressure. To estimate boiler efciency, use this rule of thumb: For every 40 F increase in stack temperature, efciency decreases by 1%. Since the stack temperature rise is 36 F, the decrease in the boiler efciency at 200 psig operating pressure is calculated as follows: 36/40 = .9%. Therefore, the boiler efciency at 200 psig operating pressure is 82.5 - .9 = 81.6%
Emissions
The emission data included in this section consists of typical emission levels for Model CB boilers equipped with 60, 30, 25, and 20 ppm LE Options when ring natural gas and No. 2 oil.
NOTICE
The data in Tables A3-10 and A3-11 represent typical emission levels only. Guaranteed emission levels are available from your local Cleaver-Brooks authorized representative.
A3-23
02-02
Model CB-LE Boilers
Firetube Boilers
Table A3-8. Predicted Fuel-to-Steam Efciencies - Natural Gas

OPERATING PRESSURE = 10 psig BOILER HP 25% 125 150 200 250 300 350 400 500 600 700 750, 800 83.3 84.4 85.0 85.0 85.3 85.3 84.5 85.5 85.7 85.7 85.8 50% 83.6 84.6 85.3 84.7 85.3 85.7 84.7 85.7 86.0 86.2 86.1 % OF LOAD 75% 83.4 84.5 85.1 84.0 84.6 85.2 84.6 85.5 85.8 86.0 85.9 100% 83.2 84.3 84.9 83.3 83.9 84.5 84.4 85.2 85.6 85.7 85.6 25% 80.4 81.5 82.2 82.0 82.6 82.6 81.8 82.8 82.9 83.0 83.1 50% 80.9 82.0 82.7 82.0 82.7 83.2 82.2 83.2 83.5 83.6 83.6 OPERATING PRESSURE = 125 psig % OF LOAD 75% 81.0 82.0 82.7 81.6 82.2 82.8 82.4 83.3 83.6 83.6 83.7 100% 81.0 82.1 82.7 81.3 81.9 82.5 82.2 83.1 83.5 83.6 83.5
Figure A3-11. Predicted Stack Temperature Increase for Pressure Greater Than 125 psig
A3-24
02-02
Firetube Boilers
Model CB-LE Boilers
Table A3-9. Predicted Fuel-to-Steam Efciencies - No. 2 Oil

OPERATING PRESSURE = 10 psig BOILER HP 25% 125 150 200 250 300 350 400 500 600 700 750, 800 86.7 87.8 88.4 88.3 88.6 88.6 87.9 88.9 89.0 89.1 89.2 % OF LOAD 50% 86.9 88.0 88.7 88.1 88.7 89.0 88.1 89.0 89.4 89.5 89.5 75% 86.7 87.8 88.4 87.4 88.0 88.5 87.9 88.9 89.2 89.3 89.3 100% 86.6 87.6 88.2 86.7 87.3 87.8 87.6 88.6 89.0 89.1 89.0 25% 83.7 84.8 85.6 85.3 85.9 85.9 85.1 86.1 86.2 86.3 86.4 50% 84.2 85.3 86.0 85.3 86.0 86.6 85.5 86.5 86.8 86.9 86.9 OPERATING PRESSURE = 125 psig % OF LOAD 75% 84.3 85.3 86.0 84.9 85.5 86.1 85.6 86.6 86.9 87.0 87.0 100% 84.3 85.4 86.0 84.7 85.2 85.8 85.5 86.4 86.8 86.9 86.8
Table A3-10. CB-LE Boilers - Natural Gas, Emission Levels

ESTIMATED LEVEL POLLUTANT 60 ppm CO NOx SOx HC/VOC5 PM ppmA lb/MMBtu ppmA lb/MMBtu ppmA lb/MMBtu ppmA lb/MMBtu ppmA lb/MMBtu 200 0.15 60 0.07 1 0.001 40 0.016 0.01 30 ppm 50/150B 0.04/0.11 30 0.035 1 0.001 40 0.016 0.01 25 ppm 50/150B 0.04/0.11 25 0.03 1 0.001 40 0.016 0.01 20 ppm 200 0.15 20 0.024 1 0.001 40 0.016 0.01
A. ppm levels are given on a dry volume basis and corrected to 3% oxygen (15% excess air). B.CO emission for 30 & 25 ppm system is 50 ppm (0.04 lb/MMBtu) when boiler is operating above 50% of rated capacity. CO emission is 150 ppm (0.11 lb/MMBtu) when boiler is operating below 50% of rated capacity.
Table A3-11. CB-LE Boilers - No. 2 Oil, Emission Levels

ESTIMATED LEVEL POLLUTANT 60 ppm LE Option CO NOx SOx HC/VOCs PM ppmA lb/MMBtu ppmA lb/MMBtu ppmA lb/MMBtu ppmA lb/MMBtu ppmA lb/MMBtu 90 0.07 185 0.25 278 0.52 50 0.025 0.025 30, 25, 20 ppm LE Option 90 0.07 140 0.187 278 0.52 60 0.030 0.025
A. ppm levels are given on a dry volume basis and corrected to 3% oxygen (15% excess air). BASED ON THE FOLLOWING CONSTITUENT LEVELS: Fuel-bound Nitrogen content = 0.05% by weight. Sulfur content = 0.5% by weight. Ash content = 0.01% by weight.
A3-25
02-02
Model CB-LE Boilers
Firetube Boilers
Typical Values Sound pressure levels (dbA) for the same boiler will vary between boiler rooms. Sound levels will vary with motor type, NOx levels, and altitudes. In addition, variations will occur between different people using different sound meters on the same boiler. And nally, no two boilers can be expected to give precisely the same sound levels. For these reasons, we can only predict, but not guarantee, sound levels (dbA).
ENGINEERING DATA
Sound Level
Table A3-12 gives a summary of predicated sound pressure levels for Model CB boilers with 30 ppm LE Options. Contact your local Cleaver-Brooks authorized representative for sound levels or other LE Options. Units The units for the sound level tables are dbA (decibels, measured on the A-weighted scale) in reference to 0.0002 microbars (20 micro-Newtons per square meter). Their reference are standardly used in specifying and reporting sound pressure levels on industrial equipment. Test Method The sound pressure levels in the above tables were obtained from tests in accordance with the ABMA Test Code for the Measurement of Sound from Packages Boilers. In accordance with this code the sound pressure levels reported were measured on the boiler centerline 4-1/2 feet vertically above the bottom of the base rails and 3 feet horizontally in front of the end of the blower motor or front surface of the electrical cabinet. Sound Level Meter The sound level meter used complies with ANSI S1.4, Type 1 (Precision). The readings are taken with the meter set for slow response and corrected for background levels. Sound Pressure The large size boilers, the need for auxiliary equipment, and the necessary interconnecting piping make it impractical (and sometimes impossible) to provide a boiler testing environment which is suitable for taking the data needed to develop Sound Pressure Power levels.
Gas-Fired Burners NOTICE

A gas pressure regulator must be installed in the gas piping to each boiler. Gas pressure regulators for Model CB Firetube Boilers are sized and selected on a job-by-job basis. Regulated gas pressure is the pressure downstream of the gas pressure regulator. Total gas pressure required for the boiler equals regulated gas pressure plus the pressure drop of the selected gas pressure regulator. Table A3-13 shows regulated gas pressure with over and undersized gas trains. Table A3-14 shows the required regulated gas pressure at the entrance to the gas trains. Table A3-15 shows minimum required gas pressure altitude conversion. The following items should be considered when selecting a regulator: Pressure Rating: The regulator must have a pressure rating at least equivalent to that of the gas distribution system. Capacity: The capacity can be determined by multiplying the maximum burning rate (CFH) by 1.15, see Table A3-16. This 15 percent over-capacity rating of the regulator provides for proper regulation. Spring Adjustment: The spring should be suitable for a range of adjustment from 50 percent under the desired regulated pressure to 50 percent over. Sharp Lock-Up: The regulator should include this feature to prevent the downstream pressure (between the regulator and the boiler) from climbing when there is no gas ow. Regulators in Parallel: This type of installation can be used if the required gas volume is very large and if the pressure drop must be kept to a minimum. Regulators in Series: This type of installation can be used if the available gas pressure is over 5, 10, or 20 psig. Depending on the regulator characteristics, one regulator would reduce the pressure to 2 to 3 psig, and a second
Table A3-12. Model CB-LE Predicted Sound Levels 30 ppm NOx Systems
BOILER HP HFO, dbA LFO, dbA HFG, dbA LFG, dbA 125 150 200 250 300 350 400 500 600 700 750 800 84 82 82 81 84 82 82 81 84 83 83 82 83 81 82 81 84 82 83 82 85 83 84 83 84 82 83 81 85 83 83 81 85 83 85 82 88 84 87 84 89 87 89 86 90 89 90 88
NOTES 1. Sound pressure levels measured on boilers operating in various locations and expressed in dbA are as shown: 2. Based on standard altitude fans and fan motors, 60 Hz. 3. Contact your local Cleaver-Brooks authorized representative for sound levels of 60, 25, or 20 ppm LE Options.
ABBREVIATIONS: HF = High Fire LF = Low Fire O = Oil G = Gas
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02-02
Firetube Boilers
regulator would reduce the pressure to the burner requirements. Regulator Location: A straight run of gas line piping should be used on both sides of the regulator to ensure proper regulator operation. This is particularly important when pilot operated regulators are used. The regulator can be located close to the gas train connection, but 2 to 3 feet of straight run piping should be used on the upstream side of the regulator. C-B O2 Trim Systems: If a C-B O2 Trim system will be utilized, contact your local Cleaver-Brooks authorized representative to be sure that a compatible regulator is selected. Table A3-16 shows maximum gas consumption for natural gas and propane vapor. Figure A3-12 shows standard gas train sizes and locations for Model CB Firetube Boilers.
Model CB-LE Boilers

Figure A3-13 shows typical gas train piping layouts for multiple boiler applications. Figure A3-14 shows standard gas train components.
Oil-Fired Burners
Fuel oil consumption information is shown on the boiler rating sheets in the Dimensions and Rating Section. Figure A3-15 shows the oil connection sizes and locations for Model CB Boilers ring No. 2 oil. Figures A3-16 through A3-18 show typical oil systems and layouts. Figures A3-19 and A3-20 show the detail of an oil transfer tank (day tank) typically utilized to provide a storage reservoir between the oil system supply pump and the boiler oil pump.
Table A3-13. Under and Oversized Standard, FM, and IRI Gas Trains, Model CB-LE Boilers
125 PIPE SIZE 2 2-1/2 3 4 PRESS REQ 12.5 9.0 7.0 6.0 PIPE SIZE 2 2-1/2 3 4 150 PRESS REQ 17.5 11.5 9.5 8.0 PIPE SIZE 2 2-1/2 3 4 200 PRESS REQ 27.0 16.5 13.5 10.0 PIPE SIZE 2-1/2 3 4 4A 250 PRESS REQ 30.5 23.0 15.5 14.5 PIPE SIZE 2-1/2 3 4 4A 300 350 PIPE SIZE 64.5 45.0 33.5 30.0 PIPE SIZE 3 4 4A 400 PRESS REQ 36.5 22.0 18.0
PRESS PRESS REQ REQ 46.0 32.5 24.0 21.5 2-1/2 3 4 4A
500 PIPE SIZE 3 4 4A PRESS REQ 59.0 35.0 27.5 PIPE SIZE 3 4 4A
600 PRESS REQ 79.5 45.5 34.5 PIPE SIZE 3 4 4A
700 PRESS REQ NA 62.0 46.0 PIPE SIZE 3 4 4A
750 PRESS REQ NA 71.5 53.5 PIPE SIZE 3 4 4A
800 PRESS REQ NA 83.0 63.0
Table A3-14. Minimum Required Regulated Gas Pressure at the Entrance to Standard, FM, and IRI Gas Trains
MODEL CB BOILER HP 250 300 350 400 500 600 700 750 800 CONN SIZE (IN.) 3 3 3 4 4 4 4 4 4 HTBA MIN GAS PRESS REQ'D 23.0 32.5 45.0 22.0 35.0 45.5 62.0 71.5 83.0
NOTES: 1.Pipe size in inches, and pressure required in inches of WC.
2. Standard gas train shown by shaded area. 3. Pressure requirement is downstream of gas pressure regulator. A. Low pressure drop Maxon valves (replaces 6" trains).
NOTES: 1. Based on 1000 Btu/cu-ft natural gas and elevations up to 700 feet. A. HTB is for high turndown (10:1) burners.
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Model CB-LE Boilers
Firetube Boilers

Table A3-16. Maximum Gas Consumption (CFH) for Natural Gas and Propane Vapor
TYPE OF GAS AND HEAT CONTENT BOILER HP 125 150 200 250 NATURAL GAS 1000 (Btu/cu-ft) 5103 6124 8165 10206 12247 14280 16329 20415 24494 28576 30618 32659 PROPANE GAS 2550 (Btu/cu-ft) 2000 2402 3202 4002 4802 5600 6404 8006 9605 11206 12007 12807
To obtain minimum required gas pressure at altitudes above 700 feet, multiply the pressure by the listed factors: Inches WC x 0.577 = oz/sq-in. Oz/sq-in x 1.732 = Inches WC Inches WC x 0.0361= psig. Oz/sq-in x 0.0625 = psig. Psig x 27.71 = Inches WC Psig x 16.0 = Oz/sq-in.
300 350 400 500 600 700 750 800
MODEL CB BOILER HP 125 150, 200 250 300, 350 400, 500, 600, 700, 750, 800 CONNECTION SIZE (IN.) (NPT) 2-1/2 2-1/2 3 3 4 LOCATION DIMENSION A (IN.) 67-1/4 67-1/2 70-1/2 70-1/2 109-1/2
Figure A3-12. Standard Gas Train Connection Size and Location
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Firetube Boilers
Model CB-LE Boilers
This figure illustrates the basic gas valve arrangement on Cleaver-Brooks Model CB boiler and shows the contractor's connection point. The valves and controls between the contractor connection point and the gas main in the street are representative of a typical installation. Actual requirements may vary depending on local codes or local gas company requirements which should be investigated prior to preparation of specifications and prior to construction.
A. Utilities service valve. B. Utilities service regulator. C. Gas meter. D. Piping from meter to boiler. E. Gas pressure regulator at burner. The size of the gas line from the meter to the gas pressure regulator at the boiler can be very important if gas pressures are marginal. The gas line sizing is dependent on: 1. Gas pressure at outlet of gas meter (C) 2. Rate of gas flow required, CFH 3. Length of pipe run (D) 4. Pressure required at contractor connection point. The local gas utility will advise the pressure that is available at the outlet of their meter. Figure A3-13. Typical Gas Piping Layout
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Model CB-LE Boilers
Firetube Boilers
INS ITEM DESCRIPTION BOILER HP 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Pilot Shut Off Cock Pilot Shut Off Cock Shut Off Cock Shut Off Cock Pilot Pressure Regulator Pilot Pressure Gauge Gas Pilot Valve High Gas Pressure Switch Low Gas Pressure Switch Main Gas Valve with POC Main Gas Valve without POC Main Gas Valve with POC Vent Valve Butterfly Valve x x x x x x x x x x
UL
FM
IRI
FM & IRI
125- 300- 125- 300- 125- 125- 300250 800 250 800 800 250 800 x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
Figure A3-14. Model CB-LE Gas Train Components
MODEL CB RECOMMENDED OIL LINEA SIZES (STANDARD PIPE) (IN. - IPS) A (IN.) STORAGE PUMP TANK TO TO BOILER OR PUMP BOILER CONNECT 1 1
BOILER HP
SUPPLY AND RETURN CONN SIZES (IN.) (NPT)
RETURN LINE TO TANK
125 150 200 250 300 350 400 500 600 700 750 800
3/4
12-1/2
3/4
34
3/4
11-3/4
11-3/4
NOTE: See No. 2 Oil Line Sizing Instruction for systems with other conditions. A. For suction line condition with a maximum of 10 Feet of lift and a total of 100 feet of suction line.
Figure A3-15. No.2 Oil Connection Size, Location, and Recommended Line Sizes
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Firetube Boilers
Model CB-LE Boilers
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Model CB-LE Boilers

CHECK VALVE STANDBY OIL PUMP GATE VALVE
Firetube Boilers
VACUUM GAUGE STRAINER GATE VALVE F.O.S.
F.O.R. ADJUSTABLE PRESSURE RELIEF VALVE (75 PSIG)
UNION GATE VALVE RELIEF VALVE (100 PSIG)
PRESSURE GAUGE
GATE VALVE CHECK VALVE

Relief valve on the boiler must be set at 100 psig so that adjustable pressure relief valve in the loop system is in control. BOILER BASE FRAME F.O.S. F.O.R.
BOILER FRONT CONTACTOR CONNECTIONS AT THIS POINT
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Firetube Boilers
Model CB-LE Boilers
Figure A3-20. Typical Arrangement
General Boiler Information

Table A3-17 shows blowdown tank sizing information. Table A3-18 provides heating surface information. Table A3-19 provides steam volume and disengaging area information Table A3-20 provides recommended steam nozzle sizes. Table A3-21 provides recommended non-return valve sizes.
For additional information, please review Section I4, General Engineering Data (Stacks) and Section F, Stacks. Stack and breeching sizes should always be provided by a reputable stack supplier who will design the stack and breeching system based on the above criteria. Your local Cleaver-Brooks authorized representative is capable of assisting in your evaluation of the stack/breeching design.

When determining boiler room air requirements, the size of the room, air ow, and velocity of air must be reviewed as follows: 1. Size (area) and location of air supply openings in boiler room. A. Two (2) permanent air supply openings in the outer walls of the boiler room are recommended. Locate (1) at each end of the boiler room, preferably below a height of 7 feet. This allows air to sweep the length of the boiler. B. Air supply openings can be louvered for weather protection, but they should not be covered with ne mesh wire, as this type of covering has poor air ow qualities and is subject to clogging by dust or dirt. C. A vent fan in the boiler room is not recommended, as it could create a slight vacuum under certain conditions and cause variations in the quantity of combustion air. This can result in unsatisfactory burner performance. D. Under no condition should the total area of the air supply openings be less than (1) square foot. E. Size the openings by using the formula: Area (sq-ft) = CFM/FPM 2. Amount of air required (cfm).


All standard Cleaver-Brooks Firetube Boilers with an LE option can support up to 2,000 lbs without additional support. LE Boilers 250 hp through 800 hp can be reinforced to support 3,000 lbs.

The design of the stack and breeching must provide the required draft at each boiler ue gas outlet. Proper draft is critical to burner performance. Although constant pressure at the ue gas outlet of the Model CB-LE is not required, it is necessary to size the stack/breeching to limit ue gas pressure variation. The allowable pressure range is 0.25" W.C. to +0.25" W.C.
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Model CB-LE Boilers

A. Combustion Air = Rated bhp x 8 cfm/bhp. B. Ventilation Air = Maximum bhp x 2 cfm/bhp C. Total recommended air = 10 cfm/bhp - up to 1000 feet elevation. Add 3 percent more per 1000 feet of added elevation. 3. Acceptable air velocity in Boiler Room (fpm). A. From oor to (7) foot height - 250 fpm B. Above (7) foot height - 500 fpm Example: Determine the area of the boiler room air supply openings for (1) 300 hp boiler at 800 feet altitude. The air openings are to be 5 feet above oor level. Air required: 300 x 10 = 3000 cfm (from 2B above). Air velocity: Up to 7 feet = 250 fpm (from 3 above). Area Required: Area = cfm = 3000/250 = 12 sq-ft total. Area/Opening: 12/2 = 6 sq-ft/opening (2 required).
BOILER HP 125 150 200 250 300 350 400 500 600 700, 750, 800
Firetube Boilers
Table A3-18. Heating Surface, Model CB-LE Boilers
HEATING SURFACE (SQ-FT) FIRESIDE 625 750 1000 1250 1500 1750 2000 2500 3000 3500 WATERSIDE 679 820 1092 1346 1623 1932 2151 2691 3262 3810
NOTICE
Consult local codes, which may supersede these requirements. Table A3-17. Model CB-LE Blowdown Tank Sizing Information
BOILER HP 125 150 200 250 300 350 400 500 600 700, 750, 800 WATER (GAL) 97 118 145 146 176 210 177 209 250 296
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Firetube Boilers
Model CB-LE Boilers
Table A3-19. Steam Volume and Disengaging Area

STEAM VOLUME CU-FT BOILER HP HIGH PRESSUREA 125 150 200 250 300 350 400 500 600 700-800 NOTE: Based on normal water level. A. Based on 150 psig design pressure. B. Based on 15 psig design pressure. 25.4 30.7 37.7 49.2 59.5 70.9 72.1 83.7 101.5 119.8 LOW PRESSUREB 36.6 44.3 54.4 70.6 85.3 101.7 97.9 113.7 137.8 162.7 STEAM DISENGAGING AREA SQ-IN HIGH PRESSUREA 5371 6511 7985 7980 9651 11507 9793 11376 13787 16273 LOW PRESSUREB 5887 7138 8752 8695 10516 12538 10593 12303 14911 17600
Table A3-20. Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity)
Boiler HP OPERATING PRESSURE PSIG 15 30 40 50 75 100 125 150 200 250 125 150 200 250 300 350 400 500 600 700 750 800 8 6 6 6 4 4 4 3 2.5 2.5 8 6 6 6 4 4 4 3 3 2.5 10 8 6 6 6 6 4 4 4 3 10 8 8 6 6 6 6 4 4 4 12 8 8 8 6 6 6 6 4 4 12 10 8 8 8 6 6 6 4 4 12 10 10 8 8 6 6 6 6 4 12 10 10 8 8 8 8 6 6 6 12 12 10 10 8 8 8 6 6 6 12 12 12 10 10 8 8 8 6 6 12 12 12 12 10 8 8 8 6 6 12 12 12 12 10 10 8 8 6 6

BOILER HP 125 150 200 250 300 350 400 500 600 700 750 800 BOILER CAPACITY (LBS/HR) 4313 5175 6900 8625 10350 12025 13800 17210 20700 24150 25875 27600 OPERATING PRESSURES (PSIG) 125 3 3 3 4 4 4 4 6 6 6 6 6 150 3 3 3 3 4 4 4 4 6 6 6 6 175 2-1/2 3 3 3 4 4 4 4 4 6 6 6 200 2-1/2 2-1/2 3 3 4 4 4 4 4 6 6 6 250 2-1/2 2-1/2 3 3 3 3 4 4 4 6 6 6
NOTES: 1. Steam nozzle sizes given in inches. 2. Recommended steam nozzle sizes based on 4000 to 5000 fpm steam velocity. Spool pieces (300 lb flanges) are available in the following sizes (in inches): 3x2-1/2x30, 4x3x30, 6x4x36, 8x6x48, 10x8x48, and 12x8x48.
NOTE: Valve sizes (300 # Flanges) given in inches.
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Model CB-LE Boilers
Firetube Boilers
DWG A
DWG B DWG C
1. Shortest boiler room length (Dwg A) is obtained by allowing for possible future tube replacement (from front or rear of boiler) through a window or doorway. Allowance is only made for minimum door swing at each end of the boiler. This arrangement provides sufcient aisle space at the front of the boiler but a tight space condition at the rear. If space permits, approximately 1.5 additional feet should be allowed at the rear for additional aisle and working space. 2. Next shortest boiler room length (Dwg B) is obtained by allowing for possible future tube replacement from the front of the boiler. Allowance is only made for minimum door swing at the rear. If space permits, approximately 1.5 additional feet should be allowed at the rear for additional aisle and working space. 3. A slightly longer boiler room (Dwg C) is obtained by allowing for possible future tube replacement from the rear of the boiler. Allowance for door swing at the front provides sufcient aisle and working space at the front.
Figure A3-21. Boiler Room Length (Typical Layouts)
125-200 82" 115"
250-350 93" 141"
400-800 102" 171"
NOTES: 1. Recommended Minimum Distance Between Boiler and Wall. Dimension A allows for a clear 42" aisle between the water column on the boiler and the wall. If space permits, this aisle should be widened. 2. Recommended Minimum Distance Between Boilers. Dimension B between boilers allows for a clear aisle of: 42" - 125 -200 hp 48" - 250-350 hp 60" - 400-800 hp If space permits, this aisle should be widened.
Figure A3-22. Boiler Room Width (Typical Layout)
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Firetube Boilers
Model CB-LE Boilers
MULTIPLE BOILERS WITH A COMMON STACK
NOTE: These stack breeching arrangements for multiple boilers are typical and not intended for your specic design requirements. For additional information, review Section F, Stacks. Stack and breeching sizes should always be provided by a reputable stack supplier who will design the stack and breeching system based on your specic criteria. Your local CLeaver-Brooks authorized representative is capable of assisting in your evaluation of stack and breeching design.
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Model CB-LE Boilers
Firetube Boilers
SAMPLE SPECIFICATION
The following sample specication is provided by Cleaver-Brook to assist you in meeting your customers specic needs and applications. The LE Option specication includes information on the base low emissions package for 60 or 30 ppm NOx (dry volume basis and corrected to 3% O2) when ring natural gas. For assistance in specifying, or for information on NOx levels below 30 ppm, please contact your local Cleaver-Brooks authorized representative. Model CB-LE Steam Boiler (125-800 hp, Steam 15-300 psig) 1.0 Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model CB-LE Hot Water Boiler (125-800 hp, 30 psig, 125 psig) 1.0 Boiler Characteristics (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Hot Water Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model CB-LE Steam Boiler (125-800 hp, Steam 15-300 psig) 1.0 Boiler Characteristics (Steam) 1.1 The Steam Boiler shall be Cleaver-Brooks Model CB, Fuel Series ______ (100, 200, 700), _____ hp designed for _____ psig (15, 150, 200, or other psig steam). The maximum operating pressure shall be _____ psig. 1.2 The boiler shall have a maximum output of _____ Btu/hr, or _____ horsepower when red with CS 12-48 _____ oil and/or natural gas, _____ Btu/cu-ft. Electrical power available will be _____ Volt _____ Phase _____ Cycle. 2.0 General Boiler Design 2.1 The boiler shall be a four pass horizontal retube updraft boiler with ve (5) square feet (except 750 or 800 hp) of heating surface per rated boiler horsepower. It shall be mounted on a heavy steel frame with integral forced draft burner and burner controls. A3-45 A3-45 A3-46 A3-46 A3-50 A3-50 A3-51 A3-38 A3-38 A3-39 A3-40 A3-44 A3-44 A3-44
NOTICE
2.1.1 The boiler shall be completely preassembled and re tested at the factory. The unit shall be ready for immediate mounting on oor or simple foundation and ready for attachment of water, steam, fuel, electrical, vent and blowdown connections. 2.1.2 The boiler shall be built to comply with the following insurance and codes ____________________ (Factory Mutual, Industrial Risk Insurance, ASME CSD-1). 2.2 Boiler Shell (Steam)
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Firetube Boilers
Model CB-LE Boilers
2.2.1 The boiler shell must be constructed in accordance with ASME Boiler Code and must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser. 2.2.2 Two lifting eyes shall be located on top of the boiler. 2.2.3 Front and rear doors on the boiler shall be hinged or davited. Doors are to be sealed with berglass tadpole gaskets and fastened tightly using heavy capscrews that thread into replaceable brass nuts. 2.2.4 Rear refractory and insulation shall be contained in the formed door, which must swing open for inspection of brick work. 2.2.5 The boiler tubes shall not include turbulators, swirlers or other add-on appurtenances. 2.2.6 Front and rear tube sheets and all ues must be fully accessible for inspection and cleaning when the doors are swung open. The boiler shall be furnished with adequate handholes to facilitate boiler inspection and cleaning. 2.2.7 A manhole shall be provided. 2.2.8 The exhaust gas vent shall be located near the front of the boiler on the top center line and shall be capable of supporting 2000 lbs and shall contain a stack thermometer. 2.2.9 The boiler shell shall contain a chemical feed connection. 2.3 Observation ports for the inspection of ame conditions shall be provided at each end of the boiler. 2.4 The boiler insulation shall consist of a 2 inch blanket under a sectional preformed sheet metal lagging. This insulation must be readily removable and capable of being reinstalled, if required. 2.5 The entire boiler base frame and other components shall be factory painted before shipment using a hard nish enamel coating. 2.6 Emission Controls 2.6.1 Boiler shall be equipped with a low emission (LE) option for guaranteed NOx performance at ________ ppm, dry volume basis and corrected to 3% O2 when ring natural gas. 2.6.2 The low emission option shall include an integral front head, burner, and boiler package, providing NOx reduction through an internal ue gas recirculation system using the combustion air fan, internal recirculation valve, and enhanced boiler design to achieve the guaranteed NOx levels. The emission control system shall not use an external fan, control valve, and piping. Boiler fuel-to-steam efciency and rated boiler capacity shall be guaranteed while the boiler is operating at the low NOx performance levels. 2.6.3 Burner, boiler, and low NOx system shall be manufactured as a package by a single manufacturer. The Low Emission Option to the CB Boiler shall included factory testing as a package, and shall bear the UL packaged label. The boiler nameplate shall include the approved UL low NOx boiler model designation. No eld assembly of the burner or low NOx equipment shall be required. 3.0 Steam Boiler Trim 3.1 Water Column A water column shall be located on the right hand side of the boiler complete with gauge glass set and water column blowdown valves. 3.1.1 Feedwater Pump Control The boiler feedwater pump control shall be included as an integral part of the water column to automatically actuate a motor driven feed water pump maintaining the boiler water level within normal limits. 3.1.2 Low Water Cutoff The low water cutoff shall be included as an integral part of the boiler feedwater control wired into the burner control circuit to prevent burner operation if the boiler water level falls below a safe level. 3.2 Auxiliary Low Water Cutoff Auxiliary low water cutoff manual reset shall be included, piped to the vessel, and wired to the burner control circuit. A manual reset device shall be used on this control.
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02-02
Model CB-LE Boilers

3.3 Steam Pressure Gauge
Firetube Boilers
The steam pressure gauge shall be located at the front of the boiler and include cock and test connection. 3.4 Safety Valves Safety valves of a type and size to comply with ASME Code requirements shall be shipped loose. 3.5 Steam Pressure Controls The steam pressure controls to regulate burner operation shall be mounted near the water column. Controls shall be a high limit (manual reset), operating limit (auto reset), and ring rate control. 4.0 Burner and Controls 4.1 Mode of Operation Burner operation shall be full modulation principle. The burner shall always return to low re position for ignition. 4.2 Blower 4.2.1 Air for combustion shall be supplied by a forced draft blower mounted in the front boiler door, above the burner, to eliminate vibration and reduce noise level. 4.2.2 Maximum sound level of the boiler/burner package shall not exceed _____ dbA (when measured in accordance with ABMA Sound Test Standards). 4.2.3 The impeller shall be cast aluminum, radial blade, carefully balanced, and directly connected to the blower motor shaft. 4.3 Combustion Air Control Combustion air damper and cam operated fuel metering valves shall be operated by a single damper control motor that regulates the re according to load demand. Potentiometer type position controls shall be provided to regulate operation of the damper control motor (remove this sentence when CB-HAWK ame safeguard is used). 4.4 Fuel Specication and Piping Select one of the following fuel types: Fuel series 700 - Gas red (4.4.1). Fuel series 100 - Light oil (No. 2) red (4.4.2). Fuel series 200 - Light oil or gas red (4.4.3). 4.4.1 Fuel Series 700 - Gas Fired 4.4.1.1 Burner Type - The burner shall be integral with the front head of the boiler and of high radiant multi-port type for gas. The burner shall be approved for operation on natural gas fuel and equipped with an LE option. 4.4.1.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include two manual shutoff valves, solenoid valve, pressure regulator and pressure gauge. 4.4.1.3 Gas Burner Piping - Gas burner piping on all units shall include primary gas shutoff valve, motor operated with proof of closure switch and plugged leakage test connection. The main gas valve(s) shall be wired to close automatically in the event of power failure, ame failure, low water or any safety shutdown condition. A lubricating plug cock or buttery shutoff valve shall be provided as a means for a tightness check of the primary shut off valve. An additional plug cock on buttery valve shall be furnished at entrance to gas train. Select one of the following: A. 125-250 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided. B. 300-800 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided. A vent valve shall be located between the safety shutoff valves. 4.4.1.4 Burner Turndown - Select one of the following: A3-40
02-02
Firetube Boilers
A. 125-200 hp. Turndown range of burner shall be 4:1 when ring natural gas.
Model CB-LE Boilers
B. 250-800 hp. Turndown range of the burner shall be 10:1 when ring natural gas with a 60 or 30 ppm LE option. (Consult with Cleaver-Brooks Representative regarding high turndown capability based on available gas pressure and 25 and 20 ppm LE options.) 4.4.2 Fuel Series 100 - Light Oil Fired 4.4.2.1 Burner Type - The burner shall be integral with the front head of the boiler, and shall be a low pressure air atomizing type approved for operation with CS12-48, Commercial No. 2 oil and equipped with an LE option. 4.4.2.2 Oil Pilot - The oil pilot shall be air atomizing type with automatic electric ignition and include oil solenoid valve. An electronic detector shall monitor the pilot so that the primary oil valve cannot open until ame has been established. 4.4.2.3 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Separate motor driven pump set, shipped loose to be installed in a location favorable to the oil storage tank, shall be provided. 4.4.2.4 Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, solenoid shutoff valves, pressure gauges and fuel strainer, all integrally mounted on the unit. A fuel oil controller shall be provided to combine all of the fuel oil controls into a single casting which is mounted on the front door of the unit. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. A low oil pressure switch shall be included in the oil piping. 4.4.2.5 Low Pressure Air Atomizing Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch. 4.4.2.6 Burner Turndown. Select one of the following: A. 125 hp through 200 hp. Turndown range shall be 4:1 when ring No. 2 oil. B. 250 hp through 800 hp Turndown range shall be 8:1 when ring No. 2 oil. (Consult your local Cleaver-Brooks authorized representative regarding No. 2 oil turndown capabilities when utilizing LE Options to achieve NOx levels of 25 or 20 ppm when ring natural gas.) 4.4.3 Fuel Series 200 - Light Oil or Gas Fired 4.4.3.1 Burner Type - The burner, integral with the front head of the boiler, shall be a combination of the low pressure air atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 Oil or natural gas. The burner shall be equipped with an LE option. 4.4.3.2 Gas Pilot - The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary fuel valve cannot open until ame has been established. The pilot train shall include two manual shut-off valves, solenoid valve, pressure regulator and pressure gauge. 4.4.3.3 Oil Burner 4.4.3.3.1 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Separate motor driven pump set, shipped loose, to be installed in a location favorable to the oil storage tank, shall be provided. 4.4.3.3.2 Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, solenoid shutoff valves, pressure gauges and fuel strainer, all integrally mounted on the unit. A fuel oil controller shall be provided to combine all of the fuel oil controls into a single casting which is mounted on the front door of the unit. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. A low oil pressure switch shall be included in the oil piping. 4.4.3.3.3 Low pressure air atomizing - Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch. 4.4.3.4 Gas Burner 4.4.3.4.1 Gas Burner Piping - gas burner piping on all units shall include primary gas shutoff valve, motor operated with proof of closure switch and plugged leakage test connection. The main gas valve(s) shall be wired to close automatically in the event of power failure, ame failure, low water or any safety shutdown condition. A lubricating plug cock or buttery shutoff valve shall be
A3-41
02-02
Model CB-LE Boilers
Firetube Boilers
provided as a means for a tightness check of the primary shut off valve. An additional plug cock or buttery valve shall be furnished at entrance to gas train. Select one of the following: A. 125-250 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided. B. 300-800 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus and additional plugged leakage test connection shall be provided. A vent valve shall be located between the safety shutoff valves. 4.4.3.5 Burner Turndown - Select one of the following: A. 125-200 hp. Turndown range of the burner shall be 4:1. B. 250-800 hp. Turndown range of the burner shall be 10:1 when ring natural gas and 8:1 on No. 2 oil. (Consult your local Cleaver-Brooks authorized representative regarding high turndown capability based on available gas pressure and No. 2 oil turndown capabilities when utilizing LE Options to achieve NOx levels of 25 or 20 ppm when ring natural gas.) 4.5 Boiler Flame Safeguard Controller and Control Panel 4.5.1 CB780 Flame Safeguard 4.5.1.1 Boilers with CB780 Control - Each boiler shall be factory equipped with ame safeguard controller providing technology and functions equal to the Cleaver-Brooks Model CB780. Controller shall be computerized solid state having sequence and ame-on lights and digital rst out fault code indications of ame safeguard trip functions. It shall include dynamic self-check logic. The controller shall have a xed operating sequence incapable of being manually altered. The sequence shall include start, pre-purge, pilot and main fuel ignition run and post-purge cycles. Controller shall be the non-recycle type for maximum safety that shall shutdown the burner and indicate as a minimum the following trip functions: pilot and main ame failure, high and low re proving switch faults, running interlocks open, false ame signal and fuel valve open (when proof of closure switch is furnished). The controller shall have a run/test switch. It shall allow interruptions to sequence just after pre-purge, during pilot ignition trial and run cycles for adjustments to ring rate motor, damper linkages and pilot ame for minimum turndown tests. 4.5.1.2 Control Panel: The control panel shall be mounted on the front door of the boiler in a location convenient to the operator. The hinged metal cabinet shall have NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet key type lock. The panel shall contain the boiler ame safeguard controller, blower motor starter, indicating lights and selector switches. The panel shall have a removable sub-base for mounting the ame safeguard controller, blower motor starter, and terminal blocks. For combination gas-oil red boilers the panel shall contain the fuel selector switch. The panel shall contain the following lights and switches: 4.5.1.3 Lights White - load demanded. White - fuel valve open. Red - low water. Red - ame failure. 4.5.1.4 Control Switches Burner On-Off. Manual-Automatic. Manual Firing Rate Control. 4.5.1.5 Oil, heat and moisture resistant wire shall be used and identied with circuit numbers corresponding to the electrical wiring diagram. 4.5.1.6 All electrical equipment and wiring shall be in conformance with Underwriters Laboratories requirements. 4.5.1.7 Boiler to be supplied with a control circuit transformer and fuse protection for the control circuit. A3-42
02-02
Firetube Boilers
4.5.2 CB-HAWK Flame Safeguard
Model CB-LE Boilers
Each boiler shall be factory equipped with a Boiler Management Control System providing technology and functions equal to the Cleaver-Brooks Model CB-HAWK. The system shall consist of a computer based boiler controller and solid state sensors totally integrated to provide automatic burner sequencing, ame supervision, and indications of system status, faults, and self-diagnostics. The boiler controller shall consist of chassis, program module, keyboard display, and ame signal amplier. It shall be the nonrecycle type and have a xed operating sequence incapable of being manually altered. The sequence shall include standby, prepurge, pilot, main fuel ignition, and run, and post-purge periods. The system shall incorporate full modulating control of fuel and combustion air as well as ring rate control based on system demand. The boiler controller shall have a non-volatile memory that retains history les and sequence status after interruptions. An 80 character, 2 line liquid crystal (LCD) display and keyboard shall be provided to adjust control settings and display 73 fault messages, 12 diagnostic messages, 38 historical messages as well as system status messages and operating pressures and temperatures. Boiler ring rate shall also be displayed in addition to the last 6 lockouts and boiler operating information when the lockout occurred. Provisions for a security access code shall be provided. Separate status indicators shall show: Ready: HAWK operational. Demand: call for heat. Main Valve: fuel valve open. Low Water: low water condition. Alarm: safety shutdowns The boiler controller shall incorporate a ve function run/test switch. The system shall be characterized for each individual model boiler. The system shall also incorporate a tailored pre-purge cycle that minimizes pre-purge energy losses, while maintaining the maximum required air changes. It shall permit the user to select a specic rate control program for precise load tracking that reduces on-off cycling due to load swings. The system shall also provide an integrated thermal stress protection program to prolong boiler life. An assured low re cutoff feature shall also be provided. The system shall monitor inputs from solid state sensor for gas pressure, oil pressure, and temperature. A single solid state sensor shall be used for both on-off and proportioning control of the burner. The high/low limits and operating set points of all sensors shall be programmable from the keyboard display. The system shall be capable of detecting a jumpered or defective sensor. A dynamic check of the gas pressure sensor shall be made prior to the main ame establishing period to ensure it is fully operational. An optional 2 way communications module with built-in modem to allow for remote control of non-safety settings and monitoring of up to 6 boilers shall also be available. Up to 3 pre-programmed telephone numbers shall be called in the event of a fault condition. Options such as Lead/Lag, Boiler Efciency, and Heating Boiler packages can be interfaced to this module without any change to the existing system structure. The communications module shall be able to interface with an IBMTM PC or compatible system. 4.5.2.1 Control Panel: The control panel shall be mounted on the front door of the boiler in a location convenient to the operator. The hinged metal cabinet shall have NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet key type lock. The panel shall contain the boiler ame safeguard controller, indicating lights and selector switches. Panel shall have a removable sub-base for mounting the ame safeguard controller, plug-in type fuel modules and terminal blocks. For combination gas-oil red boilers the plug-in fuel module shall contain the fuel selector switch. 4.5.2.2 Oil, heat, and moisture resistant wire shall be used and identied with circuit numbers corresponding to the electrical wiring diagram. 4.5.2.3 All electrical equipment and wiring shall be in conformance with Underwriters Laboratories requirements.
A3-43
02-02
Model CB-LE Boilers
Firetube Boilers
4.5.2.4 Boiler to be supplied with a control circuit transformer and fuse protection for the control circuit. 5.0 Efciency Guarantee 5.1 The boiler manufacturer shall guarantee that, at the time of startup, the boiler will achieve ________ fuel-to-steam efciency at 100% ring rate when burning natural gas and ________ fuel-to-steam efciency at 100% ring rate when burning oil (add efciency guarantees at 25%, 50%, and 75% of rating, if required). If the boiler(s) fail to achieve the corresponding guaranteed efciency as published, the boiler manufacturer will rebate, to the ultimate boiler owner, ve thousand dollars ($5,000) for every full efciency point (1.0%) that the actual efciency is below the guaranteed level. The specied boiler efciency is based on the following conditions. 5.2 Fuel specication used to determine boiler efciency: Natural Gas Carbon, % (wt) = 69.98 Hydrogen, % (wt) = 22.31 Sulfur, % (wt) = 0.0 Heating value, Btu/lb = 21,830 No. 2 Oil Carbon, % (wt) = 85.8 Hydrogen, % (wt) = 12.7 Sulfur, % (wt) = 0.2 Heating value, Btu/lb = 19,420 No. 6 Oil Carbon, % (wt) = 86.6 Hydrogen, % (wt) = 10.9 Sulfur, % (wt) = 2.09 Heating value, Btu/lb = 18,830 5.3 Efciencies are based on ambient air temperature of 80 F, relative humidity of 30%, and 15% excess air in the exhaust ue gas. 5.4 Efciencies are based on manufacturers published radiation and convection losses. (For Cleaver-Brooks radiation and convection losses, see Boiler Efciency Facts Guide, publication number CB-7767). 5.5 Any efciency verication testing will be based on the stack loss method. 6.0 Warranty 6.1 All equipment is to be guaranteed against defects in materials and/or workmanship for a period of 12 months from date of startup or 18 months from date of shipment, whichever comes rst. 7.0 Execution 7.1 Shop Tests 7.1.1 The packaged boiler must receive factory tests to check the construction, controls, and operation of the unit. All tests may be witnessed by the purchaser, if desired. 7.2 Start-up Service 7.2.1 After boiler installation is completed, the manufacturer shall provide the services of a eld representative for starting the unit and training the operator at no additional costs. 7.2.1.1 A factory approved and authorized start-up report shall be submitted to the customer/user at the time of start-up.
A3-44
02-02
Firetube Boilers
Model CB-LE Hot Water Boiler (125-800 hp, 30 psig, 125 psig) 1.0 Boiler Characteristics (Hot Water)
Model CB-LE Boilers
1.1 The Hot Water Boiler shall be Cleaver-Brooks Model CB, Fuel Series ______ (100, 200, 700), _____ hp designed for _____ psig (30, 125 psig, or other hot water). The maximum water temperature shall be _____ degree F, and the maximum system temperature drop shall be _____ degrees F. 1.2 The boiler shall have a maximum output of _____ Btu/hr, or _____ horsepower when red with CS 12-48 _____ oil and/or natural gas, _____ Btu/cu-ft. Electrical power available shall be _____Volt _____ Phase _____ Cycle. 2.0 General Boiler Design 2.1 The boiler shall be a four pass horizontal retube updraft boiler with ve (5) square feet (except 750 or 800 hp) of heating surface per rated boiler horsepower. It shall be mounted on a heavy steel frame with integral forced draft burner and burner controls. The complete package boiler shall be approved as a unit by Underwriters Laboratories and shall bear the UL/ULC label. 2.1.1 The boiler shall be completely preassembled and re tested at the factory. The unit shall be ready for immediate mounting on oor or simple foundation and ready for attachment of water, steam, fuel, electrical, vent and blowdown connections. 2.1.2 The boiler shall be built to comply with the following insurance and codes ____________________ (Factory Mutual, Industrial Risk Insurance, ASME CSD-1). 2.2 Boiler Shell (Hot Water) 2.2.1 The boiler shell must be constructed in accordance with ASME Boiler Code and must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser. 2.2.2 The hot water return and outlet connections shall be located on the top center line of the boiler. The boiler shall be designated to rapidly mix the return water with the boiler water. Forced internal circulation shall be used. 2.2.3 A dip tube shall be included as an integral part of the water outlet. 2.2.4 Two lifting eyes shall be located on top of the boiler. 2.2.5 Front and rear doors on the boiler shall be hinged or davited. Doors are to be sealed with berglass tadpole gaskets and fastened tightly using heavy capscrews that thread into replaceable brass nuts. 2.2.6 Rear refractory and insulation shall be contained in the formed door, which must swing open for inspection of brick work. 2.2.7 The boiler tubes shall not include turbulators, swirlers or other add-on appurtenances. 2.2.8 Front and rear tube sheets and all ues must be fully accessible for inspection and cleaning when the doors are swung open. The shell must be furnished with adequate handholes to facilitate boiler inspection and cleaning. 2.2.9 A manhole shall be provided. 2.2.10 The exhaust gas vent shall be located near the front of the boiler on the top center line and shall be capable of supporting 2000 lbs and shall contain a stack thermometer. 2.3 Observation ports for the inspection of ame conditions shall be provided at each end of the boiler. 2.4 The boiler insulation shall consist of a 2 inch blanket under a sectional preformed sheet metal lagging. This insulation must be readily removable and capable of being reinstalled, if required. 2.5 The entire boiler based frame and other components shall be factory painted before shipment using a hand nish enamel coating. 2.6 Emission Controls 2.6.1 Boiler shall be equipped with a low emission (LE) option for guaranteed NOx performance at ________ ppm, dry volume basis and corrected to 3% O2 when ring natural gas. 2.6.2 The low emission option shall include an integral front head, burner, and boiler package, providing NOx reduction through an internal ue gas recirculation system using the combustion air fan, internal recirculation valve, and enhanced boiler design to
A3-45
02-02
Model CB-LE Boilers
Firetube Boilers
achieve the guaranteed NOx levels. The emission control system shall not use an external fan, control valve, and piping. Boiler fuel-to-steam efciency and rated boiler capacity shall be guaranteed while the boiler is operating at the low NOx performance levels. 2.6.3 Burner, boiler, and low NOx system shall be manufactured as a package by a single manufacturer. The Low Emission Option to the CB Boiler shall included factory testing as a package, and shall bear the UL packaged label. The boiler nameplate shall include the approved UL low NOx boiler model designation. No eld assembly of the burner or low NOx equipment shall be required. 3.0 Hot Water Boiler Trim 3.1 Low Water Cutoff A low water cutoff control (manual reset) shall be mounted on the top centerline of the boiler wired into the burner control circuit to prevent burner operation if boiler water falls below a safe level. 3.2 Pressure and Temperature Gauges Pressure and temperature gauges shall be mounted on the boiler with temperature sensing element located adjacent to the hot water outlet. 3.3 Relief Valves Water relief valves of a type and size to comply with ASME Code requirements shall be shipped loose. 3.4 Temperature Controls Temperature controls to regulate burner operation shall be mounted on the unit with temperature sensing elements located adjacent to the hot water outlet. Controls shall be high limit (manual reset), operating limit (auto reset), and ring rate control. 4.0 Burner and Controls 4.1 Mode of Operation Burner operation shall be full modulation principle. The burner shall always return to low re position for ignition. 4.2 Blower 4.2.1 Air for combustion shall be supplied by a forced draft blower mounted in the front boiler door, above the burner, to eliminate vibration and reduce noise level. 4.2.2 Maximum sound level of the boiler/burner package shall not exceed _____ dbA (when measured in accordance with ABMA Sound Test Standards). 4.2.3 The impeller shall be cast aluminum, radial blade, carefully balanced, and directly connected to the blower motor shaft. 4.3 Combustion Air Control Combustion air damper and cam operated fuel metering valves shall be operated by a single damper control motor that regulates the re according to load demand. Potentiometer type position controls shall be provided to regulate operation of the damper control motor (remove this sentence when CB-HAWK ame safeguard is used). 4.4 Fuel Specication and Piping Select one of the following fuel types: Fuel series 700 - Gas red (4.4.1). Fuel series 100 - Light oil (No. 2) red (4.4.2). Fuel series 200 - Light oil or gas red (4.4.3). 4.4.1 Fuel Series 700 - Gas Fired 4.4.1.1 Burner Type - The burner shall be integral with the front head of the boiler and of high radiant multi-port type for gas. The burner shall be approved for operation on natural gas fuel and equipped with an LE option.
A3-46
02-02
Firetube Boilers
Model CB-LE Boilers
4.4.1.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include two manual shutoff valves, solenoid valve, pressure regulator and pressure gauge. 4.4.1.3 Gas Burner Piping - Gas burner piping on all units shall include primary gas shutoff valve, motor operated with proof of closure switch and plugged leakage test connection. The main gas valve(s) shall be wired to close automatically in the event of power failure, ame failure, low water or any safety shutdown condition. A lubricating plug cock or buttery shutoff valve shall be provided as a means for a tightness check of the primary shut off valve. An additional plug cock on buttery valve shall be furnished at entrance to gas train. Select one of the following: A. 125-250 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided. B. 300-800 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided. A vent valve shall be located between the safety shutoff valves. 4.4.1.4 Burner Turndown - Select one of the following: A. 125-200 hp. Turndown range of burner shall be 4:1 when ring natural gas. B. 250-800 hp. Turndown range of the burner shall be 10:1 when ring natural gas when equipped with a 60 or 30 ppm LE option. (Consult with Cleaver-Brooks Representative regarding high turndown capability based on available gas pressure and 25 and 20 ppm LE options.) 4.4.2 Fuel Series 100 - Light Oil Fired 4.4.2.1 Burner Type - The burner shall be integral with the front head of the boiler, and shall be a low pressure air atomizing type approved for operation with CS12-48, Commercial No. 2 oil and equipped with an LE option. 4.4.2.2 Oil Pilot - The oil pilot shall be air atomizing type with automatic electric ignition and include oil solenoid valve. An electronic detector shall monitor the pilot so that the primary oil valve cannot open until ame has been established. 4.4.2.3 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Separate motor driven pump set, shipped loose to be installed in a location favorable to the oil storage tank, shall be provided. 4.4.2.4 Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, solenoid shutoff valves, pressure gauges and fuel strainer, all integrally mounted on the unit. A fuel oil controller shall be provided to combine all of the fuel oil controls into a single casting which is mounted on the front door of the unit. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. A low oil pressure switch shall be included in the oil piping. 4.4.2.5 Low Pressure Air Atomizing - Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch. 4.4.2.6 Burner Turndown - Select one of the following: A. 125 hp through 200 hp. Turndown range shall be 4:1 when ring No. 2 oil. B. 250 hp through 800 hp. Turndown range shall be 8:1 when ring No. 2 oil. (Consult your local Cleaver-Brooks authorized representative regarding No. 2 oil turndown capabilities when utilizing LE Options to achieve NOx levels of 25 or 20 ppm when ring natural gas.) 4.4.3 Fuel Series 200 - Light Oil or Gas Fired 4.4.3.1 Burner Type - The burner, integral with the front head of the boiler, shall be a combination of the low pressure air atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 Oil or natural gas. The burner shall be equipped with an LE option. 4.4.3.2 Gas Pilot - The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary fuel valve cannot open until ame has been established. The pilot train shall include two manual shut-off valves, solenoid valve, pressure regulator and pressure gauge. 4.4.3.3 Oil Burner 4.4.3.3.1 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Separate motor driven pump set, shipped loose, to be installed in a location favorable to the oil storage tank, shall be provided. A3-47
02-02
Model CB-LE Boilers
Firetube Boilers
4.4.3.3.2 Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, solenoid shutoff valves, pressure gauges and fuel strainer, all integrally mounted on the unit. A fuel oil controller shall be provided to combine all of the fuel oil controls into a single casting which is mounted on the front door of the unit. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. A low oil pressure switch shall be included in the oil piping. 4.4.3.3.3 Low pressure air atomizing - Belt driven air compressor, lubricating oil tank, oil level indicator, inlet air lter, air pressure gauge and low atomizing air pressure switch. Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch. 4.4.3.4 Gas Burner 4.4.3.4.1 Gas Burner Piping - Gas burner piping on all units shall include primary gas shutoff valve, motor operated with proof of closure switch and plugged leakage test connection. The main gas valve(s) shall be wired to close automatically in the event of power failure, ame failure, low water or any safety shutdown condition. A lubricating plug cock or buttery shutoff valve shall be provided as a means for a tightness check of the primary shut off valve. An additional plug cock or buttery valve shall be furnished at entrance to gas train. Select one of the following: A. 125-250 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided. B. 300-800 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus and additional plugged leakage test connection shall be provided. A vent valve shall be located between the safety shutoff valves. 4.4.3.5 Burner Turndown - Select one of the following: A. 125-200 hp. Turndown range of the burner shall be 4:1. B. 250-800 hp. Turndown range of the burner shall be 10:1 when ring natural gas and 8:1 on No. 2 oil. (Consult your local Cleaver-Brooks authorized representative regarding high turndown capability based on available gas pressure and No. 2 oil turndown capabilities when utilizing LE Options to achieve NOx levels of 25 or 20 ppm when ring natural gas.) 4.5 Boiler Flame Safeguard Controller and Control Panel 4.5.1 CB780 Flame Safeguard 4.5.1.1 Boilers with CB780 Control - Each boiler shall be factory equipped with ame safeguard controller providing technology and functions equal to the Cleaver-Brooks Model CB780. Controller shall be computerized solid state having sequence and ame-on lights and digital rst out fault code indications of ame safeguard trip functions. It shall include dynamic self-check logic. The controller shall have a xed operating sequence incapable of being manually altered. The sequence shall include start, pre-purge, pilot and main fuel ignition run and post-purge cycles. Controller shall be the non-recycle type for maximum safety that shall shutdown the burner and indicate as a minimum the following trip functions: pilot and main ame failure, high and low re proving switch faults, running interlocks open, false ame signal and fuel valve open (when proof of closure switch is furnished). The controller shall have a run/test switch. It shall allow interruptions to sequence just after pre-purge, during pilot ignition trial and run cycles for adjustments to ring rate motor, damper linkages and pilot ame for minimum turndown tests. 4.5.1.2 Control Panel - The control panel shall be mounted on the front door of the boiler in a location convenient to the operator. The hinged metal cabinet shall have NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet key type lock. The panel shall contain the boiler ame safeguard controller, blower motor starter, indicating lights and selector switches. The panel shall have a removable sub-base for mounting the ame safeguard controller, blower motor starter, and terminal blocks. For combination gas-oil red boilers the panel shall contain the fuel selector switch. The panel shall contain the following lights and switches: 4.5.1.3 Lights White - load demanded. White - fuel valve open. A3-48
02-02
Firetube Boilers
Red - low water. Red - ame failure. 4.5.1.4 Control Switches Burner On-Off. Manual-Automatic. Manual Firing Rate Control.
Model CB-LE Boilers
4.5.1.5 Oil, heat and moisture resistant wire shall be used and identied with circuit numbers corresponding to the electrical wiring diagram. 4.5.1.6 All electrical equipment and wiring shall be in conformance with Underwriters Laboratories requirements. 4.5.1.7 Boiler to be supplied with a control circuit transformer and fuse protection for the control circuit. 4.5.2 CB-HAWK Flame Safeguard Each boiler shall be factory equipped with a Boiler Management Control System providing technology and functions equal to the Cleaver-Brooks Model CB-HAWK. The system shall consist of a computer based boiler controller and solid state sensors totally integrated to provide automatic burner sequencing, ame supervision, and indications of system status, faults, and self-diagnostics. The boiler controller shall consist of chassis, program module, keyboard display, and ame signal amplier. It shall be the nonrecycle type and have a xed operating sequence incapable of being manually altered. The sequence shall include standby, prepurge, pilot, main fuel ignition, and run, and post-purge periods. The system shall incorporate full modulating control of fuel and combustion air as well as ring rate control based on system demand. The boiler controller shall have a non-volatile memory that retains history les and sequence status after interruptions. An 80 character, 2 line liquid crystal (LCD) display and keyboard shall be provided to adjust control settings and display 73 fault messages, 12 diagnostic messages, 38 historical messages as well as system status messages and operating pressures and temperatures. Boiler ring rate shall also be displayed in addition to the last 6 lockouts and boiler operating information when the lockout occurred. Provisions for a security access code shall be provided. Separate status indicators shall show: Ready: HAWK operational. Demand: call for heat. Main Valve: fuel valve open. Low Water: low water condition. Alarm: safety shutdowns. The boiler controller shall incorporate a ve function run/test switch. The system shall be characterized for each individual model boiler. The system shall also incorporate a tailored pre-purge cycle that minimizes pre-purge energy losses, while maintaining the maximum required air changes. It shall permit the user to select a specic rate control program for precise load tracking that reduces on-off cycling due to load swings. The system shall also provide an integrated thermal stress protection program to prolong boiler life. An assured low re cutoff feature shall also be provided. The system shall monitor inputs from solid state sensor for gas pressure, oil pressure, and temperature. A single solid state sensor shall be used for both on-off and proportioning control of the burner. The high/low limits and operating set points of all sensors shall be programmable from the keyboard display. The system shall be capable of detecting a jumpered or defective sensor. A dynamic check of the gas pressure sensor shall be made prior to the main ame establishing period to ensure it is fully operational. An optional 2 way communications module with built-in modem to allow for remote control of non-safety settings and monitoring of up to 6 boilers shall also be available. Up to 3 pre-programmed telephone numbers shall be called in the event of a fault condiA3-49
02-02
Model CB-LE Boilers
Firetube Boilers
tion. Options such as Lead/Lag, Boiler Efciency, and Heating Boiler packages can be interfaced to this module without any change to the existing system structure. The communications module shall be able to interface with an IBMTM PC or compatible system. 4.5.2.1 Control Panel: The control panel shall be mounted on the front door of the boiler in a location convenient to the operator. The hinged metal cabinet shall have NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet key type lock. The panel shall contain the boiler ame safeguard controller, indicating lights and selector switches. Panel shall have a removable sub-base for mounting the ame safeguard controller, and terminal blocks. For combination gas-oil red boilers the panel shall contain the fuel selector switch. 4.5.2.2 Oil, heat, and moisture resistant wire shall be used and identied with circuit numbers corresponding to the electrical wiring diagram. 4.5.2.3 All electrical equipment and wiring shall be in conformance with Underwriters Laboratories requirements. 4.5.2.4 Boiler to be supplied with a control circuit transformer and fuse protection for the control circuit. 5.0 Efciency Guarantee 5.1 The boiler manufacturer shall guarantee that, at the time of startup, the boiler will achieve ________ fuel-to-steam efciency at 100% ring rate when burning natural gas and ________ fuel-to-steam efciency at 100% ring rate when burning oil (add efciency guarantees at 25%, 50%, and 75% of rating, if required). If the boiler(s) fail to achieve the corresponding guaranteed efciency as published, the boiler manufacturer will rebate, to the ultimate boiler owner, ve thousand dollars ($5,000) for every full efciency point (1.0%) that the actual efciency is below the guaranteed level. The specied boiler efciency is based on the following conditions. 5.2 Fuel specication used to determine boiler efciency: Natural Gas Carbon, % (wt) = 69.98 Hydrogen, % (wt) = 22.31 Sulfur, % (wt) = 0.0 Heating value, Btu/lb = 21,830 No. 2 Oil Carbon, % (wt) = 85.8 Hydrogen, % (wt) = 12.7 Sulfur, % (wt) = 0.2 Heating value, Btu/lb = 19,420 No. 6 Oil Carbon, % (wt) = 86.6 Hydrogen, % (wt) = 10.9 Sulfur, % (wt) = 2.09 Heating value, Btu/lb = 18,830 5.3 Efciencies are based on ambient air temperature of 80 F, relative humidity of 30%, and 15% excess air in the exhaust ue gas. 5.4 Efciencies are based on manufacturers published radiation and convection losses. (For Cleaver-Brooks radiation and convection losses, see Boiler Efciency Facts Guide, publication number CB-7767). 5.5 Any efciency verication testing will be based on the stack loss method. 6.0 Warranty 6.1 All equipment is to be guaranteed against defects in materials and/or workmanship for a period of 12 months from date of startup or 18 months from date of shipment, whichever comes rst.
A3-50
02-02
Firetube Boilers
7.0 Execution 7.1 Shop Tests
Model CB-LE Boilers
7.1.1 The packaged boiler must receive factory tests to check the construction, controls, and operation of the unit. All tests may be witnessed by the purchaser, if desired. 7.2 Start-up Service 7.2.1 After boiler installation is completed, the manufacturer shall provide the services of a eld representative for starting the unit and training the operator at no additional costs. 7.2.1.1 A factory approved and authorized start-up report shall be submitted to the customer/user at the time of start-up.
A3-51
02-02
Model CB-LE Boilers
Firetube Boilers
NOTES
A3-52
02-02
Section A4
MODEL CBW BOILERS
CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-3 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-3 DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-4 PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-14 Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-14 Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-14 ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-15 Blowdown Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-15 Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-17 Burner Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-18 Gas - Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-18 Gas Pressure Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-18 Oil - Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-21 No. 6 Oil Piping, Storage Tank Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-21 Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-30 Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-30 Stack and Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-30 Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-30 SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-33 Model CBW Steam Boiler (100-800 hp, Steam 15-250 psig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-33 Model CBW Hot Water Boiler (100-800 hp, 30 and 125 psig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-41
A4-1
10-02
Model CBW Boilers

ILLUSTRATIONS
Firetube Boilers
Figure A4-1. Model CBW Steam Boiler Dimensions (100 thru 800 hp) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-8 Figure A4-2. Model CBW Hot Water Boiler Dimensions (100 thru 800 hp) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . A4-10 Figure A4-3. Model CBW Space Requirements to Open Rear Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-12 Figure A4-4. Model CBW Boiler Mounting Piers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-12 Figure A4-5. Lifting Lug Location, Model CBW Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-13 Figure A4-6. Model CBW Standard Gas Train Connection Size and Location, IRI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-21 Figure A4-7. Typical Gas Piping Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-22 Figure A4-8. Gas Train Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-23 Figure A4-9. No. 2 Oil Connection Size, Location and Recommended Line Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-24 Figure A4-10. No. 6 Oil Connection Size, Location and Recommended Line Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-24 Figure A4-11.No. 2 Oil Piping, Single Boiler Installation, Remote Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-25 Figure A4-12. No. 2 Oil Piping, Multiple Boiler Installation, Remote Oil Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-25 Figure A4-13. No. 2 Oil Piping, Multiple Boiler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-26 Figure A4-14. No. 6 Oil Piping, Single Boiler Installation, Remote Oil Pumps 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-26 Figure A-15. No. 6 Oil Piping, Multiple Boiler Installation, Remote Oil Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-27 Figure A-16. No. 6 Oil Piping, Multiple Boiler Installation 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-27 Figure A-17. No. 2 Oil Transfer Tank Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-28 Figure A-18. Typical Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-28 Figure A-19. Typical Cross Section of Bundled Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-29 Figure A-20. Schematic of Standard Alstrom Hot Water Safety-Type Preheating System . . . . . . . . . . . . . . . . . . . . . . . . A4-29 Figure A-21. Boiler Room Length, Typical Layout (CBW Boilers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-31 Figure A-22. Boiler Room Width, Typical Layout (CBW Boilers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-31 Figure A-23. Breeching Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-32 TABLES Table A4-1. Model CBW Steam Boiler Ratings (15 and 150 psig Design Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-5 Table A4-2. Model CBW Hot Water Boiler Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-5 Table A4-3.Model CBW Steam Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-6 Table A4-4. Model CBW Hot Water Boiler Relief Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-6 Table A4-5. Model CBW Boiler Emission Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-14 Table A4-6. Heating Surface, Model CBW Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-15 Table A4-7. Steam Volume and Disengaging Areas, Model CBW Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-15 Table A4-8. Water Circulation Rate and Temperature Drop for Hot Water Boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-16 Table A4-9. Recommended Steam Nozzle Size (to Maintain 4000 to 5000 fpm Nozzle Velocity) . . . . . . . . . . . . . . . . . A4-16 Table A4-10. Recommended Non-Return Valve Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-17 Table A4-11. Blowdown Tank Sizing Information, CBW Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-17 Table A4-12. Model CBW Boiler Sound Pressure Level Summary (100 - 800 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-18 Table A4-13. Model CBW Minimum Required Gas Pressure at Entrance to Standard and FM Gas Trains (Downstream of Gas Pressure Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-19 Table A4-14. Model CBW Minimum Required Gas Pressure at Entrance to Gas Trains Equipped with Industrial Risk (IRI) Requirements (Downstream of Gas Pressure Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-19 Table A4-15. Minimum Required Gas Pressure Altitude Conversion at 700 ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-19 Table A4-16. Under and Oversized Standard, FM, and IRI Gas Trains, Model CBW Boilers, 100 - 800 hp . . . . . . . . . . A4-20 Table A4-17. Model CBW Boiler Maximum Consumption (CFH) for Natural Gas and Propane Vapor . . . . . . . . . . . . . A4-20 The following section contains information on Cleaver- Brooks Model CBW Boilers.
A4-2
10-02
Firetube Boilers
Model CBW Boilers

Retractable oil nozzle provides easy access and cleaning and eliminates coking of oil nozzle tip when ring gas.

The Model CBW 3-Pass Wetback boiler includes the integral front head package on a wetback boiler vessel. In addition to the features provided on all Cleaver-Brooks Firetube boilers, the following features apply to Model CBW Firetube Boilers. Three-Pass Wetback Design: Three-pass wetback design provides good boiler efciency with minimum refractory. Five square feet of heating surface per boiler horsepower (except 800 hp) provides guaranteed efciency performance and long boiler life. Hinged Front Door: Provides full access to front tube sheet and furnace. Rear furnace access manhole provided. High Turndown Burner: 4:1 turndown (gas and oil) is standard on boilers up to 250 hp. Guaranteed 10:1 turndown (gas red) 8:1 (No. 2 oil red) standard on 250 hp through 800 hp. Advanced burner design provides maximum combustion efciencies and high turndown. Reduced boiler cycling and maintenance. Boiler stays on line during low load conditions for optimum efciency and performance. Gas, No. 2 Oil, and No. 6 Oil, and Combination Gas and Oil Burners Available: High radiant annular gas entry on 100-200 hp and high radiant multi-port gas burner on 250-800 hp, designed for high gas velocities and complete fuel/air mixing, provides maximum combustion efciencies. Air atomizing oil burner available for proper oil atomization, maximum combustion efciency, and low maintenance requirements. Air atomizing compressor provided with the boiler package for clean oil burning and ease of maintenance. Combination gas/oil burners provide quick fuel changeover without re-adjustment of the burner. Fuel oil controller eliminates the need for over 40 connections, combining gauges, valves, and regulators into a single casting.
PRODUCT OFFERING
Model CBW boilers are available in low pressure steam, high pressure steam, and hot water designs. Burners are available to re natural gas, light oil, heavy oil, or a combination of oil and gas. Optional alternate fuel burners are also available. Model CBW boilers include: Three-pass wetback design. 100 hp through 800 hp. 150 psig - 250 psig high pressure steam. 15 psig low pressure steam. 30 psig or 125 psig hot water. Natural gas, light oil, or heavy oil ring. The Model CBW boiler provides the advantages of the Cleaver-Brooks integral front head in a three-pass wetback design. Available options: For option details, contact your CleaverBrooks authorized representative. In summary, options include the following: Boiler Options Auxiliary low water cut-off (standard on steam boilers). Drain valves. Additional screwed or anged tappings. Special design pressures. Surge load bafes. Seismic design. Internal hot water coils. Blowdown valves. Non-return valves. Feedwater valves and regulators. Special doors, davited, hinged, left swing. Special base rails. Surface blowdown systems. Combustion relief door. Weather-proong. Blend pump.
A4-3
10-02
Model CBW Boilers

Burner/Control Options Special modulation controls. Optional ame safeguard controller. Lead/lag system. High altitude design, up to 12,000 ft. Special insurance and code requirements (e.g., IRI, FM, ASME CSD-1). Alarm bell/silence switch. Special motor requirements (TEFC, high efciency). Remote contacts. Special purpose indicator light. Main disconnect. Elapsed time meter. Voltmeter/micro-ammeter. NEMA enclosures. Low re hold controls. Remote emergency shut-off (115V). Circuit breaker. Day/night controls. Special power requirements. Fuel Options Special gas pressure regulator. Oversized/undersized gas trains. Gas strainer. Special fuel shut-off valves. Special pilot. Alternate fuel ring (digester gas, propane, etc.). Special oil pumps.
Firetube Boilers
Table A4-4. Model CBW Hot Water Boiler Relief Valve Openings. Figure A4-1. Model CBW Steam Boiler Dimensions (100 800 hp) FigureA4-2. Model CBW Hot Water Boiler Dimensions (100 - 800 hp) Figure A4-3. Model CBW Boiler Space Requirements to Open Rear Door Figure A4-4. Model CBW Boiler Mounting Piers Figure A4-5. Lifting Lug Location, Model CBW Boilers

Dimensions and ratings for the Model CBW boilers are shown in the following tables and illustrations: Table A4-1. Model CBW Steam Boiler Ratings (15 and 150 psig Design Pressure) Table A4-2. Model CBW Hot Water Boiler Ratings Table A4-3. Model CBW Steam Boiler Safety Valve Openings.
A4-4
10-02
Firetube Boilers
BOILER HP 100 125 150 200 250 300 350 400 500
Model CBW Boilers

600 700 750 800
Table A4-1. Model CBW Steam Boiler Ratings (15 and 150 psig Design Pressure)
BOILER OUTPUT Rated Steam lb/hr (212F) Btu Output (1000 Btu/hr) 3450 3348 4313 4189 5175 5021 6900 6695 8625 8369 10350 12075 13800 17250 20700 24150 25875 27600 10043 11716 13390 16738 20085 23432 25106 26780
Approximate Fuel Consumption Light Oil gph (140000 Btu/gal) Heavy Oil gph (150000 Btu/gal) Nat. Gas cfh (1000 Btu/cu-ft) Nat. Gas Therms/hr 30.0 28.0 4185 41.9 37.5 35.0 5230 52.3 45.0 42.0 6280 62.8 60.0 56.0 8370 83.7 74.5 69.5 89.5 83.5 104.5 97.5 119.5 111.5 149.5 139.5 179.5 167.5 209.0 195.5 224.0 209.0 239.0 223.0
10460 12555 14650 16750 20925 25100 29300 31385 33500 104.6 125.5 146.5 167.5 209.3 251.0 293.0 313.8 335.0
WEIGHT IN POUNDS Normal Water Capacity 6385 6600 8050 11000 11394 13466 15861 17936 21353 25531 29835 29835 29835
Approx. Shipping Weight - 150 psig 12300 12950 14000 16850 21750 24300 26500 28750 38800 43950 50950 51200 51200 Approx. Shipping Weight - 15 psig 11250 12150 12950 15600 20300 22450 25250 27650 35800 40950 47850 48250 48250 Approx. Shipping Weight - 200 psig 12950 13560 14710 17700 23450 26200 27900 30250 41250 47250 57250 57450 57450 POWER REQUIREMENTS - ELECTRIC (60 HZ)c Blower Motor hp Exc. Gas Only Blower Motor hp Gas Only Oil Pump Motor hp No. 2 Oil Oil Pump Motor hp & No. 6 Oil Oil Heater kW No. 6 Oil Air Compressor Motor hp 5 5 1/3 1/3 5 5 5 1/2 1/2 5 7-1/2 5 1/2 1/2 5 10 10 1/2 1/2 5 7-1/2 7-1/2 1/2 1/2 7-1/2 10 7-1/2 3/4 1/2 7-1/2 15 15 3/4 3/4 7-1/2 20 20 3/4 3/4 7-1/2 15 15 3/4 3/4 20 20 3/4 3/4 30 30 1 3/4 40 40 1 3/4 50 50 1 3/4
7-1/2B 7-1/2B 7-1/2B 7-1/2B 7-1/2B 7-1/2 7-1/2 7-1/2 7-1/2 7-1/2
AIR COMPRESSOR BELT DRIVEN FROM BLOWER MOTOR
NOTES: A. Standard voltage is 230/460/575/3/60 Hz. Control circuit is 115/1/60 Hz. B. 10 kW on low pressure (15 psig) boilers. C. Larger motors may be required at higher altitudes.
Table A4-2. Model CBW Hot Water Boiler Ratings

BOILER HP 100 125 150 200 250 300 350 400 500 600 700
750
800
BOILER OUTPUT Btu Output (1000 Btu/hr) Approx. Fuel consp Light Oil gph (140000 Btu/gal) Heavy Oil gph (150000 Btu/gal) Nat. Gas CFH (1000 Btu/cu-ft) Nat. Gas Therms/hr 3348 30.0 28.0 4185 41.9 4189 37.5 35.0 5230 52.3 5021 45.0 42.0 6280 62.8 6695 60.0 56.0 8370 83.7 8369 74.5 69.5 10460 104.6 10043 89.5 83.5 12555 125.5 11716 104.5 97.5 14650 146.5 13390 119.5 111.5 16750 167.5 16738 149.5 139.5 20925 209.3 20085 179.5 167.5 23432 25106 26780 209.0 195.5
224.0 239.0 209.0 223.0
25100 29300 31385 33500 251.0 293.0
313.8 335.0
WEIGHT IN POUNDS Normal Water Capacity Approx. Shipping Weight 30 psig Approx. Shipping Weight 125 psig 8650 11350 12400 8625 12250 13050 10310 13050 14100 13960 15700 16950 14170 20400 21850 16770 22550 24400 19640 25350 26600 22140 27750 28850 28200 35900 38900 33690 41050 44300 39215 39215 39215 47950 48350 48350 51900 52000 52000
POWER REQUIREMENTS - ELECTRIC (60 HZ)B Blower Motor hp Exc Gas Only Blower Motor hp Gas Only Oil Pump Motor hp No. 2 Oil Oil Pump Motor hp No. 6 Oil Oil Heater kW No. 6 Oil Air Compressor Motor (hp) 5 5 1/3 1/3 5 5 5 1/2 1/2 5 7-1/2 5 1/2 1/2 5 10 10 1/2 1/2 5 7-1/2 7-1/2 1/2 1/2 7-1/2 10 7-1/2 3/4 1/2 7-1/2 15 15 3/4 3/4 7-1/2 20 20 3/4 3/4 10 15 15 3/4 3/4 10 7-1/2 20 20 3/4 3/4 10 7-1/2 30 30 1 3/4 10 7-1/2
40 40 1 3/4 10 7-1/2
50 50 1 3/4 10 7-1/2
AIR COMPRESSOR BELT DRIVEN FROM BLOWER MOTOR
NOTES: A. Standard voltage is 230/460/575/3/60 Hz. Control circuit is 115/1/60 Hz. B. Larger motors may be required at higher altitudes.
A4-5
10-02
Model CBW Boilers

Table A4-3. Model CBW Steam Boiler Safety Valve Openings
VALVE SET- 15 PSIG STEAM TING
Firetube Boilers
100 PSIG STEAM 125 PSIG STEAM 150 PSIG STEAM 200 PSIG STEAM 250 PSIG STEAM
NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET BOILER HP VALVES- SIZE VALVES- SIZE VALVES SIZE VALVES- SIZE VALVES- SIZE VALVES SIZE REQ'D (IN.) REQ'D (IN.) REQ'D (IN.) REQ'D (IN.) REQ'D (IN.) REQ'D (IN.) 100 125 150 200 250 300 350 400 500 600 700, 750, 800 1 1 1 2 2 2 3 3 3 4 5 2-1/2 3 3 2-1/2 (1) 2-1/2 (1) 3 3 (1) 2 (2) 3 (2) 3 (1) 2-1/2 3 3 (3) 3 (2) 2-1/2 1 2 2 2 2 2 3 3 3 4 5 2 1-1/2 (1) 2 (1) 1-1/2 2 (1) 2-1/2 (1) 2 2-1/2 (1) 2-1/2 (2) 2 (1) 2 (2) 2-1/2 2-1/2 (3) 2-1/2 (1) 2 (3) 2-1/2 (2) 2 1 2 2 2 2 2 2 2 3 3 4 2 (1) 1-1/2 (1) 1-1/4 1-1/2 (1) 2 (1) 1-1/2 2 (1) 2-1/2 (1) 2 2-1/2 2-1/2 (2) 2-1/2 (1) 2 2-1/2 (3) 2-1/2 (1) 2 1 2 2 2 2 2 2 2 2 3 3 1-1/2 (1) 1-1/2 (1) 1-1/4 (2) 1-1/4 1-1/2 (1) 2 (1) 1-1/2 (2) 2 (1) 2-1/2 (1) 2 (1) 2-1/2 (1) 2 2-1/2 (2) 2-1/2 (1) 2 (2) 2-1/2 (1) 2 1 2 2 2 2 2 2 2 2 2 2 1-1/2 (1) 1-1/4 (1) 1 1-1/4 (1) 1-1/2 (1) 1-1/4 1-1/2 (1) 2 (1) 1-1/2 2 2 (1) 2-1/2 (1) 2 2-1/2 2-1/2 1 2 2 2 2 2 2 2 2 2 2 1-1/4 1 (1) 1 (1) 1-1/4 1-1/4 (1) 1-1/2 (1) 1-1/4 1-1/2 (1) 1-1/2 (1)2 (1) 2 (1) 1-1/2 (2) 2 (1) 2 (1) 2-1/2 2-1/2
Table A4-4. Model CBW Hot Water Boiler Relief Valve Openings
VALVE SETTING BOILER HP 100 125 150 200 250 300 350 400 500 600 700, 750, 800 30 PSIG HW NO. OF VALVES REQ'D 1 1 1 2 2 2 3 3 4 4 5 OUTLET SIZE (IN.) 2-1/2 2-1/2 2-1/2 (1) 2-1/2 (1) 1-1/4 (1) 2 (1) 2-1/2 (2) 2-1/2 (2) 2-1/2 (1) 1 (1) 2 (2) 2-1/2 (1) 1 (3) 2-1/2 (3) 2-1/2 (1) 2 (1) 1 (4) 2-1/2 60 PSIG HW NO. OF VALVES REQ'D 1 1 1 1 1 2 2 2 2 3 3 OUTLET SIZE (IN.) 2 2 2-1/2 2-1/2 2-1/2 (1) 3/4 (1) 2 2-1/2 (1) 2 (1) 2-1/2 2-1/2 (1) 1-1/4 (2) 2-1/2 (1) 2 (2) 2-1/2 100 PSIG HW NO. OF VALVES REQ'D 1 1 1 1 1 1 1 2 2 2 2 OUTLET SIZE (IN.) 1-1/4 2 2 2 2-1/2 2-1/2 (1) 2-1/2 (1) 1 (1) 2-1/2 (1) 2-1/2 (1) 1-1/4 (1) 2 (1) 2-1/2 2-1/2 125 PSIG HW NO. OF VALVES REQ'D 1 1 1 1 1 1 1 1 2 2 2 OUTLET SIZE (IN.) 1-1/4 1-1/4 2 2 2 2-1/2 2-1/2 2-1/2 (1) 1 (1) 2-1/2 (1) 1-1/4 (1) 2-1/2 (1) 2-1/2 (1) 2 150 PSIG HW NO. OF VALVES REQ'D 1 1 1 1 1 1 1 1 1 2 2 OUTLET SIZE (IN.) 1-1/4 1-1/4 1- 1/4 2 2 2 2-1/2 2-1/2 2-1/2 (1) 1 (1) 2-1/2 (1) 1-1/4 (1) 2-1/2
NOTE: Hot water relief valves are Kunkle #137.
A4-6
10-02
Firetube Boilers
Model CBW Boilers
NOTES
A4-7
10-02
Model CBW Boilers
Firetube Boilers
BOILER HP
DIM
100
125
150
200
250 LENGTH
300
350
400
500
600
700
750
800
Overall Shell Base Frame Front Head Extension Flange To Nozzle (15 psig) Flange to Nozzle (150 psig)
A B C D E F
192 158 147 30 56 56
192 158 147 30 56 56
216 181 170 31 72 72
266 229 218 33 108 108
201 168 157 29 70 70 WIDTHS
228 192 181 32 90 90
253 217 206 32 108 108
281 242 231 35 118 118
250 220 206 26 101 101
289 255 240 30 111 111
324 290 276 30
326 290 276 32
326 290 276 32
127-1/2 127-1/2 127-1/2 127-1/2 127-1/2 127-1/2
Overall I.D. Boiler Center to Water Column Center to Outside Hinge Center to Lagging Centering to Auxiliary LWCO Base-Outside Base-Inside
I J K KK L LL M N
85 60 45 35 33 40
85 60 45 35 33 40
85 60 45 35 33 40
85 60 45 35 33 40
103 78 54 51 42 49 64 52
103 78 54 51 42 49 64 52
103 78 54 51 42 49 64 52
103 78 54 51 42 49 64 52
123 96 64 62 51 59 72 56
123 96 64 62 51 59 72 56
123 96 64 62 51 59 72 56
123 96 64 62 51 59 72 56
123 96 64 62 51 59 72 56
51-1/2 51-1/2 51-1/2 51-1/2 43-1/2 43-1/2 43-1/2 43-1/2
Figure A4-1. Model CBW Steam Boiler Dimensions (100 thru 800 hp) - Sheet 1 of 2
A4-8
12-02 10-02
Firetube Boilers
Model CBW Boilers
BOILER HP
DIM
100
125
150
200
250 HEIGHTS
300
350
400
500
600
700
750
800
Overall Base to Vent Outlet Base to Steam Outlet Davit - Front Base Frame Base to Bottom Boiler
OO O P DF Q R
88 85 82-3/8 12 16
88 85 82-3/8 12 16
88 85 82-3/8 12 16
88 85
106 106
106 106
106 106
106 106
126 126 122 126 12 19
126 126 122 126 12 19
126 126 122 126 12 19
126 126 122 126 12 19
126 126 122 126 12 19
82-3/8 101-1/2 101-1/2 101-1/2 101-1/2 12 16 105 10 17 105 10 17 105 10 17 105 10 17
BOILER CONNECTION Chemical Feed Feedwater - Right and Left Auxiliary Connection Steam Nozzle (15 psig)A Steam Nozzle (150 psig)B Drain - Front & Rear (15 psig) Blowdown - Front & Rear (150 psig) Surface Blow (150 lb only) Vent Stack Diameter (Flanged) Flange to Center Vent H S Z Y Y W W T BB CC 1 1-1/4 1 8 4 1-1/2 1 1-1/2 1 8 4 1-1/2 1 1-1/2 1 8 4 1-1/2 1 2 1 10 4 2 1 2 1-1/4 10 6 2 1 2 1-1/4 12 6 2 1 2-1/2 1-1/4 12 6 2 1 2-1/2 1-1/4 12 6 2 1 2-1/2 1-1/4 12 8 2 1 2-1/2 1-1/4 12 8 2 1 2-1/2 1-1/4 12 8 2 1 2-1/2 1-1/4 12 8 2 1 2-1/2 1-1/4 12 8 2
1-1/4 1 16 9-1/8
1-1/2 1 16 9-1/8
1-1/2 1 16 9-1/8
1-1/2 1 16 9-1/8
1-1/2 1 20 10-5/8
1-1/2 1 20 10-5/8
1-1/2 1 20 10-5/8
2 1 20 10-5/8
2 1 24 12-5/8
2 1 24 12-5/8
2 1 24 12-5/8
2 1 24 12-5/8
2 1 24 12-5/8
MINIMUM CLEARANCE Rear Door Swing Front Head Swing Tube Removal - Front Only Minimum Room Length for: Front Tube Removal Minimum Room Length for: Tube Removal Thru Door DD EE GG RF RD 36 67 124 318 261 36 67 124 318 261 36 67 147 364 284 36 67 195 460 332 46 89 128 342 303 46 89 152 390 327 46 89 177 440 352 46 89 202 490 377 54 108 171 445 382 54 108 206 515 417 54 108 242 586 452 54 108 242 586 452 54 108 242 586 452
NOTES: 1. Air compressor belt driven from blower motor on sizes 100 thru 400 hp. 2. Control Panel relocation on boilers 250 hp and up. 3. Base rail mounted air compressor module on sizes 500 thru 800 hp. 4. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension prints. A. Flanged 150 psig ANSI. B. Flanged 300 psig ANSI.
Figure A4-1. Model CBW Steam Boiler Dimensions (100 thru 800 hp) - Sheet 2 of 2
A4-9
10-02 12-02
Model CBW Boilers
Firetube Boilers
LWCO
BOILER HP
DIM
100
125
150
200
250
300
350
400
500
600
700
750
800
LENGTHS Overall Shell Base Frame Front Head Ext. Flange to Return Flange to Outlet A B C D E F 192 158 147 30 100 125 192 158 147 30 100 125 216 181 170 31 123 148 266 229 218 33 171 196 201 168 157 29 108 134 228 192 181 32 132 158 253 217 206 32 157 183 281 242 231 35 178 210 250 220 206 26 134 170 289 255 240 30 169 205 324 290 276 30 204 240 326 290 276 32 204 240 326 290 276 32 204 240
WIDTHS Overall I.D. Boiler Center to Entrance Box Center to Outside Hinge Center to Lagging Base-Outside Base-Inside I J K KK L M N 75-1/2 75-1/2 75-1/2 75-1/2 60 60 60 60 93 78 51 51 42 64 52 93 78 51 51 42 64 52 93 78 51 51 42 64 52 93 78 51 51 42 64 52 113 96 62 62 51 72 56 113 96 62 62 51 72 56 113 96 62 62 51 72 56 113 96 62 62 51 72 56 113 96 62 62 51 72 56
42-1/2 42-1/2 42-1/2 42-1/2 35 33 35 33 35 33 35 33
51-1/2 51-1/2 51-1/2 51-1/2 43-1/2 43-1/2 43-1/2 43-1/2
Figure A4-2. Model CBW Hot Water Boiler Dimensions (100 thru 800 hp) - Sheet 1 of 2
A4-10
12-02 10-02
Firetube Boilers
Model CBW Boilers
BOILER HP
DIM
100
125
150
200
250
300 HEIGHTS
350
400
500
600
700
750
800
Overall Base to Vent Outlet Base to Return/Outlet Davit - Front Base Frame Base to Bottom Boiler
OO O P DF Q R
88 85
88 85
88 85
88 85
106 106
106 106
106 106
106 106
126 126
126 126
126 126
126 126
126 126
82-1/2 82-1/2 82-1/2 82-1/2 101-1/2 101-1/2 101-1/2 101-1/2 123-1/2 123-1/2 123-1/2 123-1/2 123-1/2 12 16 12 16 12 16 12 16 105 10 17 105 10 17 105 10 17 105 10 17 126 12 19 126 12 19 126 12 19 126 12 19 126 12 19
BOILER CONNECTIONS Waterfill - Right & Left Auxiliary Connection Water Return Water OutletA Drain - Front & Rear Air Vent Vent Stack Dia (Flanged) S Z U Y W T BB 1-1/4 1 4 4 1-1/2 1-1/2 16 9 1-1/2 1 6 6 1-1/2 1-1/2 16 9 1-1/2 1 6 6 1-/12 1-1/2 16 9 2 1 6 6 2 1-1/2 16 9 2 1-1/4 8 8 2 1-1/2 20 10-1/2 2 1-1/4 8 8 2 1-1/2 20 10-1/2 2-1/2 1-1/4 8 8 2 1-1/2 20 10-1/2 2-1/2 1-1/4 10 10 2 2 20 10-1/2 2-1/2 1-1/4 10 10 2 2 24 12-5/8 2-1/2 1-1/4 12 12 2 2 24 12-5/8 2-1/2 1-1/4 12 12 2 2 24 12-5/8 2-1/2 1-1/4 12 12 2 2 24 12-5/8 2-1/2 1-1/4 12 12 2 2 24 12-5/8
Flange to Center Vent CC
MINIMUM CLEARANCE Rear Door Swing Front Head Swing DD EE 36 67 124 318 261 36 67 124 318 261 36 67 147 364 284 36 67 195 460 332 46 89 128 342 303 46 89 152 390 327 46 89 177 440 352 46 89 202 490 377 54 108 171 445 382 54 108 206 515 417 54 108 242 586 452 54 108 242 586 452 54 108 242 586 452
Tube Removal - Front GG Only Min. Room Length for: RF Front Tube Removal Min. Room Length for: RD Tube Removal thru Door
NOTES: 1. Air compressor belt driven from blower motor on sizes 100thru 400 hp. All compressor module on sizes 500 thru 800 hp. 2. Control Panel relocation on boilers 250 hp and up. 3. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension prints. A. 2 dip tube in outlet.
Figure A4-2. Model CBW Hot Water Boiler Dimensions (100 thru 800 hp) - Sheet 2 of 2
A4-11
10-02 12-02
Model CBW Boilers
Firetube Boilers
DIMENSIONS (INCHES) BOILER HP A 100-200 250-400 500-800 33 42 51 B 42 53 64 C 54 61 73 D 77 92 109 E 36 46 54
Figure A4-3. Model CBW Space Requirements to Open Rear Door
BOILER HP 100 125 150 200 250 300 350 400 500 600 700-800
A 6 6 6 6 6 6 6 6 6 6 6
B 9 9 9 9 12 12 12 12 14 14 14
C 147 147 170 218 157 181 206 231 206 240 276
D 39-1/2 39-1/2 39-1/2 39-1/2 46 46 46 46 50 50 50
E 57-1/2 57-1/2 57-1/2 57-1/2 70 70 70 70 78 78 78
F 4 4 4 4 6 6 6 6 8 8 8
G 44-1/2 44-1/2 44-1/2 44-1/2 52-3/8 52-3/8 52-3/8 52-3/8 56 56 56
X 9-3/4 9-3/4 9-3/4 9-3/4 22 22 22 22 24 24 24
Y 16-5/8 16-5/8 16-5/8 16-5/8 20-1/2 20-1/2 20-1/2 20-1/2 29 29 29
Figure A4-4. Model CBW Boiler Mounting Piers A4-12

10-02 12-02
Firetube Boilers
Model CBW Boilers
ALL DIMENSIONS IN INCHES BOILER HP 100 Steam Hot Water 125 Steam Hot Water 150 Steam Hot Water 200 Steam Hot Water 250 Steam Hot Water 300 Steam Hot Water 350 Steam Hot Water 400 Steam Hot Water 500 Steam Hot Water 600 Steam Hot Water 700 750 800 Steam Hot Water VIEW A B B B B B B B B B B B B B B B B B B B B B B 80 80 80 80 80 80 80 80 99 99 99 99 99 99 99 99 99 99 99 99 99 99 B 19 19 19 19 19 19 19 19 25 25 25 25 25 25 25 25 28 28 28 28 28 28 C 121 121 121 121 144 144 192 192 114 114 138 138 163 163 188 188 158 158 193 193 228 228 D 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 11 11 11 11 11 11 E 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
NOTE: A, B and C Dimensions may vary by 1/2 inch.
Figure A4-5. Lifting Lug Location, Model CBW Boilers A4-13

10-02
Model CBW Boilers
Firetube Boilers
PERFORMANCE DATA
Efficiency
Efciency on Model CBW 3-pass wetback boilers will be approximately 1-2% less than Model CB dryback boilers. See Section A2 (Model CB Boiler) for efciency information on four-pass dryback boilers. For specic fuel-to- steam efciency guarantees for Model CBW Firetube, contact your local Cleaver-Brooks authorized representative.
Emissions
The emission data included in this section (Table A4-5) consist of uncontrolled levels of nitrogen oxides (NOx) and carbon monoxide (CO) for Cleaver-Brooks Model CBW Firetube Boilers. The table includes typical emission levels. The data in Table A4-5 represents typical emission levels only. Guaranteed emission levels and emission levels for other pollutants are available from your local Cleaver-Brooks authorized representative.
Table A4-5. Model CBW Boiler Emission Data

ESTIMATED LEVELS - UNCONTROLLED POLLUTANT NATURAL GAS CO ppmA Lb/MMBtu NOx SOx HC/ VOCs PM ppmA Lb/MMBtu ppmA Lb/MMbtu ppmA Lb/MMBtu ppmA Lb/MMBtu 200 0.15 100 0.12 1 0.001 40 0.016 0.01 NO. 2 OILB 90 0.07 185 0.25 278 0.52 50 0.025 0.025 NO. 6 OILC 95 0.075 502 0.67 278 0.52 70 0.035 0.160
A. ppm levels corrected to 3% O2, dry volume basis. B. Based on fuel constituent levels of: Fuel-bound nitrogen content = 0.05% by weight Sulfur content = 0.5% by weight Ash content = 0.01% by weight C. Based on fuel constituent levels of: Fuel-bound nitrogen content = 0.7% by weight Sulfur content = 0.5% by weight Ash content = 0.1% by weight Conradson carbon residue = 16% by weight
A4-14
10-02
Firetube Boilers
Model CBW Boilers

Table A4-6. Heating Surface, Model CBW Boilers
BOILER HP 100 125 HEATING SURFACE (SQ-FT) FIRESIDE 500 625 750 1000 1250 1500 1750 2000 2500 3000 3500
ENGINEERING DATA
The following engineering information is provided for Model CBW Firetube Boilers. Additional detail is available from your local Cleaver-Brooks authorized representative. Refer to Tables A4-6 through A4-10.

Some local codes require blowdown tanks to be constructed in accordance with recommendations of the National Board of Boiler and Pressure Vessel Inspectors. The National Boards recommendations base the size of the blowdown tank on the removal of at least 4 inches of water from the boiler. Table A4-11 lists the approximate quantity of water represented by 4 inches of water at normal operating level for Cleaver-Brooks Power Boilers.
150 200 250 300 350 400 500 600 700, 750, 800
Table A4-7. Steam Volume and Disengaging Areas, Model CBW Boilers
STEAM VOLUME CU-FT BOILER HP HIGH PRESSUREA 100 125 150 200 250 300 350 400 500 600 700, 750, 800 21.5 21.5 25.1 32.8 33.9 39.6 45.5 51.5 94.4 111.9 129.5 LOW PRESSUREB 29.5 29.5 34.5 44.9 49.0 57.3 65.9 74.5 119.6 141.8 164.0
STEAM RELIEVING AREA SQ-IN HIGH PRESSUREA 5856 5856 6850 8925 7732 9043 10396 11750 13809 16387 18950 LOW PRESSUREB 6388 6388 7472 9734 8582 10022 11534 13032 14716 17438 20174
NOTE: Based on normal water level. A. Based on 150 psig design pressure. B. Based on 15 psig design pressure.
A4-15
10-02
Model CBW Boilers
Firetube Boilers
Table A4-8. Water Circulation Rate and Temperature Drop for Hot Water Boilers
BOILER BOILER OUTPUT HP (1000) BTU/HR 100 125 150 200 250 300 350 400 500 600 700 750 800 3350 4185 5025 6695 8370 10045 11720 13400 16740 20080 23450 25105 26780 SYSTEM TEMPERATURE DROP - DEGREES F 10 20 30 40 50 60 70 80 90 100
MAXIMUM CIRCULATING RATE - GPM 670 836 1005 1340 1675 2010 2350 2680 3350 4020 4690 5025 5360 335 418 503 670 838 1005 1175 1340 1675 2010 2345 2513 2680 223 279 335 447 558 670 784 895 1120 1340 1565 1675 1785 168 209 251 335 419 503 587 670 838 1005 1175 1258 1340 134 168 201 268 335 402 470 535 670 805 940 1008 1075 112 140 168 224 280 335 392 447 558 670 785 840 895 96 120 144 192 240 287 336 383 479 575 670 718 765 84 105 126 168 210 251 294 335 419 502 585 628 670 75 93 112 149 186 223 261 298 372 448 520 558 595 67 84 100 134 167 201 236 268 335 402 470 503 535
Notes: 1. See Section I2 for over-pressure requirements. 2. Minimum recommended return water temperature Model CBW Hot Water Boilers is 150 F. Minimum recommended outlet temperature for Model CBW Hot Water Boilers is 170 F. Contact your local Cleaver-Brooks authorized representative for special hot water application information.
Table A4-9. Recommended Steam Nozzle Size (to Maintain 4000 to 5000 fpm Nozzle Velocity)
BOILER HP OPERATING PRESSURE 100 125 150 200 250 300 350 400 500 600 700 750 800 PSIG 15 30 40 50 75 100 125 150 200 250 8 6 6 4 4 4 4 2.5 2 8 6 6 6 4 4 4 3 8 6 6 6 4 4 4 3 3 10 8 6 6 6 6 4 4 4 3 10 8 8 6 6 6 6 4 4 4 12 8 8 8 6 6 6 6 4 4 12 10 8 8 8 6 6 6 4 4 12 10 10 8 8 6 6 6 6 4 12 10 10 8 8 8 8 6 6 6 12 12 10 10 8 8 8 6 6 6 12 12 12 10 10 8 8 8 6 6 12 12 12 12 10 8 8 8 6 6 12 12 12 12 10 10 8 8 6 6
2.5 2.5
2.5 2.5
NOTE: Steam nozzle sizes given in inches.
A4-16
10-02
Firetube Boilers
Model CBW Boilers

BOILER HP 100 125 150 200 250 300 350 400 500 600 700 750 800 BOILER CAPACITY (LBS/HR) 3450 4313 5175 6900 8625 10350 12025 13800 17210 20700 24150 25875 27600 OPERATING PRESSURES (PSIG) 50 3 4 4 4 4 6 6 6 6 8 8 8 8 75 2-1/2 3 4 4 4 4 6 6 6 8 8 8 8 100 2-1/2 3 3 4 4 4 4 4 6 6 6 6 6 125 2-1/2 3 3 3 4 4 4 4 6 6 6 6 6 150 2-1/2 3 3 3 3 4 4 4 4 6 6 6 6 175 2-1/2 2-1/2 3 3 3 4 4 4 4 4 6 6 6 200 2-1/2 2-1/2 2-1/2 3 3 4 4 4 4 4 6 6 6 250 2-1/2 2-1/2 2-1/2 3 3 3 3 4 4 4 6 6 6
Table A4-11. Blowdown Tank Sizing Information, CBW Boilers

BOILER HP 100 125 150 200 250 300 350 400 500 600 700, 750, 800 WATER (GAL) 115 115 137 180 161 188 215 243 258 306 354
Test Method The sound pressure levels in the following tables were obtained from tests in accordance with the ABMA Test Code for the Measurement of Sound from Packages Boilers. In accordance with this code the sound pressure levels reported were measured on the boiler centerline 4-1/2 feet vertically above the bottom of the base rails and 3 feet horizontally in front of the end of the blower motor or front surface of the electrical cabinet. Sound Level Meter The sound level meter used complies with ANSI S1.4, Type 1 (Precision). The readings are taken with the meter set for slow response. Sound Pressure The large size boilers, the need for auxiliary equipment, and the necessary interconnecting piping make it impractical (and sometimes impossible) to provide a boiler testing environment which is suitable for taking the data needed to develop Sound Pressure Power levels. Typical Values Sound pressure levels (dBA) for the same boiler will vary between boiler rooms. In addition, variations will occur between different people using different sound meters on the same boiler. And nally, no two boilers can be expected to give precisely the same sound levels. For these reasons, we can only
NOTE: Quantity of water removed from boiler (gal.) by lowering normal water line 4".
Sound Level
Table A4-12 gives a summary of predicated sound pressure levels for Model CBW boilers. Units The unit for Table A4-12 is dBA (decibels, measured on the Aweighted scale) in reference to 0.0002 microbars. (20 microNewtons per square meter). They are standardly referenced in specifying and reporting sound pressure levels on industrial equipment.
A4-17
10-02
Model CBW Boilers
Firetube Boilers
Table A4-12. Model CBW Boiler Sound Pressure Level Summary (100 - 800 hp)
BOILER HP HFO, dbA LFO, dbA HFG, dbA LFG, dbA 100 83 81 81 78 125 83 81 81 78 150 83 82 80 77 200 83 81 82 78 250 88 86 84 81 300 88 86 86 82 350 89 85 86 83 400 85 81 84 81 500 83 82 82 81 600 83 82 82 81 700 85 82 85 82 750 87 83 86 83 800 88 84 87 84
Sound Pressure levels measured on boilers operating in various locations and expressed in dBA are as follows: ABBREVIATIONS: HF = High Fire LF = Low Fire O = Oil G = Gas
predict, but not guarantee, sound levels (dBA). Sound levels can also change due to motor options and altitudes. Octave Band When predicting sound pressures in octave band (e.g., db at 125 Hz), even greater variations between boilers, between sound meters, and between operators can be expected. These larger variations in the low and high frequencies make octave band levels a less reliable method of reporting than A-scale sound levels. (Since A-scale sound levels are dominated by mid- frequency sounds, the A-scale sound levels between two boilers can be in reasonable agreement even through the low and high frequencies of octave band measurement do not closely correspond.)
Table A4-15 shows conversion factors for gas pressure at elevations over 700 ft above sea level. Table A4-16 shows regulated gas pressure with over and undersized gas trains. Gas Pressure Regulators Pressure Rating: The regulator must have a pressure rating at least equivalent to that of the gas distribution system. Capacity: The capacity can be determined by multiplying the maximum burning rate (CFH) by 1.15 (Table A4-17). This 15 percent over-capacity rating of the regulator provides for proper regulation. Table A4-17 shows maximum gas consumption for natural gas and propane vapor. Spring Adjustment: The spring should be suitable for a range of adjustment from 50 percent under the desired regulated pressure to 50 percent over. Sharp Lock-Up: The regulator should include this feature to prevent the downstream pressure (between the regulator and the boiler) from climbing when there is no gas ow. Regulators in Parallel: This type of installation can be used if the required gas volume is very large and if the pressure drop must be kept to a minimum. Regulators in Series: This type of installation can be used if the available gas pressure is over 5, 10, or 20 psig. Depending on the regulator characteristics, one regulator would reduce the pressure to 2 - 3 psig, and a second regulator would reduce the pressure to the burner requirements. Regulator Location: A straight run of gas line piping should be used on both sides of the regulator to ensure proper regulator operation. This is particularly important when pilot operated regulators are used. The regulator can be located close to the gas train connection, but 2 to 3 feet of straight run piping should be used on the upstream side of the regulator.
Burner Information
Gas - Fired Burners
NOTICE
A gas pressure regulator must be installed in the gas piping to each Model CBW boiler. Gas pressure regulators for Model CBW Firetube Boilers are sized and selected on a job-by-job basis. Therefore, gas pressure requirements shown in Tables A4-13 through A4-16 list regulated gas pressure. Regulated gas pressure is the pressure downstream of the gas pressure regulator. Total gas pressure required for the boiler equals regulated gas pressure plus the pressure drop of the selected gas pressure regulator. The following items should be considered when selecting a regulator:
Table A4-13 shows regulated gas pressure requirements for Model CBW Boilers with standard or FM Gas Trains. Table A4-14 shows regulated gas pressure requirements for Model CBW Boilers with IRI Gas Trains.
A4-18
10-02
Firetube Boilers
Model CBW Boilers
Table A4-14. Model CBW Minimum Required Gas Pressure at Entrance to Gas Trains Equipped with Industrial Risk (IRI) Requirements (Downstream of Gas Pressure Regulator) Table A4-13. Model CBW Minimum Required Gas Pressure at Entrance to Standard and FM Gas Trains (Downstream of Gas Pressure Regulator)
MODEL CBW BOILER HP HTB MIN CONN SIZE MIN PRESS. (IN.) REQ'D (IN. WC) PRESSURE REQ'D 2 2.5 2.5 2.5 3 3 3 4 4 4 4 4 4 4.5 7.0 8.0 15.0 16.5 21.5 30.5 23.5 24.5 34.5 46.5 53.5 59.5 21.0 30.0 39.5 36.0 34.0 39.5 54.0 62.5 71.0 MODEL CBW BOILER HP CONN SIZE (IN.) 2 2.5 2.5 2.5 3 3 3 4 4 4 4 4 4 MIN PRESS REQ'D (IN WC) 6.0 7.0 9.0 15.0 16.5 21.5 30.5 23.5 24.5 34.5 46.5 53.5 59.5 HTB MIN GAS PRESS REQ'D 21.0 30.0 39.5 36.0 34.0 39.5 54.0 62.5 71.0
100
125 150 200 250 300 350 400 500 600 700 750 800
100 125 150 200 250 300 350 400 500 600 700 750 800
NOTES: 1. For standard and FM gas pressure requirements for Canada, refer to Table A4-14. A. Based on 1000 Btu/cu-ft natural gas and elevation up to 700 feet. B. HTB is for high turndown (10:1) burners.
NOTES: 1. Pressures shown also apply to standard and FM gas trains for Canada. A. Based on 1000 Btu/cu-ft natural gas and elevation up to 700 feet. B. HTB is for high turndown (10:1) burners.
Table A4-15. Minimum Required Gas Pressure Altitude Conversion at 700 ft

To obtain minimum required gas pressure at altitudes above 700 feet, multiply the pressure by the listed factors: Inches WC x 0.577 = oz/sq-in. oz/sq-in x 1.732 = inches WC. Inches WC x 0.0361= psig. oz/sq-in x 0.0625 = psig. psig x 27.71 = Inches WC. psig x 16.0 = oz/sq-in.
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Model CBW Boilers
Firetube Boilers
Table A4-16. Under and Oversized Standard, FM, and IRI Gas Trains, Model CBW Boilers, 100 - 800 hp
100 STD FM PIPE SIZE (IN.) 1-1/2 2 2-1/2 3 350 PIPE SIZE (IN.) 2-1/2 3 4 4A PRESS REQ 58.5 38.5 28.0 24.5 PIPE SIZE (IN.) 3 4 4A PRESS REQD 17.5 4.5 3.5 2.5 100 IRI PIPE SIZE (IN.) 1-1/2 2 2-1/2 3 400 PRESS REQD 50.5 36.0 32.0 PIPE SIZE (IN.) 3 4 4A PRESS REQD 19.0 6.0 4.0 3.0 PIPE SIZE (IN.) 2 2-1/2 3 4 500 PRESS REQD 58.0 34.0 26.5 PIPE SIZE (IN.) 3 4 4A 125 PRESS REQD 10.5 7.0 5.0 4.0 PIPE SIZE (IN.) 2 2-1/2 3 4 600 PRESS REQD 73.5 39.5 28.5 PIPE SIZE (IN.) 3 4 4A 150 PRESS REQD 15.0 9.0 7.0 5.5 PIPE SIZE (IN.) 2 2-1/2 3 4 700 PRESS REQD NA 54.0 38.0 PIPE SIZE (IN.) 3 4 4A 200 PRESS REQD 25.5 15.0 12.0 8.5 PIPE SIZE (IN.) 2-1/2 3 4 4
A
250
300
PRESS PIPE PRESS REQD SIZE (IN.) REQ 31.5 21.0 15.0 12.5 750 PRESS REQD NA 62.5 44.0 PIPE SIZE (IN.) 3 4 4A 2-1/2 3 4 4
A
42.5 30.0 21.5 19.0 800 PRESS REQD NA 71.0 51.0
NOTES: Pipe size in inches, and pressure required in inches WC. 1. Pressure requirement is downstream of gas pressure regulator. A. Low pressure drop Maxon valves (replaces 6" trains). B. Standard gas train size shown by shaded areas.
Table A4-17. Model CBW Boiler Maximum Consumption (CFH) for Natural Gas and Propane Vapor
TYPE OF GAS AND HEAT CONTENT BOILER HP 100 125 150 200 250 300 350 400 500 600 700 750 800 NATURAL GAS 1000 (Btu/cu-ft) 4185 5230 6280 8370 10460 12555 14650 16750 20925 25100 29300 31400 33500 PROPANE GAS 2550 (Btu/cu-ft) 1640 2050 2465 3280 4105 4925 5745 6570 8205 9845 11480 12310 13140
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Firetube Boilers
Gas pressure regulator selected for high turndown burners is critical at minimum ow rates. Consult your local CleaverBrooks authorized representative for proper selection. If O2 trim is used, check for regulator compatibility. Figure A4-6 shows standard gas train sizes and locations for Model CBW Firetube Boilers. Figure A4-7 shows a typical gas train piping layout for a multiple boiler application. Figure A4-8 shows gas train components. Oil - Fired Burners Fuel oil consumption information is shown on the boiler rating sheets in the Dimension and Rating Section. Figure A4-9 shows the oil connection sizes and locations for Model CBW boilers ring No. 2 oil. Figure A4-10 shows the oil connection sizes and locations for CBW Boilers ring No. 6 oil. Figures A4-11 through A4-16 show typical oil systems and layouts. Figure A4-17 shows the detail of an oil transfer tank (day tank) typically utilized to provide a storage reservoir between the oil system supply pump and the boiler oil pump.
Model CBW Boilers

No. 6 Oil Piping, Storage Tank Heating If the oil viscosity exceeds 4,000 SSU at the pumping temperature, tank preheating is required. Based on the climate conditions for the job location, the minimum pumping temperature can be predicted, and the viscosity for the particular oil at this pumping temperature can be determined. It is recommended to provide for tank and/or line heating on all No. 6 oil installations to ensure against high viscosities at decreased pumping temperatures. The following are two common methods: 1. 2. Provide a tank suction heater and bundling the steam or water lines to the heater with the oil lines. Provide electric heating equipment on the oil lines and/or in the storage tank.
! CAUTION DANGER
The temperature in the oil suction line should not exceed 130 F as higher temperatures could cause vapor binding of the oil pump and decreased oil flow.
See Figures A4-18 and A4-19 for an example of (No. 1 above) tank heating method. See Figure A4-20 for examples of preheating systems.
MODEL CBW BOILER HP 100 125 150, 200 250, 300, 350 400, 500, 600, 700, 750, 800 CONNECTION SIZE (IN.) (NPT) 2-1/2 2-1/2 2-1/2 3 4 LOCATION DIMENSION A (IN.) 67-1/2 67-1/2 67-1/2 70-1/2 109-1/2
Figure A4-6. Model CBW Standard Gas Train Connection Size and Location, IRI A4-21
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Model CBW Boilers
Firetube Boilers
This figure illustrates the basic gas valve arrangement on Cleaver-Brooks Model CBW boiler and shows the contractor's connection point. The valves and controls between the contractor connection point and the gas main in the street are representative of a typical installation. Actual requirements may vary depending on local codes or local gas company requirements which should be investigated prior to preparation of specifications and prior to construction.
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Firetube Boilers
Model CBW Boilers
INS ITEM DESCRIPTION BOILER HP 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Pilot Shut Off Cock Pilot Shut Off Cock Shut Off Cock Shut Off Cock Pilot Pressure Regulator Pilot Pressure Gauge Gas Pilot Valve High Gas Pressure Switch Low Gas Pressure Switch Main Gas Valve with POC Main Gas Valve without POC Main Gas Valve with POC Main Gas Valve without POC Vent Valve Buttery Valve x x x x x x x x x 100 x
UL
FM
IRI 125800 x x x x x x x x x x x x x x x x x x x x 100 x x x x x x x x x
FM & IRI 125250 x x x x x x x x x x x x 300800 x x x x x x x x x x
125- 300125- 300100 100 250 800 250 800 x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
x x x x x
x x
x x
x x
x x
Figure A4-8. Gas Train Components
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Model CBW Boilers
Firetube Boilers
MODEL CBW RECOMMENDED OIL LINE SIZES SUPPLY (STANDARD PIPE) AND (IN. - IPS) BOILER HP RETURN A CONNECTION (IN.) STORAGE SIZES TANK TO PUMP RETURN (IN.) (NPT) BOILER TO LINE TO OR PUMP BOILER TANK CONNECT 100, 125, 150, 3/4 12-1/2 1 1 1 200 250, 300, 350 3/4 34 1 1 1 400 400, 500, 600 3/4 36 1 1 1 700, 800 3/4 36 1 1 1 NOTE: See No. 2 Oil Line Sizing Instruction for systems with other conditions. A. For suction line condition with a maximum of 10 feet of lift and a total of 100 feet of suction line
Figure A4-9. No. 2 Oil Connection Size, Location and Recommended Line Sizes
MODEL CBW SUPPLY CONNECTION SIZE (IN.) (NPT) 100 125, 150 200 250,300, 350 400, 500, 600,700, 800 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 A (IN.) 27-3/4 49-1/2 65-1/2 89-3/4 63 RETURN CONNECTION SIZE (IN.) (NPT) 3/4 1-1/4 1-1/4 1-1/4 1-1/4 B (IN.) 19-3/4 39-1/2 39-1/2 59-3/4 48 GAS PILOT CONNECTION 4-5" WC PRESS. REQD SIZE (IN.) (NPT) 1/2 1/2 1/2 1/2 1/2 C (IN.) 28 38 38 56 54 RECOMMENDED OIL LINE SIZES (STANDARD PIPE) (IN.) STORAGE TANK TO PUMP 2 2-1/2 2-1/2 2-1/2 3 PUMP TO RETURN TO BOILER LINE TANK 1-1/4 1-1/2 1-1/2 1-1/2 2 1-1/4 2 2 2 2
BOILER HP
NOTES: 1. All dimensions in inches. 2.For suction lines with a maximum of 10 feet of lift and a total of 100 feet of suction line.
Figure A4-10. No. 6 Oil Connection Size, Location and Recommended Line Size
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Firetube Boilers
Model CBW Boilers
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Model CBW Boilers
Firetube Boilers
Figure A4-14. No. 6 Oil Piping, Single Boiler Installation, Remote Oil Pumps
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Firetube Boilers
Model CBW Boilers
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Model CBW Boilers
Firetube Boilers
ITE M A B C D E F G
SIZE 1/2 NPT See note See note 1/2 NPT See note 1/8 NPT See note
DESCRIPTION Connection to off level switch Return line to tank Oil supply connection from transfer pump Tank drain connection FOS connection Oil level test valve connection FOR connection
Figure A4-18. Typical Arrangement
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Firetube Boilers
Model CBW Boilers
Note 1: The outer jacket of the four line bundle should be protected by a waterproof covering to protect the lines and insulation from moisture damage. Tar paper and hot asphalt sealer have been successfully used as a waterproof covering. Note 2: When the bundle runs under driveways or other traffic areas, a heavy duty outer jacket of reinforced concrete, vitrified tile, or corrugated steel is recommended. Figure A4-19. Typical Cross Section of Bundled Lines
In order to properly preheat No. 6 oil, the minimum recommended boiler water temperature is 200 F. Some No. 6 oils must be preheated up to 210 F, and higher boiler water temperatures are then desirable. Although lower boiler water temperatures can be used, this condition means that the electric preheater will be doing more of the work. It is more economical to use higher temperature boiler water for preheating than to use lower temperature water which increases the electric preheating load. To ensure the most trouble-free, dependable preheating system, a boiler water-to-water-to-oil preheating system is furnished as standard equipment and is mounted, piped and wired on the boiler. This safety type system or double heat exchanger eliminates the possibility of an oil leak fouling the boiler, oil heater, piping, control valves, and circulating pumps. Insurance companies recognize this as the best system for the application. The standard system does not have provisions for a hot water line to a storage tank heater.
Figure A4-20. Schematic of Standard Alstrom Hot Water Safety-Type Preheating System
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Model CBW Boilers

Firetube Boilers
and cause variations in the quantity of combustion air. This can result in unsatisfactory burner performance. D. Under no condition should the total area of the air supply openings be less than (1) square foot. E. Size the openings by using the formula: Area (sq-ft) = CFM/FPM 2. Amount of air required (cfm). A. Combustion Air = Rated bhp x 8 cfm/bhp. B. Ventilation Air = Maximum bhp x 2 cfm/bhp C. Total recommended air = 10 cfm/bhp - up to 1000 feet elevation. Add 3 percent more per 1000 feet of added elevation. 3. Acceptable air velocity in boiler room (fpm). A. From oor to (7) foot height - 250 fpm. B. Above (7) foot height - 500 fpm. Example: Determine the area of the boiler room air supply openings for (1) 300 hp boiler at 800 feet altitude. The air openings are to be 5 feet above oor level. Air required: 300 x 10 = 3000 cfm (from 2B above). Air velocity: Up to 7 feet = 250 fpm (from 3 above). Area Required: Area = cfm = 3000/250 = 12 Sq-ft total. Area/Opening: 12/2 = 6 Sq-ft/Opening (2 required).

Cleaver-Brooks Firetube CBW Boilers can support up to 2,000 lb without additional support. Firetube boilers 250 hp through 800 hp can be reinforced to support 3,000 lbs.
Stack and Breeching Size Criteria

The design of the stack and breeching must provide the required draft at each boiler ue gas outlet. Proper draft is critical to burner performance. Although constant pressure at the ue gas outlet of the Model CBW is not required, it is necessary to size the stack/breeching to limit ue gas pressure variation. The allowable pressure range is 0.5" W.C. to +0.5" W.C. The maximum pressure variation at any ring rate for the boiler is 0.5" W.C. For additional information, please review Section I4, General Engineering Data (Stacks) and Section F, Stacks. Stack and breeching sizes should always be provided by a reputable stack supplier who will design the stack and breeching system based on the above criteria. Your local Cleaver-Brooks authorized representative is capable of assisting in your evaluation of the stack/breeching design.

When determining boiler room air requirements, the size of the room, air ow, and velocity of air must be reviewed, as follows: 1. Size (area) and location of air supply openings in boiler room A. Two (2) permanent air supply openings in the outer walls of the boiler room are recommended. Locate (1) at each end of the boiler room, preferably below a height of 7 feet. This allows air to sweep the length of the boiler. B. Air supply openings can be louvered for weather protection, but they should not be covered with ne mesh wire, as this type of covering has poor air ow qualities and is subject to clogging by dust or dirt. C. A vent fan in the boiler room is not recommended, as it could create a slight vacuum under certain conditions
NOTICE
Consult local codes which may supersede these requirements.
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Firetube Boilers
Model CBW Boilers
1. Shortest boiler room length (Dwg A) is obtained by allowing for possible future tube replacement from front of boiler through a window or doorway. Allowance is only made for minimum door swing at each end of the boiler. This arrangement provides sufficient aisle space at the front of the boiler but a tight space condition at the rear. If space permits, approximately 1.5 additional feet should be allowed at the rear for additional aisle and working space. 2. Next shortest boiler room length (Dwg B) is obtained by allowing for possible future tube replacement from the front of the boiler. Allowance is only made for minimum door swing at the rear. If space permits, approximately 1.5 additional feet should be allowed at the rear for additional aisle and working space.
Figure A4-21. Boiler Room Length, Typical Layout (CBW Boilers)
BOILER HP 100-200 250-400 500-800 Dimension A 87" 96" 106" Dimension B 127" 151" 183" NOTES: 1. Recommended Minimum Distance Between Boiler and Wall. Dimension A allows for a clear 42" aisle between the water column on the boiler and the wall. If space permits, this aisle should be widened. 2. Recommended Minimum Distance Between Boilers. Dimension B between boilers allows for a clear aisle of: 42" - 100 -200 hp 48" - 250-400 hp 60" - 500-800 hp If space permits, this aisle should be widened.
Figure A4-22. Boiler Room Width, Typical Layout (CBW Boilers)
A4-31
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Model CBW Boilers
Firetube Boilers
MULTIPLE BOILERS WITH A COMMON STACK NOTE: These stack breeching arrangements for multiple boilers are typical and not intended for your specic design requirements. For additional information, review Section F, Stacks. Stack and breeching sizes should always be provided by a reputable stack supplier who will design the stack and breeching system based on your specic criteria. Your local CLeaver-Brooks authorized representative is capable of assisting in your evaluation of stack and breeching design.
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Firetube Boilers
Model CBW Boilers
SAMPLE SPECIFICATIONS
The following sample specications are provided by Cleaver-Brooks to assist you in meeting your customers specic needs and application. The detailed burner and control specications, and detailed control specications for CB780 Flame Safeguard control and the CBHAWK Flame Safeguard control, are provided. See Section D, Controls, for additional information on control options. The sample specications are typically utilized as the base template for the complete boiler specication. Contact your local Cleaver-Brooks authorized representative for information on special insurance requirements, special code requirements, optional equipment, or general assistance in completing the specication.
Model CBW Steam Boiler (100-800 hp, Steam 15-250 psig)

1.0 Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4-33 2.0 General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-33 3.0 Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4-34 4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4-34 5.0 Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4-40 6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4-40 7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4-40
Model CBW Hot Water Boiler (100-800 hp, 30 and 125 psig)
1.0 Boiler Characteristics (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4-41 2.0 General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4-41 3.0 Hot Water Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4-41 4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4-42 5.0 Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4-48 6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4-48 7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4-48
Model CBW Steam Boiler (100-800 hp, Steam 15-250 psig)

1.0 Boiler Characteristics (Steam) 1.1 The Steam Boiler shall be Cleaver-Brooks Fuel Series ______ (100, 200, 400, 600, 700), ______ hp designed for ______ psig (15, 150, 200, or other psig steam). The maximum operating pressure shall be _____ psig and the minimum operating pressure shall be ______ psig. 1.2 The boiler shall have a maximum output of ______ Btu/hr, or ______ horsepower when wired with CS12-48 ______ oil and/or natural gas, ______ Btu/cu-ft. Electrical power available shall be ______ Volt ______ Phase ______ Cycle. 2.0 General Boiler Design 2.1 The boiler shall be a three pass horizontal retube updraft boiler with ve (5) square feet of heating surface per rated boiler horsepower (except 750 or 800 hp). It shall be mounted on a heavy steel frame with integral forced draft burner and burner controls.
NOTICE
2.1.1 The boiler shall be completely preassembled and re tested at the factory. The unit shall be ready for immediate mounting on oor or simple foundation and ready for attachment of water, fuel, electrical, vent, and blowdown connections.
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Model CBW Boilers
Firetube Boilers
2.1.2 The boiler shall be built to comply with the following insurance and codes ______________ (Factory Mutual, Industrial Risk Insurance, ASME CSD-1). 2.2 Boiler Shell (Steam) 2.1.1 The boiler shell must be constructed in accordance with ASME Boiler Code and must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser. 2.2.2 The boiler shall be furnished with a manhole and handholes to facilitate boiler inspection and cleaning. Two lifting lugs must be located on top of the boiler. 2.2.3 The front door shall be hinged or davited, the rear door shall be davited. Doors are to be sealed with berglass tadpole gaskets and fastened tightly using heavy capscrews that thread into replaceable brass nuts. 2.2.4 The boiler tubes shall not include turbulators, swirlers, or other add-on appurtenances. 2.2.5 The rear door shall be insulated with a blanket material with a steel covering to give the surface a hard durable nish. 2.2.6 The exhaust gas vent shall be located at the rear of the boiler and be capable of supporting 2000 lbs. The boiler vent shall contain a stack thermometer. 2.2.7 Observation ports for the inspection ame conditions shall be provided at each end of the boiler. 2.2.8 The boiler insulation shall consist of 2 inch blanket under a sectional preformed sheet metal lagging. The insulation must be readily removable and capable of being reinstalled, if required. 2.2.9 The entire boiler base frame and other components shall be factory painted before shipment, using a hard-nish enamel coating. 3.0 Steam Boiler Trim 3.1 Water Column A water column shall be located on the right hand side of the boiler complete with gauge glass set, and water column blowdown valves. 3.1.1 Feedwater Pump Control The boiler feedwater pump control shall be included as an integral part of the water column to automatically actuate a motor driven feedwater pump to maintain the boiler water level within normal limits. 3.1.2 Low Water Cutoff The low water cutoff shall be included as an integral part of the boiler feedwater control wired into the burner control circuit to prevent burner operation if the boiler water level falls below a safe level. 3.2 Auxiliary Low Water Cut-off Auxiliary low water cut-off shall be included, piped to the vessel, and wired to the burner control circuit. A manual reset device shall be used on this control. 3.3 Steam Pressure Gauge The steam pressure gauge shall be located at the front of the boiler and include cock and test connection. 3.4 Safety Valves Safety valves of a type and size to comply with ASME Code requirements shall be shipped loose. 3.5 Steam Pressure Controls The steam pressure control to regulate burner operation shall be mounted near the water column. Controls shall be a high limit (manual reset), operating limit (auto reset), and ring rate control. 4.0 Burner and Controls
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Firetube Boilers
4.1 Mode of Operation
Model CBW Boilers
Burner operation shall be full modulation principle. The burner shall always return to low re position for ignition. 4.2 Blower 4.2.1 Air for combustion shall be supplied by a forced draft blower mounted in the front boiler door, above the burner, to eliminate vibration and reduce noise level. 4.2.2 Maximum sound level of the boiler/burner package shall not exceed _____ dbA (when measured in accordance with ABMA Sound Test Standards). 4.2.3 The impeller shall be cast aluminum, radial blade, carefully balanced, and directly connected to the blower motor shaft. 4.3 Combustion Air Control Combustion air damper and cam operated fuel metering valves shall be operated by a single damper control motor that regulates the re according to load demand. Potentiometer type position controls shall be provided to regulate operation of the damper control motor (remove this sentence when a CB-HAWK ame safeguard is used). 4.4 Fuel Specication and Piping Select one of the following fuel types: Fuel series 700 - Gas red (para 4.4.1). Fuel series 100 - Light oil (No. 2) red (para 4.4.2). Fuel series 200 - Light oil or gas red (para 4.4.3). Fuel series 600 - No. 6 oil red (para 4.4.4). Fuel series 400 - No. oil or gas red (para 4.4.5). 4.4.1 Fuel Series 700 - Gas Fired 4.4.1.1 Burner Type - The burner shall be integral with the front head of the boiler and of high radiant annular gas entry on 100-200 hp and multi-port type gas entry on 250-800 hp. The burner shall be approved for operation on natural gas fuel. 4.4.1.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include two manual shutoff valves, solenoid valve, pressure regulator and pressure gauge. 4.4.1.3 Gas Burner Piping - Gas burner piping on all units shall include primary gas shutoff valve, motor operated with proof of closure switch and plugged leakage test connection. The main gas valve(s) shall be wired to close automatically in the event of power failure, ame failure, low water or any safety shutdown condition. A lubricating plug cock or buttery shutoff valve shall be provided as a means for a tightness check of the primary shut off valve. An additional plug cock on buttery valve shall be furnished at entrance to gas train. Select one of the following: A. 100 hp. High and low gas pressure switches shall be provided. B. 125 through 250 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided. C. 300 through 800 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided. A vent valve shall be located between the safety shutoff valves. 4.4.1.4 Burner Turndown - Select one of the following: A. 100-200 hp. Turndown range of burner shall be 4:1 when ring natural gas. B. 250-800 hp. Turndown range of the burner shall be 10:1 when ring natural gas. (Consult with Cleaver-Brooks Representative regarding high turndown capability based on available gas pressure.) 4.4.2 Fuel Series 100 - Light Oil Fired 4.4.2.1 Burner Type - The burner shall be integral with the front head of the boiler, and shall be a low pressure air atomizing type
A4-35
10-02
Model CBW Boilers

approved for operation with CS12-48, Commercial No. 2 oil.
Firetube Boilers
4.4.2.2 Oil Pilot - The oil pilot shall be air atomizing type with automatic electric ignition and include oil solenoid valve. An electronic detector shall monitor the pilot so that the primary oil valve cannot open until ame has been established. 4.4.2.3 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. The motor driven pump set, shipped loose, to be installed in a location favorable to the oil storage tank, shall be provided. 4.4.2.4 Oil Burner Piping 4.4.2.4.1 Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, solenoid shutoff valves, pressure gauges and fuel strainer, all integrally mounted on the unit. 4.4.2.4.2 A fuel oil controller shall be provided to combine all of the fuel oil controls into a single casting which is mounted on the front door of the unit. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. A low oil pressure switch shall be included in the oil piping. 4.4.2.5 Low Pressure Air Atomizing - Select one of the following: A. 100 through 400 hp. Belt driven air compressor, lubricating air tank, oil level indicator, inlet air lter, air pressure gauge, and low atomizing air pressure switch. B. 500 through 800 hp. Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch. 4.4.2.6 Burner Turndown - Select one of the following: A. 100 through 200 hp. Turndown range shall be 4:1 when ring No. 2 oil. B. 250 through 800 hp. Turndown range shall be 8:1 when ring No. 2 oil. 4.4.3 Fuel Series 200 - Light Oil or Gas Fired 4.4.3.1 Burner Type - The burner, integral with the front head of the boiler, shall be a combination of the low pressure air atomizing type for oil and high radiant annular gas entry on 100-200 hp and multi-port type gas entry on 250-800 hp. The burner shall be approved for operation with either CS12-48 Commercial No. 2 Oil or natural gas. 4.4.3.2 Gas Pilot - The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary fuel valve cannot open until ame has been established. The pilot train shall include two manual shut-off valves, solenoid valve, pressure regulator and pressure gauge. 4.4.3.3 Oil Burner 4.4.3.3.1 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. The motor driven pump set, shipped loose, to be installed in a location favorable to the oil storage tank, shall be provided. 4.4.3.3.2 Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, solenoid shutoff valves, pressure gauges and fuel strainer, all integrally mounted on the unit. A fuel oil controller shall be provided to combine all of the fuel oil controls into a single casting which is mounted on the front door of the unit. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. A low oil pressure switch shall be included in the oil piping. 4.4.3.3.3 Low pressure air atomizing. Select one of the following: A. 100 through 400 hp. Belt driven air compressor, lubricating air tank, oil level indicator, inlet air lter, air pressure gauge and low atomizing air pressure switch. B. 500 through 800 hp. Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch. 4.4.3.4 Gas Burner 4.4.3.4.1 Gas Burner Piping - gas burner piping on all units shall include primary gas shutoff valve, motor operated with proof of closure switch and plugged leakage test connection. The main gas valve(s) shall be wired to close automatically in the event of power failure, ame failure, low water or any safety shutdown condition. A lubricating plug cock or buttery shutoff valve shall be provided as a means for a tightness check of the primary shut off valve. An additional plug cock or buttery valve shall be furnished at entrance to gas train. Select one of the following:
A4-36
10-02
Firetube Boilers
A. 100 hp. High and low gas pressure switches shall be provided.
Model CBW Boilers
B. 125-250 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided. C. 300-800 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus and additional plugged leakage test connection shall be provided. A vent valve shall be located between the safety shutoff valves. 4.4.3.5 Burner Turndown - Select one of the following: A. 100 through 200 hp. Turndown range of the burner shall be 4:1. B. 250 through 800 hp. Turndown range of the burner shall be 10:1 when ring natural gas and 8:1 on No. 2 oil. (Consult your local Cleaver-Brooks authorized representative regarding high turndown capability based on available gas pressure.) 4.4.4 Fuel Series 600 - No. 6 Oil Fired 4.4.4.1 Burner Type - The burner shall be integral with the front head of the boiler and low pressure air atomizing type approved for operation with CS12-48, Commercial No. 6 Oil. 4.4.4.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary oil valve cannot open until pilot ame has been established. The pilot train shall include two manual shutoff valves, solenoid valve, pressure regulator and pressure gauge. 4.4.4.3 Oil Pump - An oil pump set with a capacity of approximately twice the maximum burning rate shall be included. A separate motor driven pump set shall be included shipped loose for location favorable to the oil storage tank. 4.4.4.4 Oil Burner Piping - A fuel oil controller combining all of the fuel oil controls into a single casing shall be provided. Oil pressure regulating devices, oil metering controls, solenoid shutoff valves, high and low oil temperature switches and necessary pressure and temperature gauges shall be included in this packaged assembly mounted on the front door of the boiler. A fuel strainer shall also be provided, mounted to the boiler. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. Flexible hoses shall be provided to allow easy removal of the nozzle for inspection when it is placed in the vice jaws located on the front door of the boiler. The metering valve shall permit circulation of hot oil to the burner at all times. The burner drawer oil piping and nozzle shall be purged of oil on each shutdown. A low oil pressure switch shall be included in the oil piping. 4.4.4.5 Low Pressure Air Atomizing - Select one of the following: A. 100 through 400 hp. Belt driven air compressor, lubricating oil tank, oil level indicator, inlet air lter, air pressure gauge and low atomizing air pressure switch. B. 500 through 800 hp. Separate air compressor modules mounted on boiler base rail with low atomizing air pressure switch. 4.4.4.6 Oil Preheat The oil shall be preheated by a steam heater and electric heater, each with thermostatic control. Both heaters shall be installed in a single compact shell mounted, piped, and wired on the boiler. The thermostatic controls shall be set to cut-out the electric heater when steam is available. Select one of the following: A. 100 through 200 hp. Electric preheater size shall be 5 kW. B. 250 through 800 hp. Electric preheater size shall be 7-1/2 kW.
NOTICE
15 psig only - 500 through 800 hp. Electric preheater size 10 kW.
4.4.5 Fuel Series 400 - No. 6 Oil or Gas Fired 4.4.5.1 Burner Type - The burner shall be integral with the front head of the boiler and shall be a combination of the low pressure
A4-37
10-02
Model CBW Boilers
Firetube Boilers
atomizing type for oil and high radiant annular gas entry on 100-200 hp and multi-port type gas entry on 250-800 hp. The burner shall be approved for operation with either CS12-48 Commercial No. 6 oil or natural gas. 4.4.5.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary oil valve cannot open until pilot ame has been established. The pilot train shall include two manual shutoff valves, solenoid valve, pressure regulator and pressure gauge. 4.4.5.3 Oil Burner 4.4.5.3.1 Oil Pump - An oil pump set with a capacity of approximately twice the maximum burning rate shall be included. 4.4.5.3.2 Oil Burner Piping - A fuel oil controller combining all of the fuel oil controls into a single casing shall be provided. Oil pressure regulating devices, oil metering controls, solenoid shutoff valves, high and low oil temperature switches, and the necessary pressure and temperature gauges shall be included in this packaged assembly mounted on the front door of the boiler. A fuel strainer shall also be provided, mounted to the boiler. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. Flexible hoses shall be provided to allow easy removal of the nozzle for inspection when it is placed in the vice jaws located on the front door of the boiler. The metering valve shall permit circulation of hot oil to the burner at all times. The burner drawer oil piping and nozzle shall be purged of oil at each shutdown. A low oil pressure switch shall be included in the oil piping. 4.4.5.4 Low Pressure Air Atomizing - Select one of the following: A. 100 through 400 hp. Belt driven air compressor, lubricating oil tank, oil level indicator, inlet air lter, air pressure gauge and low atomizing air pressure switch. B. 500 through 800 hp. Separate air compressor modules mounted on boiler base rail with low atomizing air pressure switch. 4.4.5.5 Oil Preheat - The oil shall be preheated by a steam heater and electric heater, each with thermostatic control. Both heaters shall be installed in a single compact shell mounted, piped, and wired on the boiler. The thermostatic controls shall be sent to cutout the electric heater when steam is available. Select one of the following: A. 100 through 200 hp. Electric preheater size shall be 5 kW. B. 250 through 800 hp. Electric preheater size shall be 7-1/2 kW.
NOTICE
15 psig only - 500 through 800 hp Electric preheater size 10 kW.
4.4.5.6 Gas Burner 4.4.5.6.1 Gas Burner Piping - Gas burner piping on all units shall include primary gas shutoff valve, motor operated with proof of closure switch and plugged leakage test connection. The main gas valve(s) shall be wired to close automatically in the event of power failure, ame failure, low water or any safety shutdown condition. A lubricating plug cock or buttery shutoff valve shall be provided as means for a tightness check of the primary shutoff valve. An additional plug cock or buttery valve shall be furnished at entrance to gas train. Select one of the following: A. 100 hp. High and low gas pressure switches shall be provided. B. 125 through 250 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided. C. 300 through 800 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional leakage test connection shall be provided. A vent valve shall be located between the safety shutoff valves. 4.4.5.6.2 Burner Turndown - Turndown shall be 4:1. 4.5 Boiler Flame Safeguard Controller and Control Panel 4.5.1 CB780 Flame Safeguard 4.5.1.1 Boilers with CB780 Control - Each boiler shall be factory equipped with ame safeguard controller providing technology
A4-38
10-02
Firetube Boilers
and functions equal to the Cleaver-Brooks Model CB780.
Model CBW Boilers
Controller shall be computerized solid state having sequence and ame-on lights and alpha-numeric rst out fault indications of ame safeguard trip functions. It shall include dynamic self-check logic. The controller shall have a xed operating sequence incapable of being manually altered. The sequence shall include start, pre-purge, pilot and main fuel ignition run and post-purge cycles. Controller shall be the non-recycle type for maximum safety that shall shutdown the burner and indicate as a minimum the following trip functions: pilot and main ame failure, high and low re proving switch faults, locking interlocks open, false ame signal and fuel valve open (when proof of closure switch is furnished). The controller shall have a run/test switch. It shall allow interruptions to sequence just after pre-purge, during pilot ignition trial and run cycles for adjustments to ring rate motor, damper linkages and pilot ame for minimum turndown tests. 4.5.1.2 Control Panel - The control panel shall be mounted on the front door of the boiler in a location convenient to the operator. The hinged metal cabinet shall have NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet key type lock. The panel shall contain the boiler ame safeguard controller, blower motor starter, indicating lights and selector switches. The panel shall have a removable sub-base for mounting the ame safeguard controller, blower motor starter, and terminal blocks. For combination gas-oil and heavy oil red boilers the panel shall contain the fuel selector and/or oil heater selector switch. The panel shall contain the following lights and switches: 4.5.1.3 Lights White - load demanded. White - fuel valve open. Red - low water. Red - ame failure. 4.5.1.4 Control Switches Burner On-Off. Manual-Automatic. Manual Firing Rate Control. 4.5.1.5 Oil, heat and moisture resistant wire shall be used and identied with circuit numbers corresponding to the electrical wiring diagram. 4.5.1.6 All electrical equipment and wiring shall be in conformance with Underwriters Laboratories requirements. 4.5.1.6 Boiler to be supplied with a control circuit transformer and fuse protection for the control circuit. 4.5.2 CB-HAWK Flame Safeguard Each boiler shall be factory equipped with a Boiler Management Control System providing technology and functions equal to the Cleaver-Brooks Model CB-HAWK. The system shall consist of a computer based boiler controller and solid state sensors totally integrated to provide automatic burner sequencing, ame supervision, and indications of system status, faults, and self-diagnostics. The boiler controller shall consist of chassis, program module, keyboard display, and ame signal amplier. It shall be the nonrecycle type and have a xed operating sequence incapable of being manually altered. The sequence shall include standby, prepurge, pilot, main fuel ignition, and run, and post-purge periods. The system shall incorporate full modulating control of fuel and combustion air as well as ring rate control based on system demand. The boiler controller shall have a non-volatile memory that retains history les and sequence status after interruptions. An 80 character, 2 line liquid crystal (LCD) display and keyboard shall be provided to adjust control settings and display 73 fault messages, 12 diagnostic messages, 38 historical messages as well as system status messages and operating pressures and temperatures. Boiler ring rate shall also be displayed in addition to the last 6 lockouts and boiler operating information when the lockout A4-39
10-02
Model CBW Boilers

occurred. Provisions for a security access code shall be provided. Separate status indicators shall show: Ready: HAWK operational. Demand: call for heat. Main Valve: fuel valve open. Low Water: low water condition. Alarm: safety shutdowns The boiler controller shall incorporate a ve function run/test switch.
Firetube Boilers
The system shall be characterized for each individual model boiler. The system shall also incorporate a tailored pre-purge cycle that minimizes pre-purge energy losses, while maintaining the maximum required air changes. It shall permit the user to select a specic rate control program for precise load tracking that reduces on-off cycling due to load swings. The system shall also provide an integrated thermal stress protection program to prolong boiler life. An assured low re cutoff feature shall also be provided. The system shall monitor inputs from solid state sensor for gas pressure, oil pressure, and temperature. A single solid state sensor shall be used for both on-off and proportioning control of the burner. The high/low limits and operating set points of all sensors shall be programmable from the keyboard display. The system shall be capable of detecting a jumpered or defective sensor. A dynamic check of the gas pressure sensor shall be made prior to the main ame establishing period to ensure it is fully operational. An optional 2 way communications module with built-in modem to allow for remote control of non-safety settings and monitoring of up to 6 boilers shall also be available. Up to 3 pre-programmed telephone numbers shall be called in the event of a fault condition. Options such as Lead/Lag, Boiler Efciency, and Heating Boiler packages can be interfaced to this module without any change to the existing system structure. The communications module shall be able to interface with an IBMTM PC or compatible system. 4.5.2.1 Control Panel: The control panel shall be mounted on the front door of the boiler in a location convenient to the operator. The hinged metal cabinet shall have NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet key type lock. The panel shall contain the boiler ame safeguard controller, indicating lights and selector switches. Panel shall have a removable sub-base for mounting the ame safeguard controller, and terminal blocks. For combination gas-oil and heavy oil red boilers the panel shall contain the fuel selector and/or oil heater selector switch. 4.5.2.2 Oil, heat, and moisture resistant wire shall be used and identied with circuit numbers corresponding to the electrical wiring diagram. 4.5.2.3 All electrical equipment and wiring shall be in conformance with Underwriters Laboratories requirements. 4.5.2.4 Boiler to be supplied with a control circuit transformer and fuse protection for the control circuit. 5.0 Efciency Guarantee 5.1 The boiler must be guaranteed to operate at a minimum fuel-to-steam efciency of ____ percent at 100 percent of rating when burning natural gas and ________ fuel-to-steam efciency at 100% ring rate when burning oil (Contact your local Cleaver-Brooks authorized representative for efciency details). 6.0 Warranty 6.1 All equipment is to be guaranteed against defects in materials and/or workmanship for a period of 12 months from date of startup or 18 months from date of shipment, whichever comes rst. 7.0 Execution 7.1 Shop Tests 7.1.1 The packaged boiler must receive factory tests to check the construction, controls, and operation of the unit. All tests may be witnessed by the purchaser, if desired. A4-40
10-02
Firetube Boilers
Model CBW Hot Water Boiler (100-800 hp, 30 and 125 psig)
1.0 Boiler Characteristics (Hot Water)
Model CBW Boilers
1.1 The Hot Water Boiler shall be Cleaver-Brooks Model CBW, Fuel Series ______ (100, 200, 400, 600, 700), ______ hp designed for ______ psig (30, 125, or other psig Hot Water). The maximum water temperature shall be ______ degree F, and the maximum system temperature drop shall be ______ degree F. 1.2 The boiler shall have a maximum output of ______ Btu/hr, or ______ horsepower when red with CS12-48 ______ oil and/or natural gas, ______ Btu/cu-ft. Electrical power available shall be ______ Volt ______ Phase _____ Cycle. 2.0 General Boiler Design 2.1 The boiler shall be a three pass horizontal retube updraft boiler with ve (5) square feet of heating surface per rated boiler horsepower (except 750 or 800 hp). It shall be mounted on a heavy steel frame with integral forced draft burner and burner controls. The complete packaged boiler approved as a unit by Underwriters Laboratories and shall bear the UL/ULC label. 2.1.1 The boiler shall be completely preassembled and re tested at the factory. The unit shall be ready for immediate mounting on oor or simple foundation and ready for attachment of water, fuel, electrical, vent, and blowdown connections. 2.1.2 The boiler shall be built to comply with the following insurance and codes _________________ (Factory Mutual, Industrial Risk Insurance, ASME CSD-1). 2.2 Boiler Shell (Hot Water) 2.2.1 The boiler shell must be constructed in accordance with ASME Boiler Code and must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be provided to the purchaser. 2.2.2 The hot water return and outlet connections shall be located on the top center line of the boiler. The boiler shall be designated to rapidly mix the return water with the boiler water. Forced internal circulation shall be used. 2.2.3 A dip tube shall be included as an integral part of the hot water outlet, and an air vent tapping shall be provided for removal of entrained air. 2.2.4 The boiler shall be furnished with a manhole and handholes to facilitate boiler inspection and cleaning. Two lifting lugs shall be located on top of the boiler. 2.2.5 The front door shall be hinged or davited, rear door shall be davited. Doors are to be sealed with berglass tadpole gaskets and fastened tightly using heavy capscrews that thread into replaceable brass nuts. 2.2.6 Front and rear tube sheets and all ues must be fully accessible for inspection or cleaning when the doors are swung open and rear door access plug is removed. 2.2.7 The rear door shall be insulated with a blanket material a steel covering to give the surface a hard durable nish. 2.2.8 The exhaust gas vent shall be located at the rear of the boiler and be capable of supporting 2000 lbs. The boiler vent shall contain a stack thermometer. 2.2.9 Observation ports for the inspection ame conditions shall be provided at each end of the boiler. 2.2.10 The boiler insulation shall consist of a 2 inch blanket under a sectional preformed sheet metal lagging. The insulation must be readily removable and reinstalled, if required. 2.2.11 The entire boiler base fame and other components shall be factory painted before shipment, using a hard-nish enamel coating. 3.0 Hot Water Boiler Trim 3.1 Low Water Cutoff A low water cutoff control (manual reset) shall be mounted on the top centerline of the boiler wired into the burner control circuit to prevent burner operation if boiler water falls below a safe level. 3.2 Pressure and Temperature Gauges
A4-41
10-02
Model CBW Boilers
Firetube Boilers
Pressure and temperature gauges shall be mounted on the boiler with the temperature sensing element located adjacent to the hot water outlet. 3.3 Relief Valves Water relief valves of a type and size to comply with ASME Code requirements shall be shipped loose. 3.4 Temperature Controls Temperature controls to regulate burner operation shall be mounted on the unit with temperature sensing elements located adjacent to the hot water outlet. Controls shall be high limit (manual reset), operating limit (auto reset), and ring rate control. 4.0 Burner and Controls 4.1 Mode of Operation Burner operation shall be full modulation principle. The burner shall always return to low re position for ignition. 4.2 Blower 4.2.1 Air for combustion shall be supplied by a forced draft blower mounted in the front boiler door, above the burner, to eliminate vibration and reduce noise level. 4.2.2 Maximum sound level of the boiler/burner package shall not exceed _____ dbA (when measured in accordance with ABMA Sound Test Standards). 4.2.3 The impeller shall be cast aluminum, radial blade, carefully balanced, and directly connected to the blower motor shaft. 4.3 Combustion Air Control Combustion air damper and cam operated fuel metering valves shall be operated by a single damper control motor that regulates the re according to load demand. Potentiometer type position controls shall be provided to regulate operation of the damper control motor (remove this sentence when a CB-HAWK ame safeguard is used). 4.4 Fuel Specication and Piping Select one of the following fuel types: Fuel series 700 - Gas red (para 4.4.1). Fuel series 100 - Light oil (No. 2) red (para 4.4.2). Fuel series 200 - Light oil or gas red (para 4.4.3). Fuel series 600 - No. 6 oil red (para 4.4.4). Fuel series 400 - No. oil or gas red (para 4.4.5). 4.4.1 Fuel Series 700 - Gas Fired 4.4.1.1 Burner Type - The burner shall be integral with the front head of the boiler and of high radiant annular gas entry on 100-200 hp and multi-port type gas entry on 250-800 hp. The burner shall be approved for operation on natural gas fuel. 4.4.1.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include two manual shutoff valves, solenoid valve, pressure regulator and pressure gauge. 4.4.1.3 Gas Burner Piping - Gas burner piping on all units shall include primary gas shutoff valve, motor operated with proof of closure switch and plugged leakage test connection. The main gas valve(s) shall be wired to close automatically in the event of power failure, ame failure, low water or any safety shutdown condition. A lubricating plug cock or buttery shutoff valve shall be provided as a means for a tightness check of the primary shut off valve. An additional plug cock on buttery valve shall be furnished at entrance to gas train. Select one of the following: A. 100 hp. High and low gas pressure switches shall be provided. B. 125-250 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided.
A4-42
10-02
Firetube Boilers
Model CBW Boilers
C. 300-800 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided. A vent valve shall be located between the safety shutoff valves. 4.4.1.4 Burner Turndown - Select one of the following: A. 100-200 hp. Turndown range of burner shall be 4:1 when ring natural gas. B. 250-800 hp. Turndown range of the burner shall be 10:1 when ring natural gas. (Consult with Cleaver-Brooks Representative regarding high turndown capability based on available gas pressure.) 4.4.2 Fuel Series 100 - Light Oil Fired 4.4.2.1 Burner Type - The burner shall be integral with the front head of the boiler, and shall be a low pressure air atomizing type approved for operation with CS12-48, Commercial No. 2 oil. 4.4.2.2 Oil Pilot - The oil pilot shall be air atomizing type with automatic electric ignition and include oil solenoid valve. An electronic detector shall monitor the pilot so that the primary oil valve cannot open until ame has been established. 4.4.2.3 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. The motor driven pump set, shipped loose, to be installed in a location favorable to the oil storage tank, shall be provided. 4.4.2.4 Oil Burner Piping 4.4.2.4.1 Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, solenoid shutoff valves, pressure gauges and fuel strainer, all integrally mounted on the unit. 4.4.2.4.2 A fuel oil controller shall be provided to combine all of the fuel oil controls into a single casting which is mounted on the front door of the unit. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. A low oil pressure switch shall be included in the oil piping. 4.4.2.5 Low Pressure Air Atomizing - Select one of the following: A. 100 through 400 hp. Belt driven air compressor, lubricating air tank, oil level indicator, inlet air lter, air pressure gauge, and low atomizing air pressure switch. B. 500 through 800 hp. Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch. 4.4.2.6 Burner Turndown - Select one of the following: A. 100 through 200 hp. Turndown range shall be 4:1 when ring No. 2 oil. B. 250 through 800 hp. Turndown range shall be 8:1 when ring No. 2 oil. 4.4.3 Fuel Series 200 - Light Oil or Gas Fired 4.4.3.1 Burner Type - The burner, integral with the front head of the boiler, shall be a combination of the low pressure air atomizing type for oil and high radiant annular gas entry on 100-200 hp and multi-port type gas entry on 250-800 hp. The burner shall be approved for operation with either CS12-48 Commercial No. 2 Oil or natural gas. 4.4.3.2 Gas Pilot - The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary fuel valve cannot open until ame has been established. The pilot train shall include two manual shut-off valves, solenoid valve, pressure regulator and pressure gauge. 4.4.3.3 Oil Burner 4.4.3.3.1 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. The motor driven pump set, shipped loose, to be installed in a location favorable to the oil storage tank, shall be provided. 4.4.3.3.2 Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, solenoid shutoff valves, pressure gauges and fuel strainer, all integrally mounted on the unit. A fuel oil controller shall be provided to combine all of the fuel oil controls into a single casting which is mounted on the front door of the unit. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. A low oil pressure switch shall be included in the oil piping. 4.4.3.3.3 Low pressure air atomizing. Select one of the following: A. 100 through 400 hp. Belt driven air compressor, lubricating air tank, oil level indicator, inlet air lter, air pressure gauge and low atomizing air pressure switch. A4-43
10-02
Model CBW Boilers
Firetube Boilers
B. 500 through 800 hp. Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch. 4.4.3.4 Gas Burner 4.4.3.4.1 Gas Burner Piping - gas burner piping on all units shall include primary gas shutoff valve, motor operated with proof of closure switch and plugged leakage test connection. The main gas valve(s) shall be wired to close automatically in the event of power failure, ame failure, low water or any safety shutdown condition. A lubricating plug cock or buttery shutoff valve shall be provided as a means for a tightness check of the primary shut off valve. An additional plug cock or buttery valve shall be furnished at entrance to gas train. Select one of the following: A. 100 hp. High and low gas pressure switches shall be provided. B. 125 through 250 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided. C. 300 through 800 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus and additional plugged leakage test connection shall be provided. A vent valve shall be located between the safety shutoff valves. 4.4.3.5 Burner Turndown - Select one of the following: A. 100 through 200 hp. Turndown range of the burner shall be 4:1. B. 250 through 800 hp. Turndown range of the burner shall be 10:1 when ring natural gas and 8:1 on No. 2 oil. (Consult your local Cleaver-Brooks authorized representative regarding high turndown capability based on available gas pressure.) 4.4.4 Fuel Series 600 - No. 6 Oil Fired 4.4.4.1 Burner Type - The burner shall be integral with the front head of the boiler and low pressure air atomizing type approved for operation with CS12-48, Commercial No. 6 Oil. 4.4.4.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary oil valve cannot open until pilot ame has been established. The pilot train shall include two manual shutoff valves, solenoid valve, pressure regulator and pressure gauge. 4.4.4.3 Oil Pump - An oil pump set with a capacity of approximately twice the maximum burning rate shall be included. The motor driven pump set shall be included shipped loose for location favorable to the oil storage tank. 4.4.4.4 Oil Burner Piping - A fuel oil controller combining all of the fuel oil controls into a single casing shall be provided. Oil pressure regulating devices, oil metering controls, solenoid shutoff valves, high and low oil temperature switches and necessary pressure and temperature gauges shall be included in this packaged assembly mounted on the front door of the boiler. A fuel strainer shall also be provided, mounted to the boiler. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. Flexible hoses shall be provided to allow easy removal of the nozzle for inspection when it is placed in the vice jaws located on the front door of the boiler. The metering valve shall permit circulation of hot oil to the burner at all times. The burner drawer oil piping and nozzle shall be purged of oil on each shutdown. A low oil pressure switch shall be included in the oil piping. 4.4.4.5 Low Pressure Air Atomizing - Select one of the following: A. 100 through 400 hp. Belt driven air compressor, lubricating oil tank, oil level indicator, inlet air lter, air pressure gauge and low atomizing air pressure switch. B. 500 through 800 hp. Separate air compressor modules mounted on boiler base rail with low atomizing air pressure switch. 4.4.4.6 Oil Preheat The oil shall be preheated by a safety type water-to-water-to-oil preheating system in conjunction with an electric heater, each with thermostatic control. Both heaters shall be installed in a single compact shell mounted, piped, and wired on the boiler. Select one of the following: A. 100 through 200 hp. Electric preheater size shall be 5 kW. B. 250 through 800 hp. Electric preheater size shall be 7-1/2 kW. C. 400 through 800 hp. Electric preheater size shall be 10 kW. A4-44
10-02
Firetube Boilers
4.4.5 Fuel Series 400 - No. 6 Oil or Gas Fired
Model CBW Boilers
4.4.5.1 Burner Type - The burner shall be integral with the front head of the boiler and shall be a combination of the low pressure atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 6 oil or natural gas. 4.4.5.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary oil valve cannot open until pilot ame has been established. The pilot train shall include two manual shutoff valves, solenoid valve, pressure regulator and pressure gauge. 4.4.5.3 Oil Burner 4.4.5.3.1 Oil Pump - An oil pump set with a capacity of approximately twice the maximum burning rate shall be included. 4.4.5.3.2 Oil Burner Piping - A fuel oil controller combining all of the fuel oil controls into a single casing shall be provided. Oil pressure regulating devices, oil metering controls, solenoid shutoff valves, high and low oil temperature switches, and the necessary pressure and temperature gauges shall be included in this packaged assembly mounted on the front door of the boiler. A fuel strainer shall also be provided, mounted to the boiler. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. Flexible hoses shall be provided to allow easy removal of the nozzle for inspection when it is placed in the vice jaws located on the front door of the boiler. The metering valve shall permit circulation of hot oil to the burner at all times. The burner drawer oil piping and nozzle shall be purged of oil at each shutdown. A low oil pressure switch shall be included in the oil piping. 4.4.5.4 Low Pressure Air Atomizing - Select one of the following: A. 100 through 400 hp. Belt driven air compressor, lubricating oil tank, oil level indicator, inlet air lter, air pressure gauge and low atomizing air pressure switch. B. 500 through 800 hp. Separate air compressor modules mounted on boiler base rail with low atomizing air pressure switch. 4.4.5.5 Oil Preheat - The oil shall be preheated by a safety type water-to-water-to-oil preheating system in conjunction with an electric heater, each with thermostatic control. Both heaters shall be installed in a single compact shell mounted, piped, and wired on the boiler. Select one of the following: A. 100 through 200 hp. Electric preheater size shall be 5 kW. B. 250 through 800 hp. Electric preheater size shall be 7-1/2 kW. C. 400 through 800 hp. Electric preheater size shall be 10 kW.
4.4.5.6 Gas Burner 4.4.5.6.1 Gas Burner Piping - Gas burner piping on all units shall include primary gas shutoff valve, motor operated with proof of closure switch and plugged leakage test connection. The main gas valve(s) shall be wired to close automatically in the event of power failure, ame failure, low water or any safety shutdown condition. A lubricating plug cock or buttery shutoff valve shall be provided as means for a tightness check of the primary shutoff valve. An additional plug cock or buttery valve shall be furnished at entrance to gas train. Select one of the following: A. 100 hp. High and low gas pressure switches shall be provided. B. 125 through 250 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided. C. 300 through 800 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional leakage test connection shall be provided. A vent valve shall be located between the safety shutoff valves. 4.4.5.6.2 Burner Turndown - Turndown shall be 4:1. 4.5 Boiler Flame Safeguard Controller and Control Panel 4.5.1 CB780 Flame Safeguard 4.5.1.1 Boilers with CB780 Control - Each boiler shall be factory equipped with ame safeguard controller providing technology
A4-45
10-02
Model CBW Boilers

and functions equal to the Cleaver-Brooks Model CB780.
Firetube Boilers
Controller shall be computerized solid state having sequence and ame-on lights and alpha-numeric rst out fault indications of ame safeguard trip functions. It shall include dynamic self-check logic. The controller shall have a xed operating sequence incapable of being manually altered. The sequence shall include start, pre-purge, pilot and main fuel ignition run and post-purge cycles. Controller shall be the non-recycle type for maximum safety that shall shutdown the burner and indicate as a minimum the following trip functions: pilot and main ame failure, high and low re proving switch faults, locking interlocks open, false ame signal and fuel valve open (when proof of closure switch is furnished). The controller shall have a run/test switch. It shall allow interruptions to sequence just after pre-purge, during pilot ignition trial and run cycles for adjustments to ring rate motor, damper linkages and pilot ame for minimum turndown tests. 4.5.1.2 Control Panel - The control panel shall be mounted on the front door of the boiler in a location convenient to the operator. The hinged metal cabinet shall have NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet key type lock. The panel shall contain the boiler ame safeguard controller, blower motor starter, indicating lights and selector switches. The panel shall have a removable sub-base for mounting the ame safeguard controller, blower motor starter, and terminal blocks. For combination gas-oil and heavy oil red boilers the panel shall contain the fuel selector and/or oil heater selector switch. The panel shall contain the following lights and switches: 4.5.1.3 Lights White - load demanded. White - fuel valve open. Red - low water. Red - ame failure. 4.5.1.4 Control Switches Burner On-Off. Manual-Automatic. Manual Firing Rate Control. 4.5.1.5 Oil, heat and moisture resistant wire shall be used and identied with circuit numbers corresponding to the electrical wiring diagram. 4.5.1.6 All electrical equipment and wiring shall be in conformance with Underwriters Laboratories requirements. 4.5.1.7 Boiler to be supplied with a control circuit transformer and fuse protection for the control circuit. 4.5.2 CB-HAWK Flame Safeguard Each boiler shall be factory equipped with a Boiler Management Control System providing technology and functions equal to the Cleaver-Brooks Model CB-HAWK. The system shall consist of a computer based boiler controller and solid state sensors totally integrated to provide automatic burner sequencing, ame supervision, and indications of system status, faults, and self-diagnostics. The boiler controller shall consist of chassis, program module, keyboard display, and ame signal amplier. It shall be the nonrecycle type and have a xed operating sequence incapable of being manually altered. The sequence shall include standby, prepurge, pilot, main fuel ignition, and run, and post-purge periods. The system shall incorporate full modulating control of fuel and combustion air as well as ring rate control based on system demand. The boiler controller shall have a non-volatile memory that retains history les and sequence status after interruptions. An 80 character, 2 line liquid crystal (LCD) display and keyboard shall be provided to adjust control settings and display 73 fault
A4-46
10-02
Firetube Boilers
Model CBW Boilers
messages, 12 diagnostic messages, 38 historical messages as well as system status messages and operating pressures and temperatures. Boiler ring rate shall also be displayed in addition to the last 6 lockouts and boiler operating information when the lockout occurred. Provisions for a security access code shall be provided. Separate status indicators shall show: Ready: HAWK operational. Demand: call for heat. Main Valve: fuel valve open. Low Water: low water condition. Alarm: safety shutdowns The boiler controller shall incorporate a ve function run/test switch. The system shall be characterized for each individual model boiler. The system shall also incorporate a tailored pre-purge cycle that minimizes pre-purge energy losses, while maintaining the maximum required air changes. It shall permit the user to select a specic rate control program for precise load tracking that reduces on-off cycling due to load swings. The system shall also provide an integrated thermal stress protection program to prolong boiler life. An assured low re cutoff feature shall also be provided. The system shall monitor inputs from solid state sensor for gas pressure, oil pressure, and temperature. A single solid state sensor shall be used for both on-off and proportioning control of the burner. The high/low limits and operating set points of all sensors shall be programmable from the keyboard display. The system shall be capable of detecting a jumpered or defective sensor. A dynamic check of the gas pressure sensor shall be made prior to the main ame establishing period to ensure it is fully operational. An optional 2 way communications module with built-in modem to allow for remote control of non-safety settings and monitoring of up to 6 boilers shall also be available. Up to 3 pre-programmed telephone numbers shall be called in the event of a fault condition. Options such as Lead/Lag, Boiler Efciency, and Heating Boiler packages can be interfaced to this module without any change to the existing system structure. The communications module shall be able to interface with an IBMTM PC or compatible system. 4.5.2.1 Control Panel: The control panel shall be mounted on the front door of the boiler in a location convenient to the operator. The hinged metal cabinet shall have NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet key type lock. The panel shall contain the boiler ame safeguard controller, indicating lights and selector switches. Panel shall have a removable sub-base for mounting the ame safeguard controller, and terminal blocks. For combination gas-oil and heavy oil red boilers the panel shall contain the fuel selector and/or oil heater selector switch. 4.5.2.2 Oil, heat, and moisture resistant wire shall be used and identied with circuit numbers corresponding to the electrical wiring diagram. 4.5.2.3 All electrical equipment and wiring shall be in conformance with Underwriters Laboratories requirements. 4.5.2.4 Boiler to be supplied with a control circuit transformer and fuse protection for the control circuit. 5.0 Efciency Guarantee 5.1 The boiler must be guaranteed to operate at a minimum fuel-to-water efciency of ____ percent at 100 percent of rating when burning natural gas and ________ fuel-to-steam efciency at 100% ring rate when burning oil (Contact your local Cleaver-Brooks authorized representative for efciency details). 6.0 Warranty 6.1 All equipment is to be guaranteed against defects in materials and/or workmanship for a period of 12 months from date of startup or 18 months from date of shipment, whichever comes rst.
A4-47
10-02
Model CBW Boilers

7.0 Execution 7.1 Shop Tests
Firetube Boilers
A4-48
10-02
Section A5
Model CBH Boilers
This product has been discontinued.
A5-1
02-02
Model CBH Boilers
Firetube Boilers
Notes
A5-2
02-02
Section A6
MODEL CB OHIO SPECIAL BOILERS
CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-3 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-3 DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-4 PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-4 ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-11 Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-11 Blowdown Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-11 Burner Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-13 Gas-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-13 Gas Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-16 Oil-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-17 Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-23 Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-23 Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-23 Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-23 SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-25 ILLUSTRATIONS Figure A6-1. Model CB Ohio Special Steam Boiler Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-6 Figure A6-2. Model CBW Ohio Special Steam Boiler Dimensions - Sheet 1of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-8 Figure A6-3. Space Required to Open Rear Head on Model CB and CBW Ohio Special Boilers Equipped with Davits A6-10 Figure A6-4. Model CB and CBW Ohio Special Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-10
A6-1
02-02
Ohio Special Boilers
Firetube Boilers
Figure A6-5. Model CB Ohio Special Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-11 Figure A6-6. Secondary Air Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-13 Figure A6-7. Complete Linkage Assembly, Combination Gas and Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-14 Figure A6-8. Gas Modulating Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-15 Figure A6-9. Model CB and CBW Ohio Special Gas Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-18 Figure A6-10. Typical Gas Piping Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-19 Figure A6-11. Model CB and CBW Ohio Special Firetube Boilers Standard Gas Train Connection Size and Location . A6-20 Figure A6-12. CB and CBW Ohio Special Boilers, No. 2 Oil Connection Size, Location and Recommended Line Sizes A6-20 Figure A6-13. No. 2 Oil Piping, Single Boiler Installation, Remote Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-21 Figure A6-14. No. 2 Oil Piping, Multiple Boiler Installation, Remote Oil Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-21 Figure A6-15. No. 2 Oil Piping, Multiple Boiler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-22 Figure A6-16. No. 2 Oil Transfer Tank Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-22 Figure A6-17. Boiler Room Length (Typical Layouts), Model CB Ohio Special Shown . . . . . . . . . . . . . . . . . . . . . . . . . A6-24 Figure A6-18. Boiler Room Width (Typical Layout), Model CB Ohio Special Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-24 TABLES Table A6-1. Model CB Ohio Special Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-5 Table A6-2. Model CBW Ohio Special Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-5 Table A6-3. Model CB and CBW Ohio Special Boilers Heating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-11 Table A6-4. Model CB Ohio Special Boilers Steam Volume and Disengaging Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-12 Table A6-5. Model CB and CBW Ohio Special Boilers Steam Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . . . A6-12 Table A6-6. Model CB and CBW Ohio Special Firetube Boilers Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-12 Table A6-7. Model CB and CBW Ohio Special Firetube Boilers Recommended Non-Return Valve Size . . . . . . . . . . . . A6-13 Table A6-8. Model CB and CBW Ohio Special Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-13 Table A6-9. CB and CBW Ohio Special Firetube Boilers Minimum Required Gas Pressure at Entrance to Standard and FM Gas Trains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-15 Table A6-10. CB and CBW Ohio Special Boilers Minimum Gas Pressure at Entrance to Gas Trains Equipped with Industrial Risk Insurers (IRI) Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-16 Table A6-11. Model CB and CBW Ohio Special Boilers Under and Oversized Standard and FM Gas Trains . . . . . . . . A6-16 Table A6-12. Model CB and CBW Ohio Special Boilers Under and Oversized IRI Gas Trains, . . . . . . . . . . . . . . . . . . . A6-17 Table A6-13. Minimum Required Gas Pressure Altitude Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-17
The following section contains information on Cleaver-Brooks Ohio Special Boilers.
A6-2
02-02
Firetube Boilers

Boiler Options Drain valves. Additional screwed or anged trappings. Surge load bafes. Seismic design. Blowdown valves. Non-return valves. Feedwater valves and regulators. Special doors, davited, hinged, left swing. Special base rails. Surface blowdown systems. Weather-proong. Burner/Control Options Special modulation controls. Low NOx equipment. Optional ame safeguard controller. Lead/lag system. Special insurance and code requirements (e.g., IRI, FM, CSD1). Remote contacts. Additional relay points and indicator lights. Main disconnect. Elapsed time meter. Voltmeter/micro-ampmeter. NEMA enclosures. Low red hold controls. Remote emergency shut-off (115V). Circuit breaker. Day/night controls. Special power requirements. Fuel Options Automatic fuel changeover. Special gas pressure regulator. Oversized/undersized gas trains. Gas strainer. Special fuel shut-off valves.

The Cleaver-Brooks Ohio Special Firetube boiler is designed, manufactured, and packaged by Cleaver-Brooks specically for operation in the state of Ohio, under the rules and regulations for unattended units. The unique design of the Ohio Special Boiler serves your steam needs and reduces unnecessary labor costs. All units are factory re tested and shipped as a package, ready for quick connection to utilities. In addition to the features provided on all Cleaver-Brooks Firetube boilers, the following features apply to the Ohio Specials. Unique Dimple Tube Design: Ensures high gas turbulence and increased efciency without turbulators, spinners, and other high maintenance devices. Dimple tubes also reduce the lm coefcient on the gas side to transfer more heat, thus achieving greater output with less heating surface. 358 Square Feet of Heating Surface: The greatest amount offered in any packaged boiler for unattended steam boiler operation in Ohio - means long life and years of service at the high efciencies. Low Furnace Location: Furnace located well below water level with generous clearance from bottom of boiler, allowing proper circulation. Low furnace provides additional safety margin between furnace and water level. Reduces water carryover, producing drier steam.
PRODUCT OFFERING
Cleaver-Brooks Ohio Special Firetube boilers are available high pressure steam designs. Burners are available to re natural gas, light oil, or a combination of oil and gas. Ohio Special Boilers include: Four-pass dryback design (100 hp). Two-pass dryback design (125 - 225 hp). Two-pass wetback design (125 - 200 hp). 15 psig low pressure steam. 150, 200, and 250 psig high pressure steam Natural gas or light oil ring. Available options: For option details, contact your local Cleaver-Brooks authorized representative. In summary, options include the following:
A6-3
02-02

Special pilot. Alternate fuel ring. Special oil pumps.
Firetube Boilers

For dimension and rating information for Ohio Special boilers, refer to the following tables and illustrations: Table A6-1. Model CB Ohio Special Steam Boiler Ratings. Table A6-2. Model CBW Ohio Special Boiler, Steam Boiler Ratings. Figure A6-1. Model CB Ohio Special Steam Boiler Dimensions. Figure A6-2. Model CBW Ohio Special Steam Boiler Dimensions. Figure A6-3. Space Required to Open Rear Head on Model CB Ohio Special Boilers Equipped with Davits. Figure A6-4. Lifting Lug Locations, Model CB Ohio Special Boilers. Figure A6-5. Model CB Ohio Special Boiler Mounting Piers.
PERFORMANCE DATA
For efciency and emission data for Ohio Special Boilers, contact your local Cleaver-Brooks authorized representative.
A6-4
02-02
Firetube Boilers
Table A6-1. Model CB Ohio Special Steam Boiler Ratings
BOILER HP Normal Water Capacity Approx Wt -15 psig Approx Wt -150 psig Approx Wt - 200 psig Water Capacity Flooded Steam - lbs/hr (212F) Btu Output (1000 Btu/hr) Light Oil gph (140,000 Btu/gal) Nat Gas CFH (1000 Btu/cu-ft) Nat Gas -Therms/hr Blower Motor, hp (all models) Oil Pump Motor, hp (No. 2 Oil) Air Compressor Motor hp (Oil Fired Only) 100S 4625 7800 8500 9000 5420 3450 3348 30 4185 41.9 3 1/3 2 125S 7000 9300 9900 10500 8673 4313 4184 37.4 5230 52.3 5 1/2 150S 7000 9300 9900 10500 8673 5175 5021 44.8 6277 62.8 7-1/2 1/2 175S 8500 12600 13500 14200 10485 6038 5858 52.5 7323 73.2 10 1/2
200S 8500 12600 13500 14200 10485 6900 6695 59.8 8369 83.7 15 1/2
225S 8500 12600 13500 14200 10485 7763 7531 67.5 9415 94.2 20 1/2
WEIGHT IN POUNDS
RATINGS SEA LEVEL TO 3000 FT
APPROXIMATE FUEL CONSUMPTION AT RATED CAPACITIES
POWER REQUIREMENTS - ELECTRIC (60 Hz)
Air Compressor Belt Driven From Blower Motor
NOTES: 1. Standard Voltage is 230 or 460/3/60 Hz. 2. Burner control circuit Voltage is 115/1/60 Hz,1/2 kVA load. 3. Side mounted air compressor (3 hp motor) recommended for 200S and 225S.
Table A6-2. Model CBW Ohio Special Steam Boiler Ratings

BOILER HP Normal Water Capacity Approx Wt - 15 psig Approx Wt - 150 psig Approx Wt - 200 psig Steam lbs/hr (212F) Btu Output (1000 Btu/hr) Light Oil gph (140,000 Btu/gal) Nat Gas CFH (1000 Btu/cu-ft) Nat Gas Therms/hr Blower Motor hp (all models) Oil Pump Motor hp No. 2 Oil Air Compressor Motor hp (Oil Fired Only) 125S 7000 11500 12500 13200 4313 4184 37.4 5230 52.3 5 1/2 150S WEIGHT IN POUNDS 7000 11500 12500 13200 5175 5021 44.8 6277 62.8 7-1/2 1/2 8500 13250 14300 15000 6038 5858 52.5 7323 73.2 10 1/2 8500 13350 14400 15100 6900 6695 59.8 8369 83.7 15 1/2 175S 200S
RATINGS - SEA LEVEL TO 3000 FT
APROXIMATE FUEL CONSUMPTION AT RATED CAPACTIES
POWER REQUIREMENTS - ELECTRIC (60 Hz)
Air Compressor Belt Driven From Blower Motor
NOTES: 1. Standard Voltage is 230 or 460/3/60 Hz. 2. Burner control circuit voltage is 115/1/60 Hz; 1/2 kVA Load. 3. Side mounted air compressor (3 hp motor) recommended for 200S.
A6-5
02-02
Firetube Boilers
RR/RF/RD EE I LL L K F GG D Y T E B FF DD
Z O P OO H S ELECTRICAL SERVICE CONNECTIONS (CONTROL CIRCUIT 120/1/60)

SIGHT PORT R 0.5 W C A W
Q N M
KK
MODEL HP
DIM
100S
125S LENGTH
150S
175S
200S
225S
Overall Shell Base Frame Front Head Extension (Approx) Rear Head Extension Flange to Nozzle (15 psig) Flange to Nozzle (150 psig)
A B C D E F F
171-1/2 131 130 22 18-1/2 65-1/2 72.5
163-1/2 113 112 31 19-1/2 53 53
163-1/2 113 112 31 19-1/2 53 53
200-1/2 149 148 32 19-1/2 74.5 66
204-1/2 149 148 36 19-1/2 74.5 66
207-1/2 149 148 39 19-1/2 74.5 66
Figure A6-1. Model CB Ohio Special Steam Boiler Dimensions - Sheet 1 of 2
A6-6
02-02
Firetube Boilers
MODEL HP
DIM
100S
125S WIDTH
150S
175S
200S
225S
Overall ID Boiler Center to Water Column Center to Outside Hinge Center to Lagging Center to Auxiliary LWCO Base-Outside Base-Inside
I J K KK L LL M N
73 48 39 29 27 34 37-5/8 29-5/8
85 60 45 35 33 40 52-1/2 44-1/2 HEIGHT
85 60 45 35 33 40 52-1/2 44-1/2
85 60 45 35 33 40 52-1/2 44-1/2
85 60 45 35 33 40 52-1/2 44-1/2
85 60 45 35 33 40 52-1/2 44-1/2
Overall Base to Vent Outlet Base to Steam Outlet Base Frame Base to Bottom Boiler
OO O P Q R
78-3/4 70 66 12 16
86 85 77 12 16 CONNECTIONS
86 85 77 12 16
86 85 77 12 16
86 85 77 12 16
86 85 77 12 16
Chemical Feed Feedwater, Right & Left Auxiliary Connection Steam Nozzle (15 psig)A Steam Nozzle (150 psig)B Drain-Front & Rear (15 psig only) Blowdown-Front & Rear (150 psig) Surface Blow (150 psig only) Vent Stack Dia. (Flanged) Flange to Center Vent
H S Z Y Y W W T BB CC
1 1-1/4 1 8 FLG 4 FLG 1-1/2 1-1/4 1 12 7
1 1-1/2 1 8 FLG 4 FLG 1-1/2 1-1/2 1 16 9 CLEARANCES
1 1-1/2 1 8 FLG 4 FLG 1-1/2 1-1/2 1 16 9
1 1-1/2 1 8 FLG 4 FLG 2 1-1/2 1 16 9
1 1-1/2 1 10 FLG 4 FLG 2 1-1/2 1 16 9
1 1-1/2 1 10 FLG 4 FLG 2 1-1/2 1 16 9
Rear Door Swing Front Door Swing Tube Removal, Rear Tube Removal, Front Min Room Length for Rear Tube Removal Min Room Length for Front Tube Removal Tube Removal thru Door
DD EE FF GG RR RF RD
55 55 123 113 309 299 241
32 67 103 91 283 236 212
32 67 103 91 283 236 212
32 67 139 127 355 308 248
32 67 139 127 355 308 248
32 67 139 127 355 308 248
NOTE: Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension prints. A. Flanged 150 psig ANSI B. Flanged 300 psig ANSI
Figure A6-1. Model CB Ohio Special Steam Boiler Dimensions - Sheet 2 of 2
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Firetube Boilers
Figure A6-2. Model CBW Ohio Special Steam Boiler Dimensions - Sheet 1of 2
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Firetube Boilers
BOILER NO. DIM LENGTHS Overall Shell Base Frame Front Head Extension (Approx) Flange to Nozzle (15 psig) Flange to Nozzle (150 psig) A B C D F F WIDTHS Overall ID Boiler Center to Water Column Center to Outside Hinge Center to Lagging Center to Auxiliary Water Control Base-Outside Base-Inside I J K KK L LL M N 85 60 45 35 33 40 52-1/2 44-1/2 HEIGHTS Overall Base to Vent Outlet Base to Steam Outlet Base Frame Base to Bottom Boiler OO O P Q R 86 85 82-3/8 12 16 CONNECTIONS Chemical Feed Feedwater, Right & Left Auxiliary Connection Steam Nozzle (15 psig)A Steam Nozzle (150 psig)B Drain-Front & Rear (15 psig only) Blowdown-Front & Rear (150 psig) Surface Blow (150 psig only) Vent Stack Dia. (Flanged) Flange to Center Vent H S Z Y Y W W T BB CC 1 1-1/2 1 8 4 1-1/2 1-1/2 1 16 9 1 1-1/2 1 8 4 1-1/2 1-1/2 1 16 9 86 85 82-3/8 12 16 85 60 45 35 33 40 52-1/2 44-1/2 195 159 151 31 62 64 195 159 151 31 62 64 125S 150S

175S 200S
222 186 170 32 64 64
226 186 175 36 64 64
85 60 45 35 33 40 52-1/2 44-1/2
85 60 45 35 33 40 52-1/2 44-1/2
86 85 82-3/8 12 16
86 85 82-3/8 12 16
1 1-1/2 1 8 4 2 1-1/2 1 16 9
1 1-1/2 1 10 4 2 1-1/2 1 16 9
MINIMUM CLEARANCE Rear Door Swing Front Door Swing Tube Removal, Front only Min Room Length for Front Tube Removal Tube Removal thru Door DD EE GG RF RD 28 67 89 276 254 28 67 89 276 254 28 67 116 328 281 28 67 116 328 281
NOTE: Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension prints. A. Flanged 150 psig ANSI B. Flanged 300 psig ANSI
Figure A6-2. Model CBW Ohio Special Steam Boiler Dimensions - Sheet 2 of 2
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Firetube Boilers
DIMENSION (INCHES) BOILER HP A CB 100S CB 125S thru 225S CBW 125S thru 200S 27 33 33 B 48 55 42 C 38 45 48 D 60 68 61 E 26 32 30
Figure A6-3. Space Required to Open Rear Head on Model CB and CBW Ohio Special Boilers Equipped with Davits
FRONT FLANGE
D (HOLE DIA)
BOILER HP (CB) 100S 125S-150S 175S-225S
ALL DIMENSIONS IN INCHES A 68 80 80 B 27 29-1/2 29-1/2 C 67 66 88 D 2-1/2 3 3
BOILER HP (CBW) 125S-150S 175S-225S
ALL DIMENSIONS IN INCHES A 80 80 B 19 19 C 109 148 D 3 3
Figure A6-4. Model CB and CBW Ohio Special Boilers Lifting Lug Location
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Firetube Boilers
BOILER HP CB 100S CB 125S, 150S CB 175S, 200S, 225S CBW 125S, 150S CBW 175S, 200S
A 6 6 6 6 6
B 8 9 9 9 9
C 130 112 148 151 175
D 26 39-1/2 39-1/2 39-1/2 39-1/2
E 42 57-1/2 57-1/2 57-1/2 57-1/2
F 4 4 4 4 4
G 29-5/8 44-1/2 44-1/2 44-1/2 44-1/2
X 8-1/4 10-1/4 10-1/4 9-3/4 Front 26-3/4 Rear 9-3/4 Front 26-3/4 Rear
NOTES: 1. All numbers in table are in inches. 2. 6-inch high mounting piers recommended for use beneath the boiler base frame. The use of these piers provides increased inspection accessibility to the piping beneath the boiler and added height for washing down the area beneath the boiler.
Figure A6-5. Model CB Ohio Special Boiler Mounting Piers
ENGINEERING DATA
The following engineering information is provided for the Ohio Special Boilers. Ohio Special boilers are designated by an S following the horsepower number. Additional detail is available from your local Cleaver-Brooks authorized representative.
Table A6-5 lists quantity and outlet size for safety valves supplied on Model CB and CBW Ohio Special Boilers. Table A6-6 gives recommended steam nozzle sizes based on 4000-5000 fpm steam velocity. Model CB and CBW Ohio Special Firetube Boilers. Table A6-7 shows recommended non-return valve sizes for Model CB and CBW Ohio Special Firetube Boilers.
Boiler Information
Table A6-3 shows heating surfaces for Model CB and CBW Ohio Special Boilers. Table A6-4 shows steam volume and disengaging area for Model CB Ohio Special Boilers. Table A6-3. Model CB and CBW Ohio Special Boilers Heating Surface
BOILER HP 100S 125S-150S 175S, 200S, 225S HEATING SURFACE (SQ-FT) FIRESIDE 350 358 358 WATERSIDE 388 386 384

Some local codes require blowdown tanks to be constructed in accordance with recommendations of the National Board of Boiler and Pressure Vessel Inspectors. The National Boards recommendations base the size of the blowdown tank on the removal of at least 4 inches of water from the boiler. Table A6-8 lists the approximate quantity of water represented by 4 inches of water at normal operating level for Model CB and CBW Ohio Special Boilers.
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Table A6-4. Model CB Ohio Special Boilers Steam Volume and Disengaging Area
STEAM VOLUME CU-FT BOILER HP HIGH PRESSURE 100S 125S, 150S 175S, 200S, 225S 38.5 14.3 28.4 52.7 STEAM RELIEVING AREA SQ-IN
LOW PRESSURE 23.7 38.9
HIGH PRESSURE 4367 5086 6899
LOW PRESSURE 4975 5473 7423
NOTES: Based on normal water level. A. Based on 150 psig design pressure. B. Based on 15 psig design pressure.
Table A6-5. Model CB and CBW Ohio Special Boilers Steam Boiler Safety Valve Openings
VALVE SETTING 15 PSIG STEAM 100 PSIG STEAM 125 PSIG STEAM 150 PSIG STEAM 200 PSIG STEAM 250 PSIG STEAM
BOILER NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET HP VALVES SIZE VALVES SIZE VALVES SIZE VALVES SIZE VALVES SIZE VALVES SIZE REQ'D (IN.) REQ'D (IN.) REQ'D (IN.) REQ'D (IN.) REQ'D (IN.) REQ'D (IN.) 100S 125S 150S 175S 200S 225S 1 1 1 1 1 2 2-1/2 2-1/2 3 3 3 2-1/2 1 1 1 1 2 2 2 2-1/2 2-1/2 2-1/2 2 2 1 2 1 1 1 1 2 (1) 2 (1) 1-1/2 2-1/2 2-1/2 2-1/2 2-1/2 1 1 1 1 1 1 1-1/2 2 2 2 2-1/2 2-1/2 1 1 1 1 1 1 1-1/2 1-1/2 1-1/2 2 2 2 1 1 1 1 1 1 1-1/4 1-1/2 1-1/2 1-1/2 2 2
Table A6-6. Model CB and CBW Ohio Special Firetube Boilers Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity)
BOILER HP OPERATING PRESSURE PSIG 15 30 40 50 75 100 125 150 200 100S 125S 150S 175S 200S 225S 8 6 6 4 4 4 4 2.5 2.5 8 6 6 6 4 4 4 3 2.5 8 6 6 6 4 4 4 3 3 8 6 6 6 6 4 4 4 3 10 8 6 6 6 6 4 4 4 10 8 8 6 6 6 4 4 4
NOTES: 1. Steam nozzle sizes given in inches. 2. Recommended steam nozzle sizes based on 4000 to 5000 fpm steam velocity. Spool pieces (300 psig flanges) are available in the following sizes (in inches): 3x2-1/2x30, 4x3x30, 6x4x36, 8x6x48, and 10x8x48.
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Firetube Boilers
Table A6-7. Model CB and CBW Ohio Special Firetube Boilers Recommended Non-Return Valve Size
BOILER HP 100S 125S 150S 175S 200S 225S BOILER CAPACITY (LB/HR) 3450 4313 5175 6900 8625 10350 OPERATING PRESSURES (PSIG) 50 3 4 4 4 4 4 75 2-1/2 3 4 4 4 4 100 2-1/2 3 3 3 4 4 125 2-1/2 3 3 3 3 3 150 2-1/2 3 3 3 3 3 175 2-1/2 2-1/2 3 3 3 3 200 2-1/2 2-1/2 2-1/2 2-1/2 3 3
Table A6-8. Model CB and CBW Ohio Special Blowdown Tank Sizing Information
BOILER HP 100S 125S-150S 175S-225S WATER (GAL) 80 87 118
NOTE: Quantity of water removed from boiler by lowering normal water line 4"
Burner Information
The Ohio Special Firetube Boiler encompasses an integral front head that includes the burner, combustion air fan, and controls as part of the boiler package design. The integral front head provides for burner/boiler design as a single unit maximizing the compatibility between the boiler and burner. Figure A6-6 shows secondary air ow in the Ohio Special Firetube Boiler. The rotary air damper design provides standard turn down of 4:1. Figure A6-7 shows a typical linkage assembly. The single point linkage layout allows for easy adjustment and maximum repeatability of air/fuel ratios. Included on all Ohio Special Boilers is an adjustable CAM assembly shown in Figure A6-8. Gas-Fired Burners
NOTICE
A gas pressure regulator must be installed in the gas piping to each boiler. Gas pressure regulators for Ohio Special Firetube Boilers are sized and selected on a job-by-job basis. Therefore, gas pressure requirements shown in Tables A6-9, A6-10, A6-11, A612, and A6-13 list regulated gas pressure. Regulated gas pressure is the pressure downstream of the gas pressure regulator. Total gas pressure required for the boiler equals regulated gas pressure plus the pressure drop of the selected gas pressure regulator.
Figure A6-6. Secondary Air Flow Diagram Table A6-9 shows regulated gas pressure requirements for Standard and FM gas trains for CB and CBW Ohio Special Firetube Boilers. Table A6-10 shows regulated gas pressure requirements for IRI Gas Trains for CB and CBW Ohio Special Boilers. Table A6-11 and A6-12 show regulated gas pressure with over and undersized gas trains for CB and CBW Ohio Special Firetube Boilers. Table A6-13 shows minimum required gas pressure altitude conversion. A6-13
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Firetube Boilers
Figure A6-7. Complete Linkage Assembly, Combination Gas and Oil
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Firetube Boilers
Figure A6-8. Gas Modulating Cam
Table A6-9. CB and CBW Ohio Special Firetube Boilers Minimum Required Gas Pressure at Entrance to Standard
BOILER HP CONN SIZE NET REGD (IN.) PRESS. REQD (IN. WC) 2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 11.0 8.5 13.0 16.0 21.0 27.0
and FM Gas Trains
BOILER HP
CONN SIZE (IN.) 2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2
MIN PRESS REQ'D (IN. WC) 12.0 8.5 13.0 16.0 21.0 27.0
100S 125S 150S 175S 200S 225S
100S 125S 150S 175S 200S 225S
NOTES: 1. For standard and FM gas pressure requirements for Canada, refer to Table A6-10, IRI Trains. 2. Based on 1000 Btu/cu-ft natural gas and elevations up to 700 feet.
NOTES: 1. Pressures shown also apply to standard and FM gas trains for Canada. 2. Based on 1000 Btu/cu-ft natural gas and elevation up to 700 feet.
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Firetube Boilers
Table A6-10. CB and CBW Ohio Special Boilers Minimum Gas Pressure at Entrance to Gas Trains Equipped with Industrial Risk Insurers (IRI) Requirements
100S PIPE SIZE 1-1/2 2 2-1/2 3 PRESS REQD 24.0 11.0 9.5 8.5 PIPE SIZE 2 2-1/2 3 4 125S PRESS REQD 14.5 8.5 7.5 6.5 PIPE SIZE 2 2-1/2 3 4 150S PRESS REQD 19.0 13.0 11.0 9.0 PIPE SIZE 2 2-1/2 3 4 175S PRESS REQD 23.5 16.0 12.5 10.0 PIPE SIZE 2 2-1/2 3 4 200S PRESS REQD 31.0 21.0 15.5 12.5 PIPE SIZE 2 2-1/2 3 4 225S PRESS REQD 39.0 27.0 20.0 16.0
NOTES: 1. Pipe size in inches, and pressure required in inches of WC. 2. Standard gas train shown by shaded area. 3. Pressure required is downstream of the gas pressure regulator.
Table A6-11. Model CB and CBW Ohio Special Boilers Under and Oversized Standard and FM Gas Trains
100S PIPE SIZE 1-1/2 2 2-1/2 3 PRESS REQD 29.5 12.0 10.5 9.0 PIPE SIZE 2 2-1/2 3 4 125S PRESS REQD 14.5 8.5 7.5 6.5 PIPE SIZE 2 2-1/2 3 4 150S PRESS REQD 19.0 13.0 11.0 9.0 PIPE SIZE 2 2-1/2 3 4 175S PRESS REQD 23.5 16.0 12.5 10.0 PIPE SIZE 2 2-1/2 3 4 200S PRESS REQD 31.0 21.0 15.5 12.5 PIPE SIZE 2 2-1/2 3 4 225S PRESS REQD 39 27 20 16
NOTES: 1. Pipe size in inches, and pressure required in inches WC. 2. Standard gas train shown by shaded areas. 3. Pressure required is downstream of the gas pressure regulator.
Table A6-12. Model CB and CBW Ohio Special Boilers Under and Oversized IRI Gas Trains,
Gas Pressure Regulator The following items should be considered when selecting a regulator: Pressure Rating: The regulator must have a pressure rating at least equivalent to that of the gas distribution system. Capacity: The capacity can be determined by multiplying the maximum burning rate (CFH) by 1.15, see Table A6-14. This 15 percent over-capacity rating of the regulator provides for proper regulation. Spring Adjustment: The spring should be suitable for a range of adjustment from 50 percent under the desired regulated pressure to 50 percent over. Sharp Lock-Up: The regulator should include this feature to prevent the downstream pressure (between the regulator and the boiler) from climbing when there is no gas ow.
To obtain minimum required gas pressure at altitudes above 700 feet, multiply the pressure by the listed factors: Inches WC x 0.577 = oz/sq-in. Oz/sq-in x 1.732 = Inches WC. Inches WC x 0.0361= psig. Oz/sq-in x 0.0625 = psig. Psig x 27.71 = Inches WC. Psig x 16.0 = Oz/sq-in.
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Firetube Boilers

BOILER HP TYPE OF GAS AND HEAT CONTENT NATURAL GAS 1000 (Btu/cu-ft) 4185 5230 6280 7350 8370 9415 PROPANE GAS 2550 (Btu/cu-ft) 1640 2050 2465 2870 3280 3690
Oil-Fired Burners Fuel oil consumption information is shown on the boiler rating sheets in the Dimensions and Rating Section. Figure A6-12 shows the oil connection sizes and locations for Ohio Special Boilers ring No. 2 oil. Figures A6-13 through A6-15 show typical oil systems and layouts. Figure A6-16 shows the detail of an oil transfer tank (day tank) typically utilized to provide a storage reservoir between the oil system supply pump and the boiler oil pump.
100S 125S 150S 175S 200S 225S
Regulators in Parallel: This type of installation can be used if the required gas volume is very large and if the pressure drop must be kept to a minimum. Regulators in Series: This type of installation can be used if the available gas pressure is over 5, 10, or 20 psig. Depending on the regulator characteristics, one regulator would reduce the pressure to 2 to 3 psig, and a second regulator would reduce the pressure to the burner requirements. Regulator Location: A straight run of gas line piping should be used on both sides of the regulator to ensure proper regulator operation. This is particularly important when pilot operated regulators are used. The regulator can be located close to the gas train connection, but 2 to 3 feet of straight run piping should be used on the upstream side of the regulator. Table A6-14 shows maximum gas consumption for natural gas and propane vapor. Figure A6-9 shows typical gas train components, and Figure A6-10 shows typical gas train piping layouts for multiple boiler applications. Figure A6-11 shows standard gas train sizes and locations for Model CB and CBW Ohio Special Firetube Boilers.
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Firetube Boilers
INS ITEM DESCRIPTION BOILER HP 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Pilot Shut Off Cock Pilot Shut Off Cock Shut Off Cock Shut Off Cock Pilot Pressure Regulator Pilot Pressure Gauge Gas Pilot Valve High Gas Pressure Switch Low Gas Pressure Switch Main Gas Valve with POC Main Gas Valve without POC Main Gas Valve without POC Vent Valve Buttery Valve X X X X X X X X X 100S X
UL 125S 150S 175S 200S 225S X X X X X X X X X X 100S X X X X X X X X X
FM 125S 150S 175S 200S 225S X X X X X X X X X X X X X X X X X 100S X X X X X X X X X
IRI 125S 150S 175S 200S 225S X X X X X X X X X X X X X X X X X
FM & IRI 100S X X X X X X X X X 125S 150S 175S 200S 225S X X X X X X X X X X X X X
Figure A6-9. Model CB and CBW Ohio Special Gas Train Components
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Firetube Boilers
This figure illustrates the basic gas valve arrangement on Cleaver-Brooks boilers and shows the contractor's connection point. The valves and controls between the contractor connection point and the gas main in the street are representative of a typical installation. Actual requirements may vary depending on local codes or local gas company requirements which should be investigated prior to preparation of specifications and prior to construction.
MODEL CB & CBW OHIO SPECIAL BOILERS
MODEL CB & CBW OHIO SPECIAL BOILERS
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Firetube Boilers
MODEL CB& CBW BOILER HP 100S 125S-225S CONNECTION SIZE (IN.) (NPT) 2 2-1/2 LOCATION DIMENSION A (IN.) 44 67-1/2
Figure A6-11. Model CB and CBW Ohio Special Firetube Boilers Standard Gas Train Connection Size and Location
BHP
SUPPLY AND RETURN CONN SIZES (IN.) (NPT)
RECOMMENDED OIL LINEA SIZES (STANDARD PIPE) (IN.-IPS) A (IN.) STORAGE TANK TO BOILER OR PUMP CONNECT 1 1 RETURN LINE TO TANK 1 1
PUMP TO BOILER
100S 125S-225S
3/4 3/4
11-1/2 12-1/2
1 1
NOTES: See No. 2 Oil Line Sizing Instruction for systems with other conditions A. For suction line condition with a maximum of 10 Feet of lift and a total of 100 feet of suction line.
Figure A6-12. CB and CBW Ohio Special Boilers, No. 2 Oil Connection Size, Location and Recommended Line Sizes
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Firetube Boilers
USE LAYOUT FOR: MODEL CB . . . . . . 100S - 225S MODEL CBW . . . . 125 S- 200S
USE LAYOUT FOR: MODEL CB . . 100S - 225S MODEL CBW . . . 125S - 200S
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Firetube Boilers
USE LAYOUT FOR: MODEL CB . . . . . . . 100S - 225S MODEL CBW . . . . . 125S - 200S
ITEM A B C D E F G H
SIZE 1/2 NPT See note See note 1/2 NPT See note 1/8 NPT See note No. 80
DESCRIPTION Connection to oil level switch Return line to tank Oil supply connection from transfer pump Tank drain connection FOS connection Oil level test valve connection FOR connection Oil level switch McD & Miller or equal
NOTE: Connection should be sized using recommended sizes in oil line sizing instruction.
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Firetube Boilers
Figure A6-17 shows typical boiler room length requirements. Figure A6-18 shows typical boiler room width requirements.

Example: Determine the area of the boiler room air supply openings for (1) 200 hp boiler at 800 feet altitude. The air openings are to be 5 feet above oor level. Air required: 200 x 10 = 2000 cfm (from 2B above). Air velocity: Up to 7 feet = 250 fpm (from 3 above). Area Required: Area = cfm = 2000/250 = 8 Sq-ft total. Area/Opening: 8/2 = 4 sq-ft/opening (2 required).

100 hp Ohio Special Boilers can support up to 1,000 lbs without additional support. 125-225 hp Ohio Special Boilers can support up to 2,000 lbs without additional support.
NOTICE Boiler Room Combustion Air

When determining boiler room air requirements, the size of the room, air ow, and velocity of air must be reviewed as follows: 1. Size (area) and location of air supply openings in boiler room. A. Two (2) permanent air supply openings in the outer walls of the boiler room are recommended. Locate (1) at each end of the boiler room, preferably below a height of 7 feet. This allows air to sweep the length of the boiler. B. Air supply openings can be louvered for weather protection, but they should not be covered with ne mesh wire, as this type of covering has poor air ow qualities and is subject to clogging by dust or dirt. C. A vent fan in the boiler room is not recommended, as it could create a slight vacuum under certain conditions and cause variations in the quantity of combustion air. This can result in unsatisfactory burner performance. D. Under no condition should the total area of the air supply openings be less than (1) square foot. E. Size the openings by using the formula: Area (sq-ft) = cfm/fpm 2. Amount of air required (cfm). A. Combustion air - rated bhp x 8 cfm/bhp. B. Ventilation air - rated bhp x 2 cfm/bhp or a total of 10 cfm/bhp - up to 1000 feet elevation. Add 3 percent more per 1000 feet of added elevation. 3. Acceptable air velocity in Boiler Room (fpm). A. From oor to (7) foot height - 250 fpm. B. Above (7) foot height - 500 fpm. C. Duct from air supply to boiler - 1000 fpm. Consult local codes, which may supersede these requirements.

The design of the stack and breeching must provide the required draft at each boiler ue gas outlet. Proper draft is critical to burner performance. Although constant pressure at the ue gas outlet of the Ohio Special is not required, it is necessary to size the stack/breeching to limit ue gas pressure variation. The allowable pressure range is 0.25" W.C. to +0.25" W.C. For additional information, please review Section I4, General Engineering Data (Stacks) and Section F, Stacks. Stack and breeching sizes should always be provided by a reputable stack supplier who will design the stack and breeching system based on the above criteria. Your local Cleaver-Brooks authorized representative is capable of assisting in your evaluation of the stack/breeching design.
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Firetube Boilers
DWG A - MODEL CB & CBW
DWG B - MODEL CB & CBW DWG C - MODEL CB ONLY 1. Shortest boiler room length (Dwg A) is obtained by allowing for possible future tube replacement through a window or doorway. Allowance is only made for minimum door swing at each end of the boiler. This arrangement provides sufficient aisle space at the front of the boiler but a tight space condition at the rear. If space permits, approximately 1.5 additional feet should be allowed at the rear for additional aisle and working space. 2. Next shortest boiler room length (Dwg B) is obtained by allowing for possible future tube replacement from the front of the boiler. Allowance is only made for minimum door swing at the rear. If space permits, approximately 1.5 additional feet should be allowed at the rear for additional aisle and working space. 3. A slightly longer boiler room for Model CB (Dwg C) is obtained by allowing for possible future tube replacement from the rear of the boiler. Allowance for door swing at the front provides sufficient aisle and working space at the front.
Figure A6-17. Boiler Room Length (Typical Layouts), Model CB Ohio Special Shown
100S 78 105
125S-225S 82" 115"
NOTES: 1. Recommended Minimum Distance Between Boiler and Wall. Dimension A allows for a clear 42" aisle between the water column on the boiler and the wall. If space permits, this aisle should be widened. 2. Recommended Minimum Distance Between Boilers. Dimension B between boilers allows for a clear aisle of 42. If space permits, this aisle should be widened.
Figure A6-18. Boiler Room Width (Typical Layout), Model CB Ohio Special Shown
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02-02
Firetube Boilers
The following sample specications are provided by Cleaver-Brooks to assist you in specifying your customer's specic needs and application. A separate specication for Ohio Special steam boilers Model CB and Model CBW is provided. When completing the specication, begin with the boiler specication (CB or CBW). The boiler specication includes a place for burner and for controls. Following the boiler specication are the various detailed burner specications organized by fuel type. Select the Burner specication for the fuel utilized and insert it into the boiler specication. Following the burner specications are detailed control specications for CB780 Flame Safeguard control and the CB-HAWK Flame Safeguard control. Insert the appropriate detailed control specication into the boiler specication based on the project requirements. See section 8, Boiler Controls, for additional information on control options. The Sample Specications are typically utilized as the base template for the complete boiler specication. Contact your local Cleaver-Brooks authorized representative for information on special insurance requirements, special code requirements, optional equipment, or general assistance in completing the specication. Model CB Ohio Special Boiler 1.0 Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model CBW Ohio Special Boiler 1.0 Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model CB Ohio Special Steam Boiler (100-225 hp, Steam 15, 150, 200, or 250 psig) 1.0 Boiler Characteristics (Steam) 1.1 The Steam Boiler shall be Cleaver-Brooks Model CB Ohio Special Fuel Series ____ (100, 200, 700), ____ hp designed for ____ psig (15 or ____ psig steam). The maximum operating pressure shall be ____ psig. 1.2 The boiler shall have a maximum output of ____ Btu/hr, or ____ horsepower when red with CS12-48 No. 2 oil and/or natural gas, ____ Btu/cu-ft. Electrical power available shall be ____ Volt ____ Phase ____ Cycle and 115/1/60 for the control circuit. 2.0 General Boiler Design 2.1 The boiler shall be a multi-pass horizontal retube updraft boiler with 358 square feet of total heating surface. It shall be mounted on a heavy steel frame with integral forced draft burner and burner controls. A6-31 A6-31 A6-31 A6-32 A6-35 A6-35 A6-35 A6-25 A6-25 A6-26 A6-27 A6-30 A6-30 A6-30
NOTICE
A6-25
02-02
Firetube Boilers
2.1.1 The boiler shall be completely preassembled and re tested at the factory. The unit shall be ready for immediate mounting on oor or simple foundation and ready for attachment of water, steam, fuel, electrical, vent, steam, and blowdown connections. 2.2 Boiler Shell (Steam) 2.2.1 The boiler shell must be constructed in accordance with ASME Boiler Code and must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished the purchaser. 2.2.2 Two lifting eyes shall be located on top of the boiler. 2.2.3 Front and rear doors on the boiler shall be hinged or davited. Doors are to be sealed with berglass tadpole gaskets and fastened tightly using heavy capscrews that thread into replaceable brass nuts. 2.2.4 Rear refractory and insulation shall be contained in the formed door which must swing open for inspection of brick work. 2.2.5 The boiler tubes shall not include swirlers, turbulators, or other add-on devices. 2.2.6 Front and rear tube sheets and all tubes must be fully accessible for inspection and cleaning when the doors are swung open. The boiler shall be furnished with adequate handholes to facilitate boiler inspection and cleaning. 2.2.7 For boilers 125 horsepower and over, a manhole shall be provided. 2.2.8 The exhaust gas vent shall be located near the front of the boiler on the top center line and shall be capable of supporting: A. 100 hp 1000 lbs. and shall contain a stack thermometer. B. 125-225 hp 2000 lbs. and shall contain a stack thermometer. 2.2.9 Observation ports for the inspection of ame conditions shall be provided at each end of the boiler. 2.2.10 The boiler insulation shall consist of a 2 inch berglass blanket under a sectional preformed sheet metal lagging. This insulation must be readily removable and capable of being reinstalled, if required. 2.2.11 The entire boiler base frame and other components shall be factory painted before shipment using a hard-nish enamel coating. 3.0 Steam Boiler Trim 3.1 Water Column A water column shall be located on the right hand side of the boiler complete with gauge glass set, and water column blowdown valves. 3.2 Feedwater Pump Control The boiler feedwater pump control shall be included as an integral part of the water column to automatically actuate a motor driven feedwater pump maintaining the boiler water level within normal limits. 3.3 Low Water Cutoff The low water cutoff shall be included as an integral part of the boiler feedwater control wired into the burner control circuit to prevent burner operation if the boiler water level falls below a safe level. 3.4 Auxiliary Low Water Cutoff Auxiliary low water cutoff shall be included, piped to the vessel, and wired to the burner control circuit. A manual reset device shall be used on this control. 3.5 Steam Pressure Gauge The steam pressure gauge shall be located at the front of the boiler and include cock and test connection. 3.6 Safety Relief Valves Safety valves of a type and size to comply with ASME Code requirements shall be shipped loose. 3.7 Steam Pressure Controls
A6-26
02-02
Firetube Boilers
The steam pressure control to regulate burner operation shall be mounted near the water column. 4.0 Burner 4.1 Mode of Operation
Burner operation shall be full modulation principle. The burner shall always return to low re position for ignition. 4.2 Forced Draft Blower 4.2.1 All air for combustion shall be supplied by a forced draft blower mounted in the front boiler door, above the burner, to eliminate vibration and reduce noise level. 4.2.2 Maximum sound level of the boiler/burner package shall not exceed ____ dBA (when measured in accordance with ABMA Sound Test Standards). 4.2.3 The impeller shall be cast aluminum, radial blade, carefully balanced, and directly connected to the blower motor shaft. 4.3 Combustion Air Control Combustion air damper and cam operated fuel metering valves shall be operated by a single damper control motor that regulates the re according to load demand. Single point positioning controls shall be provided to regulate operation of the damper control motor. 4.4 Fuel Specication and Piping Refer to the following fuel series specications: Fuel series 700 - gas red (para 4.4.1). Fuel series 100 - light oil red (para 4.4.2). Fuel series 200 - light oil or gas red (para 4.4.3). 4.4.1 Fuel Series 700 - Gas Fired 4.4.1.1 Burner Type - The burner shall be integral with the front head of the boiler and of high radiantannular gas entry on 125-225 hp. and multi-port type gas entry on 100 hp. The burner shall be approved for operation on natural gas fuel. 4.4.1.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include two manual shutoff valves, solenoid valve, pressure regulator and pressure gauge. 4.4.1.3 Gas Burner Piping - Gas burner piping on all units shall include primary gas shutoff valve, motor operated with proof of closure switch and plugged leakage test connection. The valve is spring return to start or stop the gas burner and to close automatically in the event of power failure, ame failure, low water or any safety shutdown condition. A lubricating plug cock or buttery shutoff valve shall be provided as a means for a tightness check of the primary shut off valve. An additional plug cock or buttery shutoff valve shall be furnished at entrance to gas train. Select one of the following: A. 100 hp High and low gas pressure switches shall be provided. B. 125-225 hp High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided. 4.4.1.4 Burner Turndown - Turndown range of the burner shall be 4:1 when ring natural gas. 4.4.2 Fuel Series 100 - Light Oil Fired 4.4.2.1 Burner Type - The burner shall be integral with the front head of the boiler, and shall be a low pressure air atomizing type approved for operation with CS12-48, Commercial No. 2 oil. 4.4.2.2 Oil Pilot - The oil pilot shall be air atomizing type with automatic electric ignition and include oil solenoid valve. An electronic detector shall monitor the pilot so that the primary oil valve cannot open until ame has been established. 4.4.2.3 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. A separate motor driven pump set, shipped loose to be installed in a location favorable to the oil storage tank, shall be provided.
A6-27
02-02
Firetube Boilers
4.4.2.4 Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, solenoid shutoff valves, pressure gauges and fuel strainer, all integrally mounted on the unit. A fuel oil controller shall be provided to combine all of the fuel oil controls into a single casting which is mounted on the front door of the unit. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. A low oil pressure switch shall be included in the oil piping. 4.4.2.5 Low Pressure Air Atomizing - Select one of the following: A. 100 hp. Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch shall be provided. B. 125 hp-225 hp. Belt driven air compressor, lubricating air tank, oil level indicator, inlet air lter, air pressure gauge, and low atomizing air pressure switch shall be provided. 4.4.2.6 Burner Turndown - Turndown range of the burner shall be 4:1 when ring No. 2 oil. 4.4.3 Fuel Series 200 - Light Oil or Gas Fired 4.4.3.1 Burner Type - The burner, integral with the front head of the boiler, shall be a combination of the low pressure air atomizing type for oil and high radiant annular gas entry on 125-225 hp and multi-port type for gas entry om 100 hp. The burner shall be approved for operation with either CS12-48 Commercial No. 2 Oil or natural gas. 4.4.3.2 Gas Pilot - The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary fuel valve cannot open until ame has been established. The pilot train shall include two manual shut-off valves, solenoid valve, pressure regulator and pressure gauge. 4.4.3.3 Oil Burner 4.4.3.3.1 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. A separate motor driven pump set, shipped loose, to be installed in a location favorable to the oil storage tank, shall be provided. 4.4.3.3.2 Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, solenoid shutoff valves, pressure gauges and fuel strainer, all integrally mounted on the unit. A fuel oil controller shall be provided to combine all of the fuel oil controls into a single casting which is mounted on the front door of the unit. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. A low oil pressure switch shall be included in the oil piping. 4.4.3.3.3 Low pressure Air Atomizing - Select one of the following: A. 100 hp. Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch shall be provided. B. 125-225 hp. Belt driven air compressor, lubricating air tank, oil level indicator, inlet air lter, air pressure gauge and low atomizing air pressure switch shall be provided. 4.4.3.4 Gas Burner 4.4.3.4.1 Gas Burner Piping - gas burner piping on all units shall include primary gas shutoff valve, motor operated with proof of closure switch and plugged leakage test connection. The valve is spring return to start or stop the gas burner and to close automatically in the event of power failure, ame failure, low water or any safety shutdown condition. A lubricating plug cock or buttery shutoff valve shall be provided as a means for a tightness check of the primary shut off valve. An additional plug cock or buttery shutoff valve shall be furnished at entrance to gas train. Select one of the following: A. 100 hp High and low gas pressure switches shall be provided. B. 125-225 hp High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided. 4.4.3.5 Burner Turndown - Turndown range of the burner shall be 4:1. 4.5 Boiler Flame Safeguard Controller and Control Panel See paragraphs 4.5.1 through 4.5.2 for boiler ame safeguard specication as indicated below. 4.5.1 CB780 Flame Safeguard Controller Each boiler shall be factory equipped with ame safeguard controller providing technology and functions equal to the CleaverBrooks Model CB780. A6-28
02-02
Firetube Boilers
Controller shall be computerized solid state having sequence and ame-on lights and digital rst out fault code indications of ame safeguard trip functions. It shall include dynamic self-check logic. The controller shall have a xed operating sequence incapable of being manually altered. The sequence shall include start, pre-purge, pilot and main fuel ignition run and post-purge cycles. Controller shall be the non-recycle type for maximum safety that shall shutdown the burner and indicate as a minimum the following trip functions: pilot and main ame failure, high and low re proving switch faults, running interlocks open, false ame signal and fuel valve open (when proof of closure switch is furnished). The controller shall have a run/test switch. It shall allow interruptions to sequence just after pre-purge, during pilot ignition trial and run cycles for adjustments to ring rate motor, damper linkages and pilot ame for minimum turndown tests. 4.5.1.1 Control Panel - The control panel shall be mounted on the front door of the boiler in a location convenient to the operator. The hinged metal cabinet will have NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet key type lock. The panel shall contain the boiler ame safeguard controller, blower motor starter, indicating lights and selector switches. The panel shall have a removable sub-base for mounting the ame safeguard controller, blower motor starter, and terminal blocks. For combination gas-oil red boilers, the panel shall contain the fuel selector switch. 4.5.1.2 Lights White - load demanded. White - fuel valve open. Red - low water. Red - ame failure. 4.5.1.3 Control Switches Burner On-Off. Manual-Automatic. Manual Firing Rate Control. 4.5.1.4 Oil, heat and moisture resistant wire shall be used and identied with circuit numbers corresponding to the electrical wiring diagram. 4.5.1.5 All electrical equipment and wiring shall be in conformance with Underwriters Laboratories requirements. 4.5.1.6 Boiler to be supplied with a control circuit transformer and fuse protection for the control circuit. 4.5.2 CB-HAWK Flame Safeguard Controller 4.5.2.1 Each boiler shall be factory equipped with a Boiler Management Control System providing technology and functions equal to the Cleaver-Brooks Model CB-HAWK. 4.5.2.2 The system shall consist of a computer based boiler controller and solid state sensors totally integrated to provide automatic burner sequencing, ame supervision, and indications of system status, faults, and self-diagnostics. 4.5.2.4 The boiler controller shall consist of chassis, program module, keyboard display, and ame signal amplier. It shall be the non-recycle type and have a xed operating sequence incapable of being manually altered. The sequence shall include standby, pre-purge, pilot, main fuel ignition, and run, and post-purge periods. 4.5.2.5 The system shall incorporate full modulating control of fuel and combustion air as well as ring rate control based on system demand. 4.5.2.6 The boiler controller shall have a non-volatile memory that retains history les and sequence status after interruptions. 4.5.2.7 An 80 character, 2 line liquid crystal (LCD) display and keyboard shall be provided to adjust control settings and display 73 fault messages, 12 diagnostic messages, 38 historical messages as well as system status messages and operating pressures and temperatures. Boiler ring rate shall also be displayed in addition to the last 6 lockouts and boiler operating information when the lockout occurred. Provisions for a security access code shall be provided. 4.5.2.8 Separate status indicators will show: Ready: HAWK operational. A6-29
02-02

Demand: call for heat. Main Valve: fuel valve open. Low Water: low water condition. Alarm: safety shutdowns. 4.5.2.9 The boiler controller shall incorporate a ve function run/test switch.
Firetube Boilers
4.5.2.10 The system shall be characterized for each individual model boiler. The system shall also incorporate a tailored pre-purge cycle that minimizes pre-purge energy losses, while maintaining the maximum required air changes. It shall permit the user to select a specic rate control program for precise load tracking that reduces on-off cycling due to load swings. The system shall also provide an integrated thermal stress protection program to prolong boiler life. An assured low re cutoff feature shall also be provided. 4.5.2.11 The system shall monitor inputs from solid state sensor for gas pressure, oil pressure, and temperature. A single solid state sensor shall be used for both on-off and proportioning control of the burner. The high/low limits and operating set points of all sensors will be programmable from the keyboard display. The system shall be capable of detecting a jumpered or defective sensor. A dynamic check of the gas pressure sensor shall be made prior to the main ame establishing period to ensure it is fully operational. 4.5.2.12 An optional 2 way communications module with built-in modem to allow for remote control of non-safety settings and monitoring of up to 6 boilers shall also be available. Up to 3 pre-programmed telephone numbers shall be called in the event of a fault condition. Options such as Lead/Lag, Boiler Efciency, and Heating Boiler packages can be interfaced to this module without any change to the existing system structure. The communications module shall be able to interface with an IBMTM PC or compatible system. 4.5.3 Control Panel 4.5.3.1 The control panel shall be mounted on the front door of the boiler in a location convenient to the operator. The hinged metal cabinet will have NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet key type lock. 4.5.3.2 The panel shall contain the boiler ame safeguard controller, blower motor starter, indicating lights and selector switches. 4.5.3.3 Panel shall have a removable sub-base for mounting the ame safeguard controller, blower motor starter, and terminal blocks. For combination gas-oil red boilers the panel shall contain the fuel selector switch. 4.5.3.4 Oil, heat, and moisture resistant wire shall be used and identied with circuit numbers corresponding to the electrical wiring diagram. 4.5.3.4 All electrical equipment and wiring shall be in conformance with Underwriters Laboratories requirements. 4.5.3.5 Boiler to be supplied with a control circuit transformer and fuse protection for the control circuit. 5.0 Efciency Guarantee 5.1 The boiler must be guaranteed to operate at a minimum fuel-to-steam efciency of ____ percent from 25 to 100 percent of rating when burning natural gas and ________ fuel-to-steam efciency at 100% ring rate when burning oil. 6.0 Warranty 6.1 All equipment is to be guaranteed against defects in materials and/or workmanship for a period of 12 months from date of startup or 18 months from date of shipment, whichever comes rst. 7.0 Execution 7.1 Shop Tests The packaged boiler must receive factory tests to check the construction, controls, and operation of the unit. All tests may be witnessed by the purchaser, if desired. 7.2 Start-up Service 7.2.1 After boiler installation is completed, the manufacturer shall provide the services of a eld representative for starting the unit and timing the operator at no additional costs. 7.2.1.1 A factory approved and authorized start-up report shall be submitted to the customer/user at the time of start-up. A6-30
02-02
Firetube Boilers
Model CBW Ohio Special Steam Boiler (125-200 hp, Steam 15, 150, 200, or 250 psig) 1.0 Boiler Characteristics (Steam) 1.1 The Steam Boiler shall be Cleaver-Brooks Model CBW Ohio Special Fuel Series ____ (100, 200, 700), ____ hp designed for ____ psig (15 or ____ psig steam). The maximum operating pressure shall be ____ psig. 1.2 The boiler shall have a maximum output of ____ Btu/hr, or ____ horsepower when red with CS12-48 No. 2 oil and/or natural gas, ____ Btu/cu-ft. Electrical power available shall be ____ Volt ____ Phase ____ Cycle and 115/1/60 for the control circuit. 2.0 General Boiler Design 2.1 The boiler shall be a multi-pass horizontal retube updraft boiler with 358 square feet of total heating surface. It shall be mounted on a heavy steel frame with integral forced draft burner and burner controls. The complete packaged boiler is built as a unit with Underwriters Laboratories listed components. The boiler shall be completely preassembled and re tested at the factory. The unit shall be ready for immediate mounting on oor or simple foundation and ready for attachment of water, steam, fuel, electrical, vent, steam, and blowdown connections. 2.2 Boiler Shell (Steam) 2.2.1 The boiler shell must be constructed in accordance with ASME Boiler Code and must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser. 2.2.2 Two lifting eyes shall be located on top of the boiler. 2.2.3 Front and rear doors on the boiler shall be hinged or davited. Doors are to be sealed with berglass tadpole gaskets and fastened tightly using heavy capscrews that thread into replaceable brass nuts. 2.2.4 Rear door must be insulated and be able to swing open for inspection. 2.2.5 The boiler tubes shall not include swirlers, turbulators, or other add-on devices. 2.2.6 The boiler shall be furnished with adequate handholes to facilitate boiler inspection and cleaning. 2.2.7 Boiler shall be supplied with a manhole. 2.2.8 The exhaust gas vent shall be located near the front of the boiler on the top center line and shall be capable of supporting 2000 lbs. and shall contain a stack thermometer. 2.2.9 Observation ports for the inspection of ame conditions shall be provided at each end of the boiler. 2.2.10 The boiler insulation shall consist of a 2 inch berglass blanket under a sectional preformed sheet metal lagging. This insulation must be readily removable and capable of being reinstalled, if required. 2.2.11 The entire boiler base frame and other components shall be factory painted before shipment using a hard-nish enamel coating. 3.0 Steam Boiler Trim 3.1 Water Column A water column shall be located on the right hand side of the boiler complete with gauge glass set, and water column blowdown valves. 3.1.1 Feedwater Pump Control The boiler feedwater pump control shall be included as an integral part of the water column to automatically actuate a motor driven feedwater pump maintaining the boiler water level within normal limits. 3.1.2 Low Water Cutoff The low water cutoff shall be included as an integral part of the boiler feedwater control wired into the burner control circuit to prevent burner operation if the boiler water level falls below a safe level.
A6-31
02-02
Firetube Boilers
3.2 Auxiliary Low Water Cutoff Auxiliary low water cutoff shall be included, piped to the vessel, and wired to the burner control circuit. A manual reset device shall be used on this control. 3.3 Steam Pressure Gauge The steam pressure gauge shall be located at the front of the boiler and include cock and test connection. 3.4 Safety Relief Valves Safety valves of a type and size to comply with ASME Code requirements shall be shipped loose. 3.5 Steam Pressure Controls The steam pressure control to regulate burner operation shall be mounted near the water column. 4.0 Burner 4.1 Mode of Operation Burner operation shall be full modulation principle. The burner shall always return to low re position for ignition. 4.2 Forced Draft Blower 4.2.1 All air for combustion shall be supplied by a forced draft blower mounted in the front boiler door, above the burner, to eliminate vibration and reduce noise level. 4.2.2 Maximum sound level of the boiler/burner package shall not exceed ____ dBA (when measured in accordance with ABMA Sound Test Standards). 4.2.3 The impeller shall be cast aluminum, radial blade, carefully balanced, and directly connected to the blower motor shaft. 4.3 Combustion Air Control Combustion air damper and cam operated fuel metering valves shall be operated by a single damper control motor that regulates the re according to load demand. Single point positioning controls shall be provided to regulate operation of the damper control motor. 4.4 Fuel Specication and Piping Refer to the following fuel series specications: Fuel series 700 - gas red (para 4.4.1). Fuel series 100 - light oil red (para 4.4.2). Fuel series 200 - light oil or gas red (para 4.4.3). 4.4.1 Fuel Series 700 - Gas Fired 4.4.1.1 Burner Type - The burner shall be integral with the front head of the boiler and of high radiant annular gas entry type for gas. The burner shall be approved for operation on natural gas fuel. 4.4.1.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include two manual shutoff valves, solenoid valve, pressure regulator and pressure gauge. 4.4.1.3 Gas Burner Piping - Gas burner piping on all units shall include two (2) motorized gas shutoff valves, one (1) valve proofof-closure type, two (2) plugged leakage test connections, and high and low gas pressure switches. The main gas valves will be wired to close automatically in the event of power failure, ame failure, low water, or any safety shutdown condition. A lubricating plug cock or buttery shutoff valve shall be provided as a means for a tightness check of the primary shut off valve. An additional plug cock or buttery shutoff valve shall be furnished at entrance to gas train. 4.4.1.4 Burner Turndown - Turndown range of the burner shall be 4:1 when ring natural gas.
A6-32
02-02
Firetube Boilers
4.4.2 Fuel Series 100 - Light Oil Fired
4.4.2.1 Burner Type - The burner shall be integral with the front head of the boiler, and shall be a low pressure air atomizing type approved for operation with CS12-48, Commercial No. 2 oil. 4.4.2.2 Oil Pilot - The oil pilot shall be air atomizing type with automatic electric ignition and include oil solenoid valve. An electronic detector shall monitor the pilot so that the primary oil valve cannot open until ame has been established. 4.4.2.3 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. A separate motor driven pump set, shipped loose to be installed in a location favorable to the oil storage tank, shall be provided. 4.4.2.4 Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, solenoid shutoff valves, pressure gauges and fuel strainer, all integrally mounted on the unit. A fuel oil controller shall be provided to combine all of the fuel oil controls into a single casting which is mounted on the front door of the unit. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. A low oil pressure switch shall be included in the oil piping. 4.4.2.5 Low pressure air atomizing system shall include belt driven air compressor, lubricating air tank, oil level indicator, inlet air lter, air pressure gauge, and low atomizing air pressure switch. 4.4.2.6 Burner Turndown - Turndown range of the burner shall be 4:1 when ring No. 2 oil. 4.4.3 Fuel Series 200 - Light Oil or Gas Fired 4.4.3.1 Burner Type - The burner, integral with the front head of the boiler, shall be a combination of the low pressure air atomizing type for oil and high radiant annular gas entry type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 Oil or natural gas. 4.4.3.2 Gas Pilot - The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary fuel valve cannot open until ame has been established. The pilot train shall include two manual shut-off valves, solenoid valve, pressure regulator and pressure gauge. 4.4.3.3 Oil Burner 4.4.3.3.1 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. A separate motor driven pump set, shipped loose, to be installed in a location favorable to the oil storage tank, shall be provided. 4.4.3.3.2 Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, solenoid shutoff valves, pressure gauges and fuel strainer, all integrally mounted on the unit. A fuel oil controller shall be provided to combine all of the fuel oil controls into a single casting which is mounted on the front door of the unit. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. A low oil pressure switch shall be included in the oil piping. 4.4.3.3.3 Low pressure air atomizing system shall include belt driven air compressor, lubricating air tank, oil level indicator, inlet air lter, air pressure gauge and low atomizing air pressure switch. 4.4.3.4 Gas Burner 4.4.3.4.1 Gas Burner Piping - Gas burner piping on all units shall include two (2) motorized gas shutoff valves, one (1) valve proofof-closure type, two (2) plugged leakage test connections, and high and low gas pressure switches. The main gas valves will be wired to close automatically in the event of power failure, ame failure, low water or any safety shutdown condition. A lubricating plug cock or buttery shutoff valve shall be provided as a means for a tightness check of the primary shut off valve. An additional plug cock or buttery shutoff valve shall be furnished at entrance to gas train. 4.4.3.5 Burner Turndown - Turndown range of the burner shall be 4:1. 4.5 Boiler Flame Safeguard Controller and Control Panel See paragraphs 4.5.1 through 4.5.2 for boiler ame safeguard specication as indicated below. 4.5.1 CB780 Flame Safeguard Controller 4.5.1.1 Each boiler shall be factory equipped with ame safeguard controller providing technology and functions equal to the Cleaver-Brooks Model CB780.
A6-33
02-02
Firetube Boilers
4.5.1.2 Controller shall be computerized solid state having sequence and ame-on lights and digital rst out fault code indications of ame safeguard trip functions. It shall include dynamic self-check logic. The controller shall have a xed operating sequence incapable of being manually altered. The sequence shall include start, pre-purge, pilot and main fuel ignition run and post-purge cycles. 4.5.1.3 Controller shall be the non-recycle type for maximum safety that shall shutdown the burner and indicate as a minimum the following trip functions: pilot and main ame failure, high and low re proving switch faults, running interlocks open, false ame signal and fuel valve open (when proof of closure switch is furnished). 4.5.1.4 The controller shall have a run/test switch. It shall allow interruptions to sequence just after pre-purge, during pilot ignition trial and run cycles for adjustments to ring rate motor, damper linkages and pilot ame for minimum turndown tests. 4.5.1.5 Control Panel - The control panel shall be mounted on the front door of the boiler in a location convenient to the operator. The hinged metal cabinet will have NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet key type lock. The panel shall contain the boiler ame safeguard controller, blower motor starter, indicating lights and selector switches. The panel shall have a removable sub-base for mounting the ame safeguard controller, blower motor starter, and terminal blocks. For combination gas-oil red boilers the panel shall contain the fuel selector switch. 4.5.1.6 Lights White - load demanded. White - fuel valve open. Red - low water. Red - ame failure. 4.5.1.7 Control Switches Burner On-Off. Manual-Automatic. Manual Firing Rate Control. 4.5.1.8 Oil, heat and moisture resistant wire shall be used and identied with circuit numbers corresponding to the electrical wiring diagram. 4.5.1.9 All electrical equipment and wiring shall be in conformance with Underwriters Laboratories requirements. 4.5.1.10 Boiler to be supplied with a control circuit transformer and fuse protection for the control circuit. 4.5.2 CB-HAWK Flame Safeguard Controller 4.5.2.1 Each boiler shall be factory equipped with a Boiler Management Control System providing technology and functions equal to the Cleaver-Brooks Model CB-HAWK. 4.5.2.2 The system shall consist of a computer based boiler controller and solid state sensors totally integrated to provide automatic burner sequencing, ame supervision, and indications of system status, faults, and self-diagnostics. 4.5.2.3 The boiler controller shall consist of chassis, program module, keyboard display, and ame signal amplier. It shall be the non-recycle type and have a xed operating sequence incapable of being manually altered. The sequence shall include standby, pre-purge, pilot, main fuel ignition, and run, and post-purge periods. 4.5.2.4 The system shall incorporate full modulating control of fuel and combustion air as well as ring rate control based on system demand. 4.5.2.5 The boiler controller shall have a non-volatile memory that retains history les and sequence status after interruptions. 4.5.2.6 An 80 character, 2 line liquid crystal (LCD) display and keyboard shall be provided to adjust control settings and display 73 fault messages, 12 diagnostic messages, 38 historical messages as well as system status messages and operating pressures and tem-
A6-34
02-02
Firetube Boilers
peratures. Boiler ring rate shall also be displayed in addition to the last 6 lockouts and boiler operating information when the lockout occurred. Provisions for a security access code shall be provided. 4.5.2.7 Separate status indicators will show: Ready: HAWK operational. Demand: call for heat. Main Valve: fuel valve open. Low Water: low water condition. Alarm: safety shutdowns 4.5.2.8 The boiler controller shall incorporate a ve function run/test switch. 4.5.2.9 The system shall be characterized for each individual model boiler. The system shall also incorporate a tailored pre-purge cycle that minimizes pre-purge energy losses, while maintaining the maximum required air changes. It shall permit the user to select a specic rate control program for precise load tracking that reduces on-off cycling due to load swings. The system shall also provide an integrated thermal stress protection program to prolong boiler life. An assured low re cutoff feature shall also be provided. 4.5.2.10 The system shall monitor inputs from solid state sensor for gas pressure, oil pressure, and temperature. A single solid state sensor shall be used for both on-off and proportioning control of the burner. The high/low limits and operating set points of all sensors will be programmable from the keyboard display. The system shall be capable of detecting a jumpered or defective sensor. A dynamic check of the gas pressure sensor shall be made prior to the main ame establishing period to ensure it is fully operational. 4.5.2.11 An optional 2 way communications module with built-in modem to allow for remote control of non-safety settings and monitoring of up to 6 boilers shall also be available. Up to 3 pre-programmed telephone numbers shall be called in the event of a fault condition. Options such as Lead/Lag, Boiler Efciency, and Heating Boiler packages can be interfaced to this module without any change to the existing system structure. The communications module shall be able to interface with an IBMTM PC or compatible system. 4.5.2.12 Control Panel - The control panel shall be mounted on the front door of the boiler in a location convenient to the operator. The hinged metal cabinet will have NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet key type lock. 4.5.2.13 The panel shall contain the boiler ame safeguard controller, blower motor starter, indicating lights and selector switches. 4.5.2.14 Panel shall have a removable sub-base for mounting the ame safeguard controller, blower motor starter, and terminal blocks. For combination gas-oil red boilers the panel shall contain the fuel selector switch. 4.5.2.15 Oil, heat, and moisture resistant wire shall be used and identied with circuit numbers corresponding to the electrical wiring diagram. 4.5.2.16 All electrical equipment and wiring shall be in conformance with Underwriters Laboratories requirements. 4.5.2.17 Boiler to be supplied with a control circuit transformer and fuse protection for the control circuit. 5.0 Efciency Guarantee 5.1 The boiler must be guaranteed to operate at a minimum fuel-to-steam efciency of ____ percent from 25 to 100 percent of rating when burning natural gas and ________ fuel-to-steam efciency at 100% ring rate when burning oil. 6.0 Warranty 6.1 All equipment is to be guaranteed against defects in materials and/or workmanship for a period of 12 months from date of startup or 18 months from date of shipment, whichever comes rst. 7.0 Execution 7.1 Shop Tests 7.1.1 The packaged boiler must receive factory tests to check the construction, controls, and operation of the unit. All tests may be witnessed by the purchaser, if desired. A6-35
02-02

7.2 Start-up Service
Firetube Boilers
7.2.1 After boiler installation is completed, the manufacturer shall provide the services of a eld representative for starting the unit and timing the operator at no additional costs. 7.2.2 A factory approved and authorized start-up report shall be submitted to the customer/user at the time of start-up.
A6-36
02-02
Section A7
Model CBE Boilers
CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-3 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-3 DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-4 PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12 Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12 ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12 Boiler Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12 Blowdown Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-14 Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-14 Burner/Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-14 Burner Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-14 Gas Fired - Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-14 Fuel Connections - Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-14 Fuel Connections - Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-14 Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-19 Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-19 Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-19 Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-19 SAMPLE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-21 ILLUSTRATIONS Figure A7-1. Model CBE Hot Water Boiler Dimensions (Page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-6 Figure A7-2. Model CBE Steam Boiler Dimensions (Page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-8 Figure A7-3. Space Required to Open Rear Head on Model CBE Boilers Equipped with Davits . . . . . . . . . . . . . . . . . . A7-10
A7-1
04-02
Model CBE
Firetube Boilers
Figure A7-4. Model CBE Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-10 Figure A7-5. Model CBE Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-11 Figure A7-6 Typical Fuel Oil Supply Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-18 Figure A7-7. Boiler Room Length (Typical Layouts) - Model CBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-20 Figure A7-8.Boiler Room Width (Typical Layout) - Model CBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-20
TABLES Table A7-1. Model CBE Hot Water Boiler Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-5 Table A7-2. Model CBE Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7- 5 Table A7-3. Predicted Fuel-to-Steam Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-12 Table A7-4. Heating Surface, Model CBE Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-13 Table A7-5.Model CBE Steam Volume and Disengaging Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-13 Table A7-6.Model CBE Steam Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-13 Table A7-7. Model CBE Hot Water Boiler Relief Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-15 Table A7-8.Model CBE Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity) . . . . . . .A7-15 Table A7-9.Model CBE Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-16 Table A7-10. Model CBE Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-16 Table A7-11.Sound Pressure Levels in DbA (Profire F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-16 Table A7-12. Model CBE Burner Selections (Profire Burner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-17 Table A7-13. Minimum Required Gas Pressure Altitude Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-17 Table A7-14.Maximum Gas Consumption (CFH) for Natural Gas - Model CBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-17 Table A7-15.Minimum Required Gas Pressure at Entrance to Standard, FM and IRI Gas Trains Model CBE (Upstream of Gas Pressure Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-18
The following information applies to the Cleaver-Brooks Model CBE Boiler.
A7-2
04-02
Firetube Boilers
Model CBE
15 - 300 psig steam. Full modulation, all sizes. Available options include the following (contact your local Cleaver-Brooks authorized representative for option details). Boiler Options: Drain valves.

The Model CBE Boiler is available as a baseline alternative to the Cleaver-Brooks Models CB or CBW Boilers. The CleaverBrooks Model CBE Boiler line provides a quality product utilizing an economical boiler/burner design. Additionally, the boiler/burner packaged UL and cUL label is available on all CBE sizes. The following features apply: Three-Pass Dryback Design: Three-pass design provides high ue gas velocities and low stack temperatures to maximize efciency. Dryback design provides full access to boiler tubes, tube sheet, and furnace for ease of maintenance. Dryback design includes single rear tube sheet construction, which reduces tube sheet stresses. Five Square Feet of Heating Surface per Boiler Horsepower: Good boiler efciency. Long boiler life. Low Furnace Location: Furnace located well below water level with generous clearance from bottom of boiler, allowing proper circulation. Low furnace provides additional safety margin between furnace and water level. Reduces water carryover, producing drier steam. Front and Rear Doors: Davit, front and rear doors, all sizes. Provides access to front and rear tube sheet and furnace. Reduced maintenance costs. Natural Gas, No. 2 Oil, or Combination Burners Available: Natural gas or No. 2 oil compatibility. Fuel changeover without burner adjustment.
Additional screwed or anged trappings. Blowdown valves. Non-return valves. Feedwater valves and regulators. Surface blowdown systems Combustion relief door. Blend pump. Surge load bafes. Seismic design. Burner/Control Options: Flame safeguard controllers. Lead/lag system. High altitude design (up to 10,000 ft). Special insurance and code requirements (e.g., IRI, FM, CSD1). Alarm bell/silence switch. Special motor requirements (TEFC, high efciency). Special purpose indicator lights. Main disconnect. Elapsed time meter. Voltmeter/micro-ammeter. NEMA enclosures. Low-re hold control. Remote emergency shut-off (115V). Circuit breaker. Day/night controls. Special power requirements. Stack thermometer. Special indicating lights.
PRODUCT OFFERING
Cleaver-Brooks Firetube Boilers are available in low pressure steam, high pressure steam, and hot water designs. Burners are available to re natural gas, No. 2 oil, or a combination of oil and gas. The CBE boiler is a baseline alternative to the Model CB or CBW in the 60 - 350 hp range. Standard product offering is: 60 - 350 hp. 30 and 125 psig hot water.
A7-3
04-02
Model CBE
Fuel Options Air atomizing oil burner, 125 200 hp. Gas strainer. Gas pressure gauge. Future gas conversion.
Firetube Boilers

Dimensions and ratings for the Model CBE Boilers are shown in the following tables and illustrations. Table A7-1. Model CBE Hot Water Boiler Ratings Table A7-2. Model CBE Steam Boiler Ratings Figure A7-1. Model CBE Hot Water Boiler Dimensions Figure A7-2. Model CBE Steam Boiler Dimensions Figure A7-3. Model CBE Boiler Space Requirements to Open Rear Door Figure A7-4. Lifting Lug Location, Model CBE Boilers Figure A7-5. Model CBE Boiler Mounting Piers
A7-4
04-02
Firetube Boilers
Table A7-1. Model CBE Hot Water Boiler Ratings
BOILER HP 60 70 80 100 125 150 200 250 300 350
Model CBE
RATINGS SEA LEVEL TO 1000 FT Btu Output (1000 Btu/hr) 2009 2343 2678 3348 4184 5021 6695 8369 10043 11716
APPROXIMATE FUEL CONSUMPTION AT RATED CAPACITY Light Oil gph (140,000 Btu/gal) Gas CFH (1000 Btu) Gas (Therm/hr) 18 2510 25.1 21 2930 29.3 24 3350 33.5 30 4185 41.9 37.5 5230 52.3 45 6280 62.8 60 8370 83.7 74.5 10460 104.6 89.5 12555 125.5 104.5 14650 146.5
POWER REQUIREMENTS SEA LEVEL TO 1000 FT (60 HZ) Oil Pump Motor hp (No. 2 oil) Blower Motor - Series 100/200 Blower Motor - Series 700 Air Compressor Motor
*
3/4 3/4
*
3/4 1/2
*
1 3/4
*
2 1-1/2
*
2 2
*
3 3
*
7-1/2 5
1/2 5 5 3
3/4 7-1/2 7-1/2 3
3/4 10 10 3
**
**
**
**
**
**
**
BOILER DATA Heating Surface sq-ft (Fireside) 300 350 400 500 625 750 1000 1250 1500 1750
* Integral oil pump. **No air compressor required (pressure atomized)

NOTE: All fractional hp motors will be single phase voltage; integral hp motors will be three-phase voltage.
Table A7-2. Model CBE Steam Boiler Ratings

BOILER HP 60 70 80 100 125 150 200 250 300 350
RATINGS - SEA LEVEL TO 1000 FT Rated Capacity (lbs/steam/hr at 212 F) Btu Output (1000 Btu/hr) 2070 2009 2415 2343 2760 2678 3450 3348 4313 4184 5175 5021 6900 6695 8625 8369 10350 10043 12075 11716
APPROXIMATE FUEL CONSUMPTION AT RATED CAPACITY Light Oil GPH (140,000 Btu/ gal) Gas CFH (1000 Btu) Gas (Therm/hr) 18 2510 25.1 21 2930 29.3 24 3350 33.5 30 4185 41.9 37.5 5230 52.3 45 6280 62.8 60 8370 83.7 74.5 10460 104.6 89.5 12555 125.5 104.5 14650 146.5
POWER REQUIREMENTS SEA LEVEL TO 1000 FT (60 HZ) Oil Pump Motor hp (No. 2 oil) Blower Motor - Series 100/200 Blower Motor - Series 700 Air Compressor Motor
*
3/4 3/4
*
3/4 1/2
*
1 3/4
*
2 1-1/2
*
2 2
*
3 3
*
7-1/2 5
1/2 5 5 3
3/4 7-1/2 7-1/2 3
3/4 10 10 3
**
**
**
**
**
**
**

NOTE: All fractional hp motors will be single phase voltage; integral hp motors will be three-phase voltage.
A7-5
04-02
Model CBE
Firetube Boilers
LWCO
BOILER HP
DIM
60
70
80
100 LENGTHS
125
150
200
250
300
350
Overall Length Shell Length Rear Frame Length Rear Head Extension Front Flange To Water Return Water Return To Water Supply Base Frame To Rear Head Water Supply To Vent Outlet
A B C E F G H R
163-1/8 123-5/8 133-3/8 7-7/8 70-1/4 24 22-1/4 20-1/2
186-1/16 201-1/16 235-1/16 199-3/16 224-3/16 273-3/16 141-5/8 152-3/8 7-7/8 88-1/4 24 22-1/4 20-1/2 157-5/8 191-5/8 151-5/8 176-5/8 225-5/8
217-7/8 161-5/8
243-7/8 187-5/8
269-7/8 213-5/8
173-9/16 207-9/16 162-9/16 187-9/16 236-9/16 177-3/16 203-3/16 229-3/16 7-7/8 104-1/4 24 22-1/4 20-1/2 7-7/8 129-1/4 24 22-1/4 29-1/2 WIDTHS 8-3/8 72-1/4 36 24-3/4 34 8-3/8 97-1/4 36 24-3/4 34 8-3/8 146-1/4 36 24-3/4 34 9-3/8 78-1/4 36 29-3/4 35-1/2 9-3/8 104-1/4 36 29-3/4 35-1/2 9-3/8 130-1/4 36 29-3/4 35-1/2
Overall Width Boiler Centerline To Lagging Base Outside Base Inside
I L M N
53 26-1/2 37-3/4 29-3/4
53 26-1/2 37-3/4 29-3/4
53 26-1/2 37-3/4 29-3/4
53 26-1/2 37-3/4 29-3/4
66 33 52-1/2 44-1/2
66 33 52-1/2 44-1/2
66 33 52-1/2 44-1/2
84 42 64 56
84 42 64 56
84 42 64 56
Figure A7-1. Model CBE Hot Water Boiler Dimensions (Page 1 of 2)
A7-6
04-02
Firetube Boilers
Model CBE
BOILER HP
DIM
60
70
80
100 HEIGHTS
125
150
200
250
300
350
Base To Boiler Centerline Boiler ID Base To Vent Outlet Base To Supply & Return Ports (30 & 125 psig) Base To Supply And Return Ports (150 psig) Base Frame Base To Rear Davit Base To Lifting Lug
D J O P
40 48 70-1/4 62-1/4
40 48 70-1/4 62-1/4
40 48 70-1/4 62-1/4
40 48 70-1/4 62-1/4
46 60 82-3/8 82-3/8
46 60 82-3/8 82-3/8
46 60 82-3/8 82-3/8
56 78 101-1/2 101-1/2
56 78 101-1/2 101-1/2
56 78 101-1/2 101-1/2
P Q T AA
70-1/4 12 72-5/8 68-3/4
70-1/4 12 72-5/8 68-3/4
70-1/4 12 72-5/8 68-3/4
70-1/4 12 72-5/8 68-3/4
82-3/8 12 88-3/8 81
82-3/8 12 88-3/8 81
82-3/8 12 88-3/8 81
101-1/2 10 107
101-1/2 10 107
101-1/2 10 107
102-9/16 102-9/16 102-9/16
CONNECTIONS Waterll (Both Sides) Air Vent Hot Water Supply & Return (30 & 125 psig) Hot Water Supply & Return (150 psig) Vent Outlet ID Boiler Drain Boiler Drain S V U 1-1/4 1-1/4 4 1-1/4 1-1/4 4 1-1/4 1-1/4 4 1-1/4 1-1/4 4 1-1/2 1-1/4 6A 1-1/2 1-1/2 6A 2 1-1/2 6A 2 1-1/2 8A 2 1-1/2 8A 2-1/2 1-1/2 8A
U Y W X
4B 10 1-1/4
4B 12 1-1/2
4B 12 1-1/2
4B 12 1-1/2
6B 16 1-1/2
6B 16 1-1/2
6B 16 2
8B 20 2
8B 20 2
8B 20 2
MISCELLANEOUS Door Swing (Minimum Rear) Tube Removal Rear Tube Removal Front Min. Boiler Room Length For Tube Removal Front Min. Boiler Room Length For Tube Removal RearC DD FF GG HH 30 82 90 244 30 100 108 280 30 109 124 312 30 143 158 380 36 93 110 298 36 118 135 348 36 167 184 446 45 105 116 323 45 131 142 375 45 157 168 427
JJ
287
327
352
420 WEIGHTS
326
376
474
348
411
463
Normal Water Weight (lbs) Shipping Weight (30 psig) Shipping Weight (125 psig
4340 6505 6705
5195 7270 7740
5920 7755 8420
7455 9055 9820
8310 10810 11735
10050 12225 13630
13475 14690 16400
13495 17655 20365
16320 19765 22870
19130 23400 26830
NOTES: 1. All connections are threaded, except as noted. 2. Manway included on 125 - 350 hp. A. 150 psig ange. B. 300 psig ange. C. Includes 4 foot clearance in front of boiler.
Figure A7-1. Model CBE Hot Water Boiler Dimensions (Page 2 of 2)
A7-7
04-02
Model CBE
Firetube Boilers
BOILER HP
DIM
60
70
80
100 LENGTHS
125
150
200
250
300
350
Overall Length Shell Length Base Frame Length Rear Head Extension Front Flange To Steam Outlet Steam Outlet To Vent Outlet Base Frame To Rear Head
A B C E F G H
163-1/8 123-5/8 133-3/8 7-7/8 49-1/4 65-1/2 22-1/4
186-1/16 141-5/8 152-3/8 7-7/8 60-1/4 72-1/2 22-1/4
201-1/16 157-5/8 173-9/16 7-7/8 70-1/4 78-1/2 22-1/4
235-1/16 191-5/8 207-9/16 7-7/8 91-1/4 91-1/2 22-1/4 WIDTHS
199-3/16 151-5/8 162-9/16 8-3/8 57-1/4 85 24-3/4
224-3/16 176-5/8 187-9/16 8-3/8 73-1/4 94 24-3/4
273-3/16 225-5/8 236-9/16 8-3/8 97-1/4 119 24-3/4
217-7/8 161-5/8 177-3/16 9-3/8 66-1/4 83-1/2 29-3/4
243-7/8 187-5/8 203-3/16 9-3/8 88-1/4 87-1/2 29-3/4
269-7/8 213-5/8 229-3/16 9-3/8 89-1/4 112-1/2 29-3/4
Overall Width Boiler Centerline To Water Column Boiler Centerline To Lagging Boiler Centerline To Aux. Water Column Base Outside Base Inside
I K L LL M N
73 39 26-1/2 34 37-3/4 29-3/4
73 39 26-1/2 34 37-3/4 29-3/4
73 39 26-1/2 34 37-3/4 29-3/4
73 39 26-1/2 34 37-3/4 29-3/4
85 45 33 40 52-1/2 44-1/2
85 45 33 40 52-1/2 44-1/2
85 45 33 40 52-1/2 44-1/2
103 54 42 49 64 56
103 54 42 49 64 56
103 54 42 49 64 56
Figure A7-2. Model CBE Steam Boiler Dimensions (Page 1 of 2)
A7-8
04-02
Firetube Boilers
Model CBE
BOILER HP
DIM
60
70
80
100 HEIGHTS
125
150
200
250
300
350
Base To Boiler Centerline Boiler ID Base To Vent Outlet Base To Steam Outlet (15 psig) Base To Steam Outlet (150 psig) Base Frame Base To Rear Davit Base To Lifting Lug
D J O P P Q T AA
40 48 70-1/4 70-1/4 67-7/8 12 72-5/8 68-3/4
40 48 70-1/4 70-1/4 67-7/8 12 72-5/8 68-3/4
40 48 70-1/4 70-1/4 67-7/8 12 72-5/8 68-3/4
40 48 70-1/4 70-1/4 70-1/4 12 72-5/8 68-3/4
46 60 82-3/8 82-3/8 82-3/8 12 88-3/8 81
46 60 82-3/8 82-3/8 82-3/8 12 88-3/8 81
46 60 82-3/8 82-3/8 82-3/8 12 88-3/8 81
56 78 101-1/2 101-1/2 101-1/2 10 107 102-9/16
56 78 101-1/2 101-1/2 101-1/2 10 107 102-9/16
56 78 101-1/2 101-1/2 101-1/2 10 107 102-9/16
CONNECTIONS Chemical Feed Feedwater Inlet (Both Sides) Surface Blowoff (150 psig Only) Steam Outlet (15 psig) Steam Outlet (150 psig) Vent Outlet ID Boiler Blowdown (36 Dia Only) Boiler Blowdown (15 psig) Boiler Blowdown (150 psig) R S V U U Y X W W 1 1-1/4 1 6A 3 10 1-1/4 1-1/4 1 1-1/4 1 6A 3 12 1-1/2 1-1/4 1 1-1/4 1 6A 3 12 1-1/2 1-1/4 1 1-1/4 1 8A 4B 12 1-1/2 1-1/4 1 1-1/2 1 8A 4B 16 1-1/2 1-1/2 1 1-1/2 1 8A 4B 16 1-1/2 1-1/2 1 2 1 10 A 4B 16 2 1-1/2 1 2 1 10 A 6B 20 2 1-1/2 1 2 1 12 A 6B 20 2 1-1/2 1 2-1/2 1 12 A 6B 20 2 1-1/2
MISCELLANEOUS Door Swing (Rear Minimum) Tube Removal Rear Tube Removal Front Min. Boiler Room Length For Tube Removal Front Min. Boiler Room Length For Tube Removal RearC DD FF GG HH 30 82 90 244 30 100 108 280 30 109 124 312 30 143 158 380 36 93 110 298 36 118 135 348 36 167 184 446 45 105 116 323 45 131 142 375 45 157 168 427
JJ
287
327
352
420 WEIGHTS
326
376
474
348
411
463
Normal Water Weight Shipping Weight (15 psig) Shipping Weight (150 psig) Shipping Weight (200 psig)
3940 6455 6875 7415
4720 7220 7690 8070
5375 7715 8370 8800
6770 9005 9590 10150
7135 10735 11660 12334
8625 12150 13345 14135
11565 14615 16325 17600
11530 17555 20000 21660
13940 19665 22770 24700
16350 23300 26730 28950
NOTES: 1. All connections are threaded, except as noted. 2. Manway included on 125 - 350 hp. A. 150 psig Flange. B. 300 psig Flange. C. Includes 4-foot clearance in front of boiler.
Figure A7-2. Model CBE Steam Boiler Dimensions (Page 2 of 2) A7-9

04-02
Model CBE
Firetube Boilers
BOILER HP 60 thru 100 125 thru 200 250 thru 350
DIMENSION (INCHES) A 27 33 42 B 45 52 61 C 38 45 58 D 61 73 90 E 30 36 45
Figure A7-3. Space Required to Open Rear Head on Model CBE Boilers Equipped with Davits
D D
NEAR SIDE
FAR SIDE
E (DIA OF HOLE)
B
A
BOILER HP 60 70 80 100 125 150 200 250 300 350
ALL DIMENSIONS IN INCHES A 68 68 68 68 80 80 80 99 99 99 B 14 14 14 14 19 19 19 18 18 18 C 187 105 121 155 106 131 180 110 136 162 D 10 10 10 10 10 10 10 10 10 10 E 2-1/2 2-1/2 2-1/2 2-1/2 3 3 3 3 3 3
Figure A7-4. Model CBE Boilers Lifting Lug Location
A7-10
04-02
Firetube Boilers
Model CBE
F G B D E B
X C
BOILER HP 60 70 80 100 125 150 200 250 300 350
A 6 6 6 6 6 6 6 6 6 6
B 8 8 8 8 9 9 9 10 10 10
C 137 156 177 211 166 191 249 181 207 233
D 25-3/4 25-3/4 25-3/4 25-3/4 44 44 44 50 50 50
E 41-3/4 41-3/4 41-3/4 41-3/4 62 62 62 70 70 70
F 4 4 4 4 4 4 4 4 4 4
G 29-5/8 29-5/8 29-5/8 29-5/8 44-1/2 44-1/2 44-1/2 56 56 56
X 8 8 8 8 8 8 8 9 9 9
Figure A7-5. Model CBE Boiler Mounting Piers
A7-11
04-02
Model CBE
Firetube Boilers
2. Efciencies are based on ambient air temperature of 80 F, relative humidity of 30%, and 15% excess air in the exhaust ue gas. 3. Efciencies are based on manufacturers published radiation and convection losses. (For Cleaver-Brooks radiation and convection losses, see Boiler Efciency Facts Guide, publication number CB-7767). 4. Any efciency verication testing will be based on the stack loss method.
PERFORMANCE DATA
Contact your local Cleaver-Brooks authorized representative for emissions or additional information.
Efficiency
Table A7-3 shows predicted fuel-to-steam efciencies (including radiation and convection losses) for Cleaver-Brooks Model CBE Firetube boilers. For specic efciencies on retube boiler offerings not listed here, contact your local CleaverBrooks authorized representative. Cleaver-Brooks offers an industry leading fuel-to-steam boiler efciency guarantee for Model CBE Firetube Boilers. The guarantee is based on the fuel-to-steam efciencies shown in the efciency tables and the following conditions. The efciency percent number is only meaningful if the specic conditions of the efciency calculations are clearly stated in the specication (see Cleaver-Brooks publication CB-7768 for a detailed description of efciency calculations). At the time of startup, the boiler will achieve fuel-to-steam efciency (as shown in Table A7-3) at 100% ring rate (add efciency guarantees at 50% of rating, if required). The specied boiler efciency is based on the following conditions. 1. Fuel specication used to determine boiler efciency: Natural Gas Carbon, % (wt) = 69.98 Hydrogen, % (wt) = 22.31 Sulfur, % (wt) = 0.0 Heating value, Btu/lb = 21,830 No. 2 Oil Carbon, % (wt) = 85.8 Hydrogen, % (wt) = 12.7 Sulfur, % (wt) = 0.2 Heating value, Btu/lb = 19,420
ENGINEERING DATA
The following engineering information is provided for Model CBE Firetube Boilers. Additional detail is available from your local Cleaver-Brooks authorized representative.
Boiler Information
Table A7-4 shows heating surfaces for model CBE Firetube boilers. Table A7-5 shows steam volume and disengaging area for model CBE Firetube boilers. Table A7-6 lists quantity and outlet size for safety valves supplied on Model CBE steam boilers. Table A7-7 lists quantity and outlet size for relief valves supplied on Model CBE hot water boilers. Tables A7-8 gives recommended steam nozzle sizes based on 4000-5000 fpm steam velocity on Model CBE Boilers. Table A7-9 shows recommended non-return valve sizes for Model CBE Firetube Boilers.

Some local codes require blowdown tanks to be constructed in accordance with recommendations of the National Board of Boiler and Pressure Vessel Inspectors. Table A7-3. Predicted Fuel-to-Steam Efciency
10 PSIG OPERATING PRESSURE BOILER HP NATURAL GAS 50 % 60 70 80 100 125 150 200 250 300 350 82.8 84.0 84.3 84.8 83.2 84.2 85.0 83.8 84.3 84.7 100 % 81.6 82.5 82.9 83.8 81.8 82.8 84.2 81.8 82.9 83.7 NO. 2 OIL 50 % 86.2 87.5 87.7 88.2 86.6 87.6 88.4 87.2 87.8 88.2 100 % 85.1 86.0 86.3 87.2 85.2 86.3 87.6 85.3 86.4 87.2
125 PSIG OPERATING PRESSURE NATURAL GAS 50 % 80.3 81.4 81.7 82.1 80.5 81.4 82.1 81.2 81.6 81.9 100 % 80.0 80.3 80.7 81.5 80.0 80.3 81.5 80.0 80.6 81.2 50 % 83.7 84.8 85.1 85.5 84.0 84.8 85.5 84.6 85.1 85.3 NO. 2 OIL 100 % 83.2 83.8 84.1 84.9 83.0 83.7 84.9 83.2 84.1 84.6
A7-12
04-02
Firetube Boilers
Model CBE
Table A7-4. Heating Surface, Model CBE Boilers

BOILER HP 60 70 80 100 125 150 200 250 300 350 HEATING SURFACE (SQ-FT) FIRESIDE 300 350 400 500 625 750 1000 1250 1500 1750 WATERSIDE 322 376 429 537 672 807 1077 1346 1615 1885
Table A7-5. Model CBE Steam Volume and Disengaging Area

STEAM VOLUME (CU-FT) STEAM RELIEVING AREA (SQ-IN) BOILER HP HIGH PRESSURE A LOW PRESSURE B HIGH PRESSURE A LOW PRESSURE B 60 70 80 100 125 150 200 250 300 350 6.39 7.58 8.65 10.91 19.04 23.00 30.78 31.96 38.56 45.15 12.92 15.35 17.50 22.08 29.67 35.93 48.19 50.18 60.68 71.18 2936 3486 3974 5014 5121 6202 8319 6872 8309 9747 3588 4261 4859 6129 5796 7018 9415 7805 9438 11071
NOTE: 1. Based on normal water level. 2. Values are based on standard controls. Optional controls may result in different values. A. Based on 150 psig design pressure. B. Based on 15 psig design pressure.
Table A7-6. Model CBE Steam Boiler Safety Valve Openings

VALVE SETTING BOILER HP 15 PSIG STEAM NO. OF VALVES REQ'D OUTLET SIZE (IN.) 100 PSIG STEAM NO. OF VALVES REQ'D OUTLET SIZE (IN.) 125 PSIG STEAM NO. OF VALVES REQ'D OUTLET SIZE (IN.) 150 PSIG STEAM NO. OF VALVES REQ'D OUTLET SIZE (IN.) 200 PSIG STEAM NO. OF VALVES REQ'D OUTLET SIZE (IN.) 250 PSIG STEAM NO. OF VALVES REQ'D OUTLET SIZE (IN.)
60 70 80 100 125 150 200 250 300 350
1 1 1 1 1 1 2 2 2 3
2 2 2-1/2 2-1/2 3 3 2-1/2 (1) 2-1/2 (1) 3 3 (1) 2 (2) 3
1 1 1 1 2 2 2 2 2 3
1-1/2 2 2 2 1-1/2 (1) 2 (1) 1-1/2 2 (1) 2-1/2 (1) 2 2-1/2 (1) 2-1/2 (2) 2
1 1 1 1 2 2 2 2 2 2
1-1/2 1-1/2 1-1/2 2 (1) 1-1/2 (1) 1-1/4 1-1/2 (1) 2 (1) 1-1/2 2 (1) 2-1/2 (1) 2 2-1/2
1 1 1 1 2 2 2 2 2 2
1-1/4 1-1/2 1-1/2 1-1/2 (1) 1-1/2 (1) 1-1/4 (1) 1-1/2 (1) 1-1/4 1-1/2 2 (1) 2-1/2 (1) 2 (1) 2-1/2 (1) 2
1 1 1 1 2 2 2 2 2 2
1-1/4 1-1/4 1-1/4 1-1/2 (1) 1-1/4 (1) 1 1-1/4 (1) 1-1/2 (1) 1-1/4 1-1/2 (1) 2 (1) 1-1/2 2
1 1 1 1 2 2 2 2 2 2
1 1-1/4 1-1/4 1-1/4 1 (1) 1 (1) 1-1/4 (1) 1-1/4 (1) 1-1/2 1-1/2 1-1/2 (1) 1-1/2 (1)2
NOTE: 1.Valve manufacturers are Kunkle, Consolidated or Conbraco, depending on availability.
A7-13
04-02
Model CBE
The National Boards recommendations base the size of the blowdown tank on the removal of at least 4 inches of water from the boiler. Table A7-10 lists the approximate quantity of water represented by 4 inches of water at normal operating level for Cleaver-Brooks Power Boilers. Fuel Connections - Gas
Firetube Boilers
Sound Level
Table A7-11 summarizes predicted sound pressure levels for Model CBE Boilers. These values are based on standard motors. Optional motor types and altitude conditions can increase sound levels. Units The units for the sound level tables are dBA (decibels, measured on the A-weighted scale) in reference to 0.0002 microbars (20 micro-Newtons per square meter). They are standardly referenced in specifying and reporting sound pressure levels on industrial equipment. Test Method The sound pressure levels in the above table were obtained from tests in accordance with the "ABMA Test Code for the Measurement of Sound from Packages Boilers." In accordance with this code, the sound pressure levels reported were measured on the boiler centerline 4-1/2 feet vertically above the bottom of the base rails and 3 feet horizontally in front of the end of the blower motor or front surface of the electrical cabinet. Sound Level Meter The sound level meter used complies with ANSI S1.4, Type 1 (Precision). The readings are taken with the meter set for slow response.
The local gas company should be consulted for requirements and authorization for installation and inspection of gas supply piping. Installation of gas supply piping and venting must be in accordance with all applicable engineering guidelines and regulatory codes. All connections made to the boiler should be arranged so that all components remain accessible for inspection, cleaning and maintenance. A drip leg should be installed in the supply piping before the connection to the gas pressure regulator. The drip leg should be at least as large as the inlet tting supplied with the boiler. Consideration must be given to both volume and pressure requirements when choosing gas supply piping size. Refer to the boiler dimension diagram provided by Cleaver-Brooks for the particular installation. Connections to the burner gas train should be made with a union, so that gas train components or the burner may be easily disconnected for inspection or service. Upon completion of the gas piping installation, the system should be checked for gas leakage and tight shutoff of all valves. Fuel Connections - Oil Oil-red burners are equipped with an oil pump, which draws fuel from a storage tank and supplies pressurized oil to the burner nozzle(s). The burner supply oil pump has a greater capacity than the burner requires for the maximum ring rate. Fuel not delivered to the nozzle is returned to the storage tank. A two-pipe (supply and return) oil system is recommended for all installations. Figure A7-6 shows a typical fuel oil supply arrangement. Oil lines must be sized for the burner and burner supply oil pump capacities. The burner supply oil pump suction should not exceed 10" Hg. If a transfer pump is used, it must have a pumping capacity at least equal to that of the burner pump(s). Supply pressure to the burner pump should not exceed 3 psig. A strainer must be installed in the supply piping upstream of the burner supply pump in order to prevent entry of foreign material into the pump, fuel control valves, or burner nozzle(s). The strainer must be sized for the burner supply pump capacity. A strainer mesh of 150 microns (0.005") is recommended. Install a check valve in the line to prevent draining of the oil suction line when the burner is not in operation. Location of the check valve varies with the system, but usually it is located as close as possible to the storage tank. Installation of a vacuum gauge in the burner supply line between the burner oil pump and the strainer is recommended. Regular observation and recording of the gauge indication will assist in determining when the strainer needs servicing. Upon completion of the oil piping installation, the system should be checked for oil or air leakage and tight shutoff of all valves.
Burner/Control Information
Burner Characteristics Burner information is shown in Table A7-12. Note that the model selection may vary for actual application factors (altitude, gas pressure, etc.). Gas Fired - Burners Table A7-13 shows conversion factors for gas pressure at elevations over 700 ft above sea level. Table A7-14 shows maximum gas consumption (CFH) for Natural Gas. Table A7-15 shows minimum and maximum gas pressure requirements for Standard, FM and IRI CBE Boiler gas trains. For oversized or undersized gas trains or altitude above 1,000 feet, contact your local Cleaver-Brooks authorized representative. A7-14
04-02
Firetube Boilers
Model CBE
Table A7-7. Model CBE Hot Water Boiler Relief Valve Openings
VALVE SETTING BOILER HP 60 70 80 100 125 150 200 250 300 350 30 PSIG HW NO. OF VALVES REQ'D 1 1 1 1 1 1 2 2 2 3 OUTLET SIZE (IN.) 2 2 2 2-1/2 2-1/2 2-1/2 (1) 2-1/2 (1) 1-1/4 (1) 2 (1) 2-1/2 2-1/2 (2) 2-1/2 (1) 1 60 PSIG HW NO. OF VALVES REQ'D 1 1 1 1 1 1 1 1 2 2 OUTLET SIZE (IN.) 1-1/4 2 2 2 2 2-1/2 (1) 2-1/2 2-1/2 (1) 1 (1) 2-1/2 (1) 2-1/2 (1) 2 100 PSIG HW NO. OF VALVES REQ'D 1 1 1 1 1 1 1 1 1 1 OUTLET SIZE (IN.) 1 1-1/4 1-1/4 1-1/4 2 2 2 2-1/2 2-1/2 2-1/2 125 PSIG HW NO. OF VALVES REQ'D 1 1 1 1 1 1 1 1 1 1 OUTLET SIZE (IN.) 1 1 1-1/4 1-1/4 1-1/4 2 2 2 2-1/2 2-1/2
NOTES: 1.Hot water relief valves are Kunkle #537.
Table A7-8. Model CBE Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity)
BOILER HP OPERATING PRESSURE PSIG 15 30 40 50 75 100 125 150 200 250 60 6 4 4 3 3 3 3 2.5 2.5 2 70 6 4 4 4 3 3 3 2.5 2.5 2 80 6 4 4 4 4 3 3 2.5 2.5 2 100 8 6 6 4 4 4 4 2.5 2.5 2 125 8 6 6 6 4 4 4 3 2.5 2.5 150 8 6 6 6 4 4 4 3 3 2.5 200 10 8 6 6 6 6 4 4 4 3 250 10 8 8 6 6 6 6 4 4 4 300 12 8 8 8 6 6 6 6 4 4 350 12 10 8 8 8 6 6 6 4 4
NOTES: 1. Steam nozzle sizes given in inches. 2. Recommended steam nozzle sizes based on 4000 to 5000 fpm steam velocity. Spool pieces (300 psig flanges) are available in the following sizes (in inches): 3x2-1/2x30, 4x3x30, 6x4x36, 8x6x48, 10x8x48, and 12x8x48.
A7-15
04-02
Model CBE
Firetube Boilers
Table A7-9. Model CBE Recommended Non-Return Valve Size

BOILER HP 100 125 150 200 250 300 350 BOILER CAPACITY (LBS/HR) 3450 4313 5175 6900 8625 10350 12025 OPERATING PRESSURES (PSIG) 50 3 4 4 4 4 6 6 75 2-1/2 3 4 4 4 4 6 100 2-1/2 3 3 4 4 4 4 125 2-1/2 3 3 3 4 4 4 150 2-1/2 3 3 3 3 4 4 175 2-1/2 2-1/2 3 3 3 4 4 200 2-1/2 2-1/2 2-1/2 3 3 4 4 250 2-1/2 2-1/2 2-1/2 3 3 3 3
Note: Valve sizes (300 psig Flanges) given in inches.
Table A7-10. Model CBE Blowdown Tank Sizing Information

BOILER HP 60 70 80 100 125 150 200 250 300 350 WATER (GAL) 51 60 69 87 92 111 147 122 147 172
NOTE: Quantity of water removed from boiler by lowering normal water line 4"
Table A7-11. Sound Pressure Levels in DbA (Prore F)

BOILER HP 60 70 80 100 125 GAS HIGH FIRE LOW FIRE 77.0 78.0 75.0 74.0 76.5 76.5 75.5 74.5 76.5 68.5 NO. 2 OIL HIGH FIRE LOW FIRE 77.0 75.5 74.0 72.0 76.5 76.0 76.0 75.0 79.0 76.0 80.0 76.0 83.0 85.0 83.0 78.0 84.5 80.5 89.0 84.0 77.5 73.5 84.5 87.0 82.0 74.5 83.5 78.5 88.0 84.0 150 200 250 300 350
A7-16
04-02
Firetube Boilers
Model CBE
Table A7-12. Model CBE Burner Selections (Prore Burner)

BOILER HP MAX ALTITIUDE (FT) BURNER SIZE
60 70 80 100 125 150 200 250 300 350
2000 3500 1500 1500 3500 2500 1500 2000 2500 1000
1 2 2 2 3 3 3 4 4 4

ALTITUDE (FT) CORRECTION FACTOR ALTITUDE (FT) CORRECTION FACTOR
Table A7-14. Maximum Gas Consumption (CFH) for Natural Gas - Model CBE
BOILER HP NATURAL GAS 1000 (BTU/CU-FT)
1000 2000 3000 4000 5000
1.04 1.07 1.11 1.16 1.21
6000 7000 8000 9000 -
1.25 1.30 1.35 1.40 -
60 70 80 100 125 150
2510 2930 3350 4185 5230 6280 8370 10460 12555 14650
To obtain minimum required gas pressure at altitudes above 700 feet, multiply the pressure by the listed factors: inches WC x 0.577 = oz/sq-in. oz/sq-in x 1.732 = inches WC. i inches WC x 0.0361= psig. oz/sq-in x 0.0625 = psig. psig x 27.71 = Inches WC. psig x 16.0 = oz/sq-in.
200 250 300 350
A7-17
04-02
Model CBE
Firetube Boilers
Table A7-15. Minimum Required Gas Pressure at Entrance to Standard, FM and IRI Gas Trains - Model CBE (Upstream of Gas Pressure Regulator)
MAX 1 PSIG INLET, MIN SUPPLY PRESSURE (WC) UL 11.0 8.5 11.0 16.0 12.5 18.5 19.5 23.5 N/A N/A FM 11.0 8.5 11.0 16.0 12.5 18.5 19.5 23.5 N/A N/A 11.5 9.0 11.5 17.0 12.5 18.5 19.5 23.5 N/A N/A IRI 13.0 12.5 14.5 22.0 16.0 23.0 22.5 27.5 39.0 41.5 MAX 10 PSIG INLET**, MIN SUPPLY PRESSURE (WC) UL FM 13.0 12.5 14.5 22.0 16.0 23.0 22.5 27.5 39.0 41.5 13.5 13.0 15.0 23.0 16.0 23.0 22.5 27.5 39.0 41.5 IRI
BOILER HP 60 70 80 100 125 150 200 250 300 350
STD PIPE SIZE (Inches) 2* 2* 2* 2* 2 2 2-1/2 2-1/2 2-1/2 3
* Gas pressure regulator is 1-1/2 inch.

** Use max 10 psig for all boilers destined for Canada.
Figure A7-6. Typical Fuel Oil Supply Arrangement
A7-18
04-02
Firetube Boilers
Figure A7-7 shows typical boiler room length requirements. Figure A7-8 shows typical boiler room width requirements. openings are to be 5 feet above oor level.
Model CBE
Air required: 300 x 10 = 3000 cfm (from 2B above). Air velocity: Up to 7 feet = 250 fpm (from 3 above). Area Required: Area = cfm = 3000/250 = 12 Sq-ft total.

60-100 hp Model CBE Boilers can support up to 1000 lbs without additional support. 125-350 hp Model CBE Boilers can support up to 2000 lbs without additional support.
Area/Opening: 12/2 = 6 sq-ft/opening (2 required).
NOTICE

When determining boiler room air requirements, the size of the room, air ow, and velocity of air must be reviewed as follows: 1. Size (area) and location of air supply openings in boiler room. A. Two (2) permanent air supply openings in the outer walls of the boiler room are recommended. Locate (1) at each end of the boiler room, preferably below a height of 7 feet. This allows air to sweep the length of the boiler. B. Air supply openings can be louvered for weather protection, but they should not be covered with ne mesh wire, as this type of covering has poor air ow qualities and is subject to clogging by dust or dirt. C. A vent fan in the boiler room is not recommended, as it could create a slight vacuum under certain conditions and cause variations in the quantity of combustion air. This can result in unsatisfactory burner performance. D. Under no condition should the total area of the air supply openings be less than (1) square foot. E. Size the openings by using the formula: Area (sq-ft) = CFM/FPM 2. Amount of air required (cfm). A. Combustion Air = Rated bhp x 8 cfm/bhp. B. Ventilation Air = Maximum bhp x 2 cfm/bhp C. Total recommended air = 10 cfm/bhp - up to 1000 feet elevation. Add 3 percent more per 1000 feet of added elevation. 3. Acceptable air velocity in Boiler Room (fpm). A. From oor to (7) foot height - 250 fpm. B. Above (7) foot height - 500 fpm. Example: Determine the area of the boiler room air supply openings for (1) 300 hp boiler at 800 feet altitude. The air

The design of the stack and breeching must provide the required draft at each boiler ue gas outlet. Proper draft is critical to burner performance. Although constant pressure at the ue gas outlet of the Model CBE is not required, it is necessary to size the stack/breeching to limit ue gas pressure variation. The allowable pressure range is 0.25" W.C. to +0.25" W.C. For additional information, please review Section I4, General Engineering Data (Stacks) and Section F, Stacks. Stack and breeching sizes should always be provided by a reputable stack supplier who will design the stack and breeching system based on the above criteria. Your local Cleaver-Brooks authorized representative is capable of assisting in your evaluation of the stack/breeching design.
A7-19
04-02
Model CBE
Firetube Boilers
1. Shortest boiler room length (Dwg A) is obtained by allowing for possible future tube replacement (from front or rear of boiler) through a window or doorway. Allowance is only made for minimum door swing at each end of the boiler. This arrangement provides sufficient aisle space at the front of the boiler but a tight space condition at the rear. If space permits, approximately 1.5 additional feet should be allowed at the rear for additional aisle and working space. 2. Next shortest boiler room length (Dwg B) is obtained by allowing for possible future tube replacement from the front of the boiler. Allowance is only made for minimum door swing at the rear. If space permits, approximately 1.5 additional feet should be allowed at the rear for additional aisle and working space. 3. A slightly longer boiler room (Dwg C) is obtained by allowing for possible future tube replacement from the rear of the boiler. Allowance for door swing at the front provides sufficient aisle and working space at the front.
Figure A7-7. Boiler Room Length (Typical Layouts) - Model CBE
BOILER HP Dimension A (inches) Dimension B (inches)
60-100 78 105
125-200 82 115
250-350 93 141
NOTES: 1. Recommended Minimum Distance Between Boiler and Wall. Dimension A allows for a clear 42" aisle between the water column on the boiler and the wall. If space permits, this aisle should be widened. 2. Recommended Minimum Distance Between Boilers. Dimension B between boilers allows for a clear aisle of: 42" - 60-200 hp 48" - 250-350 hp If space permits, this aisle should be widened.
Figure A7-8. Boiler Room Width (Typical Layout) - Model CBE A7-20
04-02
Firetube Boilers
Model CBE
The following sample specication are provided by Cleaver-Brooks to assist you in meeting your customers specic needs and application. The Sample Specications are typically utilized as the base template for the complete boiler specication. Contact your local Cleaver-Brooks authorized representative for information on special insurance requirements, special code requirements, optional equipment, or general assistance in completing the specication. Model CBE Steam Boiler (60-350 hp, Steam 15-300 psig) 1.0 Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model CBE Hot Water Boiler (60-350 hp, 30 psig, 125 psig) 1.0 Boiler Characteristics (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Hot Water Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model CBE Steam Boiler (60-350 hp, Steam 15-300 psig) 1.0 Boiler Characteristics (Steam) 1.1 The Steam Boiler shall be Cleaver-Brooks Model CBE, Fuel Series ______ (100, 200, 700), _____ hp designed for _____ psig (15, 150, 200, or other psig steam). The maximum operating pressure shall be _____ psig. 1.2 The boiler shall have a maximum output of _____ Btu/hr, or _____ horsepower when red with CS 12-48 No. 2 oil and/or natural gas, _____ Btu/cu-ft. Electrical power available will be _____ Volt _____ Phase _____ Cycle and 115/1/160 for the control circuit. 2.0 General Boiler Design 2.1 The boiler shall be a three pass horizontal retube updraft boiler with ve (5) square feet of heating surface per rated boiler horsepower. It shall be mounted on a heavy steel frame with forced draft burner and burner controls. 2.1.1 Approvals: Underwriters Laboratories Inc. The complete boiler package shall be approved and listed as a unit by Underwriters Laboratories. 2.1.2 The boiler shall be completely preassembled and re tested at the factory. The unit shall be ready for immediate mounting on oor or simple foundation and ready for attachment of water, steam, fuel, electrical, vent and blowdown connections. 2.2 Boiler Shell (Steam) 2.2.1 The boiler shell must be constructed in accordance with ASME Boiler Code and must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser. 2.2.2 Two lifting eyes shall be located on top of the boiler. 2.2.3 Front and rear doors on the boiler shall be davited. A7-26 A7-26 A7-26 A7-27 A7-29 A7-29 A7-30 A7-21 A7-21 A7-22 A7-22 A7-25 A7-25 A7-25
A7-21
04-02
Model CBE
Firetube Boilers
2.2.4 Refractory and insulation shall be contained in the rear smoke box and door; door shall swing open for inspection. 2.2.5 The boiler tubes shall not include turbulators, swirlers or other add-on appurtenances. 2.2.6 Front and rear tube sheets and all ues must be accessible for inspection and cleaning when the doors are swung open. The boiler shall be furnished with adequate handholes to facilitate boiler inspection and cleaning. 2.2.7 For boilers over 100 horsepower, a manhole shall be provided. 2.2.8 The exhaust gas vent shall be located near the rear of the boiler on the top center line and shall be capable of supporting: 60-100 hp. 1000 lbs 125-350 hp. 2000 lbs 2.2.9 Observation ports for the inspection of ame conditions shall be provided at each end of the boiler. 2.2.10 The boiler insulation shall consist of a 2 inch blanket under a sectional preformed sheet metal lagging. This insulation must be readily removable and capable of being reinstalled, if required. 2.2.11 The entire boiler based frame and other components shall be factory painted before shipment using a hard nished enamel coating. 3.0 Steam Boiler Trim 3.1 Water Column A water column shall be located on the right hand side of the boiler complete with gauge glass set and water column blowdown valves. 3.1.1 Feedwater Pump Control The boiler feedwater pump control shall be included as an integral part of the water column to automatically actuate a motor driven feed water pump maintaining the boiler water level within normal limits. 3.1.2 Low Water Cutoff The low water cutoff shall be included as an integral part of the boiler feedwater control wired into the burner control circuit to prevent burner operation if the boiler water level falls below a safe level. 3.2 Auxiliary Low Water Cutoff Auxiliary low water cutoff manual reset shall be included, piped to the vessel, and wired to the burner control circuit. A manual reset device shall be used on this control. 3.3 Steam Pressure Gauge The steam pressure gauge shall be located at the front of the boiler and include cock and test connection. 3.4 Safety Relief Valves Safety valves of a type and size to comply with ASME Code requirements shall be shipped loose. 3.5 Steam Pressure Controls The steam pressure controls to regulate burner operation shall be mounted near the water column. 4.0 Burner and Controls 4.1 Mode of Operation Burner operation shall be the full modulation principle. The burner shall always return to low re position for ignition. 4.2 Blower 4.2.1 All air for combustion shall be supplied by a forced draft blower mounted on the burner, to eliminate vibration and reduce noise level.
A7-22
04-02
Firetube Boilers
Model CBE
4.2.2 Maximum sound level of the boiler/burner package shall not exceed _____ dbA (when measured in accordance with ABMA Sound Test Standards). 4.3 Combustion Air Control Combustion air damper and fuel control valve shall be operated by a single damper control motor that regulates the ame according to load demand. Potentiometer type position controls shall be provided to regulate operation of the damper control motor. 4.4 Fuel Specication and Piping Select one of the following fuel types: Fuel series 700 - Gas red (para 4.4.1). Fuel series 100 - Light oil (No. 2) red (para 4.4.2). Fuel series 200 - Light oil or gas red (para 4.4.3). 4.4.1 Fuel Series 700 - Gas Fired 4.4.1.1 Burner Type - The burner shall be mounted at the front of the boiler and be of high radiant multi-port type for gas. The burner shall be approved for operation on natural gas fuel. 4.4.1.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include one (1) shut-off valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only). 4.4.1.3 Gas Burner Piping - Select one of the following: A. 60-100 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valve shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. B. 125-250 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. C. 300 and 350 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. 4.4.2 Fuel Series 100 - Light Oil Fired 4.4.2.1 Burner Type - The burner shall be mounted at the front of the boiler, and shall be approved for operation with CS12-48, Commercial No. 2 oil. 4.4.2.2 Ignition System - Select one of the following: A. 60-100 hp. The burner shall employ a direct spark ignition system. A high voltage spark generated by a transformer shall be used to ignite the main burner. B. 125-350 hp. The burner shall employ a gas pilot ignition system. A separate pilot gas cock, gas pressure regulator, pilot and safety shutoff gas valve. 4.4.2.3 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Select one of the following: A. 60-200 hp. Pump shall be an integral part of the burner and mechanically driven. B. 250-350 hp. Pump shall be motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided.
A7-23
04-02
Model CBE
4.4.2.4 Oil Burner Piping - Select one of the following:
Firetube Boilers
A. 60 to 200 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, and pressure gauge all integrally mounted on the unit. B. 250-350 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, low oil pressure switch, and pressure gauge all integrally mounted on the unit. 4.4.2.5 Oil Atomization Type-Select one of the following: A. 60-200 hp. Burner shall include a complete mechanical oil atomizing system and be of the pressure atomizing type. B. 250-350 hp. Burner shall be a low pressure air atomizing type, including a shipped loose air compressor assembly. 4.4.3 Fuel Series 200 - Light Oil or Gas Fired 4.4.3.1 Burner Type - Select one of the following: A. 60-200 hp. The burner, mounted at the front of the boiler, shall be a combination pressure atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 oil or natural gas. B. 250-350 hp. The burner, mounted at the front of the boiler, shall be a combination of low pressure air atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 oil or natural gas. 4.4.3.2 Gas Pilot - The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary fuel valve cannot open until ame has been established. The pilot train shall include one (1) manual shut-off valve, solenoid valve, and pressure regulator. 4.4.3.3 Oil Burner 4.4.3.3.1 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Select one of the following: A. 60-200 hp. Pump shall be an integral part of the burner and mechanically driven. B. 250-350 hp. Pump shall be motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided. 4.4.3.3.2 Oil Burner Piping - Select one of the following: A. 60-200 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, and pressure gauge all integrally mounted on the unit. B. 250-350 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, low oil pressure switch and pressure gauge all integrally mounted on the unit. 4.4.3.3.3 Oil Atomization Type - Select one of the following: A. 60-200 hp. Burner shall include a complete mechanical oil atomizing system and be of the pressure atomizing type. B. 250-350 hp. Burner shall be a low pressure air atomizing type, including a shipped loose air compressor assembly. 4.4.3.4 Gas Burner Piping - Select one of the following: A. 60-100 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connection, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. B. 125-250 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valve shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition.
A7-24
04-02
Firetube Boilers
Model CBE
C. 300 and 350 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water or any abnormal shutdown condition. 4.5 Control Panel and Flame Safeguard Controller 4.5.1 Control Panel A factory prewired control panel shall be supplied with the boiler-burner package. Panel may be mounted on the burner or boiler. 4.5.2 The panel will have a NEMA 1A rating and contain the ame safeguard controller, burner motor starter, control circuit fuse, selector switches, indicating light and terminal strips. Lights shall indicate load demand, ame failure, low water, and fuel valve open. 4.5.3 80-350 hp. The panel shall contain a control circuit transformer and fuse protection. 4.5.4 The ame safeguard controller shall be a CB110 ame monitor with EPD170 program module. Flame detector shall be ultraviolet type. 5.0 Efciency Guarantee 5.1 The boiler must be guaranteed to operate at a minimum fuel-to-steam efciency of ____ percent at 100 percent of rating when burning natural gas and ________ fuel-to-steam efciency at 100% ring rate when burning oil (Contact your local CleaverBrooks authorized representative for efciency details). 6.0 Warranty 6.1 All equipment is to be guaranteed against defects in materials and/or workmanship for a period of 12 months from date of startup or 18 months from date of shipment, whichever comes rst. 7.0 Execution 7.1 Shop Tests 7.1.1 The packaged boiler must receive factory tests to check the construction, controls, and operation of the unit. All tests may be witnessed by the purchaser, if desired. 7.2 Start-up Service 7.2.1 After boiler installation is completed, the manufacturer shall provide the services of a eld representative for starting the unit and training the operator at no additional costs. 7.2.1.1 A factory approved and authorized start-up report shall be submitted to the customer/user at the time of start-up.
A7-25
04-02
Model CBE
Model CBE Hot Water Boiler (60-350 hp, 30 psig, 125 psig) 1.0 Boiler Characteristics (Hot Water)
Firetube Boilers
1.1 The Hot Water Boiler shall be Cleaver-Brooks Model CBE, Fuel Series ______ (100, 200, 700), _____ hp designed for _____ psig (30, 125, or other psig hot water). The maximum water temperature will be _____ degree F, and the maximum system temperature drop will be _____ degree F. 1.2 The boiler shall have a maximum output of _____ Btu/hr, or _____ horsepower when red with CS 12-48 No. 2 oil and/or natural gas, _____ Btu/cu-ft. Electrical power available will be _____ Volt _____ Phase _____ Cycle and 115/1/160 for the control circuit. 2.0 General Boiler Design 2.1 The boiler shall be a three pass horizontal retube updraft boiler with ve (5) square feet of heating surface per rated boiler horsepower. It shall be mounted on a heavy steel frame with forced draft burner and burner controls. 2.1.1 Approvals: Underwriters Laboratories Inc. The complete boiler package shall be approved and listed as a unit by Underwriters Laboratories. 2.1.2 The boiler shall be completely preassembled and re tested at the factory. The unit shall be ready for immediate mounting on oor or simple foundation and ready for attachment of water, steam, fuel, electrical, vent and blowdown connections. 2.2 Boiler Shell (Hot Water) 2.2.1 The boiler shell must be constructed in accordance with ASME Boiler Code and must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser. 2.2.2 The hot water return and outlet connections shall be located on the top center line of the boiler. The boiler shall be designated to rapidly mix the return water with the boiler water. Forced internal circulation shall be used. 2.2.3 A dip tube shall be included as an integral part of the water outlet. 2.2.4 Two lifting eyes shall be located on top of the boiler. 2.2.5 Front and rear doors on the boiler shall be davited. Doors are to be sealed with Kaowool gaskets and fastened tightly using heavy capscrews that thread into replaceable brass nuts. 2.2.6 Refractory and insulation shall be contained in the rear smoke box and door; door shall swing open for inspection. 2.2.7 The boiler tubes shall not include turbulators, swirlers or other add-on appurtenances. 2.2.8 Front and rear tube sheets and all ues must be fully accessible for inspection and cleaning when the doors are swung open. The shell must be furnished with adequate handholes to facilitate boiler inspection and cleaning. 2.2.9 For boilers over 100 horsepower, a manhole shall be provided. 2.2.10 The exhaust gas vent shall be located near the rear of the boiler on the top center line and shall be capable of supporting: 60-100 hp. 1000 lbs. 125-350 hp. 2000 lbs. 2.2.11 Observation ports for the inspection of ame conditions shall be provided at each end of the boiler. 2.2.12 The boiler insulation shall consist of a 2 inch blanket under a sectional preformed sheet metal lagging. This insulation must be readily removable and capable of being reinstalled, if required. 2.2.13 The entire boiler based frame and other components shall be factory painted before shipment using a hand nished enamel coating. 3.0 Hot Water Boiler Trim 3.1 Hot Water Connections The hot water outlet and return connections shall be located on the top center line of the boiler. The internal design of these connections shall provide forced internal circulation, mixing return water with the hot water within the boiler. A7-26
04-02
Firetube Boilers
3.2 Dip Tube
Model CBE
The dip tube, an integral part of the hot water outlet, and an air vent tapping in the boiler shell must be provided for removal of entrained air. 3.3 Low Water Cutoff A low water cutoff control (manual reset) shall be mounted on the top centerline of the boiler wired into the burner control circuit to prevent burner operation if boiler water falls below a safe level. A manual reset device shall be used on this control. 3.4 Pressure and Temperature Gauges Pressure and temperature gauges shall be mounted on the boiler with temperature sensing element located adjacent to the hot water outlet. 3.5 Relief Valves Water relief valves of a type and size to comply with ASME Code requirements shall be shipped loose. 3.6 Temperature Controls Temperature controls to regulate burner operation shall be mounted on the unit with temperature sensing elements located adjacent to the hot water outlet. 4.0 Burner 4.1 Mode of Operation Burner operation shall be the full modulation principle. The burner shall always return to low re position for ignition. 4.2 Blower 4.2.1 All air for combustion shall be supplied by a forced draft blower mounted on the burner, to eliminate vibration and reduce noise level. 4.2.2 Maximum sound level of the boiler/burner package shall not exceed _____ dbA (when measured in accordance with ABMA Sound Test Standards). 4.2.3 The impeller shall be cast aluminum, radial blade, carefully balanced, and directly connected to the blower motor shaft. 4.3 Combustion Air Control Combustion air damper and fuel control valve shall be operated by a single damper control motor that regulates the ame according to load demand. Potentiometer type position controls shall be provided to regulate operation of the damper control motor. 4.4 Fuel Specication and Piping Select one of the following fuel types: Fuel series 700 - Gas red (4.4.1). Fuel series 100 - Light oil (No. 2) red (4.4.2). Fuel series 200 - Light oil or gas red (4.4.3). 4.4.1 Fuel Series 700 - Gas Fired 4.4.1.1 Burner Type - The burner shall be mounted at the front of the boiler and of high radiant multi-port type for gas. The burner shall be approved for operation on natural gas fuel. 4.4.1.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include one (1) shut-off valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only). 4.4.1.3 Gas Burner Piping - Select one of the following: A. 60-100 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure
A7-27
04-02
Model CBE
Firetube Boilers
switches. The gas valve shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. B. 125-250 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. C. 300 and 350 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. 4.4.2 Fuel Series 100 - Light Oil Fired 4.4.2.1 Burner Type - The burner shall be mounted at the front of the boiler, and shall be approved for operation with CS12-48, Commercial No. 2 oil. 4.4.2.2 Ignition System - Select one of the following: A. 60-100 hp. The burner shall employ a direct spark ignition system. A high voltage spark generated by a transformer shall be used to ignite the main burner. B. 125-350 hp. The burner shall employ a gas pilot ignition system. A separate pilot gas cock, gas pressure regulator, and pilot safety shutoff gas valve. 4.4.2.3 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Select one of the following: A. 60-200 hp. Pump shall be an integral part of the burner and mechanically driven. B. 250-350 hp. Pump shall be motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided. 4.4.2.4 Oil Burner Piping - Select one of the following: A. 60-200 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, and pressure gauge all integrally mounted on the unit. B. 250-350 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, low oil pressure switch, and pressure gauge all integrally mounted on the unit. 4.4.2.5 Oil Atomization Type - Select one of the following: A. 60-200 hp. Burner shall include a complete mechanical oil atomizing system and be of the pressure atomizing type. B. 250-350 hp. Burner shall be a low pressure air atomizing type, including a shipped loose air compressor assembly. 4.4.3 Fuel Series 200 - Light Oil or Gas Fired 4.4.3.1 Burner Type - Select one of the following: A. 60-200 hp. The burner, mounted at the front of the boiler, shall be a combination pressure atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 oil or natural gas. B. 250-350 hp. The burner, mounted at the front of the boiler, shall be a combination of low pressure air atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 oil or natural gas. 4.4.3.2 Gas Pilot - The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary fuel valve cannot open until ame has been established. The pilot train shall include one (1) manual shut-off valve, solenoid valve, and pressure regulator.
A7-28
04-02
Firetube Boilers
4.4.3.3 Oil Burner
Model CBE
4.4.3.3.1 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Select one of the following: A. 60-200 hp. Pump shall be an integral part of the burner and mechanically driven. B. 250-350 hp. Pump shall be motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided. 4.4.3.3.2 Oil Burner Piping - Select one of the following: A. 60-200 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, and pressure gauge all integrally mounted on the unit. B. 250-350 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, low oil pressure switch and pressure gauge all integrally mounted on the unit. 4.4.3.3.3 Oil Atomization Type - Select one of the following: A. 60-200 hp. Burner shall include a complete mechanical oil atomizing system and be of the pressure atomizing type. B. 250-350 hp. Burner shall be a low pressure air atomizing type, including a shipped loose air compressor assembly. 4.4.3.4 Gas Burner Piping - Select one of the following: A. 60-100 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connection, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. B. 125-250 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. C. 300 and 350 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water or any abnormal shutdown condition. 4.5 Control Panel and Flame Safeguard Controller 4.5.1 Control Panel A factory prewired control panel shall be supplied with the boiler-burner package. Panel may be mounted on the burner or boiler. 4.5.2 The panel will have a NEMA 1A rating and contain the ame safeguard controller, burner motor starter, control circuit fuse, selector switches, indicating light and terminal strips. Lights shall indicate load demand, ame failure, low water, and fuel valve open. 4.5.3 80-350 hp. The panel shall contain a control circuit transformer and fuse protection. 4.5.4 The ame safeguard controller shall be a CB110 ame monitor with EPD170 program module. Flame detector shall be ultraviolet type. 5.0 Efciency Guarantee 5.1 The boiler must be guaranteed to operate at a minimum fuel-to-water efciency of ____ percent at 100 percent of rating when burning natural gas and ________ fuel-to-steam efciency at 100% ring rate when burning oil (Contact your local Cleaver-Brooks authorized representative for efciency details). 6.0 Warranty 6.1 All equipment is to be guaranteed against defects in materials and/or workmanship for a period of 12 months from date of
A7-29
04-02
Model CBE
start-up or 18 months from date of shipment, whichever comes rst. 7.0 Execution 7.1 Shop Tests
Firetube Boilers
A7-30
04-02
Section A8
Model CEW Boilers
CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-3 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-3 DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-4 PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-11 ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-11 Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-11 Blowdown Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-12 Burner/Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-12 Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-12 Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-12 Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-12 Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-13 SAMPLE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-21 ILLUSTRATIONS Figure A8-1. Model CEW Steam Boiler Dimensions (Page 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8- 6 Figure A8-2. Model CEW Hot Water Boiler Dimensions (Page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-8 Figure A8-3. Space Required to Open Rear Head on Model CEW Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-10 Figure A8-4. Model CEW Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-10 Figure A8-5. Model CEW Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-11 Figure A8-6. Typical Fuel Oil Supply Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-18 Figure A8-7. Boiler Room Length (Typical Layouts) - Model CEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-19 Figure A8-8. Boiler Room Width (Typical Layout) - Model CEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-19
A8-1
10-02
Model CEW
Firetube Boilers
TABLES Table A8-1. Model CEW Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A8-5 Table A8-2. Model CEW Hot Water Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A8-5 Table A8-3. Model CEW Steam Volume and Disengaging Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A8-14 Table A8-4. Model CEW Steam Boiler Safety Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A8-14 Table A8-5. Model CEW Hot Water Boiler Relief Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A8-15 Table A8-6. Model CEW Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A8-15 Table A8-7. Model CEW Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A8-16 Table A8-8. Model CEW Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A8-16 Table A8-9. Model CEW Standard Burner Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A8-17 Table A8-10. Altitude Correction for Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A8-17 Table A8-11. Model CEW Minimum and Maximum Required Gas Pressure at Entrance to Standard, FM and IRI Gas Trains (Upstream of Gas Pressure Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A8-18
The following information applies to the Cleaver-Brooks Model CEW Boiler.
A8-2
10-02
Firetube Boilers
Model CEW
Seismic design. Burner/Control Options: Flame safeguard controllers. Lead/lag system. High altitude design. Special insurance and code requirements (e.g., IRI, FM, CSD-1). Alarm bell/silence switch. Special motor requirements (TEFC, high efciency). Special indicating lights.

The Cleaver-Brooks Model CEW Boiler line provides a quality product utilizing a baseline boiler/burner design. Additionally, the boiler/burner packaged UL and cUL label is available on 125 - 800 hp. The following features apply: Three-Pass Wetback Design: Three-pass design provides high ue gas velocities and low stack temperatures to maximize efciency. Five square feet of heating surface per boiler horsepower (except for the 750 and 800 hp) provides guaranteed efciency performance and long boiler life. Front and Rear Doors: Davit, front and rear doors, all sizes. Provides access to front and rear tube sheet. Large rear access plug for turnaround and furnace access. Rear door completely covers and insulates rear tube sheet. Natural Gas, No. 2 Oil, or Combination Burners Available: Combination gas/oil burners provide quick fuel changeover without burner adjustment.
Main disconnect. Elapsed time meter. Voltmeter/micro-ammeter. NEMA enclosures. Low-re hold control. Remote emergency shut-off (115V). Circuit breakers. Day/night controls. Special power requirements. Stack thermometer. Fuel Options Air atomizing oil burner, 125 200 hp. Gas strainer. Gas pressure gauge. Future gas conversion. Oversized/undersized gas trains.
PRODUCT OFFERING
Cleaver-Brooks Model CEW Boilers are available in low pressure steam, high pressure steam, and hot water designs. Burners are available to re natural gas, No. 2 oil, or a combination of oil and gas. Standard product offering is: 125 - 800 hp. 30 and 125 psig hot water. 15 - 250 psig steam. Full modulation, all sizes. Available options include the following (contact your local Cleaver-Brooks authorized representative for option details). Boiler Options: Drain valves. Additional screwed or anged trappings. Blowdown valves. Non-return valves. Feedwater valves and regulators. Surface blowdown systems. Blend pump. Surge load bafes.
A8-3
10-02
Model CEW
Firetube Boilers

Dimensions and ratings for the Model CEW Boilers are shown in the following tables and illustrations. The information is subject to change without notice. Table A8-1. Model CEW Steam Boiler Ratings Table A8-2. Model CEW Hot Water Boiler Ratings Figure A8-2. Model CEW Steam Boiler Dimensions Figure A8-1. Model CEW Hot Water Boiler Dimensions Figure A8-3. Model CEW Boiler Space Requirements to Open Rear Door Figure A8-4. Lifting Lug Location, Model CEW Boilers Figure A8-5. Model CEW Boiler Mounting Piers
A8-4
10-02
Firetube Boilers
Table A8-1. Model CEW Steam Boiler Ratings
BOILER HP 125 150 200 250 300 350 400 500 600 700
Model CEW
750
800
RATINGS - SEA LEVEL TO 1000 FT Rated Capacity (lbs-steam/hr from and at 212 F) Btu Output (1000 Btu/hr) 4313 4184 5175 5021 6900 6695 8625 8369 10350 10043 12075 11716 13800 13390 17250 16738 20700 20085 24150 23433 25875 25106 27600 26780
APPROXIMATE FUEL CONSUMPTION AT RATED CAPACITY Light Oil gph (140,000 Btu/gal) Gas CFH (1000 Btu) Gas (Therm/hr) 37.5 5230 52.3 45 6280 62.8 60 8370 83.7 74.5 10460 104.6 89.5 12555 125.5 104.5 14650 146.5 119.5 16750 167.5 149.5 20925 209.3 179.5 25100 251.0 209 29300 293.0 224 31385 313.9 239 33500 335.0
POWER REQUIREMENTS SEA LEVEL TO 1000 FT (60 HZ) Oil Pump Motor hp (oil ring only) Blower Motor - Series 100/200A Blower Motor - Series 700A * 2 2 ** N/A * 3 3 ** N/A * 7-1/2 5 ** N/A 1/2 5 5 3 N/A 3/4 7-1/2 7-1/2 3 N/A BOILER DATA Heating Surface sq-ft (Fireside) 625 750 1000 1250 1500 1750 2000 2500 3000 3500 3500 3500 3/4 10 10 3 N/A 3/4 20 20 5 1/2 3/4 25 25 5 3/4 3/4 30 30 7-1/2 3/4 1 40 40 7-1/2 3/4 1 60 60 7-1/2 3/4 1 60 60 7-1/2 3/4
Air Comp. Motor (oil ring only) Oil Meter. Pump Mtr (oil ring only)

NOTE:All fractional hp motors will be single phase voltage except oil metering pump motor(3-phase); integral hp motors will be 3-phase voltage. A. For altitudes over 1000 ft. contact your local Cleaver-Brooks representative for verication of motor hp.
Table A8-2. Model CEW Hot Water Boiler Ratings
BOILER HP
125
150
200
250
300
350
400
500
600
700
750
800
RATINGS SEA LEVEL TO 1000 FT Btu Output (1000 Btu/hr) 4184 5021 6695 8369 10043 11716 13390 16738 20085 23433 25106 26780
APPROXIMATE FUEL CONSUMPTION AT RATED CAPACITY Light Oil gph (140,000 Btu/gal) Gas CFH (1000 Btu) Gas (Therm/hr) 37.5 5230 52.3 45 6280 62.8 60 8370 83.7 74.5 10460 104.6 89.5 12555 125.5 104.5 14650 146.5 119.5 16750 167.5 149.5 20925 209.3 179.5 25100 251 209 29300 293 224 31385 313.8 239 33500 335
POWER REQUIREMENTS SEA LEVEL TO 1000 FT (60 HZ) Oil Pump Motor hp (oil ring only) Blower Motor - Series 100/200A Blower Motor - Series 700A Air Comp. Motor (oil ring only) Oil Meter. Pump Mtr (oil ring only) * 2 2 ** N/A * 3 3 ** N/A * 7-1/2 5 ** N/A 1/2 5 5 3 N/A 3/4 7-1/2 7-1/2 3 N/A BOILER DATA Heating Surface sq-ft (Fireside) 625 750 1000 1250 1500 1750 2000 2500 3000 3500 3500 3500 3/4 10 10 3 N/A 3/4 20 20 5 1/2 3/4 25 25 5 3/4 3/4 30 30 7-1/2 3/4 1 40 40 7-1/2 3/4 1 60 60 7-1/2 3/4 1 60 60 7-1/2 3/4

NOTE:All fractional hp motors will be single phase voltage except oil metering pump motor(3-phase); integral hp motors will be 3-phase voltage. A. For altitudes over 1000 ft. contact your local Cleaver-Brooks representative for verication of motor hp.
A8-5
10-02
Model CEW
Firetube Boilers
RF/RD I LL L GG K E B Y T BB CC DD 4"
J O OA
P
(NEARSIDE) (BOTH SIDES)
G S
Q N M FRONT VIEW W C A RIGHT SIDE VIEW
W H
BOILER HP
DIM
125
150
200
250
300 LENGTHS
350
400
500
600
700
750
800
Overall Shell Base Frame Base Frame to Rear Flange Flange to Steam Nozzle
A B C H E
201-3/4 158 166-3/4 19-1/8 56
224-3/4 181 189-3/4 19-1/8 72
272-3/4 229 237-3/4 19-1/8 108
216-7/16 240-7/16 265-7/16 168 179-1/2 22 70 192 203-1/2 22 90 WIDTHS 217 228-1/2 22 108
300 242 225-7/8 22 118
282-1/2 219-3/4 203-3/4 22 100-3/4
319 254-3/4 238-3/4 22 110-3/4
354 289-3/4 273-3/4 22 127-1/4
356-7/8 289-3/4 273-3/4 22 127-1/4
359 289-3/4 273-3/4 22 127-1/4
OverallC I. D. Boiler Center to Water Column Center to Lagging Center to Auxil.iary LWCO Base Outside Base Inside
I J K L LL M N
85 60 45 33 40 52-1/2 44-1/2
85 60 45 33 40 52-1/2 44-1/2
85 60 45 33 40 52-1/2 44-1/2
103 78 54 42 49 64 56
103 78 54 42 49 64 56
103 78 54 42 49 64 56
103 78 54 42 49 64 56
121 96 63 51 58 71-7/8 58-7/8
121 96 63 51 58 71-7/8 58-7/8
121 96 63 51 58 71-7/8 58-7/8
121 96 63 51 58 71-7/8 58-7/8
121 96 63 51 58 71-7/8 58-7/8
Figure A8-1. Model CEW Steam Boiler Dimensions (Page 1 of 2)
A8-6
10-02 12-02
Firetube Boilers
Model CEW
BOILER HP
DIM
125
150
200
250
300
350
400
500
600
700
750
800
HEIGHTS Base To Boiler Centerline Base To Vent Outlet Base to Rear Door Davit Base To Steam Outlet Base Frame Base to Bottom Boiler D O OA P Q R 46 85 86-1/2 82-3/8 12 16 46 85 86-1/2 82-3/8 12 16 46 85 86-1/2 82-3/8 12 16 56 106 106 101-1/2 10 17 56 106 106 101-1/2 10 17 56 106 106 101-1/2 10 17 56 106 106 101-1/2 10 17 67 126 126 122 12 19 67 126 126 122 12 19 67 126 126 122 12 19 67 126 126 122 12 19 67 126 126 122 12 19
CONNECTIONS Chemical Feed Feedwater Inlet (Both Sides) Steam Nozzle (15 psig)A Steam Nozzle (150 psig)
B
G S Y Y W W T BB CC
1 1-1/2 8 4 1-1/2 1-1/2 1 16 9-1/8
1 1-1/2 8 4 1-1/2 1-1/2 1 16 9-1/8
1 2 10 4 2 1-1/2 1 16 9-1/8
1 2 10 6 2 1-1/2 1 20 10-5/8
1 2 12 6 2 1-1/2 1 20 10-5/8
1 2-1/2 12 6 2 1-1/2 1 20 10-5/8
1 2-1/2 12 6 2 2 1 20 10-5/8
1 2-1/2 12 8 2 2 1 24 12-5/8
1 2-1/2 12 8 2 2 1 24 12-5/8
1 2-1/2 12 8 2 2 1 24 12-5/8
1 2-1/2 12 8 2 2 1 24 12-5/8
1 2-1/2 12 8 2 2 1 24 12-5/8
Drain - Front & Rear (15 psig) Blowdown - Front & Rear (150 psig) Surface Blowoff Vent Stack Diameter (Flanged) Flange to Center Vent
MISCELLANEOUS Rear Door Swing Tube Removal - Front Only Min. Boiler Room Length For Tube Removal Front Min. Boiler Room Length For Tube Removal Thru Door DD GG RF 36 124 318 36 147 364 36 195 460 46 128 342 46 152 390 46 177 440 46 202 490 54 171 445 54 206 515 54 242 586 54 242 586 54 242 586
RD
270
293
341
295
319
344
378
369
405
440
443
445
WEIGHTS Normal Water Weight Shipping Weight (15 psig) Shipping Weight (150 psig) Shipping Weight (200 psig) 6600 12150 12950 13600 8050 12950 14000 14900 11000 15600 16850 18200 11394 20300 21750 23600 13466 22450 24300 26400 15861 25250 26500 28860 17936 27650 28750 31380 21353 35800 38800 43550 25531 40950 43950 49400 29835 47850 50950 57150 29835 48250 51200 57150 29835 48250 51200 57150
NOTES: Accompanying dimensions, while sufciently accurate for layout purposes, must be conrmed for actual option requirements. A. 150 psig Flange. B. 300 psig Flange. C. Overall width may increase with the addition of electrical options due to control panel mounting.
Figure A8-1. Model CEW Steam Boiler Dimensions (Page 2 of 2)
A8-7
10-02 12-02
Model CEW
Firetube Boilers
RF/RD I
L
GG F K E LWCO T
B U Y BB CC
DD 4"
LWCO O OA S
(BOTH SIDES)
J P
Q
N M
R W C A RIGHT SIDE VIEW W H
FRONT VIEW
BOILER HP
DIM
125
150
200
250
300
350
400
500
600
700
750
800
LENGTHS Overall Shell Base Frame Base Rail to Rear Flange Flange To Return Flange to Outlet A B C H E F 201-3/4 158 166-3/4 19-1/8 100 125 224-3/4 181 189-3/4 19-1/8 123 148 272-3/4 216-7/16 240-7/16 265-7/16 229 237-3/4 19-1/8 171 196 168 179-1/2 22 108 134 192 203-1/2 22 132 158 WIDTHS OverallB I. D. Boiler Center to Lagging Center to LWCO Controller Base-Outside Base-Inside I J L K M N 70 60 33 37 52-1/2 44-1/2 70 60 33 37 52-1/2 44-1/2 70 60 33 37 52-1/2 44-1/2 88 78 42 46 64 56 88 78 42 46 64 56 88 78 42 46 64 56 88 78 42 46 64 56 106 96 51 55 71-7/8 58-7/8 106 96 51 55 71-7/8 58-7/8 106 96 51 55 71-7/8 58-7/8 106 96 51 55 71-7/8 58-7/8 106 96 51 55 71-7/8 58-7/8 217 228-1/2 22 157 183 300 242 225-7/8 22 182 208 282-1/2 219-3/4 203-3/4 22 133-3/4 169-3/4 319 254-3/4 238-3/4 22 156-3/4 192-3/4 354 289-3/4 273-3/4 22 203-3/4 239-3/4 356-7/8 289-3/4 273-3/4 22 203-3/4 239-3/4 359 289-3/4 273-3/4 22 203-3/4 239-3/4
Figure A8-2. Model CEW Hot Water Boiler Dimensions (Page 1 of 2)
A8-8
10-02 12-02
Firetube Boilers
Model CEW
BOILER HP
DIM
125
150
200
250
300
350
400
500
600
700
750
800
HEIGHTS Base To Boiler Centerline Base To Vent Outlet Base to Rear Door Davit Base to Return/Outlet Base Frame Base to Bottom Boiler D O OA P Q R 46 85 86-1/2 82-1/2 12 16 46 85 86-1/2 82-1/2 12 16 46 85 86-1/2 82-1/2 12 16 56 106 106 101-1/2 10 17 56 106 106 101-1/2 10 17 56 106 106 101-1/2 10 17 56 106 106 101-1/2 10 17 67 126 126 122 12 19 67 126 126 122 12 19 67 126 126 122 12 19 67 126 126 122 12 19 67 126 126 122 12 19
CONNECTIONS Waterll (Both Sides) Water Return Water OutletA Drain - Front & Rear Air Vent Vent Stack Dia (Flanged) Flange to Center Vent S U Y W T BB CC 1-1/2 6 6 1-1/2 1-1/2 16 9 1-1/2 6 6 1-1/2 1-1/2 16 9 2 6 6 2 1-1/2 16 9 2 8 8 2 1-1/2 20 10-1/2 2 8 8 2 1-1/2 20 10-1/2 2-1/2 8 8 2 1-1/2 20 10-1/2 2-1/2 10 10 2 1-1/2 20 10-1/2 2-1/2 10 10 2 2 24 12-5/8 2-1/2 12 12 2 2 24 12-5/8 2-1/2 12 12 2 2 24 12-5/8 2-1/2 12 12 2 2 24 12-5/8 2-1/2 12 12 2 2 24 12-5/8
MISCELLANEOUS Rear Door Swing Tube Removal - Front Only Min. Room Length for: Front Tube Removal Min. Room Length for: Tube Removal thru Door DD GG RF 36 124 318 36 147 364 36 195 460 46 128 342 46 152 390 46 177 440 46 202 490 54 171 445 54 206 515 54 242 586 54 242 586 54 242 586
RD
270
293
341
295
319
344
378
369
405
440
443
445
WEIGHTS Normal Water Weight (lbs) Shipping Weight (30 psig) Shipping Weight (125 psig 8625 12250 13050 10310 13050 14100 13960 15700 16950 14170 20400 21850 16770 22550 24400 19640 25350 26600 22140 27750 28850 28200 35900 38900 33690 41050 44300 39215 47950 51900 39215 48350 52000 39215 48350 52000
NOTES: Accompanying dimensions, while sufciently accurate for layout purposes, must be conrmed for actual option requirements. A. 2 dip tube in outlet. B. Overall width may increase with the addition of electrical options, due to control panel mounting.
Figure 8-2. Model CEW Hot Water Boiler Dimensions (Page 2 of 2)
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Model CEW
Firetube Boilers
BOILER HP 125-200 250-400 500-800
Figure A8-3. Space Required to Open Rear Head on Model CEW Boilers
BOILER HP 125 150 200 250 300 350 400 500 600 700,750, 800 Steam Hot Water Steam Hot Water Steam Hot Water Steam Hot Water Steam Hot Water Steam Hot Water Steam Hot Water Steam Hot Water Steam Hot Water Steam Hot Water
ALL DIMENSIONS IN INCHES A 80 80 80 99 99 99 99 119 119 119 B 19 19 19 25 25 25 25 29 29 29 C 121 144 192 114 138 163 188 158 193 228 D 10 10 10 10 10 10 10 11 11 11 E 3 3 3 3 3 3 3 3 3 3
NOTE: A, B and C dimensions may vary by 1 inch.
Figure A8-4. Model CEW Boilers Lifting Lug Location A8-10

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Firetube Boilers
Model CEW
BOILER HP 125 150 200 250 300 350 400 500 600 700, 750, 800
A 6 6 6 6 6 6 6 6 6 6
B 9 9 9 9 9 9 9 12 12 12
C 170 193 241 183 207 232 229 207 242 277
D 39-1/2 39-1/2 39-1/2 51 51 51 51 53-3/8 53-3/8 53-3/8
E 57-1/2 57-1/2 57-1/2 69 69 69 69 77-3/8 77-3/8 77-3/8
F 4 4 4 4 4 4 4 6-1/2 6-1/2 6-1/2
G 44-1/2 44-1/2 44-1/2 56 56 56 56 58-7/8 58-7/8 58-7/8
X 9-1/2 9-1/2 9-1/2 10-1/2 10-1/2 10-1/2 10-1/2 13-1/2 13-1/2 13-1/2
NOTE: All numbers in table are in inches. 6-inch high mounting piers recommended for use beneath the boiler base frame. The use of these piers provides increased inspection accessibility to the piping beneath the boiler and added height for washing down the area beneath the boiler.
Figure A8-5. Model CEW Boiler Mounting Piers
PERFORMANCE DATA
Contact your local Cleaver-Brooks authorized representative for efciencies or additional information. Cleaver-Brooks CEW boilers are available with the standard burner package, or optional induced ue gas recirculation. Refer to the Model CEW-LN in Section A9.
Boiler Information
Table A8-3 shows steam volume and disengaging area for model CEW boilers. Table A8-4 lists quantity and outlet size for safety valves supplied on Model CEW steam boilers. Table A8-5 lists quantity and outlet size for relief valves supplied on Model CEW hot water boilers. Table A8-6 gives recommended steam nozzle sizes on Model CEW Boilers. Table A8-7 shows recommended non-return valve sizes for Model CEW Boilers.
ENGINEERING DATA
The following engineering information is provided for Model CEW Boilers. Additional detail is available from your local Cleaver-Brooks authorized representative.
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Model CEW Blowdown Water Requirements

Some local codes require blowdown tanks to be constructed in accordance with recommendations of the National Board of Boiler and Pressure Vessel Inspectors. The National Boards recommendations base the size of the blowdown tank on the removal of at least 4 inches of water from the boiler. Table A8-8 lists the approximate quantity of water represented by 4 inches of water at normal operating level for CleaverBrooks Model CEW Boilers. Fuel Connections - Oil
Firetube Boilers
Oil-red burners are equipped with an oil pump, which draws fuel from a storage tank and supplies pressurized oil to the burner nozzle(s). The burner supply oil pump has a greater capacity than the burner requires for the maximum ring rate. Fuel not delivered to the nozzle is returned to the storage tank. A two-pipe (supply and return) oil system is recommended for all installations. Figure A8-6 shows a typical fuel oil supply arrangement. Oil lines must be sized for the burner and burner supply oil pump capacities. The burner supply oil pump suction should not exceed 10" Hg. If a transfer pump is used, it must have a pumping capacity at least equal to that of the burner pump(s). Supply pressure to the burner pump should not exceed 3 psig. A strainer must be installed in the supply piping upstream of the burner supply pump in order to prevent entry of foreign material into the pump, fuel control valves, or burner nozzle(s). The strainer must be sized for the burner supply pump capacity. A strainer mesh of 150 microns (0.005") is recommended. Install a check valve in the line to prevent draining of the oil suction line when the burner is not in operation. Location of the check valve varies with the system, but usually it is located as close as possible to the storage tank. Installation of a vacuum gauge in the burner supply line between the burner oil pump and the strainer is recommended. Regular observation and recording of the gauge indication will assist in determining when the strainer needs servicing. Upon completion of the oil piping installation, the system should be checked for oil or air leakage and tight shutoff of all valves.
Burner Characteristics Maximum altitude for standard burners is shown in Table A810. Note that altitude correction and burner changes are required for higher altitudes which may alter dimensions, motor hp and gas pressures. Gas-Fired Burners Table A8-10 shows correction factors for gas pressure at elevations over 700 ft above sea level. Table A8-11 shows minimum and maximum gas pressure requirements for Standard, FM and IRI CEW Boiler gas trains upstream of the gas pressure regulator. For oversized or undersized gas trains or altitude above 2,000 feet, contact your local Cleaver-Brooks authorized representative. Fuel Connections - Gas The local gas company should be consulted for requirements and authorization for installation and inspection of gas supply piping. Installation of gas supply piping and venting must be in accordance with all applicable engineering guidelines and regulatory codes. All connections made to the boiler should be arranged so that all components remain accessible for inspection, cleaning and maintenance. A drip leg should be installed in the supply piping before the connection to the gas pressure regulator. The drip leg should be at least as large as the inlet tting supplied with the boiler. Consideration must be given to both volume and pressure requirements when choosing gas supply piping size. Refer to the boiler dimension diagram provided by Cleaver-Brooks for the particular installation. Connections to the burner gas train should be made with a union, so that gas train components or the burner may be easily disconnected for inspection or service. Upon completion of the gas piping installation, the system should be checked for gas leakage and tight shutoff of all valves.


125 - 800 hp Model CEW Boilers can support up to 2000 lbs without additional support. 125 - 800 hp Model CEW Boilers can be reinforced to support up to 3000 lbs.

When determining boiler room air requirements, the size of the room, air ow, and velocity of air must be reviewed as follows: 1. Size (area) and location of air supply openings in boiler room. A. Two (2) permanent air supply openings in the outer walls of the boiler room are recommended. Locate one (1) at
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Firetube Boilers
each end of the boiler room, preferably below a height of 7 feet. This allows air to sweep the length of the boiler. B. Air supply openings can be louvered for weather protection, but they should not be covered with ne mesh wire, as this type of covering has poor air ow qualities and is subject to clogging by dust or dirt. C. A vent fan in the boiler room is not recommended, as it could create a slight vacuum under certain conditions and cause variations in the quantity of combustion air. This can result in unsatisfactory burner performance. D. Under no condition should the total area of the air supply openings be less than one (1) square foot. E. Size the openings by using the formula: Area (sq-ft) = CFM/FPM 2. Amount of air required (cfm). A. Combustion Air = Rated bhp x 8 cfm/bhp. B. Ventilation Air = Maximum bhp x 2 cfm/bhp or a total of 10 cfm/bhp - up to 1000 feet elevation. Add 3 percent more per 1000 feet of added elevation. 3. Acceptable air velocity in Boiler Room (fpm). A. From oor to (7) foot height - 250 fpm. B. Above (7) foot height - 500 fpm. Example: Determine the area of the boiler room air supply openings for (1) 300 hp boiler at 800 feet altitude. The air openings are to be 5 feet above oor level. Air required: 300 x 10 = 3000 cfm (from 2B above). Air velocity: Up to 7 feet = 250 fpm (from 3 above). Area Required: Area = cfm/fpm = 3000/250 = 12 Sq-ft total. Area/Opening: 12/2 = 6 sq-ft/opening (2 required).
Model CEW
For additional information, please review Section I4, General Engineering Data (Stacks) and Section F, Stacks. Stack and breeching sizes should always be provided by a reputable stack supplier who will design the stack and breeching system based on the above criteria. Your local Cleaver-Brooks authorized representative is capable of assisting in your evaluation of the stack/breeching design.
NOTICE

The design of the stack and breeching must provide the required draft at each boiler ue gas outlet. Proper draft is critical to burner performance. Although constant pressure at the ue gas outlet of the Model CEW is not required, it is necessary to size the stack/breeching to limit ue gas pressure variation. The allowable pressure range is 0.25 W.C. to +0.25 W.C.
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Model CEW
Firetube Boilers
Table A8-3. Model CEW Steam Volume and Disengaging Areas
BOILER HP 125 150 200 250 300 350 400 500 600 700,750, 800
STEAM VOLUME (CU-FT) HIGH PRESSURE (A) 21.5 25.1 32.8 33.9 39.6 45.5 51.5 94.4 111.9 129.5 LOW PRESSURE (B) 29.5 34.5 44.9 49.0 57.3 65.9 74.5 119.6 141.8 164.0
STEAM RELIEVING AREA (SQ-IN) HIGH PRESSURE (A) 5856 6850 8925 7732 9043 10396 11750 13809 16387 18950 LOW PRESSURE (B) 6388 7472 9734 8582 10022 11534 13032 14716 17438 20174
NOTE: Based on normal water level. Values are based on standard controls. Optional controls may result in different values. A. Based on 150 psig design pressure. B. Based on 15 psig design pressure.
Table A8-4. Model CEW Steam Boiler Safety Valve Outlet Size
VALVE SETTING BOILER HP 15 PSIG STEAM NO. OF VALVES REQ'D OUTLET SIZE (IN.) 150 PSIG STEAM NO. OF VALVES REQ'D OUTLET SIZE (IN.) 200 PSIG STEAM NO. OF VALVES REQ'D OUTLET SIZE (IN.) 250 PSIG STEAM NO. OF VALVES REQ'D OUTLET SIZE (IN.)
125 150 200 250 300 350 400 500 600 700,750, 800
1 1 2 2 2 3 3 3 4 5
3 3 2-1/2 (1) 2-1/2 (1) 3 3 (1) 2 (2) 3 (2) 3 (1) 2-1/2 3 (3) 3 (1) 2-1/2 (3) 3 (2) 2-1/2
2 2 2 2 2 2 2 2 3 3
(1) 1-1/2 (1) 1-1/4 (1) 1-1/2 (1) 1-1/4 1-1/2 (1) 2 (1)1-1/2 2 (1) 2-1/2 (1) 2 (1) 2-1/2 (1) 2 2-1/2 (2) 2-1/2 (1) 2 (2) 2-1/2 (1) 2
2 2 2 2 2 2 2 2 2 2
(1) 1-1/4 (1) 1 1-1/4 (1) 1-1/2 (1) 1-1/4 1-1/2 (1) 2 (1) 1-1/2 2 2 (1) 2-1/2 (1) 2 2-1/2 2-1/2
2 2 2 2 2 2 2 2 2 2
1 (1) 1 (1) 1-1/4 1-1/4 (1) 1-1/2 (1) 1-1/4 1-1/2 (1) 1-1/2 (1)2 (1) 1-1/2 (1) 2 2 (1) 2 (1) 2-1/2 2-1/2
NOTE: Valve manufacturers are Kunkle, Consolidated or Conbraco, depending on availability. Valve requirements can vary with special pressure settings.
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Firetube Boilers
Model CEW
Table A8-5. Model CEW Hot Water Boiler Relief Valve Outlet Size
VALVE SETTING BOILER HP 125 150 200 250 300 350 400 500 600 700,750,800 30 PSIG HW NO. OF VALVES REQ'D 1 1 2 2 2 3 3 4 4 5 OUTLET SIZE (IN.) 2-1/2 2-1/2 (1) 2-1/2 (1) 1-1/4 (1) 2 (1) 2-1/2 2-1/2 (2) 2-1/2 (1) 1 (1) 2 (2) 2-1/2 (1) 1 (3) 2-1/2 (3) 2-1/2 (1) 2 (1) 1 (4) 2-1/2 125 PSIG HW NO. OF VALVES REQ'D 1 1 1 1 1 1 1 2 2 2 OUTLET SIZE (IN.) 1-1/4 2 2 2 2-1/2 2-1/2 2-1/2 (1) 1 (1) 2-1/2 (1) 1-1/4 (1) 2-1/2 (1) 2-1/2 (1) 2 150 PSIG HW NO. OF VALVES REQ'D 1 1 1 1 1 1 1 1 2 2 OUTLET SIZE (IN.) 1-1/4 1-1/4 2 2 2 2-1/2 2-1/2 2-1/2 (1) 1 (1) 2-1/2 (1) 1-1/4 (1) 2-1/2
Table A8-6. Model CEW Recommended Steam Nozzle Size
BOILER HP OPERATING PRESSURE PSIG 15 30 40 50 75 100 125 150 200 250 125 8 6 6 6 4 4 4 3 2.5 2.5 150 8 6 6 6 4 4 4 3 3 2.5 200 10 8 6 6 6 6 4 4 4 3 250 10 8 8 6 6 6 6 4 4 4 300 12 8 8 8 6 6 6 6 4 4 350 12 10 8 8 8 6 6 6 4 4 400 12 10 10 8 8 6 6 6 6 4 500 12 10 10 8 8 8 8 6 6 6 600 12 12 10 10 8 8 8 6 6 6 700 12 12 12 10 10 8 8 8 6 6 750 12 12 12 12 10 8 8 8 6 6 800 12 12 12 12 10 10 8 8 6 6
NOTES: Steam nozzle sizes given in inches. Spool pieces (300 psig flanges) are available in the following sizes (in inches): 3x2-1/2x30, 4x3x30, 6x4x36, 8x6x48, 10x8x48, and 12x8x48. All standard steam nozzle sizes for the 150 psig design pressure or greater are the same as 125 psig operating pressure on the above table. To increase or decrease the standard size, request the change with your local Cleaver-Brooks authorized representative.
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Model CEW
Firetube Boilers
Table A8-7. Model CEW Recommended Non-Return Valve Size
BOILER HP 125 150 200 250 300 350 400 500 600 700 750 800
BOILER CAPACITY (LBS/HR) 4313 5175 6900 8625 10350 12025 13800 17210 20700 24150 25875 27600
OPERATING PRESSURES (PSIG) 50 4 4 4 4 6 6 6 6 8 8 8 8 75 3 4 4 4 4 6 6 6 8 8 8 8 100 3 3 4 4 4 4 4 6 6 6 6 6 125 3 3 3 4 4 4 4 6 6 6 6 6 150 3 3 3 3 4 4 4 4 6 6 6 6 175 2-1/2 3 3 3 4 4 4 4 4 6 6 6 200 2-1/2 2-1/2 3 3 4 4 4 4 4 6 6 6 250 2-1/2 2-1/2 3 3 3 3 4 4 4 6 6 6
Table A8-8. Model CEW Blowdown Tank Sizing Information

BOILER HP 125 150 200 250 300 350 400 500 600 700,750,800 WATER (GAL) 115 137 180 161 188 215 243 258 306 354
NOTE: Quantity of water removed from boiler by lowering normal water line 4". Optional level controls can alter water quantities.
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Firetube Boilers
Model CEW
Table A8-9. Model CEW Standard Burner Altitude
BOILER HP
125 150 200 250 300 350 400 500 600 700 750 800
MAX ALTITIUDE (FT)

3500 2500 1500 2000 2500 1000 2000 2000 2000 2000 2000 2000
Note: Altitude correction and burner changes required for higher altitude.
Table A8-10. Altitude Correction for Gas
ALTITUDE (FT) 1000 2000 3000 4000 5000
CORRECTION FACTOR 1.04 1.07 1.11 1.16 1.21
ALTITUDE (FT) 6000 7000 8000 9000 -
CORRECTION FACTOR 1.25 1.30 1.35 1.40 -
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Model CEW
Firetube Boilers
Table A8-11. Model CEW Minimum and Maximum Required Gas Pressure at Entrance to Standard, FM and IRI Gas Trains (Upstream of Gas Pressure Regulator)
BOILER HP
125 150 200 250 300 350 400 500 600 700 750 800
PIPE SIZE (Inches)

2 2 2-1/2 2-1/2 2-1/2 3 3 3 3 3 3 3
PRESSURE REQUIRED ( WC) Minimum

12.5 18.0 19.5 23.5 37.5 41.5 91.0 75.0 115.0 135.0 145.0 185.0
Maximum
27.7 27.7 27.7 27.7 277.0 277.0 140.0 210.0 160.0 175.0 225.0 277.0
Note: For undersized or oversized gas trains or altitudes above 1,000 feet, contact your local Cleaver-Brooks representative.
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Firetube Boilers
Model CEW
1. Shortest boiler room length (Dwg A) is obtained by allowing for possible future tube replacement (from front or rear of boiler) through a window or doorway. Allowance is only made for minimum door swing at each end of the boiler. This arrangement provides sufficient aisle space at the front of the boiler but a tight space condition at the rear. If space permits, approximately 1.5 additional feet should be allowed at the rear for additional aisle and working space. 2. Next shortest boiler room length (Dwg B) is obtained by allowing for possible future tube replacement from the front of the boiler. Allowance is only made for minimum door swing at the rear. If space permits, approximately 1.5 additional feet should be allowed at the rear for additional aisle and working space.
Figure A8-7. Boiler Room Length (Typical Layouts) - Model CEW
125-200 82 115
250-400 93 141
500-800 102 171
NOTES: 1. Recommended Minimum Distance Between Boiler and Wall. Dimension A allows for a clear 42" aisle between the water column on the boiler and the wall. If space permits, this aisle should be widened. 2. Recommended Minimum Distance Between Boilers. Dimension B between boilers allows for a clear aisle of: 42" - 125-200 hp 48" - 250-400 hp 60 - 500-800 hp If space permits, this aisle should be widened.
Figure A8-8. Boiler Room Width (Typical Layout) - Model CEW A8-19
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Model CEW
Firetube Boilers
Notes
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Firetube Boilers
Model CEW
The following sample specication is provided by Cleaver-Brooks to assist you in meeting your customers specic needs and application. The Sample Specications are typically utilized as the base template for the complete boiler specication. Contact your local Cleaver-Brooks authorized representative for information on special insurance requirements, special code requirements, optional equipment, or general assistance in completing the specication. Model CEW Steam Boiler (125 - 800 hp, 15 - 250 psig) 1.0 Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model CEW Hot Water Boiler (125 - 800 hp, 30 psig, 125 psig) 1.0 Boiler Characteristics (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Hot Water Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 Boiler Characteristics (Steam) 1.1 The Steam Boiler shall be Cleaver-Brooks Model CEW, Fuel Series ______ (100, 200, 700), _____ hp designed for _____ psig (15, 150, 200, 250 psig steam). The maximum operating pressure shall be _____ psig. 1.2 The boiler shall have a maximum output of _____ Btu/hr, or _____ horsepower when red with CS 12-48 No. 2 oil and/or natural gas, _____ Btu/cu-ft. Electrical power available will be _____ Volt _____ Phase _____ Cycle and 115/1/60 for the control circuit. 2.0 General Boiler Design 2.1 The boiler shall be a three pass wetback horizontal retube updraft boiler with ve (5) square feet of heating surface per rated boiler horsepower (except for the 750 and 800 hp). It shall be mounted on a heavy steel frame with forced draft burner and burner controls. 2.1.1 Approvals: The complete burner/boiler package shall be approved as a unit by Underwriters Laboratories Inc. and bear the UL, cUL label. 2.1.2 The boiler shall be completely preassembled and re tested at the factory. The unit shall be ready for immediate mounting on oor or simple foundation and ready for attachment of water, steam, fuel, electrical, vent and blowdown connections. 2.2 Boiler Shell (Steam) 2.2.1 The boiler shell must be constructed in accordance with ASME Boiler Code and must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser. 2.2.2 Two lifting eyes shall be located on top of the boiler. 2.2.3 Front and rear doors on the boiler shall be davited. A8-26 A8-26 A8-26 A8-27 A8-29 A8-29 A8-30 A8-21 A8-21 A8-22 A8-22 A8-25 A8-25 A8-25
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Model CEW
Firetube Boilers
2.2.4 The rear door shall be insulated with a blanket material and a steel covering to give the surface a hard durable nish. 2.2.5 The boiler tubes shall not include turbulators, swirlers or other add-on appurtenances. 2.2.6 The boiler shall be furnished with a manhole and handholes to facilitate boiler inspection and cleaning. 2.2.7 The exhaust gas vent shall be located near the rear of the boiler on the top center line and shall be capable of supporting 2000lbs. 2.2.8 Observation ports for the inspection of ame conditions shall be provided at each end of the boiler. 2.2.9 The boiler insulation shall consist of a 2 inch blanket under a sectional preformed sheet metal lagging. This insulation must be readily removable and capable of being reinstalled, if required. 2.2.10 The entire boiler based frame and other components shall be factory painted before shipment using a hard nish enamel coating. 3.0 Steam Boiler Trim 3.1 Water Column A water column shall be located on the right hand side of the boiler complete with gauge glass set and water column blowdown valves. 3.1.1 Feedwater Pump Control The boiler feedwater pump control shall be included as an integral part of the water column to automatically actuate a motor driven feed water pump maintaining the boiler water level within normal limits. 3.1.2 Low Water Cutoff The low water cutoff shall be included as an integral part of the boiler feedwater control wired into the burner control circuit to prevent burner operation if the boiler water level falls below a safe level. 3.2 Auxiliary Low Water Cutoff The auxiliary low water cutoff shall be included, piped to the vessel, and wired to the burner control circuit. A manual reset device shall be used for this control. 3.3 Steam Pressure Gauge The steam pressure gauge shall be located at the front of the boiler and include cock and test connection. 3.4 Safety Relief Valves Safety valves of a type and size to comply with ASME Code requirements shall be shipped loose. 3.5 Steam Pressure Controls The steam pressure controls to regulate burner operation shall be mounted near the water column. 4.0 Burner and Controls 4.1 Mode of Operation Burner operation shall be the full modulation principle. The burner shall always return to low re position for ignition. 4.2 Blower 4.2.1 All air for combustion shall be supplied by a forced draft blower mounted on the burner, to eliminate vibration and reduce noise level. 4.2.2 Maximum sound level of the boiler/burner package shall not exceed _____ dBA (when measured in accordance with ABMA Sound Test Standards). 4.2.3 The impeller shall be fabricated aluminum with radial blade, carefully balanced, and directly connected to the blower motor shaft.
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Firetube Boilers
4.3 Combustion Air Control
Model CEW
Combustion air damper and fuel control valve (125-350 hp) or cam operated fuel metering valve (400-800 hp) shall be operated by a single damper control motor that regulates the ame according to load demand. Potentiometer type position controls shall be provided to regulate operation of the damper control motor. 4.4 Fuel Specication and Piping Select one of the following fuel types: Fuel series 700 - Gas red (para 4.4.1). Fuel series 100 - Light oil (No. 2) red (para 4.4.2). Fuel series 200 - Light oil or gas red (para 4.4.3). 4.4.1 Fuel Series 700 - Gas Fired 4.4.1.1 Burner Type - The burner shall be mounted at the front of the boiler and be of high radiant multi-port type for gas. The burner shall be approved for operation on natural gas fuel. 4.4.1.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include one (1) shut-off valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only). 4.4.1.3 Gas Burner Piping - Select one of the following: A. 125 - 250 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. B. 300 - 350 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. C. 400 - 800 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, two (2) motorized gas valves and one (1) valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. 4.4.2 Fuel Series 100 - Light Oil Fired 4.4.2.1 Burner Type - The burner shall be mounted at the front of the boiler, and shall be approved for operation with CS12-48, Commercial No. 2 oil. 4.4.2.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include one (1) shut-off valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only). 4.4.2.3 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Select one of the following: A. 125 - 200 hp. Pump shall be an integral part of the burner and mechanically driven. B. 250 - 800 hp. Pump shall be motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided. 4.4.2.4 Oil Burner Piping - Select one of the following: A. 125 - 200 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, and pressure gauge all integrally mounted on the unit. B. 250 - 350 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, atomizing air proving switch, low oil pressure switch, and pressure gauge all integrally mounted on the unit.
A8-23
10-02
Model CEW
Firetube Boilers
C. 400 - 800 hp. Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one (1) motorized oil valve with proof of closure switch, pressure relief valve, atomizing air proving switch, and low oil pressure switch all integrally mounted on the unit. 4.4.2.5 Oil Atomization Type - Select one of the following: A. 125 - 200 hp. Burner shall include a complete mechanical oil atomizing system and be of the pressure atomizing type. B. 250 - 800 hp. Burner shall be a low pressure air atomizing type, including a shipped loose air compressor assembly. 4.4.3 Fuel Series 200 - Light Oil or Gas Fired 4.4.3.1 Burner Type - Select one of the following: A. 125 - 200 hp. The burner, mounted at the front of the boiler, shall be a combination pressure atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 oil or natural gas. B. 250 - 800 hp. The burner, mounted at the front of the boiler, shall be a combination of low pressure air atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 oil or natural gas. 4.4.3.2 Gas Pilot - The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary fuel valve cannot open until ame has been established. The pilot train shall include one (1) manual shut-off valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only). 4.4.3.3 Oil Burner 4.4.3.3.1 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Select one of the following: A. 125 - 200 hp. Pump shall be an integral part of the burner and mechanically driven. B. 250 - 800 hp. Pump shall be motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided. 4.4.3.3.2 Oil Burner Piping - Select one of the following: A. 125 - 200 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, and pressure gauge all integrally mounted on the unit. B. 250 - 350 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, atomizing air proving switch, low oil pressure switch and pressure gauge all integrally mounted on the unit. C. 400 - 800 hp. Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one (1) motorized oil valve with proof of closure switch, pressure relief valve, atomizing air proving switch, and low oil pressure switch all integrally mounted on the unit. 4.4.3.3.3 Oil Atomization Type - Select one of the following: A. 125 - 200 hp. Burner shall include a complete mechanical oil atomizing system and be of the pressure atomizing type. B. 250 - 800 hp. Burner shall be a low pressure air atomizing type, including a shipped loose air compressor assembly. 4.4.3.4 Gas Burner Piping - Select one of the following: A. 125 - 250 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. B. 300 - 350 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition.
A8-24
10-02
Firetube Boilers
Model CEW
C. 400 - 800 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, two (2) motorized gas valves and one (1) valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water or any abnormal shutdown condition. 4.5 Control Panel and Flame Safeguard Controller 4.5.1 Control Panel A factory prewired control panel shall be supplied with the boiler/burner package. Panel may be mounted on the burner or boiler. 4.5.2 The panel will have a NEMA 1A rating and contain the ame safeguard controller, burner motor starter, air compressor motor starter, oil metering pump motor starter, control circuit transformer and fuses, selector switches, indicating lights and terminal strips. Lights shall indicate load demand, ame failure, low water, and fuel valve open. 4.5.3 The panel shall contain fuse protection for the burner motor, air compressor motor, and oil metering pump. 4.5.4 The ame safeguard controller shall be a CB110 ame monitor with EPD170 program module. Flame detector shall be ultraviolet type. 5.0 Efciency Guarantee 5.1 The boiler must be guaranteed to operate at a minimum fuel-to-steam efciency of ____ percent at 100 percent of rating when burning natural gas and ________ fuel-to-steam efciency at 100% ring rate when burning oil (Contact your local CleaverBrooks authorized representative for efciency details). 6.0 Warranty 6.1 All equipment is to be guaranteed against defects in materials and/or workmanship for a period of 12 months from date of startup or 18 months from date of shipment, whichever comes rst. 7.0 Execution 7.1 Shop Tests 7.1.1 The packaged boiler must receive factory tests to check the construction, controls, and operation of the unit. All tests may be witnessed by the purchaser, if desired. 7.2 Start-up Service 7.2.1 After boiler installation is completed, the manufacturer shall provide the services of a eld representative for starting the unit and training the operator at no additional costs. 7.2.1.1 A factory approved and authorized start-up report shall be submitted to the customer/user at the time of start-up.
A8-25
10-02
Model CEW
Model CEW Hot Water Boiler (125 - 800 hp, 30 psig, 125 psig) 1.0 Boiler Characteristics (Hot Water)
Firetube Boilers
1.1 The Hot Water Boiler shall be Cleaver-Brooks Model CEW, Fuel Series ______ (100, 200, 700), _____ hp designed for _____ psig (30, 125, or other psig hot water). The maximum water temperature will be _____ degree F, and the maximum system temperature drop will be _____ degree F. 1.2 The boiler shall have a maximum output of _____ Btu/hr, or _____ horsepower when red with CS 12-48 No. 2 oil and/or natural gas, _____ Btu/cu-ft. Electrical power available will be _____ Volt _____ Phase _____ Cycle and 115/1/60 for the control circuit. 2.0 General Boiler Design 2.1 The boiler shall be a three pass wetback horizontal retube updraft boiler with ve (5) square feet of heating surface per rated boiler horsepower (except for the 750 and 800 hp.) It shall be mounted on a heavy steel frame with forced draft burner and burner controls. 2.1.1 Approvals: The complete burner/boiler package shall be approved as a unit by Underwriters Laboratories Inc. and bear the UL, cUL label. 2.1.2 The boiler shall be completely preassembled and re tested at the factory. The unit shall be ready for immediate mounting on oor or simple foundation and ready for attachment of water, steam, fuel, electrical, vent and blowdown connections. 2.2 Boiler Shell (Hot Water) 2.2.1 The boiler shell must be constructed in accordance with ASME Boiler Code and must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser. 2.2.2 The hot water return and outlet connections shall be located on the top center line of the boiler. The boiler shall be designed to rapidly mix the return water with the boiler water. Forced internal circulation shall be used. 2.2.3 A dip tube shall be included as an integral part of the water outlet. 2.2.4 Two lifting eyes shall be located on top of the boiler. 2.2.5 Front and rear doors on the boiler shall be davited. 2.2.6 The rear door shall be insulated with a blanket material and a steel covering to give the surface a hard durable nish. 2.2.7 The boiler tubes shall not include turbulators, swirlers or other add-on appurtenances. 2.2.8 The boiler shall be furnished with a manhole and handholes to faciliate boiler inspection and cleaning. 2.2.9 The exhaust gas vent shall be located near the rear of the boiler on the top center line and shall be capable of supporting 2000 lbs. 2.2.10 Observation ports for the inspection of ame conditions shall be provided at each end of the boiler. 2.2.11 The boiler insulation shall consist of a 2 inch blanket under a sectional preformed sheet metal lagging. This insulation must be readily removable and capable of being reinstalled, if required. 2.2.12 The entire boiler based frame and other components shall be factory painted before shipment using a hard nish enamel coating. 3.0 Hot Water Boiler Trim 3.1 Hot Water Connections The hot water outlet and return connections shall be located on the top center line of the boiler. The internal design of these connections shall provide forced internal circulation, mixing return water with the hot water within the boiler. 3.2 Dip Tube The dip tube, an integral part of the hot water outlet, and an air vent tapping in the boiler shell must be provided for removal of air.
A8-26
10-02
Firetube Boilers
3.3 Low Water Cutoff
Model CEW
A low water cutoff control shall be mounted on the top centerline of the boiler wired into the burner control circuit to prevent burner operation if boiler water falls below a safe level. A manual reset device shall be used on this control. 3.4 Pressure and Temperature Gauges Pressure and temperature gauges shall be mounted on the boiler with temperature sensing element located adjacent to the hot water outlet. 3.5 Relief Valves Water relief valves of a type and size to comply with ASME Code requirements shall be shipped loose. 3.6 Temperature Controls The temperature controls to regulate burner operation shall be mounted on the unit with temperature sensing elements located adjacent to the hot water outlet. 4.0 Burner and Controls 4.1 Mode of Operation Burner operation shall be the full modulation principle. The burner shall always return to low re position for ignition. 4.2 Blower 4.2.1 All air for combustion shall be supplied by a forced draft blower mounted on the burner, to eliminate vibration and reduce noise level. 4.2.2 Maximum sound level of the boiler/burner package shall not exceed _____ dBA (when measured in accordance with ABMA Sound Test Standards). 4.2.3 The impeller shall be fabricated aluminum with radial blade, carefully balanced, and directly connected to the blower motor shaft. 4.3 Combustion Air Control Combustion air damper and fuel control valve (125-350 hp) or cam operated fuel metering valve (400-800 hp) shall be operated by a single damper control motor that regulates the ame according to load demand. Potentiometer type position controls shall be provided to regulate operation of the damper control motor. 4.4 Fuel Specication and Piping Select one of the following fuel types: Fuel series 700 - Gas red (4.4.1). Fuel series 100 - Light oil (No. 2) red (4.4.2). Fuel series 200 - Light oil or gas red (4.4.3). 4.4.1 Fuel Series 700 - Gas Fired 4.4.1.1 Burner Type - The burner shall be mounted at the front of the boiler and of high radiant multi-port type for gas. The burner shall be approved for operation on natural gas fuel. 4.4.1.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include one (1) shut-off valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only). 4.4.1.3 Gas Burner Piping - Select one of the following: A. 125 - 250 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition.
A8-27
10-02
Model CEW
Firetube Boilers
B. 300 - 350 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. C. 400 - 800 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, two (2) motorized gas valves and one (1) valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. 4.4.2 Fuel Series 100 - Light Oil Fired 4.4.2.1 Burner Type - The burner shall be mounted at the front of the boiler, and shall be approved for operation with CS12-48, Commercial No. 2 oil. 4.4.2.2 Gas Pilot - The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary fuel valve cannot open until ame has been established. The pilot train shall include one (1) manual shut-off valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only). 4.4.2.3 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Select one of the following: A. 125 - 200 hp. Pump shall be an integral part of the burner and mechanically driven. B. 250 - 800 hp. Pump shall be motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided. 4.4.2.4 Oil Burner Piping - Select one of the following: A. 125 - 200 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, and pressure gauge all integrally mounted on the unit. B. 250 - 350 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, atomizing air proving switch, low oil pressure switch, and pressure gauge all integrally mounted on the unit. C. 400 - 800 hp. Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one (1) motorized oil valve with proof of closure switch, pressure relief valve, atomizing air proving switch, and low oil pressure switch all integrally mounted on the unit. 4.4.2.5 Oil Atomization Type - Select one of the following: A. 125 - 200 hp. Burner shall include a complete mechanical oil atomizing system and be of the pressure atomizing type. B. 250 - 800 hp. Burner shall be a low pressure air atomizing type, including a shipped loose air compressor assembly. 4.4.3 Fuel Series 200 - Light Oil or Gas Fired 4.4.3.1 Burner Type - Select one of the following: A. 125 - 200 hp. The burner, mounted at the front of the boiler, shall be a combination pressure atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 oil or natural gas. B. 250 - 800 hp. The burner, mounted at the front of the boiler, shall be a combination of low pressure air atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 oil or natural gas. 4.4.3.2 Gas Pilot - The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary fuel valve cannot open until ame has been established. The pilot train shall include one (1) manual shut-off valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only). 4.4.3.3 Oil Burner 4.4.3.3.1 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Select one A8-28
10-02
Firetube Boilers
of the following: A. 125 - 200 hp. Pump shall be an integral part of the burner and mechanically driven.
Model CEW
B. 250 - 800 hp. Pump shall be motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided. 4.4.3.3.2 Oil Burner Piping - Select one of the following: A. 125 - 200 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, and pressure gauge all integrally mounted on the unit. B. 250 - 350 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, atomizing air proving switch, low oil pressure switch and pressure gauge all integrally mounted on the unit. C. 400 - 800 hp. Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one (1) motorized oil valve with proof of closure switch, pressure relief valve, atomizing air proving switch, and low oil pressure switch all integrally mounted on the unit. 4.4.3.3.3 Oil Atomization Type - Select one of the following: A. 125 - 200 hp. Burner shall include a complete mechanical oil atomizing system and be of the pressure atomizing type. B. 250 - 800 hp. Burner shall be a low pressure air atomizing type, including a shipped loose air compressor assembly. 4.4.3.4 Gas Burner Piping - Select one of the following: A. 125 - 250 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. B. 300 - 350 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. C. 400 - 800 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, two (2) motorized gas valves and one (1) valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water or any abnormal shutdown condition. 4.5 Control Panel and Flame Safeguard Controller 4.5.1 Control Panel A factory prewired control panel shall be supplied with the boiler/burner package. Panel may be mounted on the burner or boiler. 4.5.2 The panel will have a NEMA 1A rating and contain the ame safeguard controller, burner motor starter, air compressor starter, oil metering pump motor starter, control circuit transformer and fuses, selector switches, indicating lights and terminal strips. Lights shall indicate load demand, ame failure, low water, and fuel valve open. 4.5.3 The panel shall contain fuse protection for the burner motor, air compressor motor, and the oil metering pump. 4.5.4 The ame safeguard controller shall be a CB110 ame monitor with EPD170 program module. Flame detector shall be ultraviolet type. 5.0 Efciency Guarantee 5.1 The boiler must be guaranteed to operate at a minimum fuel-to-water efciency of ____ percent at 100 percent of rating when burning natural gas and ________ fuel-to-steam efciency at 100% ring rate when burning oil (Contact your local Cleaver-Brooks authorized representative for efciency details). 6.0 Warranty 6.1 All equipment is to be guaranteed against defects in materials and/or workmanship for a period of 12 months from date of A8-29
10-02
Model CEW
start-up or 18 months from date of shipment, whichever comes rst. 7.0 Execution 7.1 Shop Tests
Firetube Boilers
A8-30
10-02
Section A9
Model CEW-LN Boilers
CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-3 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-3 DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-3 PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-11 ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-11 Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-11 Blowdown Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-11 Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-12 Burner/Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-12 BURNER CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-12 GAS FIRED - BURNERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-12 FUEL CONNECTIONS - GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-12 FUEL CONNECTIONS - OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-12 Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-12 Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-13 Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-13 Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-13 SAMPLE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-21 ILLUSTRATIONS Figure A9-1. Model CEW-LN Steam Boiler Dimensions (Page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-6 Figure A9-2. Model CEW-LN Hot Water Boiler Dimensions (Page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-8 Figure A9-3. Space Required to Open Rear Head on Model CEW-LN Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-10 Figure A9-4. Model CEW-LN Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-10
A9-1
10-02 12-02
Model CEW-LN
Firetube Boilers
Figure A9-5. Model CEW-LN Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-11 Figure A9-6 Typical Fuel Oil Supply Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-18 Figure A9-7. Boiler Room Length (Typical Layouts) - Model CEW-LN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-19 Figure A9-8. Boiler Room Width (Typical Layout) - Model CEW-LN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-19
TABLES Table A9-2. Model CEW-LN Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-5 Table A9-1. Model CEW-LN Hot Water Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-5 Table A9-3. Model CEW-LN Steam Volume and Disengaging Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-14 Table A9-4. Model CEW-LN Steam Boiler Safety Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-14 Table A9-5 .Model CEW-LN Hot Water Boiler Relief Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-15 Table A9-6. Model CEW-LN Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-15 Table A9-7. Model CEW-LN Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-16 Table A9-8. Model CEW-LN Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-16 Table A9-9. Sound Pressure Levels in dBA at 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-16 Table A9-10. Model CEW-LN Standard Burner Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-17 Table A9-11. Altitude Correction for Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-17 Table A9-12. Model CEW LN Minimum and Maximum Required Gas Pressure at Entrance to Standard, FM and IRI Gas Trains (Upstream of Gas Pressure Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-18
Available as an option to the model CEW retube wetback boiler (125-800 hp), the low NOx option provides maximum NOx reduction at all ring rates while maintaining top of the line boiler performance. The low NOx option is for 30 ppm on natural gas corrected to 3% O2
A9-2
10-02
Firetube Boilers
Model CEW-LN

The Cleaver-Brooks Model CEW-LN Boiler line provides a quality product utilizing a baseline boiler/burner design. In addition to the features of the Model CEW Boiler, the low NOx option of the CEW-LN provides the following: Burner Low NOx Package: UL and cUL approval. Guaranteed low nitrogen oxide (NOx) performance.
PRODUCT OFFERING
The Low NOx option currently is available on: 125 - 800 hp. 30 and 125 psig hot water. 15 - 250 psig steam. Natural gas, No. 2 oil, and combination red. For available option details contact your local Cleaver-Brooks authorized representative.

Dimensions and ratings for the Model CEW-LN Boilers are shown in the following tables and illustrations. The information is subject to change without notice. Table A9-1. Model CEW-LN Steam Boiler Ratings Table A9-2. Model CEW-LN Hot Water Boiler Ratings Figure A9-1. Model CEW-LN Steam Boiler Dimensions Figure A9-2. Model CEW-LN Hot Water Boiler Dimensions Figure A9-3. Model CEW-LN Boiler Space Requirements to Open Rear Head. Figure A9-4. Lifting Lug Location, Model CEW-LN Boilers Figure A9-5. Model CEW-LN Boiler Mounting Piers
A9-3
10-02
Model CEW-LN
Firetube Boilers
Notes
A9-4
10-02
Firetube Boilers
Table A9-1. Model CEW-LN Steam Boiler Ratings
BOILER HP 125 150 200 250 300 350 400 500 600
Model CEW-LN
700
750
800
RATINGS - SEA LEVEL TO 2000 FT Rated Capacity (lbs-steam/hr from and at 212 F) Btu Output (1000 Btu/hr) 4312 4184 5175 5021 6900 6695 8625 8369 10350 10043 12075 11716 13800 13390 17250 16738 20700 20085 24150 23433 25875 25106 27600 26780
APPROXIMATE FUEL CONSUMPTION AT RATED CAPACITY Light Oil GPH (140,000 Btu/gal) Gas CFH (1000 Btu/cu-ft) Gas (Therm/hr) 37.5 5230 52.3 45 6280 62.8 60 8370 83.7 74.5 10460 104.6 89.5 12555 125.5 104.5 14650 146.5 119.5 16750 167.5 149.5 20925 209.3 179.5 25100 251.0 209 29300 293.0 224 31385 313.9 239 33500 335.0
POWER REQUIREMENTS SEA LEVEL TO 2000 FT (60 HZ) Oil Pump Motor hp (oil ring only) Blower Motor
A
1/2 5 1 N/A
1/2 7-1/2 1 N/A
1/2 10 1 N/A
1/2 15 2 N/A
3/4 15 2 N/A
3/4 20 5 1/2
3/4 25 5 1/2
3/4 30 5 3/4
3/4 40 7-1/2 3/4
1 60 7-1/2 3/4
1 60 7-1/2 3/4
1 60 15 1
Air Compressor Motor (oil ring only) Oil Meter. Pump Mtr (oil ring only)
BOILER DATA Heating Surface sq-ft (Fireside) 625 750 1000 1250 1500 1750 2000 2500 3000 3500 3500 3500
NOTE:All fractional hp motors will be single phase voltage except oil meter pump motor(3-phase); integral hp motors will be 3-phase voltage. A. For altitudes over 2000 ft. contact your local Cleaver-Brooks representative for verication of motor hp.
Table A9-2. Model CEW-LN Hot Water Boiler Ratings

BOILER HP 125 150 200 250 300 350 400 500 600 700 750 800
RATINGS SEA LEVEL TO 2000 FT Btu Output (1000 Btu/hr) 4184 5021 6695 8369 10043 11716 13390 16738 20085 23433 25106 26780
APPROXIMATE FUEL CONSUMPTION AT RATED CAPACITY Light Oil gph (140,000 Btu/gal) Gas CFH (1000 Btu/cu-ft.) Gas (Therm/hr) 37.5 5230 52.3 45 6280 62.8 60 8370 83.7 74.5 10460 104.6 89.5 12555 125.5 104.5 14650 146.5 119.5 16750 167.5 149.5 20925 209.3 179.5 25100 251 209 29300 293 224 31385 313.8 239 33500 335
POWER REQUIREMENTS SEA LEVEL TO 2000 FT (60 HZ) Oil Pump Motor hp (oil ring only) Blower Motor
A
1/2 5 1 N/A
1/2 7-1/2 1 N/A
1/2 10 1 N/A
1/2 15 2 N/A
3/4 15 2 N/A
3/4 20 5 1/2
3/4 25 5 1/2
3/4 30 5 3/4
3/4 40 7-1/2 3/4
1 60 7-1/2 3/4
1 60 7-1/2 3/4
1 60 15 1
Air Compressor Motor (oil ring only) Oil Meter. Pump Mtr (oil ring only)
BOILER DATA Heating Surface sq-ft (Fireside) 625 750 1000 1250 1500 1750 2000 2500 3000 3500 3500 3500
NOTE:All fractional hp motors will be single phase voltage except oil meter pump motor(3-phase); integral hp motors will be 3-phase voltage. A. For altitudes over 2000 ft. contact your local Cleaver-Brooks representative for verication of motor hp.
A9-5
12-02 10-02
Model CEW-LN
Firetube Boilers
RF/RD DD 4" BB CC T Y B E GG
KK LL L
I K
(FAR SIDE)
G S
OO OA
(BOTH SIDES)
W H
R W
C
V
N M
A LEFT SIDE VIEW
FRONT VIEW
BOILER HP
DIM
125
150
200
250
300
350
400
500
600
700
750
800
LENGTHS Overall Shell Base Frame Base Frame to Rear Flange Flange to Nozzle A B C H E 206 158 144-3/4 19-1/8 56 229-1/2 181 167-3/4 19-1/8 72 272-1/2 229 215-3/4 19-1/8 108 223 168 151-7/8 22 70 247 192 175-7/8 22 90 275 217 200-7/8 22 108 305 242 225-7/8 22 118 284 219-3/4 203-3/4 22 100-3/4 319 254-3/4 238-3/4 22 110-3/4 356-7/8 289-3/4 273-3/4 22 127-1/4 359 289-3/4 273-3/4 22 127-1/4 364-1/2 289-3/4 273-3/4 22 127-1/4
WIDTHS Overall
C
I J K KK V L LL M N
92 60 47 45 6 33 40 52-1/2 44-1/2
92 60 47 45 6 33 40 52-1/2 44-1/2
92 60 47 45 6 33 40 52-1/2 44-1/2
110-1/2 78 56 54-1/2 6 42 49 64 56
111-1/2 78 56 55-1/2 8 42 49 64 56
111-1/2 78 56 55-1/2 8 42 49 64 56
111-1/2 78 56 55-1/2 8 42 49 64 56
132-1/2 96 65 67-1/2 8 51 58 71-7/8 58-7/8
133-1/2 96 65 68-1/2 10 51 58 71-7/8 58-7/8
133-1/2 96 65 68-1/2 10 51 58 71-7/8 58-7/8
133-1/2 96 65 68-1/2 10 51 58 71-7/8 58-7/8
133-1/2 96 65 68-1/2 10 51 58 71-7/8 58-7/8
I. D. Boiler Center to Control Panel Center to Outside FGR Pipe FGR Duct Size Center to Lagging Center to Auxiliary LWCO Base Outside Base Inside
Figure A9-1. Model CEW-LN Steam Boiler Dimensions (Page 1 of 2)
A9-6
10-02
12-02
Firetube Boilers
Model CEW-LN
BOILER HP
DIM
125
150
200
250
300
350
400
500
600
700
750
800
HEIGHTS Base To Boiler Centerline Base To Vent Outlet Base to rear Door Davit Base to Vent Extension Base To Steam Outlet Base Frame Base to Bottom Boiler D O OA OO P Q R 46 85 86-1/2 99 82-3/8 12 16 46 85 86-1/2 99 82-3/8 12 16 46 85 86-1/2 99 82-3/8 12 16 56 106 106 123 101-1/2 10 17 56 106 106 123 101-1/2 10 17 56 106 106 123 101-1/2 10 17 56 106 106 123 101-1/2 10 17 67 126 126 146 122 12 19 67 126 126 146 122 12 19 67 126 126 146 122 12 19 67 126 126 146 122 12 19 67 126 126 146 122 12 19
CONNECTIONS Chemical Feed Feedwater Inlet (Both Sides) Steam Nozzle (15 psig)A Steam Nozzle (150 psig)B Drain - Front & Rear (15 psig) Blowdown - Front & Rear (150 psig) Surface Blow (150 lb only) Vent Stack Diameter (Flanged) Flange to Center Vent G S Y Y W W T BB CC 1 1-1/2 8 4 1-1/2 1-1/2 1 16 9-1/8 1 1-1/2 8 4 1-1/2 1-1/2 1 16 9-1/8 1 2 10 4 2 1-1/2 1 16 9-1/8 1 2 10 6 2 1-1/2 1 20 10-5/8 1 2 12 6 2 1-1/2 1 20 10-5/8 1 2-1/2 12 6 2 1-1/2 1 20 10-5/8 1 2-1/2 12 6 2 2 1 20 10-5/8 1 2-1/2 12 8 2 2 1 24 12-5/8 1 2-1/2 12 8 2 2 1 24 12-5/8 1 2-1/2 12 8 2 2 1 24 12-5/8 1 2-1/2 12 8 2 2 1 24 12-5/8 1 2-1/2 12 8 2 2 1 24 12-5/8
MISCELLANEOUS Rear Door Swing Tube Removal - Front Only Min. Boiler Room Length For Tube Removal Front Min. Boiler Room Length For Tube Removal Thru Door DD GG RF 36 124 318 36 147 364 36 195 460 46 128 342 46 152 390 46 177 440 46 202 490 54 171 445 54 206 515 54 242 586 54 242 586 54 242 586
RD
274
298
341
301
325
353
383
370
405
443
445
451
WEIGHTS Normal Water Weight Shipping Weight (15 psig) Shipping Weight (150 psig) 6600 12150 12950 8050 12950 14000 11000 15600 16850 11394 20300 21750 13466 22450 24300 15861 25250 26500 17936 27650 28750 21353 35800 38800 25531 40950 43950 29835 47850 50950 29835 48250 51200 29835 48250 51200
NOTES: Accompanying dimensions, while sufciently accurate for layout purposes, must be conrmed for actual option requirements. A. 150 psig Flange. B. 300 psig Flange. C. Overall width may increase with the addition of electrical options, due to control panel mounting.
Figure A9-1. Model CEW-LN Steam Boiler Dimensions (Page 2 of 2)
A9-7
12-02 10-02
Model CEW-LN
Firetube Boilers
DD 4" BB CC
RF/RD B F Y
U
GG E LWCO
KK L
J P
(BOTH SIDES)
O S
D
OO OA
R W H C A LEFT SIDE VIEW W
V N M FRONT VIEW
BOILER HP
DIM
125
150
200
250
300 LENGTHS
350
400
500
600
700
750
800
Overall Shell Base Frame Base Rail to Rear Flange Flange To Return Flange to Outlet
A B C H E F
206 158 144-3/4 19-1/8 100 125
229-1/2 181 167-3/4 19-1/8 123 148
272-1/2 229 215-3/4 19-1/8 171 196
223 168 151-7/8 22 108 134
247 192 175-7/8 22 132 158 WIDTHS
275 217 200-7/8 22 157 183
305 242 225-7/8 22 182 208
284 219-3/4 203-3/4 22 133-3/4 169-3/4
319 254-3/4 238-3/4 22 156-3/4 192-3/4
356-7/8 289-3/4 273-3/4 22 203-3/4 239-3/4
359 289-3/4 273-3/4 22 203-3/4 239-3/4
364-1/2 289-3/4 273-3/4 22 203-3/4 239-3/4
Overall WidthB I. D. Boiler Center to Control Panel Center to Outside FGR Pipe FGR Duct Size Center to Lagging Base-Outside Base-Inside
I J K KK V L M N
92 60 47 45 6 33 52-1/2 44-1/2
92 60 47 45 6 33 52-1/2 44-1/2
92 60 47 45 6 33 52-1/2 44-1/2
110-1/2 78 56 54-1/2 6 42 64 56
111-1/2 78 56 55-1/2 8 42 64 56
111-1/2 78 56 55-1/2 8 42 64 56
111-1/2 78 56 55-1/2 8 42 64 56
132-1/2 96 65 67-1/2 8 51 71-7/8 58-7/8
133-1/2 96 65 68-1/2 10 51 71-7/8 58-7/8
133-1/2 96 65 68-1/2 10 51 71-7/8 58-7/8
133-1/2 96 65 68-1/2 10 51 71-7/8 58-7/8
133-1/2 96 65 68-1/2 10 51 71-7/8 58-7/8
Figure A9-2. Model CEW-LN Hot Water Boiler Dimensions (Page 1 of 2)
A9-8
10-02
12-02
Firetube Boilers
Model CEW-LN
BOILER HP
DIM
125
150
200
250
300
350
400
500
600
700
750
800
HEIGHTS Base To Boiler Centerline Base To Vent Outlet Base to Rear Door Davit Base to Vent Extension Base to Return/Outlet Base Frame Base to Bottom Boiler D O OA OO P Q R 46 85 86-1/2 99 82-1/2 12 16 46 85 86-1/2 99 82-1/2 12 16 46 85 86-1/2 99 82-1/2 12 16 56 106 106 123 101-1/2 10 17 56 106 106 123 101-1/2 10 17 56 106 106 123 101-1/2 10 17 56 106 106 123 101-1/2 10 17 67 126 126 146 122 12 19 67 126 126 146 122 12 19 67 126 126 146 122 12 19 67 126 126 146 122 12 19 67 126 126 146 122 12 19
CONNECTIONS Waterll (Both Sides) Water Return Water OutletA Drain - Front & Rear Air Vent Vent Stack Dia (Flanged) Flange to Center Vent S U Y W T BB CC 1-1/2 6 6 1-1/2 1-1/2 16 9 1-1/2 6 6 1-1/2 1-1/2 16 9 2 6 6 2 1-1/2 16 9 2 8 8 2 1-1/2 20 10-1/2 2 8 8 2 1-1/2 20 10-1/2 2-1/2 8 8 2 1-1/2 20 10-1/2 2-1/2 10 10 2 1-1/2 20 10-1/2 2-1/2 10 10 2 2 24 12-5/8 2-1/2 12 12 2 2 24 12-5/8 2-1/2 12 12 2 2 24 12-5/8 2-1/2 12 12 2 2 24 12-5/8 2-1/2 12 12 2 2 24 12-5/8
MISCELLANEOUS Rear Door Swing Tube Removal - Front Only Min. Room Length for: Front Tube Removal Min. Room Length for: Tube Removal thru Door DD GG RF 36 124 318 36 147 364 36 195 460 46 128 342 46 152 390 46 177 440 46 202 490 54 171 445 54 206 515 54 242 586 54 242 586 54 242 586
RD
274
298
341
301
325
353
383
370
405
443
445
451
WEIGHTS Normal Water Weight (lbs) Shipping Weight (30 psig) Shipping Weight (125 psig 8625 12250 13050 10310 13050 14100 13960 15700 16950 14170 20400 21850 16770 22550 24400 19640 25350 26600 22140 27750 28850 28200 35900 38900 33690 41050 44300 39215 47950 51900 39215 48350 52000 39215 48350 52000
NOTES: Accompanying dimensions, while sufciently accurate for layout purposes, must be conrmed for actual option requirements. A. 2 dip tube in outlet. B. Overall width may increase with the addition of electrical options, due to control panel mounting.
Figure A9-1. Model CEW-LN Hot Water Boiler Dimensions (Page 2 of 2)
A9-9
12-02 10-02
Model CEW-LN
Firetube Boilers
BOILER HP 125-200 250-400 500-800
Figure A9-3. Space Required to Open Rear Head on Model CEW-LN Boilers
BOILER HP 125 150 200 250 300 350 400 500 600 700,750, 800 Steam Hot Water Steam Hot Water Steam Hot Water Steam Hot Water Steam Hot Water Steam Hot Water Steam Hot Water Steam Hot Water Steam Hot Water Steam Hot Water
ALL DIMENSIONS IN INCHES A 80 80 80 99 99 99 99 119 119 119 B 19 19 19 25 25 25 25 29 29 29 C 121 144 192 114 138 163 188 158 193 228 D 10 10 10 10 10 10 10 11 11 11 E 3 3 3 3 3 3 3 3 3 3
NOTE: A, B and C dimensions may vary by 1 inch.
Figure A9-4. Model CEW-LN Boilers Lifting Lug Location A9-10

10-02 12-02
Firetube Boilers
Model CEW-LN
BOILER HP 125 150 200 250 300 350 400 500 600 700-800
A 6 6 6 6 6 6 6 6 6 6
B 9 9 9 9 9 9 9 12 12 12
C 148 171 219 155 179 204 229 207 242 277
D 39-1/2 39-1/2 39-1/2 51 51 51 51 53-3/8 53-3/8 53-3/8
E 57-1/2 57-1/2 57-1/2 69 69 69 69 77-3/8 77-3/8 77-3/8
F 4 4 4 4 4 4 4 6-1/2 6-1/2 6-1/2
G 44-1/2 44-1/2 44-1/2 56 56 56 56 58-7/8 58-7/8 58-7/8
X 9-1/2 9-1/2 9-1/2 10-1/2 10-1/2 10-1/2 10-1/2 13-1/2 13-1/2 13-1/2
NOTE: All numbers in table are in inches. 6-inch high mounting piers recommended for use beneath the boiler base frame. The use of these piers provides increased inspection accessibility to the piping beneath the boiler and added height for washing down the area beneath the boiler.
Figure A9-5. Model CEW-LN Boiler Mounting Piers
PERFORMANCE DATA
Contact your local Cleaver-Brooks authorized representative for efciencies or additional information.
Table A9-5 lists quantity and outlet size for relief valves supplied on Model CEW-LN hot water boilers. Table A9-6 gives recommended steam nozzle sizes based on 4000-5000 fpm steam velocity on Model CEW-LN Boilers. Table A9-7 shows recommended non-return valve sizes for Model CEW-LN Boilers.
ENGINEERING DATA
The following engineering information is provided for Model CEW-LN Firetube Boilers. Additional detail is available from your local Cleaver-Brooks authorized representative.

Some local codes require blowdown tanks to be constructed in accordance with recommendations of the National Board of Boiler and Pressure Vessel Inspectors. The National Boards recommendations base the size of the blowdown tank on the removal of at least 4 inches of water from the boiler. Table A9-8 lists the approximate quantity of water represented by 4 inches of water at normal operating level for Cleaver-Brooks Model CEW-LN Boilers. A9-11
Boiler Information
Table A9-3 shows steam volume and disengaging area for model CEW-LN boilers. Table A9-4 lists quantity and outlet size for safety valves supplied on Model CEW-LN steam boilers.
10-02
Model CEW-LN Sound Level

Table A9-9 summarizes predicted sound pressure levels for Model CEW-LN Boilers. These values are based on standard motors. Optional motor types and altitude conditions can increase sound levels. Units The units for the sound level tables are dBA (decibels, measured on the A-weighted scale) in reference to 0.0002 microbars (20 micro-Newtons per square meter). They are standardly referenced in specifying and reporting sound pressure levels on industrial equipment. Test Method The sound pressure levels in the above table were obtained from tests in accordance with the "ABMA Test Code for the Measurement of Sound from Packages Boilers. In accordance with this code, the sound pressure levels reported were measured on the boiler centerline 4-1/2 feet vertically above the bottom of the base rails and 3 feet horizontally in front of the end of the blower motor or front surface of the electrical cabinet. Sound Level Meter The sound level meter used complies with ANSI S1.4, Type 1 (Precision). The readings are taken with the meter set for slow response. tion, cleaning and maintenance.
Firetube Boilers
A drip leg should be installed in the supply piping before the connection to the gas pressure regulator. The drip leg should be at least as large as the inlet tting supplied with the boiler. Consideration must be given to both volume and pressure requirements when choosing gas supply piping size. Refer to the boiler dimension diagram provided by Cleaver-Brooks for the particular installation. Connections to the burner gas train should be made with a union, so that gas train components or the burner may be easily disconnected for inspection or service. Upon completion of the gas piping installation, the system should be checked for gas leakage and tight shutoff of all valves. Fuel Connections - Oil Oil-red burners are equipped with an oil pump, which draws fuel from a storage tank and supplies pressurized oil to the burner nozzle(s). The burner supply oil pump has a greater capacity than the burner requires for the maximum ring rate. Fuel not delivered to the nozzle is returned to the storage tank. A two-pipe (supply and return) oil system is recommended for all installations. Figure A9-6 shows a typical fuel oil supply arrangement. Oil lines must be sized for the burner and burner supply oil pump capacities. The burner supply oil pump suction should not exceed 10" Hg. If a transfer pump is used, it must have a pumping capacity at least equal to that of the burner pump(s). Supply pressure to the burner pump should not exceed 3 psig. A strainer must be installed in the supply piping upstream of the burner supply pump in order to prevent entry of foreign material into the pump, fuel control valves, or burner nozzle(s). The strainer must be sized for the burner supply pump capacity. A strainer mesh of 150 microns (0.005") is recommended. Install a check valve in the line to prevent draining of the oil suction line when the burner is not in operation. Location of the check valve varies with the system, but usually it is located as close as possible to the storage tank. Installation of a vacuum gauge in the burner supply line between the burner oil pump and the strainer is recommended. Regular observation and recording of the gauge indication will assist in determining when the strainer needs servicing. Upon completion of the oil piping installation, the system should be checked for oil or air leakage and tight shutoff of all valves.
Burner Characteristics Burner altitude limits for standard conguration is shown in Table A9-10. Higher altitudes may require different congurations, including dimensions, motor hp and gas pressures. Gas Fired - Burners Table A9-11 shows conversion factors for gas pressure at elevations over 700 ft. above sea level. Table A9-12 shows maximum and minimum gas consumption (CFH) for Natural Gas. For oversized or undersized gas trains or altitude above 1,000 feet, contact your local Cleaver-Brooks authorized representative. Fuel Connections - Gas The local gas company should be consulted for requirements and authorization for installation and inspection of gas supply piping. Installation of gas supply piping and venting must be in accordance with all applicable engineering guidelines and regulatory codes. All connections made to the boiler should be arranged so that all components remain accessible for inspec-

A9-12
10-02
Firetube Boilers
125 - 800 hp Model CEW-LN Boilers can support up to 2000 lbs without additional support. 125 - 800 hp Model CEW-LN Boilers can be reinforced to support up to 3000 lbs.
Model CEW-LN
Area/Opening: 12/2 = 6 sq-ft./opening (2 required).
NOTICE

When determining boiler room air requirements, the size of the room, air ow, and velocity of air must be reviewed as follows: 1. Size (area) and location of air supply openings in boiler room. A. Two (2) permanent air supply openings in the outer walls of the boiler room are recommended. Locate one (1) at each end of the boiler room, preferably below a height of 7 feet. This allows air to sweep the length of the boiler. B. Air supply openings can be louvered for weather protection, but they should not be covered with ne mesh wire, as this type of covering has poor air ow qualities and is subject to clogging by dust or dirt. C. A vent fan in the boiler room is not recommended, as it could create a slight vacuum under certain conditions and cause variations in the quantity of combustion air. This can result in unsatisfactory burner performance. D. Under no condition should the total area of the air supply openings be less than one (1) square foot. E. Size the openings by using the formula: Area (sq-ft.) = CFM/FPM 2. Amount of air required (cfm). A. Combustion Air = Rated bhp x 8 cfm/bhp. B. Ventilation Air = Maximum bhp x 2 cfm/bhp or a total of 10 cfm/bhp - up to 1000 feet elevation. Add 3 percent more per 1000 feet of added elevation. 3. Acceptable air velocity in Boiler Room (fpm). A. From oor to (7) foot height - 250 fpm. B. Above (7) foot height - 500 fpm. Example: Determine the area of the boiler room air supply openings for (1) 300 hp boiler at 800 feet altitude. The air openings are to be 5 feet above oor level. Air required: 300 x 10 = 3000 cfm (from 2B above). Air velocity: Up to 7 feet = 250 fpm (from 3 above). Area Required: Area = cfm/fpm = 3000/250 = 12 Sq-ft. total.

The design of the stack and breeching must provide the required draft at each boiler ue gas outlet. Proper draft is critical to burner performance. Although constant pressure at the ue gas outlet of the Model CEW-LN is not required, it is necessary to size the stack/breeching to limit ue gas pressure variation. The allowable pressure range is 0.25 W.C. to +0.25 W.C. For additional information, please review Section I4, General Engineering Data (Stacks) and Section F, Stacks. Stack and breeching sizes should always be provided by a reputable stack supplier who will design the stack and breeching system based on the above criteria. Your local Cleaver-Brooks authorized representative is capable of assisting in your evaluation of the stack/breeching design.
A9-13
10-02
Model CEW-LN
Firetube Boilers
Table A9-3. Model CEW-LN Steam Volume and Disengaging Areas

BOILER HP 125 150 200 250 300 350 400 500 600 700,750, 800 STEAM VOLUME (CU-FT) HIGH PRESSURE (A) 21.5 25.1 32.8 33.9 39.6 45.5 51.5 94.4 111.9 129.5 LOW PRESSURE (B) 29.5 34.5 44.9 49.0 57.3 65.9 74.5 119.6 141.8 164.0 STEAM RELIEVING AREA (SQ-IN) HIGH PRESSURE (A) 5856 6850 8925 7732 9043 10396 11750 13809 16387 18950 LOW PRESSURE (B) 6388 7472 9734 8582 10022 11534 13032 14716 17438 20174
Table A9-4. Model CEW-LN Steam Boiler Safety Valve Outlet Size
125 150 200 250 300 350 400 500 600 700,750, 800
1 1 2 2 2 3 3 3 4 5
3 3 2-1/2 (1) 2-1/2 (1) 3 3 (1) 2 (2) 3 (2) 3 (1) 2-1/2 3 (3) 3 (1) 2-1/2 (3) 3 (2) 2-1/2
2 2 2 2 2 2 2 2 3 3
(1) 1-1/2 (1) 1-1/4 (1) 1-1/2 (1) 1-1/4 1-1/2 (1) 2 (1)1-1/2 2 (1) 2-1/2 (1) 2 (1) 2-1/2 (1) 2 2-1/2 (2) 2-1/2 (1) 2 (2) 2-1/2 (1) 2
2 2 2 2 2 2 2 2 2 2
(1) 1-1/4 (1) 1 1-1/4 (1) 1-1/2 (1) 1-1/4 1-1/2 (1) 2 (1) 1-1/2 2 2 (1) 2-1/2 (1) 2 2-1/2 2-1/2
2 2 2 2 2 2 2 2 2 2
1 (1) 1 (1) 1-1/4 1-1/4 (1) 1-1/2 (1) 1-1/4 1-1/2 (1) 1-1/2 (1)2 (1) 1-1/2 (1) 2 2 (1) 2 (1) 2-1/2 2-1/2
A9-14
10-02
Firetube Boilers
Model CEW-LN
Table A9-5. Model CEW-LN Hot Water Boiler Relief Valve Outlet Size
VALVE SETTING BOILER HP 125 150 200 250 300 350 400 500 600 700,750,800 30 PSIG HW NO. OF VALVES REQ'D 1 1 2 2 2 3 3 4 4 5 OUTLET SIZE (IN.) 2-1/2 2-1/2 (1) 2-1/2 (1) 1-1/4 (1) 2 (1) 2-1/2 2-1/2 (2) 2-1/2 (1) 1 (1) 2 (2) 2-1/2 (1) 1 (3) 2-1/2 (3) 2-1/2 (1) 2 (1) 1 (4) 2-1/2 125 PSIG HW NO. OF VALVES REQ'D 1 1 1 1 1 1 1 2 2 2 OUTLET SIZE (IN.) 1-1/4 2 2 2 2-1/2 2-1/2 2-1/2 (1) 1 (1) 2-1/2 (1) 1-1/4 (1) 2-1/2 (1) 2-1/2 (1) 2 150 PSIG HW NO. OF VALVES REQ'D 1 1 1 1 1 1 1 1 2 2 OUTLET SIZE (IN.) 1-1/4 1-1/4 2 2 2 2-1/2 2-1/2 2-1/2 (1) 1 (1) 2-1/2 (1) 1-1/4 (1) 2-1/2
Table A9-6. Model CEW-LN Recommended Steam Nozzle Size

BOILER HP OPERATING PRESSURE PSIG 15 30 40 50 75 100 125 150 200 250 125 8 6 6 6 4 4 4 3 2.5 2.5 150 8 6 6 6 4 4 4 3 3 2.5 200 10 8 6 6 6 6 4 4 4 3 250 10 8 8 6 6 6 6 4 4 4 300 12 8 8 8 6 6 6 6 4 4 350 12 10 8 8 8 6 6 6 4 4 400 12 10 10 8 8 6 6 6 6 4 500 12 10 10 8 8 8 8 6 6 6 600 12 12 10 10 8 8 8 6 6 6 700 12 12 12 10 10 8 8 8 6 6 750 12 12 12 12 10 8 8 8 6 6 800 12 12 12 12 10 10 8 8 6 6
NOTE: Steam nozzle sizes given in inches. Spool pieces (300 psig flanges) are available in the following sizes (in inches): 3x2-1/2x30, 4x3x30, 6x4x36, 8x6x48, 10x8x48, and 12x8x48.
A9-15
10-02
Model CEW-LN
Firetube Boilers
Table A9-7. Model CEW-LN Recommended Non-Return Valve Size

BOILER HP 125 150 200 250 300 350 400 500 600 700 750 800 BOILER CAPACITY (LBS/HR) 4313 5175 6900 8625 10350 12025 13800 17210 20700 24150 25875 27600 OPERATING PRESSURES (PSIG) 50 4 4 4 4 6 6 6 6 8 8 8 8 75 3 4 4 4 4 6 6 6 8 8 8 8 100 3 3 4 4 4 4 4 6 6 6 6 6 125 3 3 3 4 4 4 4 6 6 6 6 6 150 3 3 3 3 4 4 4 4 6 6 6 6 175 2-1/2 3 3 3 4 4 4 4 4 6 6 6 200 2-1/2 2-1/2 3 3 4 4 4 4 4 6 6 6 250 2-1/2 2-1/2 3 3 3 3 4 4 4 6 6 6
Table A9-8. Model CEW-LN Blowdown Tank Sizing Information

BOILER HP 125 150 200 250 300 350 400 500 600 700,750,800 WATER (GAL) 115 137 180 161 188 215 243 258 306 354
Table A9-9. Sound Pressure Levels in dBA at 3

BOILER HP 125 150 200 250 300 350 GAS HIGH FIRE LOW FIRE 87 80 88 81 88 82 89 81 89 81 90 81 NO. 2 OIL HIGH FIRE LOW FIRE 87 81 89 81 89 80 90 81 90 81 91 82 91 82 92 82 92 83 93 83 93 84 95 86 90 81 91 81 91 82 93 83 93 83 93 85 400 500 600 700 750 800
A9-16
10-02
Firetube Boilers
Model CEW-LN
Table A9-10. Model CEW-LN Standard Burner Altitude

BOILER HP 125 150 200 250 300 350 400 500 600 700 750 800 MAX ALTITIUDE (FT) 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000
Note: Altitude correction and burner changes required for higher altitude.

A9-17
10-02
Model CEW-LN
Firetube Boilers
Table A9-12. Model CEW LN Minimum and Maximum Required Gas Pressure at Entrance to Standard, FM and IRI Gas Trains (Upstream of Gas Pressure Regulator)
PRESSURE REQUIRED (WC) Minimum 125 150 200 250 300 350 400 500 600 700 750 800 2 2-1/2 3 3 3 3 3 3 3 3 3 3 35.0 23.0 42.0 25.0 41.0 51.0 44.0 51.0 115.0 132.0 176.0 191.0 Maximum 138.0 27.7 138.0 27.7 138.0 138.0 138.0 138.0 166.0 221.0 263.0 277.0
BOILER HP
PIPE SIZE (Inches)
A9-18
10-02
Firetube Boilers
Model CEW-LN
Figure A9-7. Boiler Room Length (Typical Layouts) - Model CEW-LN
125-200 82 115
250-400 93 141
500-800 102 171
NOTES: 1. Recommended Minimum Distance Between Boiler and Wall. Dimension A allows for a clear 42" aisle between the water column on the boiler and the wall. If space permits, this aisle should be widened. 2. Recommended Minimum Distance Between Boilers. Dimension B between boilers allows for a clear aisle of: 42" - 125-200 hp 48" - 250-400 hp 60 - 500-800 hp If space permits, this aisle should be widened.
Figure A9-8. Boiler Room Width (Typical Layout) - Model CEW-LN A9-19
10-02
Model CEW-LN
Firetube Boilers
Notes
A9-20
10-02
Firetube Boilers
Model CEW-LN
The following sample specication is provided by Cleaver-Brooks to assist you in meeting your customers specic needs and application. The Sample Specication is typically utilized as the base template for the complete boiler specication. The LN option includes information on the Low NOx package for 30 ppm NOx (dry volume basis and corrected to 3% O2) when ring natural gas. Contact your local Cleaver-Brooks authorized representative for information on special insurance requirements, special code requirements, optional equipment, or general assistance in completing the specication. Model CEW-LN Steam Boiler (125 - 800 hp, 15 - 250 psig) 1.0 Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model CEW-LN Hot Water Boiler (125 - 800 hp, 30 psig, 125 psig) 1.0 Boiler Characteristics (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Hot Water Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 Boiler Characteristics (Steam) 1.1 The Steam Boiler shall be Cleaver-Brooks Model CEW-LN, Fuel Series ______ (100, 200, 700), _____ hp designed for _____ psig (15, 150, 200, 250 psig steam). The maximum operating pressure shall be _____ psig. 1.2 The boiler shall have a maximum output of _____ Btu/hr, or _____ horsepower when red with CS 12-48 No. 2 oil and/or natural gas, _____ Btu/cu-ft. Electrical power available will be _____ Volt _____ Phase _____ Cycle and 115/1/60 for the control circuit. 2.0 General Boiler Design 2.1 The boiler shall be a three pass wetback horizontal retube updraft boiler with ve (5) square feet of heating surface per rated boiler horsepower (except for the 750 and 800 hp). It shall be mounted on a heavy steel frame with forced draft burner and burner controls. 2.1.1 Approvals: The complete burner/ boiler Low NOx package shall be approved as a unit by Underwriters Laboratories Inc. and bear the UL/cUL label. 2.1.2 The boiler shall be completely preassembled and re tested at the factory. The unit shall be ready for immediate mounting on oor or simple foundation and ready for attachment of water, steam, fuel, electrical, vent and blowdown connections. 2.2 Boiler Shell (Steam) 2.2.1 The boiler shell must be constructed in accordance with ASME Boiler Code and must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser. 2.2.2 Two lifting eyes shall be located on top of the boiler. 2.2.3 Front and rear doors on the boiler shall be davited. 2.2.4 The rear door shall be insulated with a blanket material and a steel covering to give the surface a hard durable nish. A9-26 A9-26 A9-27 A9-27 A9-29 A9-29 A9-29 A9-21 A9-21 A9-22 A9-22 A9-25 A9-25 A9-25
A9-21
10-02
Model CEW-LN
2.2.5 The boiler tubes shall not include turbulators, swirlers or other add-on appurtenances.
Firetube Boilers
2.2.6 The boiler shall be furnished with a manhole and handholes to facilitate boiler inspection and cleaning. 2.2.7 The exhaust gas vent shall be located near the rear of the boiler on the top centerline and shall be capable of supporting 2000 lbs. 2.2.8 Observation ports for the inspection of ame conditions shall be provided at each end of the boiler. 2.2.9 The boiler insulation shall consist of a 2 inch blanket under a sectional preformed sheet metal lagging. This insulation must be readily removable and capable of being reinstalled, if required. 2.2.10 The entire boiler based frame and other components shall be factory painted before shipment using a hard nish enamel coating. 2.3 Emission Controls 2.3.1 Boiler shall be equipped with a low emission (LN) option for guaranteed NOx performance at 30 ppm, dry volume basis and corrected to 3% O2 when ring natural gas. 2.3.2 The low emission (LN) option shall include a burner and boiler package to provide NOx reduction through an induced ue gas recirculation system using the burner blower assembly, a control valve, a shutoff valve, electrical interlocks, and ue gas recirculation piping. Boiler fuel-to-steam efciency and rated boiler capacity shall be guaranteed while the boiler is operating at the low NOx performance levels. 2.3.3 Burner, boiler and low NOx system shall be manufactured as a package by a single manufacturer. The Low Nox option to the Cleaver-Brooks boiler shall include factory testing as a package, and the burner shall bear the UL or CSA label. 3.0 Steam Boiler Trim 3.1 Water Column A water column shall be located on the right hand side of the boiler complete with gauge glass set and water column blowdown valves. 3.1.1 Feedwater Pump Control The boiler feedwater pump control shall be included as an integral part of the water column to automatically actuate a motor driven feed water pump maintaining the boiler water level within normal limits. 3.1.2 Low Water Cutoff The low water cutoff shall be included as an integral part of the boiler feedwater control wired into the burner control circuit to prevent burner operation if the boiler water level falls below a safe level. 3.2 Auxiliary Low Water Cutoff The auxiliary low water cutoff shall be included, piped to the vessel, and wired to the burner control circuit. A manual reset device shall be used for this control. 3.3 Steam Pressure Gauge The steam pressure gauge shall be located at the front of the boiler and include cock and test connection. 3.4 Safety Relief Valves Safety valves of a type and size to comply with ASME Code requirements shall be shipped loose. 3.5 Steam Pressure Controls The steam pressure controls to regulate burner operation shall be mounted near the water column. 4.0 Burner and Controls 4.1 Mode of Operation
A9-22
10-02
Firetube Boilers
Model CEW-LN
Burner operation shall be the full modulation principle. The burner shall always return to low re position for ignition. 4.2 Blower 4.2.1 All air for combustion shall be supplied by a forced draft blower mounted on the burner, to eliminate vibration and reduce noise level. 4.2.2 Maximum sound level of the boiler/burner package shall not exceed _____ dBA (when measured in accordance with ABMA Sound Test Standards). 4.2.3 The impeller shall be fabricated aluminum with radial blade, carefully balanced, and directly connected to the blower motor shaft. 4.3 Combustion Air Control Combustion air damper and fuel control valve shall be operated by a single damper control motor that regulates the ame according to load demand. Potentiometer type position controls shall be provided to regulate operation of the damper control motor. 4.4 Fuel Specication and Piping Select one of the following fuel types: Fuel series 700 - Gas red (para 4.4.1). Fuel series 100 - Light oil (No. 2) red (para 4.4.2). Fuel series 200 - Light oil or gas red (para 4.4.3). 4.4.1 Fuel Series 700 - Gas Fired 4.4.1.1 Burner Type - The burner shall be mounted at the front of the boiler and be of high radiant multi-port type for gas. The burner shall be approved for operation on natural gas fuel. 4.4.1.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include one (1) shut-off valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only). 4.4.1.3 Gas Burner Piping - Select one of the following: A. 125 - 250 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. B. 300 - 800 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, two (2) motorized gas valves and one (1) valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. 4.4.2 Fuel Series 100 - Light Oil Fired 4.4.2.1 Burner Type - The burner shall be mounted at the front of the boiler, and shall be approved for operation with CS12-48, Commercial No. 2 oil. 4.4.2.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include one (1) shut-off valve, solenoid vale, pressure regulator, and one (1) plugged leakage test connection (Canada only). 4.4.2.3 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Pump shall be motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided. 4.4.2.4 Oil Burner Piping - Select one of the following: A. 125 - 350 hp. Fuel oil piping on the unit shall include oil metering system, two (2) solenoid oil shut-off valves, pressure relief valve, and atomizing air proving switch all integrally mounted on the unit.
A9-23
10-02
Model CEW-LN
Firetube Boilers
B. 400 - 800 hp. Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one (1) motorized oil valve with proof of closure switch, pressure relief valve, atomizing air proving switch, and low oil pressure switch all integrally mounted on the unit. 4.4.2.5 Oil Atomization Type - Select one of the following: A. 125 - 300 hp. Burner shall be a low pressure air atomizing type, including a burner mounted integral air compressor. B. 350 - 800 hp. Burner shall be a low pressure air atomizing type, including a shipped loose air compressor assembly. 4.4.3 Fuel Series 200 - Light Oil or Gas Fired 4.4.3.1 Burner Type - The burner, mounted at the front of the boiler, shall be a combination of low pressure air atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 oil or natural gas. 4.4.3.2 Gas Pilot - The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary fuel valve cannot open until ame has been established. The pilot train shall include one (1) manual shut-off valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only). 4.4.3.3 Oil Burner 4.4.3.3.1 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Pump shall be motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided. 4.4.3.3.2 Oil Burner Piping - Select one of the following: A. 125 - 350 hp. Fuel oil piping on the unit shall include oil metering system, two (2) solenoid oil shut-off valves, pressure relief valve, and atomizing air proving switch all integrally mounted on the unit. B. 400 - 800 hp. Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one (1) motorized oil valve with proof of closure switch, pressure relief valve, atomizing air proving switch, and low oil pressure switch all integrally mounted on the unit. 4.4.3.3.3 Oil Atomization Type - Select one of the following: A. 125 - 300 hp. Burner shall be a low pressure air atomizing type, including a burner mounted integral air compressor. B. 350 - 800 hp. Burner shall be a low pressure air atomizing type, including a shipped loose air compressor assembly. 4.4.3.4 Gas Burner Piping - Select one of the following: A. 125 - 250 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. B. 300 - 800 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, two (2) motorized gas valves and one (1) valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water or any abnormal shutdown condition. 4.5 Control Panel and Flame Safeguard Controller 4.5.1 Control Panel A factory prewired control panel shall be supplied with the boiler/burner package. Panel may be mounted on the burner or boiler. 4.5.2 The panel will have a NEMA 1A rating and contain the ame safeguard controller, burner motor starter, air compressor motor starter, oil metering pump motor starter, control circuit transformer and fuses, selector switches, indicating lights and terminal strips. Lights shall indicate load demand, ame failure, low water, and fuel valve open. 4.5.3 The panel shall contain fuse protection for blower motor, air compressor, and oil metering pump. 4.5.4 The ame safeguard controller shall be a CB110 ame monitor with EPD170 program module. Flame detector shall be ultraviolet type. A9-24
10-02
Firetube Boilers
5.0 Efciency Guarantee
Model CEW-LN
5.1 The boiler must be guaranteed to operate at a minimum fuel-to-steam efciency of ____ percent at 100 percent of rating when burning natural gas and ________ fuel-to-steam efciency at 100% ring rate when burning oil (Contact your local CleaverBrooks authorized representative for efciency details). 6.0 Warranty 6.1 All equipment is to be guaranteed against defects in materials and/or workmanship for a period of 12 months from date of startup or 18 months from date of shipment, whichever comes rst. 7.0 Execution 7.1 Shop Tests 7.1.1 The packaged boiler must receive factory tests to check the construction, controls, and operation of the unit. All tests may be witnessed by the purchaser, if desired. 7.2 Start-up Service 7.2.1 After boiler installation is completed, the manufacturer shall provide the services of a eld representative for starting the unit and training the operator at no additional costs. 7.2.1.1 A factory approved and authorized start-up report shall be submitted to the customer/user at the time of start-up.
A9-25
10-02
Model CEW-LN
Model CEW-LN Hot Water Boiler (125 - 800 hp, 30 psig, 125 psig) 1.0 Boiler Characteristics (Hot Water)
Firetube Boilers
1.1 The Hot Water Boiler shall be Cleaver-Brooks Model CEW-LN, Fuel Series ______ (100, 200, 700), _____ hp designed for _____ psig (30, 125, or other psig hot water). The maximum water temperature will be _____ degree F, and the maximum system temperature drop will be _____ degree F. 1.2 The boiler shall have a maximum output of _____ Btu/hr, or _____ horsepower when red with CS 12-48 No. 2 oil and/or natural gas, _____ Btu/cu-ft. Electrical power available will be _____ Volt _____ Phase _____ Cycle and 115/1/60 for the control circuit. 2.0 General Boiler Design 2.1 The boiler shall be a three pass wetback horizontal retube updraft boiler with ve (5) square feet of heating surface per rated boiler horsepower (except for the 750 and 800 hp.) It shall be mounted on a heavy steel frame with forced draft burner and burner controls. 2.1.1 Approvals: The complete burner/ boiler Low NOx package shall be approved as a unit by Underwriters Laboratories Inc. and bear the UL/cUL label. 2.1.2 The boiler shall be completely preassembled and re tested at the factory. The unit shall be ready for immediate mounting on oor or simple foundation and ready for attachment of water, steam, fuel, electrical, vent and blowdown connections. 2.2 Boiler Shell (Hot Water) 2.2.1 The boiler shell must be constructed in accordance with ASME Boiler Code and must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser. 2.2.2 The hot water return and outlet connections shall be located on the top center line of the boiler. The boiler shall be designed to rapidly mix the return water with the boiler water. Forced internal circulation shall be used. 2.2.3 A dip tube shall be included as an integral part of the water outlet. 2.2.4 Two lifting eyes shall be located on top of the boiler. 2.2.5 Front and rear doors on the boiler shall be davited. 2.2.6 The rear door shall be insulated with a blanket material and a steel covering to give the surface a hard durable nish. 2.2.7 The boiler tubes shall not include turbulators, swirlers or other add-on appurtenances. 2.2.8 The boiler shall be furnished with a manhole and handholes to faciliate boiler inspection and cleaning. 2.2.9 The exhaust gas vent shall be located near the rear of the boiler on the top centerline and shall be capable of supporting 2000 lbs. 2.2.10 Observation ports for the inspection of ame conditions shall be provided at each end of the boiler. 2.2.11 The boiler insulation shall consist of a 2 inch blanket under a sectional preformed sheet metal lagging. This insulation must be readily removable and capable of being reinstalled, if required. 2.2.12 The entire boiler based frame and other components shall be factory painted before shipment using a hard nish enamel coating. 2.3 Emission Controls 2.3.1 Boiler shall be equipped with a low emission (LN) option for guaranteed NOx performance at 30 ppm, dry volume basis and corrected to 3% O2 when ring natural gas. 2.3.2 The low emission (LN) option shall include a burner and boiler package to provide NOx reduction through an induced ue gas recirculation system using the burner blower assembly, a control valve, a shutoff valve, electrical interlocks, and ue gas recirculation piping. Boiler fuel-to-water efciency and rated boiler capacity shall be guaranteed while the boiler is operating at the low NOx performance levels.
A9-26
10-02
Firetube Boilers
Model CEW-LN
2.3.3 Burner, boiler and low NOx system shall be manufactured as a package by a single manufacturer. The Low NOx option to the Cleaver-Brooks boiler shall include factory testing as a package, and the burner shall bear the UL or CSA label. 3.0 Hot Water Boiler Trim 3.1 Hot Water Connections The hot water outlet and return connections shall be located on the top center line of the boiler. The internal design of these connections shall provide forced internal circulation, mixing return water with the hot water within the boiler. 3.2 Dip Tube The dip tube, an integral part of the hot water outlet, and an air vent tapping in the boiler shell must be provided for removal of air. 3.3 Low Water Cutoff A low water cutoff control shall be mounted on the top centerline of the boiler wired into the burner control circuit to prevent burner operation if boiler water falls below a safe level. A manual reset device shall be used on this control. 3.4 Pressure and Temperature Gauges Pressure and temperature gauges shall be mounted on the boiler with temperature sensing element located adjacent to the hot water outlet. 3.5 Relief Valves Water relief valves of a type and size to comply with ASME Code requirements shall be shipped loose. 3.6 Temperature Controls The temperature controls to regulate burner operation shall be mounted on the unit with temperature sensing elements located adjacent to the hot water outlet. 4.0 Burner and Controls 4.1 Mode of Operation Burner operation shall be the full modulation principle. The burner shall always return to low re position for ignition. 4.2 Blower 4.2.1 All air for combustion shall be supplied by a forced draft blower mounted on the burner, to eliminate vibration and reduce noise level. 4.2.2 Maximum sound level of the boiler/burner package shall not exceed _____ dBA (when measured in accordance with ABMA Sound Test Standards). 4.2.3 The impeller shall be fabricated aluminum with radial blade, carefully balanced, and directly connected to the blower motor shaft. 4.3 Combustion Air Control Combustion air damper and fuel control valve shall be operated by a single damper control motor that regulates the ame according to load demand. Potentiometer type position controls shall be provided to regulate operation of the damper control motor. 4.4 Fuel Specication and Piping Select one of the following fuel types: Fuel series 700 - Gas red (4.4.1). Fuel series 100 - Light oil (No. 2) red (4.4.2). Fuel series 200 - Light oil or gas red (4.4.3). 4.4.1 Fuel Series 700 - Gas Fired
A9-27
10-02
Model CEW-LN
Firetube Boilers
4.4.1.1 Burner Type - The burner shall be mounted at the front of the boiler and of high radiant multi-port type for gas. The burner shall be approved for operation on natural gas fuel. 4.4.1.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include one (1) shut-off valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only). 4.4.1.3 Gas Burner Piping - Select one of the following: A. 125 - 250 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. B. 300 - 800 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, two (2) motorized gas valves and one (1) valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. 4.4.2 Fuel Series 100 - Light Oil Fired 4.4.2.1 Burner Type - The burner shall be mounted at the front of the boiler, and shall be approved for operation with CS12-48, Commercial No. 2 oil. 4.4.2.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include one (1) shut-off valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only). 4.4.2.3 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Pump shall be motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided. 4.4.2.4 Oil Burner Piping - Select one of the following: A. 125 - 350 hp. Fuel oil piping on the unit shall include oil metering system, two (2) solenoid oil shut-off valves, pressure relief valve, and atomizing air proving switch all integrally mounted on the unit. B. 400 - 800 hp. Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one (1) motorized oil valve with proof of closure switch, pressure relief valve, atomizing air proving switch, and low oil pressure switch all integrally mounted on the unit. 4.4.2.5 Oil Atomization Type - Select one of the following: A. 125 - 300 hp. Burner shall be a low pressure air atomizing type, including a burner mounted integral air compressor. B. 350 - 800 hp. Burner shall be a low pressure air atomizing type, including a shipped loose air compressor assembly. 4.4.3 Fuel Series 200 - Light Oil or Gas Fired 4.4.3.1 Burner Type - The burner, mounted at the front of the boiler, shall be a combination of low pressure air atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 oil or natural gas. 4.4.3.2 Gas Pilot - The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary fuel valve cannot open until ame has been established. The pilot train shall include one (1) manual shut-off valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only). 4.4.3.3 Oil Burner 4.4.3.3.1 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Pump shall be motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided. 4.4.3.3.2 Oil Burner Piping - Select one of the following: A. 125 - 350 hp. Fuel oil piping on the unit shall include oil metering system, two (2) solenoid oil shut-off valves, pressure
A9-28
10-02
Firetube Boilers
relief valve, and atomizing air proving switch all integrally mounted on the unit.
Model CEW-LN
B. 400 - 800 hp. Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one (1) oil motorized oil valve with proof of closure switch, pressure relief valve, atomizing air proving switch, and low oil pressure switch all integrally mounted on the unit. 4.4.3.3.3 Oil Atomization Type - Select one of the following: A. 125 - 300 hp. Burner shall be a low pressure air atomizing type, including a burner mounted integral air compressor. B. 350 - 800 hp. Burner shall be a low pressure air atomizing type, including a shipped loose air compressor assembly. 4.4.3.4 Gas Burner Piping - Select one of the following: A. 125 - 250 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. B. 300 - 800 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, two (2) motorized gas valves and one (1) valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water or any abnormal shutdown condition. 4.5 Control Panel and Flame Safeguard Controller 4.5.1 Control Panel A factory prewired control panel shall be supplied with the boiler/burner package. Panel may be mounted on the burner or boiler. 4.5.2 The panel will have a NEMA 1A rating and contain the ame safeguard controller, burner motor starter, air compressor motor starter, oil metering pump motor starter, control circuit transformer and fuses, selector switches, indicating lights and terminal strips. Lights shall indicate load demand, ame failure, low water, and fuel valve open. 4.5.3 The panel shall contain fuse protection for blower motor, air compressor motor, and oil metering pump. 4.5.4 The ame safeguard controller shall be a CB110 ame monitor with EPD170 program module. Flame detector shall be ultraviolet type. 5.0 Efciency Guarantee 5.1 The boiler must be guaranteed to operate at a minimum fuel-to-water efciency of ____ percent at 100 percent of rating when burning natural gas and ________ fuel-to-steam efciency at 100% ring rate when burning oil (Contact your local Cleaver-Brooks authorized representative for efciency details). 6.0 Warranty 6.1 All equipment is to be guaranteed against defects in materials and/or workmanship for a period of 12 months from date of start-up or 18 months from date of shipment, whichever comes rst. 7.0 Execution 7.1 Shop Tests 7.1.1 The packaged boiler must receive factory tests to check the construction, controls, and operation of the unit. All tests may be witnessed by the purchaser, if desired. 7.2 Start-up Service 7.2.1 After boiler installation is completed, the manufacturer shall provide the services of a eld representative for starting the unit and training the operator at no additional costs. 7.2.1.1 A factory approved and authorized start-up report shall be submitted to the customer/user at the time of start-up.
A9-29
10-02
Model CEW-LN
Firetube Boilers
Notes
A9-30
10-02
Section A10
Model CEW Ohio Special Boilers
CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-3 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-3 DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-4 PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-9 ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-9 Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-9 Blowdown Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-10 Burner/Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-10 BURNER CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-10 GAS - FIRED BURNERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-10 FUEL CONNECTIONS - GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-10 FUEL CONNECTIONS - OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-10 Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-10 Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-10 Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-10 Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-11 SAMPLE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-17 ILLUSTRATIONS Figure A10-1. Model CEW Ohio Special Steam Boiler Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A10-2. Space Required to Open Rear Head on Model CEW Ohio Special Boilers . . . . . . . . . . . . . . . . . . . . . . . Figure A10-3. Model CEW Ohio Special Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure A10-4. Model CEW Ohio Special Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A10-6 A10-8 A10-8 A10-9
A10-1
02-02
Model CEW Ohio Special
Firetube Boilers
Figure A10-5. Typical Fuel Oil Supply Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-15 Figure A10-6. Boiler Room Length (Typical Layouts) - Model CEW Ohio Special . . . . . . . . . . . . . . . . . . . . . . . . . . A10-16 Figure A10-7. Boiler Room Width (Typical Layout) - Model CEW Ohio Special . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-16
TABLES Table A10-1. Model CEW Ohio Special Steam Boiler Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-5 Table A10-2. Model CEW Ohio Special Steam Volume and Disengaging Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-12 Table A10-3. Model CEW Ohio Special Steam Boiler Safety Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-12 Table A10-4. Model CEW Ohio Special Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-13 Table A10-5. Model CEW Ohio Special Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-13 Table A10-6. Model CEW Ohio Special Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-14 Table A10-7. Altitude Correction for Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-14 Table A10-8. Model CEW Ohio Special Minimum and Maximum Required Gas Pressure at Entrance to Standard, FM and IRI Gas Trains (Upstream of Gas Pressure Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-15
The following information applies to the Cleaver-Brooks Model CEW Ohio Special Boiler.
A10-2
02-02
Firetube Boilers

Surge load bafes. Seismic design. Burner/Control Options: Flame safeguard controllers. Lead/lag system. Special insurance and code requirements (e.g., IRI, FM, CSD-1). Alarm bell/silence switch.

The Model CEW Ohio Special Firetube boiler is designed, manufactured, and packaged by Cleaver-Brooks specically for operation in the state of Ohio, under the rules and regulations for unattended units. The unique design of the Ohio Special Boiler serves your steam needs and reduces unnecessary labor costs. All units are factory re tested and shipped as a package, ready for quick connection to utilities. In addition to the features provided on all Cleaver-Brooks Firetube boilers, the following features apply to the Model CEW Ohio Specials. Less than 360 Square Feet of Heating Surface: The greatest amount offered in any packaged boiler for unattended steam boiler operation in Ohio - means long life and years of service at the high efciencies. Front and Rear Doors: Davited, front and rear doors, all sizes. Provides access to front and rear tube sheet. Large rear access plug for turnaround and furnace access. Rear door completely covers and insulates rear tube sheet. Natural Gas, No. 2 Oil, or Combination Burners Available: Combination gas/oil burners provide quick fuel changeover without burner adjustment.
Special motor requirements (TEFC, high efciency). Special indicating lights. Main disconnect. Elapsed time meter. NEMA enclosures. Low-re hold control. Remote emergency shut-off (115V). Circuit breakers. Day/night controls. Special power requirements. Stack thermometer. Fuel Options: Gas strainer. Gas pressure gauge. Future gas conversion. Oversized/undersized gas trains.
PRODUCT OFFERING
Cleaver-Brooks Model CEW Ohio Special Boilers are available in low pressure steam and high pressure steam designs. Burners are available to re natural gas, No. 2 oil, or a combination of oil and gas. Standard product offering is: 100 - 225 hp. Three pass wetback design. 15 - 250 psig steam. Full modulation, all sizes. Available options include the following (contact your local Cleaver-Brooks authorized representative for option details). Boiler Options: Drain valves. Additional screwed or anged tappings. Blowdown valves. Non-return valves. Feedwater valves and regulators. Surface blowdown systems.
A10-3
02-02
Firetube Boilers

Dimensions and ratings for the Model CEW Ohio Special Boilers are shown in the following tables and illustrations. The information is subject to change without notice. Table A10-1. Model CEW Ohio Special Steam Boiler Ratings Figure A10-1. Model CEW Ohio Special Steam Boiler Dimensions Figure A10-2. Model CEW Ohio Special Boiler Space Requirements to Open Rear Door Figure A10-3. Lifting Lug Location, Model CEW Ohio Special Boilers Figure A10-4. Model CEW Ohio Special Boiler Mounting Piers
A10-4
02-02
Firetube Boilers
Table A10-1. Model CEW Ohio Special Steam Boiler Ratings
BOILER HP
100S
125S
150S
175S
200S
225S
RATINGS - SEA LEVEL TO 1000 FT Rated Capacity (lbs-steam/hr from and at 212 F) Btu Output (1000 Btu/hr) 3450 3348 4312 4184 5175 5021 6037 5858 6900 6695 7762 7532
APPROXIMATE FUEL CONSUMPTION AT RATED CAPACITY Light Oil gph (140,000 Btu/gal) Gas CFH (1000 Btu/ft ) Gas (Therm/hr)
3
29.9 4184 41.8
37.4 5230 52.3
44.8 6277 62.8
52.3 7323 73.2
59.8 8369 83.7
67.2 9415 94.1
POWER REQUIREMENTS SEA LEVEL TO 1000 FT (60 HZ) Oil Pump Motor hp (oil ring only) Blower Motor, hp (NO. 2 oil& combination) Blower Motor, hp Air Comp. Motor, hp 1/2 2 1-1/2 2 1/2 3 3 2 1/2 5 5 2 1/2 5 5 3 1/2 7.5 7-1/2 3 1/2 10 10 3
WEIGHTS IN POUNDS Normal Water Capacity Approx. Wt. -15 psig Approx. Wt. -150 psig Approx. Wt. -200 psig Approx. Wt. -250 psig BOILER DATA Heating Surface sq-ft (Fireside) 354 354 354 358 358 358 7430 10311 12558 13632 15079 7430 10311 12558 13632 15079 7430 10311 12558 13632 15079 8293 11150 13515 14465 16029 8293 11150 13515 14465 16029 8293 11150 13515 14465 N/A
NOTE: All fractional hp motors will be single phase voltage, integral hp motors will be 3-phase voltage.
A10-5
02-02
Firetube Boilers
RF/RD I LL L GG K E B Y T BB
CC
DD 4"
J O OA P G
(NEARSIDE)
S
(BOTH SIDES)
Q N M FRONT VIEW W C A RIGHT SIDE VIEW
W H
DIM BOILER HP
100S150S (inches)
175S225S
LENGTHS Overall Shell Base Frame Base Frame to Rear Flange Flange to Steam Nozzle A B C H E WIDTHS Overall
C
207-1/2 157-3/8 174-7/8 13-1/2 63-7/8
228-1/2 170-3/8 196-1/2 13-1/2 56-1/4
I J K L LL M N
85 60 45 33 40 52-1/2 44-1/2
85 60 45 33 40 52-1/2 44-1/2
I. D. Boiler Center to Water Column Center to Lagging Center to Auxilliary LWCO Base Outside Base Inside
Figure A10-1. Model CEW Ohio Special Steam Boiler Dimensions (Page 1 of 2)
A10-6
12-02 02-02
Firetube Boilers
DIM BOILER HP
100S150S (inches)
175S225S
HEIGHTS Base to Boiler Centerline Base to Vent Outlet Base to rear Door Davit Base to Steam Outlet Base Frame Base to Bottom Boiler D O OA P Q R CONNECTIONS Chemical Feed Feedwater Inlet (Both Sides) Steam Nozzle (15 psig)A Steam Nozzle (150 psig)
B
46 85 86-1/2 82-3/8 12 16
46 85 86-1/2 82-3/8 12 16
G S Y Y W W T T BB CC MISCELLANEOUS
1 1-1/2 8 4 1-1/2 1-1/2 1 1-1/2 16 10-1/8
1 1-1/2 10 4 2 1-1/2 1 1-1/2 16 10-1/8
Drain - Front & Rear (15 psig) Blowdown - Front & Rear (150 psig) Surface Blowoff (150 psig) Surface Blowoff (15 psig) Vent Stack Diameter (Flanged) Flange to Center Vent
Rear Door Swing Tube Removal - Front Only Min. Boiler Room Length For Tube Removal Front Min. Boiler Room Length For Tube Removal Thru Door
DD GG RF
36 124 318
36 137 344
RD
276
297
NOTES: Accompanying dimensions, while sufciently accurate for layout purposes, must be conrmed for actual option requirements. A. 150 psig Flange. B. 300 psig Flange. C. Overall width may increase with the addition of electrical options due to control panel mounting.
Figure A10-1. Model CEW Ohio Special Steam Boiler Dimensions (Page 2 of 2)
A10-7
02-02 12-02
Firetube Boilers
BOILER HP 100S-225S
DIMENSION (INCHES) A 33 B 42 C 54 D 77 E 36
Figure A10-2. Space Required to Open Rear Head on Model CEW Ohio Special Boilers
BOILER HP 100S-150S 175S-225S Steam Steam
ALL DIMENSIONS IN INCHES A 80 80 B 19 19 C 120-1/2 133-1/2 D 10 10 E 3 3
Figure A10-3. Model CEW Ohio Special Boilers Lifting Lug Location
A10-8
12-02 02-02
Firetube Boilers
BOILER HP 100S-150S 175S-225S
A 6 6
B 9 9
C 175 196-1/2
D 39-1/2 39-1/2
E 57-1/2 57-1/2
F 4 4
G 44-1/2 44-1/2
X 9-1/2 9-1/2
NOTE: All dimensions are in inches. 6-inch high mounting piers recommended for use beneath the boiler base frame. The use of these piers provides increased inspection accessibility to the piping beneath the boiler and added height for washing down the area beneath the boiler.
Figure A10-4. Model CEW Ohio Special Boiler Mounting Piers
PERFORMANCE DATA
Contact your local Cleaver-Brooks authorized representative for efciencies or additional information.
Boiler Information
Table A10-2 shows steam volume and disengaging area for Model CEW Ohio Special boilers. Table A10-3 lists quantity and outlet size for safety valves supplied on Model CEW Ohio Special boilers. Table A10-4 gives recommended steam nozzle sizes on Model CEW Ohio Special Boilers. Table A10-5 shows recommended non-return valve sizes for Model CEW Ohio Special Boilers.
ENGINEERING DATA
The following engineering information is provided for Model CEW Ohio Special Boilers. Model CEW Ohio Special Boilers are designated by an S following the horsepower number. Additional detail is available from your local Cleaver-Brooks authorized representative.
A10-9
02-02
Model CEW Ohio Special Blowdown Water Requirements

Some local codes require blowdown tanks to be constructed in accordance with recommendations of the National Board of Boiler and Pressure Vessel Inspectors. The National Boards recommendations base the size of the blowdown tank on the removal of at least 4 inches of water from the boiler. Table A10-6 lists the approximate quantity of water represented by 4 inches of water at normal operating level for Cleaver-Brooks Model CEW Ohio Special Boilers. Fuel Connections - Oil
Firetube Boilers
Oil-red burners are equipped with an oil pump, which draws fuel from a storage tank and supplies pressurized oil to the burner nozzle(s). The burner supply oil pump has a greater capacity than the burner requires for the maximum ring rate. Fuel not delivered to the nozzle is returned to the storage tank. A two-pipe (supply and return) oil system is recommended for all installations. Figure A10-5 shows a typical fuel oil supply arrangement. Oil lines must be sized for the burner and burner supply oil pump capacities. The burner supply oil pump suction should not exceed 10" Hg. If a transfer pump is used, it must have a pumping capacity at least equal to that of the burner pump(s). Supply pressure to the burner pump should not exceed 3 psig. A strainer must be installed in the supply piping upstream of the burner supply pump in order to prevent entry of foreign material into the pump, fuel control valves, or burner nozzle(s). The strainer must be sized for the burner supply pump capacity. A strainer mesh of 150 microns (0.005") is recommended. Install a check valve in the line to prevent draining of the oil suction line when the burner is not in operation. Location of the check valve varies with the system, but usually it is located as close as possible to the storage tank. Installation of a vacuum gauge in the burner supply line between the burner oil pump and the strainer is recommended. Regular observation and recording of the gauge indication will assist in determining when the strainer needs servicing. Upon completion of the oil piping installation, the system should be checked for oil or air leakage and tight shutoff of all valves.
Burner Characteristics Note that altitude correction and burner changes are required for higher altitudes which may alter dimensions, motor hp and gas pressures. Gas-Fired Burners Table A10-7 shows correction factors for gas pressure at elevations over 700 ft above sea level. Table A10-8 shows minimum and maximum gas pressure requirements for Standard, FM and IRI CEW Ohio Special Boiler gas trains upstream of the gas pressure regulator. For oversized or undersized gas trains or altitude above 1,000 feet, contact your local Cleaver-Brooks authorized representative. Fuel Connections - Gas The local gas company should be consulted for requirements and authorization for installation and inspection of gas supply piping. Installation of gas supply piping and venting must be in accordance with all applicable engineering guidelines and regulatory codes. All connections made to the boiler should be arranged so that all components remain accessible for inspection, cleaning and maintenance. A drip leg should be installed in the supply piping before the connection to the gas pressure regulator. The drip leg should be at least as large as the inlet tting supplied with the boiler. Consideration must be given to both volume and pressure requirements when choosing gas supply piping size. Refer to the boiler dimension diagram provided by Cleaver-Brooks for the particular installation. Connections to the burner gas train should be made with a union, so that gas train components or the burner may be easily disconnected for inspection or service. Upon completion of the gas piping installation, the system should be checked for gas leakage and tight shutoff of all valves.


100 - 225 hp Model CEW Ohio Special Boilers can support up to 2000 lbs without additional support. 100 - 225 hp Model CEW Ohio Special Boilers can be reinforced to support up to 3000 lbs.

When determining boiler room air requirements, the size of the room, air ow, and velocity of air must be reviewed as follows: 1. Size (area) and location of air supply openings in boiler room. A. Two (2) permanent air supply openings in the outer walls of the boiler room are recommended. Locate one (1) at
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Firetube Boilers
each end of the boiler room, preferably below a height of 7 feet. This allows air to sweep the length of the boiler. B. Air supply openings can be louvered for weather protection, but they should not be covered with ne mesh wire, as this type of covering has poor air ow qualities and is subject to clogging by dust or dirt. C. A vent fan in the boiler room is not recommended, as it could create a slight vacuum under certain conditions and cause variations in the quantity of combustion air. This can result in unsatisfactory burner performance. D. Under no condition should the total area of the air supply openings be less than one (1) square foot. E. Size the openings by using the formula: Area (sq-ft) = CFM/FPM 2. Amount of air required (cfm). A. Combustion Air = Rated bhp x 8 cfm/bhp. B. Ventilation Air = Maximum bhp x 2 cfm/bhp or a total of 10 cfm/bhp - up to 1000 feet elevation. Add 3 percent more per 1000 feet of added elevation. 3. Acceptable air velocity in Boiler Room (fpm). A. From oor to (7) foot height - 250 fpm. B. Above (7) foot height - 500 fpm. Example: Determine the area of the boiler room air supply openings for (1) 300 hp boiler at 800 feet altitude. The air openings are to be 5 feet above oor level. Air required: 300 x 10 = 3000 cfm (from 2B above). Air velocity: Up to 7 feet = 250 fpm (from 3 above). Area Required: Area = cfm/fpm = 3000/250 = 12 Sq-ft total. Area/Opening: 12/2 = 6 sq-ft/opening (2 required).
Model CEW Ohio Special Stack/Breeching Size Criteria

The design of the stack and breeching must provide the required draft at each boiler ue gas outlet. Proper draft is critical to burner performance. Although constant pressure at the ue gas outlet of the Model CEW Ohio Special is not required, it is necessary to size the stack/breeching to limit ue gas pressure variation. The allowable pressure range is 0.25 W.C. to +0.25 W.C. and up to +0.5 at high re, when an economizer is used. The maximum pressure variation at any ring rate for the boiler is 0.25" W.C. For additional information, please review Section I4, General Engineering Data (Stacks) and Section F, Stacks. Stack and breeching sizes should always be provided by a reputable stack supplier who will design the stack and breeching system based on the above criteria. Your local Cleaver-Brooks authorized representative is capable of assisting in your evaluation of the stack/breeching design.
NOTICE
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Firetube Boilers
Table A10-2. Model CEW Ohio Special Steam Volume and Disengaging Areas
BOILER HP 100S-150S 175S-225S STEAM VOLUME (CU-FT) HIGH PRESSURE (A) 23.5 25.8 LOW PRESSURE (B) 27.1 29.7 STEAM RELIEVING AREA (SQ-IN) HIGH PRESSURE (A) 5990 6566 LOW PRESSURE (B) 6221 6826
Table A10-3. Model CEW Ohio Special Steam Boiler Safety Valve Outlet Size
100S 125S 150S 175S 200S 225S
1 1 1 1 1 2
2-1/2 2-1/2 3 3 2-1/2 2-1/2
1 1 1 1 1 1
1-1/2 2 2 2 2-1/2 2-1/2
1 1 1 1 1 1
1-1/2 1-1/2 1-1/2 2 2 2
1 1 1 1 1 N/A
1-1/4 1-1/2 1-1/2 1-1/2 2 N/A
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Firetube Boilers
Table A10-4. Model CEW Ohio Special Recommended Steam Nozzle Size
BOILER HP OPERATING PRESSURE PSIG 15 30 40 50 75 100 125 150 200 100S 8 6 6 4 4 4 4 2.5 2.5 125S 8 6 6 6 4 4 4 3 2.5 150S 8 6 6 6 4 4 4 3 3 175S 8 6 6 6 6 4 4 4 3 200S 10 8 6 6 6 6 4 4 4 225S 10 8 8 6 6 6 4 4 4
NOTES: Steam nozzle sizes given in inches. Spool pieces (300 psig flanges) are available in the following sizes (in inches): 3x2-1/2x30, 4x3x30, 6x4x36, 8x6x48, 10x8x48, and 12x8x48. All standard steam nozzle sizes for the 150 psig design pressure or greater are the same as 125 psig operating pressure on the above table. To increase or decrease the standard size, request the change with your local Cleaver-Brooks authorized representative.
Table A10-5. Model CEW Ohio Special Recommended Non-Return Valve Size
BOILER HP 100S 125S 150S 175S 200S 225S BOILER CAPACITY (LB/HR) 3450 4313 5175 6900 8625 10350 OPERATING PRESSURES (PSIG) 50 3 4 4 4 4 4 75 2-1/2 3 4 4 4 4 100 2-1/2 3 3 3 4 4 125 2-1/2 3 3 3 3 3 150 2-1/2 3 3 3 3 3 175 2-1/2 2-1/2 3 3 3 3 200 2-1/2 2-1/2 2-1/2 2-1/2 3 3
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Firetube Boilers
Table A10-6. Model CEW Ohio Special Blowdown Tank Sizing Information
BOILER HP 100S-150S 175S-225S WATER (GAL) 110 120

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Firetube Boilers
Table A10-8. Model CEW Ohio Special Minimum and Maximum Required Gas Pressure at Entrance to Standard, FM and IRI Gas Trains (Upstream of Gas Pressure Regulator)
PRESSURE REQUIRED (WC) BOILER HP PIPE SIZE (Inches) MAX 1 PSIG INLET, MIN SUPPLY PRESSURE (WC) UL
100S 125S 150S 175S 200S 225S 2 2 2 2-1/2 2-1/2 2-1/2 14 23.5 22 20.5 25.5 N/A
MAX 10 PSIG INLET, MIN SUPPLY PRESSURE (WC) UL

19.5 32.5 27 22.5 28.5 36
FM
14 23.5 22 20.5 25.5 N/A
IRI
15.5 23.5 22 20.5 25.5 N/A
FM
19.5 32.5 27 22.5 28.5 36
IRI
21 32.5 27 22.5 28.5 36
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Firetube Boilers
Figure A10-6. Boiler Room Length (Typical Layouts)
100S-225S 82 115
NOTES: 1. Recommended Minimum Distance Between Boiler and Wall. Dimension A allows for a clear 42" aisle between the water column on the boiler and the wall. If space permits, this aisle should be widened. 2. Recommended Minimum Distance Between Boilers. Dimension B between boilers allows for a clear aisle of 42. If space permits, this aisle should be widened.
Figure A10-7. Boiler Room Width (Typical Layout) A10-16

02-02
Firetube Boilers
The following sample specication is provided by Cleaver-Brooks to assist you in meeting your customers specic needs and application. The Sample Specications are typically utilized as the base template for the complete boiler specication. Contact your local Cleaver-Brooks authorized representative for information on special insurance requirements, special code requirements, optional equipment, or general assistance in completing the specication. Model CEW Ohio Special Steam Boiler (100 - 225 hp, 15 - 250 psig) 1.0 Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-17 A10-17 A10-18 A10-18 A10-20 A10-20 A10-20
1.0 Boiler Characteristics (Steam) 1.1 The Steam Boiler shall be Cleaver-Brooks Model CEW Ohio Special, Fuel Series ______ (100, 200, 700), _____ hp designed for _____ psig (15, 150, 250 psig steam). The maximum operating pressure shall be _____ psig. 1.2 The boiler shall have a maximum output of _____ Btu/hr, or _____ horsepower when red with CS 12-48 No. 2 oil and/or natural gas, _____ Btu/cu-ft. Electrical power available will be _____ Volt _____ Phase _____ Cycle and 115/1/60 for the control circuit. 2.0 General Boiler Design 2.1 The boiler shall be a three pass wetback horizontal retube updraft boiler with less than 360 square feet of total heating surface. It shall be mounted on a heavy steel frame with forced draft burner and burner controls. The complete packaged boiler is built as a unit with Underwriters Laboratories listed controls. 2.1.1 The boiler shall be completely preassembled and re tested at the factory. The unit shall be ready for immediate mounting on oor or simple foundation and ready for attachment of water, steam, fuel, electrical, vent and blowdown connections. 2.2 Boiler Shell (Steam) 2.2.1 The boiler shell must be constructed in accordance with ASME Boiler Code and must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser. 2.2.2 Two lifting eyes shall be located on top of the boiler. 2.2.3 Front and rear doors on the boiler shall be davited. 2.2.4 The rear door shall be insulated with a blanket material and a steel covering to give the surface a hard durable nish. 2.2.5 The boiler tubes shall not include turbulators, swirlers or other add-on appurtenances. 2.2.6 The boiler shall be furnished with a manhole and handholes to facilitate boiler inspection and cleaning. 2.2.7 The exhaust gas vent shall be located near the rear of the boiler on the top center line and shall be capable of supporting 2000lbs. 2.2.8 Observation ports for the inspection of ame conditions shall be provided at each end of the boiler. 2.2.9 The boiler insulation shall consist of a 2 inch blanket under a sectional preformed sheet metal lagging. This insulation must be readily removable and capable of being reinstalled, if required. 2.2.10 The entire boiler base frame and other components shall be factory painted before shipment using a hard nish enamel coating. A10-17
02-02

3.0 Steam Boiler Trim 3.1 Water Column
Firetube Boilers
A water column shall be located on the right hand side of the boiler complete with gauge glass set and water column blowdown valves. 3.1.1 Feedwater Pump Control The boiler feedwater pump control shall be included as an integral part of the water column to automatically actuate a motor driven feed water pump maintaining the boiler water level within normal limits. 3.1.2 Low Water Cutoff The low water cutoff shall be included as an integral part of the boiler feedwater control wired into the burner control circuit to prevent burner operation if the boiler water level falls below a safe level. 3.2 Auxiliary Low Water Cutoff The auxiliary low water cutoff shall be included, piped to the vessel, and wired to the burner control circuit. A manual reset device shall be used for this control. 3.3 Steam Pressure Gauge The steam pressure gauge shall be located at the front of the boiler and include cock and test connection. 3.4 Safety Relief Valves Safety valves of a type and size to comply with ASME Code requirements shall be shipped loose. 3.5 Steam Pressure Controls The steam pressure controls to regulate burner operation shall be mounted near the water column. 4.0 Burner and Controls 4.1 Mode of Operation Burner operation shall be the full modulation principle. The burner shall always return to low re position for ignition. 4.2 Blower 4.2.1 All air for combustion shall be supplied by a forced draft blower mounted on the burner, to eliminate vibration and reduce noise level. 4.2.2 Maximum sound level of the boiler/burner package shall not exceed _____ dBA (when measured in accordance with ABMA Sound Test Standards). 4.2.3 The impeller shall be fabricated aluminum with radial blade, carefully balanced, and directly connected to the blower motor shaft. 4.3 Combustion Air Control Combustion air damper and fuel control valve shall be operated by a single damper control motor that regulates the ame according to load demand. Potentiometer type position controls shall be provided to regulate operation of the damper control motor. 4.4 Fuel Specication and Piping Select one of the following fuel types: Fuel series 700 - Gas red (para 4.4.1). Fuel series 100 - Light oil (No. 2) red (para 4.4.2). Fuel series 200 - Light oil or gas red (para 4.4.3).
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Firetube Boilers
4.4.1 Fuel Series 700 - Gas Fired
4.4.1.1 Burner Type - The burner shall be mounted at the front of the boiler and be of high radiant multi-port type for gas. The burner shall be approved for operation on natural gas fuel. 4.4.1.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include one (1) shutoff valve, solenoid valve, and pressure regulator. 4.4.1.3 Gas Burner Piping - Select one of the following: A. 100 hp. Gas burner piping on all units shall include two (2) manual shutoff valves, gas pressure regulator, one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valve shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. B. 125 - 225 hp. Gas burner piping on all units shall include two (2) manual shutoff valves, gas pressure regulator, one (1) solenoid, one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valve shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. 4.4.2 Fuel Series 100 - Light Oil Fired 4.4.2.1 Burner Type - The burner shall be mounted at the front of the boiler, and shall be approved for operation with CS12-48, Commercial No. 2 oil. 4.4.2.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include one (1) shutoff valve, solenoid valve, and pressure regulator. 4.4.2.3 Oil Pump - An oil pump with a capacity sufcient for the maximum burning rate shall be included. Pump shall be motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided. 4.4.2.4 Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shutoff valves, atomizing air proving switch, low oil pressure switch, and pressure gauge all integrally mounted on the unit. 4.4.2.5 Oil Atomization Type - Burner shall be a low pressure air atomizing type, including a shipped loose air compressor assembly. 4.4.3 Fuel Series 200 - Light Oil or Gas Fired 4.4.3.1 Burner Type - The burner, mounted at the front of the boiler, shall be a combination of low pressure air atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 oil or natural gas. 4.4.3.2 Gas Pilot - The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary fuel valve cannot open until pilot ame has been established. The pilot train shall include one (1) manual shutoff valve, solenoid valve, and pressure regulator. 4.4.3.3 Oil Burner 4.4.3.3.1 Oil Pump - An oil pump with a capacity sufcient for the maximum burning rate shall be included. Pump shall be motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided. 4.4.3.3.2 Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shutoff valves, atomizing air proving switch, low oil pressure switch and pressure gauge all integrally mounted on the unit. 4.4.3.3.3 Oil Atomization Type - Burner shall be a low pressure air atomizing type, including a shipped loose air compressor assembly.
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4.4.3.4 Gas Burner Piping - Select one of the following:
Firetube Boilers
A. 100 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valve shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. B. 125 - 225 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid, one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. 4.5 Control Panel and Flame Safeguard Controller 4.5.1 Control Panel A factory prewired control panel shall be supplied with the boiler/burner package. Panel will be mounted on the burner. 4.5.2 The panel will have a NEMA 1A rating and contain the ame safeguard controller, burner motor starter, air compressor motor starter, control circuit transformer and fuses, selector switches, indicating lights and terminal strips. Lights shall indicate load demand, ame failure, low water, and fuel valve open. 4.5.3 The panel shall contain fuse protection for the burner motor and air compressor motor. 4.5.4 The ame safeguard controller shall be a CB110 ame monitor with EPD170 program module. Flame detector shall be ultraviolet type. 5.0 Efciency Guarantee 5.1 The boiler must be guaranteed to operate at a minimum fuel-to-steam efciency of ____ percent at 100 percent of rating when burning natural gas and ________ fuel-to-steam efciency at 100% ring rate when burning oil (Contact your local CleaverBrooks authorized representative for efciency details). 6.0 Warranty 6.1 All equipment is to be guaranteed against defects in materials and/or workmanship for a period of 12 months from date of startup or 18 months from date of shipment, whichever comes rst. 7.0 Execution 7.1 Shop Tests 7.1.1 The packaged boiler must receive factory tests to check the construction, controls, and operation of the unit. All tests may be witnessed by the purchaser, if desired. 7.2 Start-up Service 7.2.1 After boiler installation is completed, the manufacturer shall provide the services of a eld representative for starting the unit and training the operator at no additional costs. 7.2.1.1 A factory approved and authorized start-up report shall be submitted to the customer/user at the time of start-up.
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Section A11
Model CBL
CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-3 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-3 DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-4 PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-9 Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-9 ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-10 Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-10 Blowdown Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-10 Burner/Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-10 Burner Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-10 Gas-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-10 Fuel Connections - Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-10 Fuel Connections - Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-10 Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-11 Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-11 Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-11 Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-11 SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-19 Model CBL Steam Boiler (800-1500 hp, Steam 15-250 psig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-19
A11-1
02-02
Model CBL
Firetube Boilers
ILLUSTRATIONS Figure A11-1. Model CBL Steam Boiler Dimensions, 4 Pass (Page 1 of 2) (4 pass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-6 Figure A11-2. Space Required to Open Rear Doors on Model CBL Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-8 Figure A11-3. Model CBL Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-8 Figure A11-4. Model CBL Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-9 Figure A11-5. No. 2 Oil Piping, Single Boiler Installation, Oil Pump Integral With Boiler . . . . . . . . . . . . . . . . . . . . . . A11-17 Figure A11-6. No. 6 Oil Piping, Single Boiler Installation, Remote Oil Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-17 Figure A11-7. Boiler Room Length (Typical Layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-18 Figure A11-8. Boiler Room Width (Typical Layouts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-18
TABLES Table A11-1. Model CBL Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-5 Table A11-2. Heating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-5 Table A11-3. Predicted Fuel-to-Steam Efficiencies (%) Model CBL Boilers- 125 psig, Natural Gas, 5sq. ft./BHP, 4 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-13 Table A11-4. Predicted Fuel-to-Steam Efficiencies (%) Model CBL Boilers- 125 psig, No. 2 Oil, 5sq. ft./BHP, 4 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-13 Table A11-5. Predicted Fuel-to-Steam Efficiencies (%) Model CBL Boilers- 125 psig, No. 6 Oil, 5sq. ft./BHP, 4 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-13 Table A11-6. Predicted Fuel-to-Steam Efficiencies (%) Model CBL Boilers- 125 psig, Natural Gas, 4 sq. ft./BHP, 3 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-14 Table A11-7. Predicted Fuel-to-Steam Efficiencies (%) Model CBL Boilers- 125 psig, No. 2 Oil, 4 sq. ft./BHP, 3 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-14 Table A11-8. Predicted Fuel-to-Steam Efficiencies (%) Model CBL Boilers- 125 psig, No. 6 Oil, 4 sq. ft./BHP, 3 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-14 Table A11-9. Model CBL Steam Boiler Safety Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-15 Table A11-10. Model CBL Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-15 Table A11-11. Model CBL Steam Volume and Disengaging Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-16 Table A11-12. Model CBL Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-16 Table A11-13. Model CBL Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-16 Table A11-14. Altitude Correction for Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-16
The following information applies to the Cleaver-Brooks Model CBL Boiler.
A11-2
02-02
Firetube Boilers
Model CBL
Feedwater valves and regulators. Surface blowdown systems. Surge load bafes. Seismic design. Burner/Control Options: Flame safeguard controllers.

The Model CBL Firetube boiler is designed, manufactured, and packaged by Cleaver-Brooks. All units are factory re tested and shipped as a package, ready for quick connection to utilities. In addition to the features provided on all CleaverBrooks Firetube boilers, the following features apply to the Model CBL. Three Pass or Four Pass Design: The packaged boiler offers high efciency, exibility, reliability, safety and ease of operation. Front and Rear Doors: Davited, front and rear doors, all sizes. Provides access to front tube sheet and furnace. Large rear access plug for turnaround and furnace access. Rear door completely covers and insulates rear tube sheet. Natural Gas, No. 2 Oil, No. 6 Oil, or Combination Burners Available: Combination gas/oil burners provide quick fuel changeover without burner adjustment.
Lead/lag system. Special insurance and code requirements (e.g., IRI, FM, NFPA8501). Alarm bell/silence switch. Special motor requirements (TEFC, high efciency). Special indicating lights. Main disconnect. Elapsed time meter. NEMA enclosures. Remote emergency shut-off (115V). Circuit breakers. Day/night controls. Special power requirements. Low NOx Equipment. CB HAWK Fuel Options: Gas strainer. Gas pressure gauge. Future gas conversion. Oversized/undersized gas trains. Optional Oil Pumps.
PRODUCT OFFERING
Cleaver-Brooks Model CBL Boilers are available in high pressure steam designs. Burners are available to re natural gas, No. 2 oil, No. 6 oil, or a combination of oil and gas. Standard product offering is: 800 - 1500 hp. Three pass wetback design or four pass wetback design. 4 or 5 square foot of heating surface per boiler horsepower 15- 250 psig steam in most sizes. 30 & 125 psig hot water in most sizes. Full modulation, all sizes. Available options include the following (contact your local Cleaver-Brooks authorized representative for option details). Boiler Options: Additional screwed or anged tappings. Blowdown valves. Non-return valves.
A11-3
02-02
Model CBL
Firetube Boilers

Dimensions and ratings for the Model CBL Boilers are shown in the following tables and illustrations. The information is subject to change without notice. Table A11-1. Model CBL Steam Boiler Ratings Table A11-2. Heating Surface Figure A11-1. Model CBL Steam Boiler Dimensions Figure A11-2. Model CBL Boiler Space Requirements to Open Rear Door Figure A11-3. Lifting Lug Location, Model CBL Boilers Figure A11-4. Model CBL Boiler Mounting Piers
A11-4
02-02
Firetube Boilers
Model CBL
Table A11-1. Model CBL Steam Boiler Ratings

BOILER HP 800 900 1000 1100
B
1200
1300
1400
1500
RATINGS - SEA LEVEL TO 1000 FT Rated Capacity (lbs-steam/hr from and at 212 F) Btu Output (1000 Btu/hr) 27600 26780 31050 30125 34500 33475
37950 36820
41400 40170
44850 43515
48300 46865
51750 50210
POWER REQUIREMENTS SEA LEVEL TO 1000 FT (60 HZ) Blower Motor, hp A(Gas and Oil) Oil Pump Motor hp (#2 oil) Oil Pump Motor hp (#6 oil) Air Comp. Motor, hp (#2 oil) Oil heater Kw (#6 oil) 60 1 1 7-1/2 10 60 1 1 15 10 60 1 1 15 10 75 1 1 15 15 75 1-1/2 1 15 15 75 1-1/2 1 15 15 75 NA NA NA NA 75 NA NA NA NA
NOTE: A. 1400 and 1500 hp blower motor is for natural gas only. B. Ratings based on nominal 80% efciency. C. Ratings based on 60 hertz, please verify 50 hertz ratings with factory.
Table A11-2. Heating Surface

Boiler Square Foot Heating Surface
4000
4500
5000
5500
6000
Approximate Fuel Consumption D 5 sq.ft./bhp Natural Gas A (cfh) No. 2 Oil B (gph) No. 6 Oil C (gph) 800 33475 239.3 223.4 900 37660 269.0 251.1 1000 41845 299.0 279.0 1100 46025 329.0 307.0 1200 50215 359.0 335.0
4 sq.ft./bhp Natural Gas A (cfh) No. 2 Oil B (gph) No. 6 Oil C(gph)
1000 41845 299.0 279.0
1100 46025 329.0 307.0
1200 50215 359.0 335.0
1300 54395 388.5 363.0
1400 58585 NA NA
1500 62765 NA NA
Note: A. Natural gas based on heating value of 1000 BTU/cu.ft B. No. 2 oil based on heating value of 140,000 BTU/gal. C. No. 6 oil based on heating value of 150,000 BTU/gal. D. Ratings based on nominal 80% efficiency.
A11-5
02-02
Model CBL
Firetube Boilers
I J L K GG CC
BB RF/RD E B Y T
P F O D Q N M W A G
R C
W H
BOILER SQUARE FOOT HEATING SURFACE Boiler Horsepower@ 5 ft2/bhp Boiler Horsepower @ 4 ft2/bhp LENGTHS Overall * Shell Base Frame * Base Frame to Rear Flange Flange to Steam Nozzle WIDTHS Overall With Trim I. D. Boiler Center to Water Column Center to Lagging Base Outside Base Inside
DIM
4000 800 1000
4500 900 1100
5000 1000 1200
5500 1100 1300
6000 1200 1500
6500D 1300 -
7000D 1400 -
7500D 1500 -
A B C H E
367 293 285 26 148
394 323 317 26 148
386 288 282 26 148
411 312 304 26 148
434 335 327 26 148
387 304 296 26 148
406 323 315 26 148
425 342 334 26 148
I J K L M N
144 114 72 59-1/2 96 80
144 114 72 59-1/2 96 80
156 126 78 65-3/4 96 80
156 126 78 65-3/4 96 80
156 126 78 65-3/4 96 80
168 138 84 71 3/4 96 80
168 138 84 71 3/4 96 80
168 138 84 71 3/4 96 80
* Approximate - varies with burner selection
Figure A11-1. Model CBL Steam Boiler Dimensions, 4 Pass (Page 1 of 2) (4 pass)
A11-6
02-02
Firetube Boilers
Model CBL
BOILER SQUARE FOOT HEATING SURFACE Boiler Horsepower@ 5 ft2/bhp Boiler Horsepower @ 4 ft2/bhp
DIM
4000 800 1000
4500 900 1100
5000 1000 1200 HEIGHTS
5500 1100 1300
6000 1200 1500
6500D 1300 -
7000D 1400 -
7500D 1500 -
Base to piping connections Base to Boiler Centerline Base to Vent Outlet Base to Steam Outlet Base Frame Base to Bottom Boiler
F D O P Q R
146 77-1/2 141 141 12 20
146 77-1/2 141 141 12 20
158 83-3/4 153-1/2 153-1/2 12 20
158 83-3/4 153-1/2 153-1/2 12 20
158 83-3/4 153-1/2 153-1/2 12 20
171 89 3/4 165 1/2 165 1/2 12 20
171 89 3/4 165 1/2 165 1/2 12 20
171 89 3/4 165 1/2 165 1/2 12 20
CONNECTIONS Chemical Feed Feedwater Inlet (Both Sides) Steam NozzleA (5 ft2/bhp) Steam NozzleA (4 ft2/bhp) Blowdown - Front & Rear Surface Blowoff Vent Stack Diameter (Flanged) Flange to Center Vent G S Y Y W T BB CC 3/4 3 8 10 2 1 32 17-1/2 3/4 3 10 10 2 1 32 17-1/2 3/4 3 10 10 2 1 36 19-1/2 3/4 3 10 10 2 1 36 19-1/2 3/4 3 10 12 2 1 36 19-1/2 3/4 3 10 2 1 42 24 3/4 3 12 2 1 42 24 3/4 3 12 2 1 42 24
MISCELLANEOUS Rear Door Swing
AA GG RF
246 537
276 597
217 538
241 586
264 632
233 665
252 703
271 741
Tube Removal - Front Only Min. Boiler Room Length For Tube Removal Front Min. Boiler Room Length For Tube Removal Thru Door Normal Water Weight (Lbs) Flooded Water Weight (Lbs) Approx. Wt. 15/30 psig (Lbs.) Approx. Wt. 150 psig (Lbs.) Approx. Wt. 200 psig (Lbs.) Approx. Wt. 250 psig (Lbs.)
RD
484 43800 54500 58000 65000 73500 81300
514 49400 61300 63000 71000 80200 89000
489 49300 65300 73100 79600 88600 97200
513 54000 71900 77200 85300 95200 104500
536 60000 78300 82200 90900 101500 N/A
528 61000 83000 87000 97300 107800 N/A
547 66000 89000 91700 102600 N/A N/A
566 71000 96000 96600 108200 N/A N/A
NOTES: Accompanying dimensions, while sufciently accurate for layout purposes, must be conrmed for actual option requirements. A. 300 psig Flange. See recommended steam nozzle size chart for operating pressure greater than 125 psig. B. Add 11 1/2 inches to dimension B for a three pass boiler. C. Reference Figure A11-2. D. 6500, 7000 & 7500 square foot boiler are for a 30ppm option on natural gas.
Figure A11-1. Model CBL Steam Boiler Dimensions, 4 Pass (Page 2 of 2) (4 pass)
A11-7
02-02
Model CBL
Firetube Boilers
"D" "B" "A" BOILER ID 114" 126" 138" A 60 66 72 DIMENSION (INCHES) B 72 78 84 C 39 52 66 D 82 93 105 E 22
3-PASS BOILER SHOWN. 4 PASS VENT STUB ON OPPOSITE END.
REAR DOOR 33 45 MAXIMUM REAR MINIMUM SIDE
"E" "C"
MINIMUM REAR MAXIUM SIDE
Figure A11-2. Space Required to Open Rear Doors on Model CBL Boilers
BOILER SQUARE FOOT OF HEATING SURFACE
BHP 4 sq.ft. 5 sq.ft.
4000 4500 5000 5500 6000 6500 7000 7500
1000 1100 1200 1300 1500 -
800 900 1000 1100 1200 1300 1400 1500
138 138 150 150 150 162 162 162
47 47 47 47 47 47 47 47
205 238 200 222 247 216 235 254
12 12 12 12 12 12 12 12
3 3 3 3 3 3 3 3
Figure A11-3. Model CBL Boilers Lifting Lug Location
A11-8
02-02
Firetube Boilers
Model CBL
H
E
BOILER SQUARE FOOT OF HEATING SURFACE 4000 4500 5000 5500 6000 6500 7000 7500
BHP 4 sq-ft 1000 1100 1200 1300 1500 5 sq-ft 800 900 1000 1100 1200 1300 1400 1500
A 6 6 6 6 6 6 6 6
B 12 12 12 12 12 12 12 12
C * * * * * * * *
D 76 76 76 76 76 76 76 76
E 100 100 100 100 100 100 100 100
F 8 8 8 8 8 8 8 8
G 80 80 80 80 80 80 80 80
H 12 12 15 15 15 15 15 15
NOTE: All numbers in table are in inches. 6-inch high mounting piers recommended for beneath the boiler frame. The use of these piers provides increased inspection accessibility to the piping beneath the boiler and added height for washing down the area beneath the boiler. The (*) varies with horsepower rating and burner selection, see Dimension Diagram for job-specic mounting pier length.
Figure A11-4. Model CBL Boiler Mounting Piers
PERFORMANCE DATA
Efficiency
Tables A11-3, A11-4, A115, A11-6, A117, and A11-8 show predicted fuel-to-steam efciencies (including radiation and convection losses) for Cleaver-Brooks Model CBL Firetube boilers. For specic efciencies on retube boiler offerings not listed here, contact your local Cleaver-Brooks authorized representative. Cleaver-Brooks offers an industry leading fuel-to-steam boiler efciency guarantee for Model CBL Firetube Boilers. The guarantee is based on the fuel-to-steam efciencies shown in the efciency tables and the following conditions. The efciency percent number is only meaningful if the specic conditions of the efciency calculations are clearly stated in the specication (see Cleaver-Brooks publication
CB-7767 for a detailed description of efciency calculations). The boiler manufacturer shall guarantee that, at the time of startup, the boiler will achieve fuel-to-steam efciency (as shown in the tables listed above) at 100% ring rate (add efciency guarantees at 25%, 50%, and 75% of rating, if required). If the boiler(s) fail to achieve the corresponding guaranteed efciency as published, the boiler manufacturer will rebate, to the ultimate boiler owner, ve thousand dollars ($5,000) for every full efciency point (1.0%) that the actual efciency is below the guaranteed level. The specied boiler efciency is based on the following conditions. 1. Fuel specication used to determine boiler efciency: Natural Gas Carbon,% (wt) = 69.98
A11-9
02-02
Model CBL
Hydrogen,% (wt) = 22.31 Sulfur,% (wt) = 0.0 Heating value, Btu/lb = 21,830 No. 2 Oil Carbon,% (wt) = 85.8 Hydrogen,% (wt) = 12.7 Sulfur,% (wt) = 0.2 Heating value, Btu/lb = 19,420 No. 6 Oil Carbon,% (wt) = 86.6 Hydrogen,% (wt) = 10.9 Sulfur,% (wt) = 2.09 Heating value, Btu/lb = 18,830 2. Efciencies are based on ambient air temperature of 80 F, relative humidity of 30%, and 15% excess air in the exhaust ue gas. 3. Efciencies are based on the following radiation and convection losses. Firing rate of 25% - 1.2%, 50% - 0.6%, 75% 0.4%, and 100% - 0.3%.
Firetube Boilers Burner/Control Information

Burner Characteristics Note that altitude correction and burner changes are required for higher altitudes which may alter dimensions, motor hp and gas pressures. Also 50 Hz applications and low NOx options should be reviewed by the Cleaver-Brooks authorized representative. Gas-Fired Burners Table A11-13 shows correction factors for gas pressure at elevations over 700 ft. above sea level. For oversized or undersized gas trains or altitude above 1,000 feet, contact your local Cleaver-Brooks authorized representative. Fuel Connections - Gas The local gas company should be consulted for requirements and authorization for installation and inspection of gas supply piping. Installation of gas supply piping and venting must be in accordance with all applicable engineering guidelines and regulatory codes. All connections made to the boiler should be arranged so that all components remain accessible for inspection, cleaning and maintenance. A drip leg should be installed in the supply piping before the connection to the gas pressure regulator. The drip leg should be at least as large as the inlet tting supplied with the boiler. Consideration must be given to both volume and pressure requirements when choosing gas supply piping size. Refer to the boiler dimension diagram provided by Cleaver-Brooks for the particular installation. Connections to the burner gas train should be made with a union, so that gas train components or the burner may be easily disconnected for inspection or service. Upon completion of the gas piping installation, the system should be checked for gas leakage and tight shutoff of all valves. Fuel Connections - Oil
ENGINEERING DATA
The following engineering information is provided for Model CBL Boilers. Additional detail is available from your local Cleaver-Brooks authorized representative.
Boiler Information
Table A11-11 shows steam volume and disengaging area for Model CBL boilers. Table A11-9 lists quantity and outlet size for safety valves supplied on Model CBL boilers. Table A11-10 gives recommended steam nozzle sizes on Model CBL Boilers. Table A11-12 shows recommended non-return valve sizes for Model CBL Boilers.

Some local codes require blowdown tanks to be constructed in accordance with recommendations of the National Board of Boiler and Pressure Vessel Inspectors. The National Boards recommendations base the size of the blowdown tank on the removal of at least 4 inches of water from the boiler. Table A11-13 lists the approximate quantity of water represented by 4 inches of water at normal operating level for Cleaver-Brooks Model CBL Boilers.
Oil-red burners are equipped with an oil pump, which draws fuel from a storage tank and supplies pressurized oil to the burner nozzle(s). The burner supply oil pump has a greater capacity than the burner requires for the maximum ring rate. Fuel not delivered to the nozzle is returned to the storage tank. A two-pipe (supply and return) oil system is recommended for all installations. Figure A11-6 shows a typical fuel oil supply arrangement. Oil lines must be sized for the burner and burner supply oil pump capacities. The burner supply oil pump suction should not exceed 10" Hg. If a transfer pump is used, it must have a pumping capacity at least equal to that of the burner pump(s). Supply pressure to the burner pump should not exceed 3 psig.
A11-10
02-02
Firetube Boilers
A strainer must be installed in the supply piping upstream of the burner supply pump in order to prevent entry of foreign material into the pump, fuel control valves, or burner nozzle(s). The strainer must be sized for the burner supply pump capacity. A strainer mesh of 150 microns (0.005") is recommended. Install a check valve in the line to prevent draining of the oil suction line when the burner is not in operation. Location of the check valve varies with the system, but usually it is located as close as possible to the storage tank. Installation of a vacuum gauge in the burner supply line between the burner oil pump and the strainer is recommended. Regular observation and recording of the gauge indication will assist in determining when the strainer needs servicing. Upon completion of the oil piping installation, the system should be checked for oil or air leakage and tight shutoff of all valves. 3.
Model CBL
C. A vent fan in the boiler room is not recommended, as it could create a slight vacuum under certain conditions and cause variations in the quantity of combustion air. This can result in unsatisfactory burner performance. D. Under no condition should the total area of the air supply openings be less than one (1) square foot. E. Size the openings by using the formula: Area (sq-ft) = CFM/FPM 2. Amount of air required (cfm). A. Combustion Air = Rated bhp x 8 cfm/bhp. B. Ventilation Air = Maximum bhp x 2 cfm/bhp or a total of 10 cfm/bhp - up to 1000 feet elevation. Add 3 percent more per 1000 feet of added elevation. Acceptable air velocity in Boiler Room (fpm). A. From oor to (7) foot height - 250 fpm. B. Above (7) foot height - 500 fpm. Example: Determine the area of the boiler room air supply openings for (1) 1000 hp boiler at 800 feet altitude. The air openings are to be 5 feet above oor level. Air required: 1000 x 10 = 10000 cfm (from 2B above). Air velocity: Up to 7 feet = 250 fpm (from 3 above). Area Required: Area = cfm/fpm = 10000/250 = 40 Sq-ft total. Area/Opening: 40/2 = 20 sq-ft/opening (2 required).


Model CBL Boilers can support up to 2000 lbs. without additional support. Model CBL Boilers can be reinforced to support up to 3000 lbs.

When determining boiler room air requirements, the size of the room, air ow, and velocity of air must be reviewed as follows: 1. Size (area) and location of air supply openings in boiler room. A. Two (2) permanent air supply openings in the outer walls of the boiler room are recommended. Locate one (1) at each end of the boiler room, preferably below a height of 7 feet. This allows air to sweep the length of the boiler. B. Air supply openings can be louvered for weather protection, but they should not be covered with ne mesh wire, as this type of covering has poor air ow qualities and is subject to clogging by dust or dirt.
NOTICE

The design of the stack and breeching must provide the required draft at each boiler ue gas outlet. Proper draft is critical to burner performance. Although constant pressure at the ue gas outlet of the Model CBL is not required, it is necessary to size the stack/breeching to limit ue gas pressure variation. The allowable pressure range is 0.50 W.C. to +0.50 W.C. The maximum pressure variation at any ring rate for the boiler is 0.50" W.C.
A11-11
02-02
Model CBL
The low NOx option allowable pressure range is -0.25 W.C. to +0.25 W.C. The maximum pressure variation at any ring rate for the boiler is 0.25W.C. For additional information, please review Section I4, General Engineering Data (Stacks) and Section F, Stacks. Stack and breeching sizes should always be provided by a reputable stack supplier who will design the stack and breeching system based on the above criteria. Your local Cleaver-Brooks authorized representative is capable of assisting in your evaluation of the stack/breeching design.
Firetube Boilers
A11-12
02-02
Firetube Boilers
Model CBL
Table A11-3. Predicted Fuel-to-Steam Efficiencies (%) Model CBL Boilers- 125 psig, Natural Gas, 5sq. ft./BHP, 4 Pass
BOILER HP FIRING RATE (%) 25 50 75 100
800 900 1000 1100 1200
82.7 82.8 82.7 82.8 82.8
83.1 83.2 83.1 83.2 83.2
83.1 83.2 83.1 83.2 83.2
83.0 83.1 83.0 83.1 83.2
Table A11-4. Predicted Fuel-to-Steam Efficiencies (%) Model CBL Boilers- 125 psig, No. 2 Oil, 5sq. ft./BHP, 4 Pass
800 900 1000 1100 1200
86.2 86.2 86.2 86.2 86.2
86.5 86.6 86.5 86.6 86.6
86.5 86.6 86.5 86.6 86.7
86.4 86.5 86.4 86.5 86.6
Table A11-5. Predicted Fuel-to-Steam Efficiencies (%) Model CBL Boilers- 125 psig, No. 6 Oil, 5sq. ft./BHP, 4 Pass
800 900 1000
86.5 86.6 86.5
86.9 87.0 86.9
86.9 87.0 86.9
86.8 86.9 86.8
A11-13
02-02
Model CBL
Firetube Boilers
Table A11-6. Predicted Fuel-to-Steam Efficiencies (%) Model CBL Boilers- 125 psig, Natural Gas, 4 sq. ft./BHP, 3 Pass
1000 1100 1200 1300 1400 1500
82.4 82.5 82.4 82.5 82.5 82.5
82.4 82.6 82.4 82.6 82.6 82.7
82.0 82.4 82.0 82.3 82.3 82.5
81.5 82.0 81.6 81.9 82.0 82.1
Table A11-7. Predicted Fuel-to-Steam Efficiencies (%) Model CBL Boilers- 125 psig, No. 2 Oil, 4 sq. ft./BHP, 3 Pass
1000 1100 1200 1300
85.8 85.9 85.8 85.9
85.8 86.0 85.8 86.0
85.4 85.8 85.5 85.7
85.0 85.4 85.0 85.4
Table A11-8. Predicted Fuel-to-Steam Efficiencies (%) Model CBL Boilers- 125 psig, No. 6 Oil, 4 sq. ft./BHP, 3 Pass
1000
86.2
86.2
85.8
85.3
A11-14
02-02
Firetube Boilers
Model CBL
Table A11-9. Model CBL Steam Boiler Safety Valve Outlet Size
VALVE SETTING BOILER HP 15 PSIG STEAM NO. OF VALVES REQ'D OUTLET SIZE (FPT) 150 PSIG STEAM NO. OF VALVES REQ'D OUTLET SIZE (FPT) 200 PSIG STEAM NO. OF VALVES REQ'D OUTLET SIZE (FPT) 250 PSIG STEAM NO. OF VALVES REQ'D OUTLET SIZE (FPT)
800 900 1000 1100 1200 1300 1400 1500
7 8 8 -
4 4 4 -
2 2 2 2 2 3 3 3
1-3 1-4 1-3 1-4 4 4 4 2-3 1-4 1-3 2-4 1-3 2-4
2 2 2 2 2 3 3 3
1 - 2 1/2 1-3 3 3 1-3 1-4 1-3 1-4 1 - 2 1/2 2-3 3 3
2 2 2 2 2 -
2 1/2 1 - 2 1/2 1-3 1 - 2 1/2 1-3 3 3 -
NOTES: Table A11-8 only applies to 5 Sq Ft/BHP units. Valve manufacture is Kunkle. Valve requirements can vary with special pressure settings.
Table A11-10. Model CBL Recommended Steam Nozzle Size

BOILER HP OPERATING PRESSURE PSIG 12 30 50 75 100 125 150 200 225 800 18 14 12 10 10 8 8 8 6 900 18 16 12 10 10 10 8 8 8 1000 20 16 12 12 10 10 8 8 8 1100 20 16 14 12 10 10 10 8 8 1200 24 18 16 12 12 10 10 8 8 1300 24 18 16 12 12 10 10 NA NA 1400 24 18 16 12 12 12 10 NA NA 1500 24 20 16 14 12 12 10 NA NA
NOTES: Steam nozzle sizes given in inches. All standard steam nozzle sizes for the 150 psig design pressure or greater are the same as 125 psig operating pressure on the above table. To increase or decrease the standard size, request the change with your local Cleaver-Brooks authorized representative.
A11-15
02-02
Model CBL
Table A11-11. Model CBL Steam Volume and Disengaging Areas
4000 4500 5000 5500 6000 6500 7000 7500
Firetube Boilers
BHP 4 SQ.FT.
1000 1100 1200 1300 1500 -
STEAM VOLUME (CU-FT) 5 SQ.FT.

800 900 1000 1100 1200 1300 1400 1500
STEAM RELIEVING AREA (SQ-IN) HIGH PRESSURE (A)

20566 23105 24141 26372 28908 28918 31079 33242
HIGH PRESSURE (A)

155 174 250 273 300 352 379 405
NOTE: Based on normal water level. Values are based on standard controls. Optional controls may result in different values. A. Based on 150 psig design pressure.
Table A11-12. Model CBL Recommended Non-Return Valve Size

BOILER HP 800 900 1000 1100 1200 1300 1400 1500 CAPACITY LBS.PER HR. 27600 31050 34500 37950 41400 44850 48300 51750 OPERATING PRESSURE 50 8 8 8 8 10 10 10 10 75 8 8 8 8 8 8 10 10 100 8 8 8 8 8 8 8 10 125 6 6 6 8 8 8 8 8 150 6 6 6 6 8 8 8 8 175 6 6 6 6 8 8 8 8 200 6 6 6 6 8 N/A N/A N/A 225 6 6 6 6 6 N/A N/A N/A
Table A11-13. Model CBL Blowdown Tank Sizing Information

4000 4500 5000 5500 6000 6500 7000 7500 BHP 4 SQ.FT. 1000 1100 1200 1300 1500 5 SQ.FT. 800 900 1000 1100 1200 1300 1400 1500 WATER (GAL)

356 400 418 460 500 500 538 575
To obtain minimum required gas pressure at altitudes above 700 feet, multiply the pressure by the listed factors: inches WC x 0.577 = oz/sq-in. oz/sq-in x 1.732 = inches WC. inches WC x 0.0361= psig. oz/sq-in x 0.0625 = psig. psig x 27.71 = Inches WC. psig x 16.0 = oz/sq-in.
A11-16
02-02
Firetube Boilers
Model CBL
Figure A11-5. No. 2 Oil Piping, Single Boiler Installation, Oil Pump Integral With Boiler
Figure A11-6. No. 6 Oil Piping, Single Boiler Installation, Remote Oil Pumps
A11-17
02-02
Model CBL
Firetube Boilers
1. Shortest boiler room length (Dwg A) is obtained by allowing for possible future tube replacement from front of boiler through a window or doorway. Allowance is only made for minimum door swing at each end of the boiler. This arrangement provides sufficient aisle space at the front of the boiler but a tight space condition at the rear. If space permits, approximately 1.5 additional feet should be allowed at the rear for additional aisle and working space. 2. Next shortest boiler room length (Dwg B) is obtained by allowing for possible future tube replacement from the front of the boiler. Allowance is only made for minimum door swing at the rear. If space permits, approximately 1.5 additional feet should be allowed at the rear for additional aisle and working space. BOILER SQUARE FOOT OF HEATING SURFACE
4000 4500 5000 5500 6000 6500 7000 7500
BHP 4 sq.ft.
1000 1100 1200 1300 1500 -
A 5 sq.ft.
800 900 1000 1100 1200 1300 1400 1500 610 670 606 654 700 642 680 718
484 514 489 513 536 515 534 553
NOTE: A = Minimum length based on removing tubes in the boiler room. B = Minimum length based on removing tubes through a wall opening.
Figure A11-7. Boiler Room Length (Typical Layout)
Boiler Square Foot of Heating Surface Dimension A (inches) Dimension B (inches)
4000-4500 117 198
5000-6000 123 210
6500-7500 129 222
For reference to Boiler Horsepower per square foot see A11-7
Figure A11-8. Boiler Room Width (Typical Layouts) A11-18

02-02
Firetube Boilers
Model CBL
The following sample specications are provided by Cleaver-Brooks to assist you in meeting your customers specic needs and application. The detailed burner and control specications, and detailed control specications for CB100E Flame Safeguard control are provided. See Section D, Controls, for additional information on control options. The Sample Specications are typically utilized as the base template for the complete boiler specication. Contact your local Cleaver-Brooks authorized representative for information on special insurance requirements, special code requirements, optional equipment, or general assistance in completing the specication.
Model CBL Steam Boiler (800 - 1500 hp, 15 - 250 psig) 1.0 Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-19 2.0 General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-19 3.0 Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-20 4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-20 5.0 Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-24 6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-24 7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-24
Model CBL Steam Boiler (800-1500 hp, Steam 15-250 psig)

1.0 Boiler Characteristics (Steam) 1.1 The Steam Boiler shall be Cleaver-Brooks Fuel Series ______ (100, 200, 400, 600, 700), ______ hp designed for ______ psig (15, 150, 200, or 250 psig steam). The maximum operating pressure shall be _____ psig and the minimum operating pressure shall be ______ psig. 1.2 The boiler shall have a maximum output of ______ Btu/hr, or ______ horsepower when red with CS12-48 ______ oil and/or natural gas, ______ Btu/cu-ft. Electrical power available shall be ______ Volt ______ Phase ______ Cycle. 2.0 General Boiler Design 2.1 The boiler shall be a three pass or four pass horizontal retube updraft boiler with ________ square feet of heating surface per rated boiler horsepower. It shall be mounted on a heavy steel frame with integral forced draft burner and burner controls. 2.1.1 The boiler shall be completely preassembled and re tested at the factory. The unit shall be ready for immediate mounting on oor or simple foundation and ready for attachment of water, fuel, electrical, vent, and blowdown connections. 2.1.2 The boiler shall be built to comply with the following insurance and codes ______________ (Factory Mutual, Industrial Risk Insurance, ASME, NFPA 8501). 2.2 Boiler Shell (Steam) 2.1.1 The boiler shell must be constructed in accordance with ASME Boiler Code and must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser. 2.2.2 The boiler shall be furnished with a manhole and handholes to facilitate boiler inspection and cleaning. Two lifting lugs must be located on top of the boiler.
A11-19
02-02
Model CBL
Firetube Boilers
2.2.3 The front door shall be davited and the rear door shall be davited. Doors are to be sealed with berglass tadpole gaskets and fastened tightly using heavy capscrews that thread into replaceable brass nuts. 2.2.4 The boiler tubes shall not include turbulators, swirlers, or other add-on appurtenances. 2.2.5 The rear door shall be insulated with a blanket material with a steel covering to give the surface a hard durable nish. 2.2.6 The exhaust gas vent shall be located at the front or rear of the boiler and be capable of supporting 2000 lbs. The boiler vent shall contain a stack thermometer. 2.2.7 Observation ports for the inspection ame conditions shall be provided at each end of the boiler. 2.2.8 The boiler insulation shall consist of 2 inch blanket under a sectional pre-formed sheet metal lagging. The insulation must be readily removable and capable of being reinstalled, if required. 2.2.9 The entire boiler base frame and other components shall be factory-painted before shipment, using a hard-nish enamel coating. 3.0 Steam Boiler Trim 3.1 Water Column A water column shall be located on the right-hand side of the boiler complete with gauge glass set, and water column blowdown valves. 3.1.1 Modulating feedwater Control The boiler modulating feedwater control and valve shall be included to automatically maintain the boiler water level within normal limits. 3.1.2 Low Water Cutoff The low water cutoff shall be included and wired into the burner control circuit to prevent burner operation if the boiler water level falls below a safe level. 3.2 Auxiliary Low Water Cut-off Auxiliary low water cut-off shall be included, piped to the vessel, and wired to the burner control circuit. A manual reset device shall be used on this control. 3.3 Steam Pressure Gauge The steam pressure gauge shall be located at the front of the boiler and include cock and test connection. 3.4 Safety Valves Safety valves of a type and size to comply with ASME Code requirements shall be shipped loose. 3.5 Steam Pressure Controls The steam pressure control to regulate burner operation shall be mounted near the water column. Controls shall be a high limit (manual reset), operating limit (auto reset), and ring rate control. 4.0 Burner and Controls 4.1 Mode of Operation 4.1.1 Burner operation shall be full modulation principle. The burner shall always return to low re position for ignition. 4.1.2 A low re hold control is mounted and wired on the boiler. 4.2 Blower 4.2.1 Air for combustion shall be supplied by a forced draft blower mounted on the burner, to eliminate vibration and reduce noise level.
A11-20
02-02
Firetube Boilers
Model CBL
4.2.2 Maximum sound level of the boiler/burner package shall not exceed _____ dbA (when measured in accordance with ABMA Sound Test Standards). 4.2.3 The impeller shall be cast aluminum with radial blade, carefully balanced, and directly connected to the blower motor shaft. 4.3 Combustion Air Control Combustion air damper and cam-operated fuel metering valve shall be operated by a single damper control motor that regulates the ame according to load demand. Potentiometer type position controls shall be provided to regulate operation of the damper control motor. 4.4 Fuel Specication and Piping Select one of the following fuel types: Fuel series 700 - Gas-red (para 4.4.1). Fuel series 100 - Light oil (No. 2) red (para 4.4.2). Fuel series 200 - Light oil or gas-red (para 4.4.3). Fuel series 600 - No. 6 oil-red (para 4.4.4). Fuel series 400 - No. 6 oil or gas-red (para 4.4.5). 4.4.1 Fuel Series 700 - Gas-Fired 4.4.1.1 Burner Type - The burner shall be mounted at the front of the boiler and of high radiant multi-port type gas entry. The burner shall be approved for operation on natural gas fuel. 4.4.1.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include one manual shutoff valve, solenoid valve, pressure regulator and one (1) plugged leakage test connection (Canada only). 4.4.1.3 Gas Burner Piping - Gas burner piping on all units shall include a gas pressure regulator, a primary gas shutoff valve, motor operated with proof of closure switch and plugged leakage test connection. The main gas valves shall be wired to close automatically in the event of power failure, ame failure, low water or any safety shutdown condition. A lubricating plug cock shall be provided as a means for a tightness check of the primary shutoff valve. An additional plug cock shall be furnished at entrance to gas train. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided. A vent valve shall be located between the safety shutoff valves. 4.4.1.4 Burner Turndown: Turndown range of the burner shall be 10:1 when ring natural gas. (Consult with Cleaver-Brooks Representative regarding high turndown capability based on available gas pressure.) 4.4.2 Fuel Series 100 - Light Oil-Fired 4.4.2.1 Burner Type - The burner shall be mounted at the front of the boiler, and shall be a low pressure air atomizing type approved for operation with CS12-48, Commercial No. 2 oil. 4.4.2.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include one manual shutoff valve, solenoid valve, pressure regulator and one (1) plugged leakage test connection (Canada only). 4.4.2.3 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. The motordriven pump set, shipped loose, to be installed in a location favorable to the oil storage tank, shall be provided. 4.4.2.4 Oil Burner Piping 4.4.2.4.1 Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, low oil pressure switch, two (2) motorized oil valves and pressure gauges, all integrally mounted on the unit. 4.4.2.5 Low Pressure Air Atomizing: Separate air compressor module, shipped loose with burner mounted low atomizing air pressure switch.
A11-21
02-02
Model CBL
4.4.2.6 Turndown range shall be 8:1 when ring No. 2 oil. 4.4.3 Fuel Series 200 - Light Oil or Gas-Fired
Firetube Boilers
4.4.3.1 Burner Type - The burner shall be mounted at the front of the boiler and shall be a combination of the low pressure air atomizing type for oil and multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 Oil or natural gas. 4.4.3.2 Gas Pilot - The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary fuel valve cannot open until ame has been established. The pilot train shall include one manual shut-off valve, solenoid valve, pressure regulator and pressure gauge and one (1) plugged leakage test connection (Canada only). 4.4.3.3 Oil Burner 4.4.3.3.1 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. The motordriven pump set, shipped loose, shall be provided, to be installed in a location favorable to the oil storage tank. 4.4.3.3.2 Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, low oil pressure switch, one (1) solenoid shutoff valve, one (1) motorized oil valve, and pressure gauges all integrally mounted on the unit. 4.4.3.3.3 Low pressure Air Atomizing - Separate air compressor module, shipped loose with burner-mounted low-atomizing air pressure switch. 4.4.3.3.4 Burner Turndown - Turndown range shall be 8:1 when ring No. 2 oil. 4.4.3.4 Gas Burner 4.4.3.4.1 Gas Burner Piping - Gas burner piping on all units shall include a gas pressure regulator, and a primary gas shutoff valve, motor-operated with proof-of-closure switch and plugged leakage test connection. The main gas valves shall be wired to close automatically in the event of power failure, ame failure, low water or any safety shutdown condition. A lubricating plug cock shall be provided as a means for a tightness check of the primary shutoff valve. An additional plug cock shall be furnished at entrance to gas train. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus and additional plugged leakage test connection shall be provided. A vent valve shall be located between the safety shutoff valves. 4.4.3.4.2 Burner Turndown - Turndown range shall be 10:1 when ring natural gas. 4.4.4 Fuel Series 600 - No. 6 Oil-Fired 4.4.4.1 Burner Type - The burner shall be mounted at the front of the boiler and low pressure air atomizing type approved for operation with CS12-48, Commercial No. 6 Oil. 4.4.4.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary oil valve cannot open until pilot ame has been established. The pilot train shall include one manual shutoff valve, solenoid valve, pressure regulator and pressure gauge and one (1) plugged leakage test (Canada only). 4.4.4.3 Oil Pump - An oil pump set with a capacity of approximately twice the maximum burning rate shall be included. The motor driven pump set, shipped loose, to be installed in a location favorable to the oil storage tank shall be provided. 4.4.4.4 Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, low oil pressure switch, one (1) solenoid shutoff valve, one (1) motorized oil valve and pressure gauges all integrally mounted on the unit. 4.4.4.5 Low Pressure Air-Atomizing - Separate air compressor module, shipped loose with the burner-mounted low-atomizing air pressure switch. 4.4.4.6 Oil Preheat The oil shall be preheated by a steam heater and electric heater, each with thermostatic control. Both heaters shall be installed in a single compact shell; mounted, piped, and wired. The thermostatic controls shall be set to cut-out the electric heater when steam is available. 4.4.4.7 Burner Turndown - Turndown range will be 4:1 when ring No. 6 oil. 4.4.5 Fuel Series 400 - No. 6 Oil or Gas-Fired
A11-22
02-02
Firetube Boilers
Model CBL
4.4.5.1 Burner Type - The burner shall be mounted at the front the boiler and shall be a combination of the low pressure atomizing type for oil and multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 6 oil or natural gas. 4.4.5.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary oil valve cannot open until pilot ame has been established. The pilot train shall include one manual shutoff valve, solenoid valve, pressure regulator and pressure gauge, and one (1) plugged leakage test connection. (Canada only.) 4.4.5.3 Oil Burner 4.4.5.3.1 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. The motor driven pump set, shipped loose, shall be provided to be installed in a location favorable to the oil storage tank. 4.4.5.3.2 Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, low oil pressure switch, two (2) motorized oil valves, and pressure gauges all integrally mounted on the unit. 4.4.5.4 Low Pressure Air-Atomizing: Separate air compressor module shipped loose with burner mounted low atomizing air pressure switch. 4.4.5.5 Oil Preheat - The oil shall be preheated by a steam heater and electric heater, each with thermostatic control. Both heaters shall be installed in a single compact shell mounted, piped, and wired. The thermostatic controls shall be sent to cut-out the electric heater when steam is available. 4.4.5.6 Burner Turndown - Turndown range will be 4:1 when ring No. 6 oil. 4.4.5.7 Gas Burner 4.4.5.7.1 Gas Burner Piping - Gas burner piping on all units shall include a gas pressure regulator, and a primary gas shutoff valve, motor-operated with proof-of-closure switch and plugged leakage test connection. The main gas valves shall be wired to close automatically in the event of power failure, ame failure, low water or any safety shutdown condition. A lubricating plug cock shall be provided as means for a tightness check of the primary shutoff valve. An additional plug cock shall be furnished at entrance to gas train. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged leakage test connection shall be provided. A vent valve shall be located between the safety shutoff valves. 4.4.5.7.2 Burner Turndown - Turndown range shall be 4:1 when ring natural gas. 4.5 Boiler Flame Safeguard Controller and Control Panel 4.5.1 CB100E Flame Safeguard 4.5.1.1 Each boiler shall be factory-equipped with ame safeguard controller providing technology and functions equal to the Cleaver-Brooks Model CB100E. Flame safeguard shall be a Cleaver-Brooks Model CB 100E microprocessor-based control to monitor all critical boiler and burner interlocks, control and supervise burner light-off sequence, and initiate an orderly safety procedure in the event of interlock or ame failure. The system shall provide status, fault history, and diagnostic information by means of a BACKLIT LCD display. The system shall be approved by UL, FM, and CSA, and shall be acceptable by IRI. 4.5.2 Control Panel A factory prewired control panel shall be supplied with the boiler/burner package. Panel may be mounted on the burner or boiler. 4.5.3 The panel will have a NEMA 1A rating and contain the ame safeguard controller, burner motor starter, air compressor motor starter, oil-metering pump motor starter, control circuit transformer and fuses, selector switches, indicating lights and terminal strips. Lights shall indicate load demand, ame failure, low water, and fuel valve open.
A11-23
02-02
Model CBL
Firetube Boilers
4.5.3 The panel shall contain fuse protection for the burner motor, air compressor motor, and oil metering pump. 5.0 Efciency Guarantee 5.1 The boiler must be guaranteed to operate at a minimum fuel-to-steam efciency of ____ percent at 100 percent of rating when burning natural gas and ________ fuel-to-steam efciency at 100% ring rate when burning oil (Contact your local Cleaver-Brooks authorized representative for efciency details). 6.0 Warranty 6.1 All equipment is to be guaranteed against defects in materials and/or workmanship for a period of 12 months from date of startup, or 18 months from date of shipment; whichever comes rst. 7.0 Execution 7.1 Shop Tests 7.1.1 The packaged boiler must receive factory tests to check the construction, controls, and operation of the unit. All tests may be witnessed by the purchaser, if desired. 7.2 Start-up Service 7.2.1 After boiler installation is completed, the manufacturer shall provide the services of a eld representative for starting the unit and training the operator at no additional costs. 7.2.1.1 A factory-approved and authorized start-up report shall be submitted to the customer/user at the time of start-up.
A11-24
02-02
Section A12
Model ICB
CONTENTS Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-3 Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-3 Dimensions and Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-4 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-13 Engineering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-13 Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-13 Blowdown Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-13 Burner/Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-13 Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-14 Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-14 Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-14 Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-14 Sample Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-20
A12-1
12-02
Model ICB
Firetube Boilers
ILLUSTRATIONS Figure A12-1. Model ICB Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-7 Figure A12-2. Model ICB Hot Water Boiler Dimensions, 4-Pass and 3-Pass (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-9 Figure A12-3. Space Required to Open Rear Head on Model ICB Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-11 Figure A12-4. Model ICB Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-11 Figure A12-5. Model ICB Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-12 Figure A12-6. Typical Fuel Oil Supply Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-18 Figure A12-7. Boiler Room Length (Typical Layouts) Model ICB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-19 Figure A12-8. Boiler Room Width (Typical Layout) Model ICB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-19 TABLES Table A12-1. Model ICB Steam Boiler Ratings, 4-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-5 Table A12-2. Model ICB Steam Boiler Ratings, 3-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-5 Table A12-3. Model ICB Hot Water Boiler Ratings, 4-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-6 Table A12-4. Model ICB Hot Water Boiler Ratings, 3-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-6 Table A12-5. Model ICB Steam Boiler Dimensions, 4-Pass and 3-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-8 Table A12-6. Model ICB Hot Water Boiler Dimensions, 4-Pass and 3-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-10 Table A12-7. Model ICB Steam Volume and Disengaging Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-15 Table A12-8. Model ICB Steam Boiler Safety Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-15 Table A12-9. Model ICB Hot Water Boiler Relief Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-16 Table A12-10. Model ICB Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-16 Table A12-11. Model ICB Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-17 Table A12-12. Model ICB Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-17 Table A12-13. Altitude Correction for Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-17 Table A12-14. Sound Levels in dBA for 4-Pass ICB Boilers at High Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-17 Table A12-15. Model ICB, Standard, Minimum Required Gas Pressure at Entrance to Standard, FM & IRI Gas Trains (Upstream of Gas Pressure Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-18 The following information applies to the Cleaver-Brooks Model ICB Boiler.
A12-2
12-02
Firetube Boilers
Model ICB
Available options include the following (contact your local Cleaver-Brooks Authorized Representative for option details). Boiler Options: Three-pass design. Drain valves. Additional screwed or anged tappings. Blowdown valves. Non-return valves. Feedwater valves and regulators. Surface blowdown systems. Blend pump. Surge load bafes. Seismic design. Burner/Control Options: Flame safeguard controllers. Lead/lag system. High altitude design. Special insurance and code requirements (e.g., IRI, FM, CSD-1). Alarm bell/silence switch. Special motor requirements (TEFC, high efciency). Special indicating lights. Main disconnect. Elapsed time meter. Voltmeter/micro-ammeter. NEMA enclosures. Low-re hold control. Remote emergency shut-off (115V). Circuit breakers. Day/night controls. Special power requirements. Stack thermometer. Fuel Options Air atomizing oil burner, 200 800 hp. Pressure atomizing oil burner, 100 150 hp. Gas strainer. Gas pressure gauge. Future gas conversion. Oversized/undersized gas trains.

The Cleaver-Brooks Model ICB Boiler line provides a quality product utilizing a baseline boiler/burner design. Additionally, the boiler/burner package has the UL/cUL label. The following features apply: Four-Pass Intercooled Design: Four-pass design provides high ue gas velocities and low stack temperatures to maximize efciency. Three-Pass Intercooled Design (optional): Versatile design offered with choice of three or four-pass construction to meet application needs. Intercooled Rear Turnaround: Rear furnace turnaround area is uid cooled and has a davited access opening for full accessibility to 2nd pass tubes and furnace. It eliminates conned space issues and provides for ease of maintenance. All tubes can be removed from either the front or rear of the boiler. Front and Rear Doors: Davit, front and rear doors, all sizes. Provides access to front and rear tube sheet. Rear door completely covers and insulates rear tube sheet. Natural Gas, No. 2 Oil, or Combination Burners Available: Combination gas/oil burners provide quick fuel changeover without burner adjustment.
PRODUCT OFFERING
Cleaver-Brooks Model ICB Boilers are available in low pressure steam, high pressure steam, and hot water designs. Burners are available to re natural gas, No. 2 oil, or a combination of oil and gas. Standard product offering is: 100 800 hp. 30 and 125 psig hot water. 15 300 psig steam. Full modulation, all sizes.
A12-3
12-02
Model ICB
Firetube Boilers

Dimensions and ratings for the Model ICB Boilers are shown in the following tables and illustrations. The information is subject to change without notice. Table A12-1. Model ICB Steam Boiler Ratings, 4-Pass Table A12-2. Model ICB Steam Boiler Ratings, 3-Pass (Optional) Table A12-3. Model ICB Hot Water Boiler Ratings, 4-Pass Table A12-4. Model ICB Hot Water Boiler Ratings, 3-Pass (Optional) Figure A12-1. Model ICB Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional) Table A12-5. Model ICB Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional) Figure A12-2. Model ICB Hot Water Boiler Dimensions, 4-Pass and 3-Pass (Optional) Table A12-6. Model ICB Hot Water Boiler Dimensions, 4-Pass and 3-Pass (Optional) Figure A12-3. Space Required to Open Rear Head on Model ICB Boilers Figure A12-4. Model ICB Boilers Lifting Lug Location Figure A12-5. Model ICB Boiler Mounting Piers
A12-4
12-02
Firetube Boilers
Table A12-1. Model ICB Steam Boiler Ratings, 4-Pass
BOILER H.P. BURNER MODEL RATINGS SEA LEVEL TO 700 FT. Rated Capacity (lbs-steam/hr from and at 212F) Btu Output (1000 Btu/hr) 3450 3348 4313 4184 5175 5021 6900 6695 8625 8369 10350 10043 12075 11716 13800 13390 17250 16738 20700 20085 100 FP-3 125 FP-3 150 FP-3 200 FP-4 250 FP-4 300 D145P 350 D175P 400 D210P 500 D252P 600 D300P
Model ICB
700 D336P
800 D378P
24150 23433
27600 26780
APPROXIMATE FUEL CONSUMPTION AT RATED CAPACITY BASED ON NOMINAL 82% EFFICIENCY Light Oil gph (140,000 Btu/gal) Gas CFH (1000 Btu) Gas (Therm/hr) 29.2 4082 40.8 36.4 5103 51.0 43.7 6124 61.2 58.3 8165 81.7 72.9 10206 102.1 87.5 12247 122.5 102.1 14280 142.8 116.6 16329 163.3 145.8 20415 204.2 175.0 24494 245.0 204.1 28576 285.8 233.3 32659 326.6
POWER REQUIREMENTS SEA LEVEL TO 700 FT. (60 HZ) Blower Motor hp Separate Compressor Motor hp (Oil only) Integral Oil/Air Motor hp (Oil only) Oil Metering Pump Motor hp (Oil only) Circulating Oil Pump Motor hp (Oil only) BOILER DATA Heating Surface sq-ft. (Fireside) 353 438 555 729 885 1055 1384 1522 1734 2094 3244 3641 3 ** * 5 ** * 7-1/2 ** * 7-1/2 3 1/2 7-1/2 3 1/2 15 2 3/4 20 5 1/2 3/4 25 5 3/4 3/4 30 7-1/2 3/4 3/4 40 7-1/2 3/4 3/4 60 7-1/2 3/4 1 60 15 1 1
* = Integral oil pump ** = No air compressor required (pressure atomized system) NOTE: All fractional hp motors will be single phase voltage except oil metering pump motor (3-phase); integral motors will be 3-phase voltage.
Table A12-2. Model ICB Steam Boiler Ratings, 3-Pass

BOILER H.P. BURNER MODEL RATINGS SEA LEVEL TO 700 FT. Rated Capacity (lbs-steam/hr from and at 212F) Btu Output (1000 Btu/hr) 3450 3348 4313 4184 5175 5021 6900 6695 8625 8369 10350 10043 12075 11716 13800 13390 17250 16738 20700 20085 24150 23433 27600 26780 100 FP-3 125 FP-3 150 FP-3 200 FP-4 250 FP-4 300 FP-4 350 FP-4 400 D175P 500 D210P 600 D252P 700 D300P 800 D336P
APPROXIMATE FUEL CONSUMPTION AT RATED CAPACITY BASED ON NOMINAL 80% EFFICIENCY Light Oil gph (140,000 Btu/gal) Gas CFH (1000 Btu) Gas (Therm/hr) 29.9 4184 41.8 37.5 5230 52.3 45.0 6280 62.8 60.0 8370 83.7 74.5 10460 104.6 89.5 12555 125.5 104.5 14650 146.5 119.5 16750 167.5 149.5 20925 209.3 179.5 25100 251.0 209 29300 293.0 239 33500 335.0
POWER REQUIREMENTS SEA LEVEL TO 700 FT. (60 HZ) Blower Motor hp Separate Compressor Motor hp (Oil only) Integral Oil/Air Motor hp (Oil only) Oil Metering Pump Motor hp (Oil only) Circulating Oil Pump Motor hp (Oil only) BOILER DATA Heating Surface sq-ft. (Fireside) 353 438 555 729 885 1055 1384 1522 1734 2094 3244 3641 2 ** * 3 ** * 5 ** * 7-1/2 3 1/2 7-1/2 3 1/2 10 3 3/4 10 3 3/4 20 5 1/2 3/4 25 5 3/4 3/4 30 7-1/2 3/4 3/4 40 7-1/2 3/4 1 60 7-1/2 3/4 1
A12-5
12-02
Model ICB
Table A12-3. Model ICB Hot Water Boiler Ratings, 4-Pass
BOILER H.P. BURNER MODEL RATINGS SEA LEVEL TO 700 FT. Btu Output (1000 Btu/hr) 3348 4184 5021 6695 8369 10043 11716 13390 16738 100 FP-3 125 FP-3 150 FP-3 200 FP-4 250 FP-4 300 D145P 350 D175P 400 D210P 500 D252P
Firetube Boilers
600 D300P
700 D336P
800 D378P
20085
23433
26780
POWER REQUIREMENTS SEA LEVEL TO 700 FT. (60 HZ) Blower Motor hp Separate Compressor Motor hp (Oil only) Integral Oil/Air Motor hp (Oil only) Oil Metering Pump Motor hp (Oil only) Circulating Oil Pump Motor hp (Oil only) BOILER DATA Heating Surface sq-ft. (Fireside) 353 438 555 729 885 1055 1384 1522 1734 2094 3244 3641 3 ** * 5 ** * 7-1/2 ** * 7-1/2 3 1/2 7-1/2 3 1/2 15 2 3/4 20 5 1/2 3/4 25 5 3/4 3/4 30 7-1/2 3/4 3/4 40 7-1/2 3/4 3/4 60 7-1/2 3/4 1 60 15 1 1
Table A12-4. Model ICB Hot Water Boiler Ratings, 3-Pass

BOILER H.P. BURNER MODEL RATINGS SEA LEVEL TO 700 FT. Btu Output (1000 Btu/hr) 3348 4184 5021 6695 8369 10043 11716 13390 16738 20085 23433 26780 100 FP-3 125 FP-3 150 FP-3 200 FP-4 250 FP-4 300 FP-4 350 FP-4 400 D175P 500 D210P 600 D252P 700 D300P 800 D336P
POWER REQUIREMENTS SEA LEVEL TO 700 FT. (60 HZ) Blower Motor hp Separate Compressor Motor hp (Oil only) Integral Oil/Air Motor hp (Oil only) Oil Metering Pump Motor hp (Oil only) Circulating Oil Pump Motor hp (Oil only) BOILER DATA Heating Surface sq-ft. (Fireside) 353 438 555 729 885 1055 1384 1522 1734 2094 3244 3641 2 ** * 3 ** * 5 ** * 7-1/2 3 1/2 7-1/2 3 1/2 10 3 3/4 10 3 3/4 20 5 1/2 3/4 25 5 3/4 3/4 30 7-1/2 3/4 3/4 40 7-1/2 3/4 1 60 7-1/2 3/4 1
A12-6
12-02
Firetube Boilers
4-PASS ICB STANDARD STEAM BOILERS
Model ICB
3-PASS ICB STANDARD STEAM BOILERS
Figure A12-1. Model ICB Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional)
A12-7
12-02
Model ICB
Table A12-5. Model ICB Steam Boiler Dimensions, 4-Pass and 3-Pass
BOILER H.P. LENGTHS Overall (3-Pass) Overall (4-Pass) Shell Base Frame Base Frame to Rear Flange Flange to Steam Nozzle WIDTHS Overall I.D. Boiler Center to Water Column Center to Lagging Center to Auxiliary LWCO Base Outside Base Inside HEIGHTS Base to Boiler Centerline Base to Vent Outlet Base to Rear Door Davit Base to Steam Outlet Base Frame Base to Bottom Boiler CONNECTIONS Chemical Feed Feedwater Inlet (Both Sides) Steam Nozzle (15 psig) 150 LB. FLG. Steam Nozzle (150 psig) 300 LB. FLG. Drain Front & Rear (15 psig) Blowdown-Front & Rear(150 psig) Surface Blowoff (150 psig only) Vent Stack Diameter (Flanged) Flange to Center Vent MINIMUM CLEARANCES Rear Door Swing Tube Removal Front Tube Removal Rear DD GG HH 34" 95" 96-1/2" 34" 121" 36" 119" 36" 160" 43" 122" 43" 148" 46" 149" 46" 165" 53" 146" G S Y Y W W T BB CC 1" 1-1/4" 8" 4" 1-1/2" 1-1/4" 1" 16" 9-1/8" 1" 1-1/2" 8" 4" 1-1/2" 1-1/2" 1" 16" 9-1/8" 1" 1-1/2" 8" 4" 1-1/2" 1-1/2" 1" 16" 9-1/8" 1" 2" 10" 4" 2" 1-1/2" 1" 16" 9-1/8" 1" 2" 10" 6" 2" 1-1/2" 1" 20" 10-5/8" 1" 2" 12" 6" 2" 1-1/2" 1" 20" 10-5/8" 1" 2-1/2" 12" 6" 2" 1-1/2" 1" 20" 10-5/8" 1" 2-1/2" 12" 6" 2" 2" 1" 20" 10-5/8" 1" 2-1/2" 12" 8" 2" 2" 1" 24" 12-5/8" F O OA P Q R 44-1/2" 80-3/4" 82-1/4" 78-3/8" 12" 16" 44-1/2" 80-3/4" 82-1/4" 78-3/8" 12" 16" 46" 85" 86-1/2" 82-3/8" 12" 16" 46" 85" 86-1/2" 82-3/8" 12" 16" 54" 101" 101" 96-1/4" 10" 17" 54" 101" 101" 96-1/4" 10" 17" 56" 106" 106" 56" 106" 106" 65-1/2" I J K L LL M N 80" 55" 42-1/2" 30-1/2" 37-1/2" 47-1/2" 39-1/2" 80" 55" 42-1/2" 30-1/2" 37-1/2" 47-1/2" 39-1/2" 85" 60" 45" 33" 40" 52-1/2" 44-1/2" 85" 60" 45" 33" 40" 52-1/2" 44-1/2" 97" 72" 51" 39" 46" 58-1/2" 50-1/2" 97" 72" 51" 39" 46" 58-1/2" 50-1/2" 103" 78" 54" 42" 49" 64" 56" 103" 78" 54" 42" 49" 64" 56" 117" 92" 61" 49" 56" 68" 55" A A B C D E 171" 171" 197" 197" 195" 195" 243-1/2" 208-1/2" 234-1/2" 237-1/2" 243-1/2" 208-1/2" 241" 247" 263" 268" 255" DIM 100 125 150 200 250 300 350 400 500
Firetube Boilers
600
700
800
290-1/2" 281-1/2" 306-1/2" 312"
257-1/2" 290-1/2" 284-1/2"
127-7/8" 153-7/8" 151-7/8" 192-7/8" 160-7/8" 186-7/8" 189-7/8" 205-7/8" 195-3/4" 228-3/4" 219-7/8" 241-7/8" 124-3/8" 150-3/8" 148-3/8" 189-3/8" 157-3/8" 183-3/8" 184-3/8" 200-3/8" 187-1/4" 220-1/4" 211-3/8" 233-3/8" 9-1/2" 55-7/8" 9-1/2" 61-7/8" 9-1/2" 65-7/8" 9-1/2" 77-7/8" 9-1/2" 68-7/8" 9-1/2" 80-7/8" 9-1/2" 78-7/8" 9-1/2" 94-7/8" 14-1/2" 82-3/4" 14-1/2" 106-3/4" 14-1/2" 98-7/8" 14-1/2" 111-7/8"
117" 92" 61" 49" 56" 68" 55"
131" 106" 68" 56" 63" 74-3/4" 61-3/4"
131" 106" 68" 56" 63" 74-3/4" 61-3/4"
65-1/2"
71"
71"
122-1/2" 122-1/2" 135-5/8" 135-5/8" 122-1/2" 122-1/2" 135-5/8" 135-5/8" 118" 12" 19" 118" 12" 19" 130-5/8" 130-5/8" 12" 17-1/2" 12" 17-1/2"
101-1/2" 101-1/2" 10" 17" 10" 17"
1" 2-1/2" 12" 8" 2" 2" 1" 24" 12-5/8"
1" 2-1/2" 12" 8" 2" 2" 1" 24" 12-5/8"
1" 2-1/2" 12" 8" 2" 2" 1" 24" 12-5/8"
53" 179"
60" 170"
60" 192"
122-1/2" 120-1/2" 161-1/2" 126-1/2" 152-1/2" 150-1/2" 166-1/2" 148-1/2" 181-1/2" 172-1/2" 194-1/2"
MINIMUM BOILER ROOM LENGTH ALLOWING FOR DOOR SWING AND TUBE REMOVAL FROM: Front of Boiler Rear of Boiler (3-Pass) Rear of Boiler (4-Pass) Thru Window or Door (3-Pass) Thru Window or Door (4-Pass) WEIGHTS Normal Water Weight (lbs) Shipping Weight (15psig) (lbs) Shipping Weight (150psig) (lbs) 5,140 10,123 10,877 6,515 11,303 12,220 7,184 11,931 13,112 9,612 14,106 15,637 10,175 16,958 17,613 12,278 19,051 20,404 13,192 22,344 25,344 14,593 23,918 27,175 17,870 28,934 31,990 21,780 33,189 36,780 26,638 41,179 45,724 30,026 45,226 50,244 RF RR RR RD RD 257" 309" 307" 389" 441" 441" 326" 371" 371" 378" 423" 385" 427" 417" 395" 461" 510" 510" 450" 492" 495" 494" 539" 544-1/2"
303-1/2" 355-1/2" 351-1/2" 303-1/2" 355-1/2" 351-1/2" 237" 237" 263" 263" 263" 263"
468-1/2" 441-1/2" 444" 340"
429-1/2" 436-1/2" 473-1/2" 341" 346"
311-1/2" 283-1/2" 309-1/2" 315-1/2" 311-1/2" 283-1/2" 316" 325"
375-1/2" 373-1/2" 398-1/2" 404"
342-1/2" 375-1/2" 376-1/2"
NOTE: Accompanying dimensions, while sufciently accurate for layout purposes, must be conrmed for actual option requirements.
A12-8
12-02
Firetube Boilers
4-PASS ICB STANDARD HOT WATER BOILERS
Model ICB
3-PASS ICB STANDARD HOT WATER BOILERS
Figure A12-2. Model ICB Hot Water Boiler Dimensions, 4-Pass and 3-Pass (Optional)
A12-9
12-02
Model ICB
Table A12-6. Model ICB Hot Water Boiler Dimensions, 4-Pass and 3-Pass
BOILER H.P. LENGTHS Overall (3-Pass) Overall (4-Pass) Shell Base Frame Base Frame to Rear Flange Flange to Return Flange to Outlet WIDTHS Overall I.D. Boiler Center to LWCO Controller Base Outside Base Inside HEIGHTS Base to Boiler Centerline Base to Vent Outlet Base to Rear Door Davit Base to Return/Outlet Base Frame Base to Bottom Boiler CONNECTIONS Waterll (Both Sides) Water Return Water Outlet Drain Front & Rear Air Vent Vent Stack Diameter (Flanged) Flange to Center Vent MINIMUM CLEARANCES Rear Door Swing Tube Removal Front Tube Removal Rear DD GG HH 34" 95" 96-1/2" 34" 121" 36" 119" 36" 160" 43" 122" 43" 148" 46" 149" 46" 165" 53" 146" S U Y W T BB CC 1-1/2" 4" 4" 1-1/2" 1-1/2" 16" 9-1/8" 1-1/2" 6" 6" 1-1/2" 1-1/2" 16" 9-1/8" 1-1/2" 6" 6" 1-1/2" 1-1/2" 16" 9-1/8" 2" 6" 6" 2" 1-1/2" 16" 9-1/8" 2" 8" 8" 2" 1-1/2" 20" 10-5/8" 2" 8" 8" 2" 1-1/2" 20" 10-5/8" 2-1/2" 8" 8" 2" 1-1/2" 20" 10-5/8" 2-1/2" 10" 10" 2" 1-1/2" 20" 10-5/8" 2-1/2" 10" 10" 2" 2" 24" 12-5/8" H O OA P Q R 44-1/2" 80-3/4" 82-1/4" 78-3/8" 12" 16" 44-1/2" 80-3/4" 82-1/4" 78-3/8" 12" 16" 46" 85" 86-1/2" 82-3/8" 12" 16" 46" 85" 86-1/2" 82-3/8" 12" 16" 54" 101" 101" 96-1/4" 10" 17" 54" 101" 101" 96-1/4" 10" 17" 56" 106" 106" 56" 106" 106" 65-1/2" I J K M N 65" 55" 34-1/2" 47-1/2" 39-1/2" 65" 55" 34-1/2" 47-1/2" 39-1/2" 70" 60" 37 52-1/2" 44-1/2" 70" 60" 37" 52-1/2" 44-1/2" 82" 72" 43" 58-1/2" 50-1/2" 82" 72" 43" 58-1/2" 50-1/2" 88" 78" 46" 64" 56" 88" 78" 46" 64" 56" 102" 92" 53" 68" 55" A A B C D E F 171" 171" 197" 197" 195" 195" 243-1/2" 208-1/2" 234-1/2" 237-1/2" 243-1/2" 208-1/2" 241" 247" 263" 268" 255" DIM 100 125 150 200 250 300 350 400 500
Firetube Boilers
600
700
800
290-1/2" 281-1/2" 306-1/2" 312"
257-1/2" 290-1/2" 284-1/2"
127-7/8" 153-7/8" 151-7/8" 192-7/8" 160-7/8" 186-7/8" 189-7/8" 205-7/8" 195-3/4" 228-3/4" 219-7/8" 241-7/8" 124-3/8" 150-3/8" 148-3/8" 189-3/8" 157-3/8" 183-3/8" 184-3/8" 200-3/8" 187-1/4" 220-1/4" 211-3/8" 233-3/8" 9-1/2" 82" 97-1/2" 9-1/2" 98" 123" 9-1/2" 95-5/8" 9-1/2" 9-1/2" 9-1/2" 9-1/2" 9-1/2" 14-1/2" 14-1/2" 14-1/2" 14-1/2"
136-5/8" 101-5/8" 115-5/8" 117-5/8" 132-5/8" 125-1/2" 143-1/2" 139-1/2" 161-1/2" 175" 171" 193"
120-5/8" 161-5/8" 127-5/8" 141-5/8" 143-5/8" 158-5/8" 152-1/2"
102" 92" 53" 68" 55"
116" 106" 60" 74-3/4" 61-3/4"
116" 106" 60" 74-3/4" 61-3/4"
65-1/2"
71"
71"
122-1/2" 122-1/2" 135-5/8" 135-5/8" 122-1/2" 122-1/2" 135-5/8" 135-5/8" 118" 12" 19" 118" 12" 19" 130-5/8" 130-5/8" 12" 17-1/2" 12" 17-1/2"
101-1/2" 101-1/2" 10" 17" 10" 17"
2-1/2" 12" 12" 2" 2" 24" 12-5/8"
2-1/2" 12" 12" 2" 2" 24" 12-5/8"
2-1/2" 12" 12" 2" 2" 24" 12-5/8"
53" 179"
60" 170"
60" 192"
122-1/2" 120-1/2" 161-1/2" 126-1/2" 152-1/2" 150-1/2" 166-1/2" 148-1/2" 181-1/2" 172-1/2" 194-1/2"
MINIMUM BOILER ROOM LENGTH ALLOWING FOR DOOR SWING AND TUBE REMOVAL FROM: Front of Boiler Rear of Boiler (3-Pass) Rear of Boiler (4-Pass) Thru Window or Door (3-Pass) Thru Window or Door (4-Pass) WEIGHTS Normal Water Weight (lbs) Shipping Weight (30psig) (lbs) Shipping Weight (125psig) (lbs) 5,848 10,123 10,238 7,397 11,303 11,418 8,378 11,931 13,153 11,180 14,106 15,679 11,940 16,958 18,609 14,380 19,051 21,270 16,190 22,344 24,522 17,884 23,918 26,631 22,572 28,934 32,175 27,431 33,189 36,972 32,991 41,179 47,122 37,120 45,226 51,782 RF RR RR RD RD 257" 309" 307" 389" 441" 441" 326" 371" 371" 378" 423" 385" 427" 417" 395" 461" 510" 510" 450" 492" 495" 494" 539" 544-1/2"
303-1/2" 355-1/2" 351-1/2" 303-1/2" 355-1/2" 351-1/2" 237" 237" 263" 263" 263" 263"
468-1/2" 441-1/2" 444" 340"
429-1/2" 436-1/2" 473-1/2" 341" 346"
311-1/2" 283-1/2" 309-1/2" 315-1/2" 311-1/2" 283-1/2" 316" 325"
375-1/2" 373-1/2" 398-1/2" 404"
342-1/2" 375-1/2" 376-1/2"
A12-10
12-02
Firetube Boilers
Model ICB
ALL DIMENSIONS IN INCHES BOILER HP 100 125 150 200 250 300 350 400 500 600 700 800 A 31 33 39 42 49 56 B 45 47 53 56 65 74 C 47 52 58 61 69 80 D 70 80 86 92 106 121 E 34 36 43 46 53 60
Figure A12-3. Space Required to Open Rear Head on Model ICB Boilers
ALL DIMENSIONS IN INCHES BOILER HP 100 125 150 200 250 300 350 400 500 600 700 800 A 75-1/4 75-1/4 79-1/2 79-1/2 94 94 99 99 115-1/2 115-1/2 128-1/4 128-1/4 B 21-3/8 21-3/8 25-3/8 25-3/8 32 32 32 32 34 34 34 34 C 81-1/4 107-1/4 96-1/2 137-1/2 96-1/4 122-1/4 123-1/4 139-1/4 125-3/4 158-3/4 151 173 D 10 10 10 10 10 10 10 10 11 11 11 11 E 3 3 3 3 3 3 3 3 3 3 3 3
NOTE: A, B, and C dimensions may vary by 1 inch.
Figure A12-4. Model ICB Boilers Lifting Lug Location
A12-11
12-02
Model ICB
Firetube Boilers
" E"
ALL DIMENSIONS IN INCHES BOILER HP 100 125 150 200 250 300 350 400 500 600 700 800 A 6 6 6 6 6 6 6 6 6 6 6 6 B 9 9 9 9 9 9 9 9 12 12 12 12 C 127-1/2 153-1/2 151-1/2 192-1/2 160-1/2 186-1/2 187-1/2 203-1/2 190-1/2 223-1/2 214-1/2 236-1/2 D 34-1/2 34-1/2 39-1/2 39-1/2 45-1/2 45-1/2 51 51 49-1/2 49-1/2 56-1/4 56-1/4 E 52-1/2 52-1/2 57-1/2 57-1/2 63-1/2 63-1/2 69 69 73-1/2 73-1/2 80-1/4 80-1/4 F 4 4 4 4 4 4 4 4 6-1/2 6-1/2 6-1/2 6-1/2 G 39-1/2 39-1/2 44-1/2 44-1/2 50-1/2 50-1/2 56 56 55 55 61-3/4 61-3/4 X 17-1/2 17-1/2 17-1/2 17-1/2 17-1/2 17-1/2 17-1/2 17-1/2 20-1/2 20-1/2 20-1/2 20-1/2
NOTE: 6-inch high mounting piers recommended for use beneath the boiler base frame. The use of these piers provides increased inspection accessibility to the boiler and added height for washing down the area beneath the boiler.
Figure A12-5. Model ICB Boiler Mounting Piers
A12-12
12-02
Firetube Boilers
Model ICB
Gas-Fired Burners
PERFORMANCE DATA
Contact your local Cleaver-Brooks Authorized Representative for efciencies or additional information. Cleaver-Brooks ICB boilers are available with the standard burner package, or optional induced ue gas recirculation, refer to the Model ICB-LN in Section A13.
Table A12-13 lists minimum required gas pressure for altitude correction. Table A12-15 shows minimum and maximum gas pressure requirements for Standard, FM and IRI ICB Boiler gas trains upstream of the gas pressure regulator. For oversized or undersized gas trains or altitude above 700 feet, contact your local Cleaver-Brooks Authorized Representative.
Fuel Connections Gas
ENGINEERING DATA
The following engineering information is provided for Model ICB Boilers. Additional detail is available from your local Cleaver-Brooks Authorized Representative. Boiler Information Table A12-7 shows steam volume and disengaging area for Model ICB Boilers. Table A12-8 lists quantity and outlet size for safety valves supplied on Model ICB Steam Boilers. Table A12-9 lists quantity and outlet size for relief valves supplied on Model ICB Hot Water Boilers. Table A12-10 gives recommended steam nozzle sizes on Model ICB Boilers. Table A12-11 shows recommended non-return valve sizes for Model ICB Boilers. Blowdown Water Requirements Some local codes require blowdown tanks to be constructed in accordance with recommendations of the National Board of Boiler and Pressure Vessel Inspectors. The National Boards recommendations base the size of the blowdown tank on the removal of at least 4 inches of water from the boiler. Table A12-12 lists the approximate quantity of water represented by 4 inches of water at normal operating level for Cleaver-Brooks Model ICB Boilers. Burner/Control Information
Burner Characteristics
The local gas company should be consulted for requirements and authorization for installation and inspection of gas supply piping. Installation of gas supply piping and venting must be in accordance with all applicable engineering guidelines and regulatory codes. All connections made to the boiler should be arranged so that all components remain accessible for inspection, cleaning and maintenance. A drip leg should be installed in the supply piping before the connection to the gas pressure regulator. The drip leg should be at least as large as the inlet tting supplied with the boiler. Consideration must be given to both volume and pressure requirements when choosing gas supply piping size. Refer to the boiler dimension diagram provided by Cleaver-Brooks for the particular installation. Connections to the burner gas train should be made with a union, so that gas train components or the burner may be easily disconnected for inspection or service. Upon completion of the gas piping installation, the system should be checked for gas leakage and tight shutoff of all valves.
Fuel Connections Oil
Maximum altitude for standard burners is 700 feet. Contact your local Cleaver-Brooks Authorized Representative for higher altitude availability. Note that altitude correction and burner changes are required for higher altitudes which may alter dimensions, motor hp and gas pressures.
A12-13
12-02
Model ICB
A strainer must be installed in the supply piping upstream of the burner supply pump in order to prevent entry of foreign material into the pump, fuel control valves, or burner nozzle(s). The strainer must be sized for the burner supply pump capacity. A strainer mesh of 150 microns (0.005") is recommended. Install a check valve in the line to prevent draining of the oil suction line when the burner is not in operation. Location of the check valve varies with the system, but usually it is located as close as possible to the storage tank. Installation of a vacuum gauge in the burner supply line between the burner oil pump and the strainer is recommended. Regular observation and recording of the gauge indication will assist in determining when the strainer needs servicing. Upon completion of the oil piping installation, the system should be checked for oil or air leakage and tight shutoff of all valves. Boiler Room Information Figure A12-7 shows typical boiler room length requirements. Figure A12-8 shows typical boiler room width requirements. Stack Support Capabilities 100 800 hp Model ICB Boilers can support up to 2000 lbs without additional support. 100 800 hp Model ICB Boilers can be reinforced to support up to 3000 lbs. Boiler Room Combustion Air When determining boiler room air requirements, the size of the room, air ow, and velocity of air must be reviewed as follows: 1. Size (area) and location of air supply openings in boiler room. A. Two (2) permanent air supply openings in the outer walls of the boiler room are recommended. Locate one (1) at each end of the boiler room, preferably below a height of 7 feet. This allows air to sweep the length of the boiler. B. Air supply openings can be louvered for weather protection, but they should not be covered with ne mesh wire, as this type of covering has poor air ow qualities and is subject to clogging by dust or dirt. C. A vent fan in the boiler room is not recommended, as it could create a slight vacuum under certain conditions and cause variations in the quantity of combustion air. This can result in unsatisfactory burner performance.
Firetube Boilers
D. Under no condition should the total area of the air supply openings be less than one (1) square foot. E. Size the openings by using the formula: Area (sq-ft) = CFM/FPM 2. Amount of air required (cfm). A. Combustion Air = Rated bhp x 8 cfm/bhp. B. Ventilation Air = Maximum bhp x 2 cfm/bhp or a total of 10 cfm/bhp up to 1000 feet elevation. Add 3 percent more per 1000 feet of added elevation. 3. Acceptable air velocity in Boiler Room (fpm). A. From oor to (7) foot height 250 fpm. B. Above (7) foot height 500 fpm. Example: Determine the area of the boiler room air supply openings for (1) 300 hp boiler at 800 feet altitude. The air openings are to be 5 feet above oor level. Air required: 300 x 10 = 3000 cfm (from 2B above). Air velocity: Up to 7 feet = 250 fpm (from 3 above). Area Required: Area = cfm/fpm = 3000/250 = 12 sq-ft total. Area/Opening: 12/2 = 6 sq-ft/opening (2 required).
NOTICE
Consult local codes, which may supersede these requirements. Stack/Breeching Size Criteria The design of the stack and breeching must provide the required draft at each boiler ue gas outlet. Proper draft is critical to burner performance. Although constant pressure at the ue gas outlet of the Model ICB is not required, it is necessary to size the stack/breeching to limit ue gas pressure variation. The allowable pressure range is 0.25" W.C. to +0.25" W.C. For additional information, please review Section I4, General Engineering Data (Stacks) and Section F, Stacks. Stack and breeching sizes should always be provided by a reputable stack supplier who will design the stack and breeching system based on the above criteria. Your local Cleaver-Brooks Authorized Representative is capable of assisting in your evaluation of the stack/breeching design.
A12-14
12-02
Firetube Boilers
Table A12-7. Model ICB Steam Volume and Disengaging Areas
STEAM VOLUME CU-FT BOILER HP 100 125 150 200 250 300 350 400 500 600 700 800 HIGH PRESSURE (A) 11.2 14 19 25 27.8 33.2 47.9 52.6 74.5 89.6 100.8 112.7 LOW PRESSURE (B) 16.5 20.5 26.3 34.6 41.4 49.4 66.3 72.9 94.9 114.2 127 142 STEAM RELIEVING AREA SQ-IN HIGH PRESSURE (A) 3917 4882 5472 7200 6811 8122 9374 10296 11405 13723 14602 16315 LOW PRESSURE (B) 4363 5443 5990 7891 7618 9072 10238 11246 12168 14630 15538 17381
Model ICB
NOTE: 1. Based on normal water level. A. Based on 150 psig design pressure. B. Based on 15 psig design pressure.
Table A12-8. Model ICB Steam Boiler Safety Valve Outlet Size
VALVE SETTING 15 PSIG STEAM NO. OF VALVES REQD 1 1 1 2 2 2 3 3 3 4 5 OUTLET SIZE (IN.) 2-1/2 3 3 2-1/2 (1) 2-1/2 (1) 3 3 (1) 2 (2) 3 (2) 3 (1) 2-1/2 3 (3) 3 (1) 2-1/2 (3) 3 (2) 2-1/2 150 PSIG STEAM NO. OF VALVES REQD 1 2 2 2 2 2 2 2 2 3 3 OUTLET SIZE (IN.) 1-1/2 (1) 1-1/2 (1) 1-1/4 (1) 1-1/2 (1) 1-1/4 1-1/2 (1) 2 (1) 1-1/2 2 (1) 2-1/2 (1) 2 (1) 2-1/2 (1) 2 2-1/2 (2) 2-1/2 (1) 2 (2) 2-1/2 (1) 2 200 PSIG STEAM NO. OF VALVES REQD 1 2 2 2 2 2 2 2 2 2 2 OUTLET SIZE (IN.) 1-1/2 (1) 1-1/4 (1) 1 1-1/4 (1) 1-1/2 (1) 1-1/4 1-1/2 (1) 2 (1) 1-1/2 2 2 (1) 2-1/2 (1) 2 2-1/2 2-1/2 250 PSIG STEAM NO. OF VALVES REQD 1 2 2 2 2 2 2 2 2 2 2 OUTLET SIZE (IN.) 1-1/4 1 (1) 1 (1) 1-1/4 1-1/4 (1) 1-1/2 (1) 1-1/4 1-1/2 (1) 1-1/2 (1) 2 (1) 1-1/2 (1) 2 2 (1) 2 (1) 2-1/2 2-1/2
BOILER HP 100 125 150 200 250 300 350 400 500 600 700, 800
A12-15
12-02
Model ICB
Table A12-9. Model ICB Hot Water Boiler Relief Valve Outlet Size
VALVE SETTING 30 PSIG HW NO. OF VALVES REQD 1 1 1 2 2 2 3 3 4 4 5 OUTLET SIZE (IN.) 2-1/2 2-1/2 2-1/2 (1) 2-1/2 (1) 1-1/4 (1) 2 (1) 2-1/2 2-1/2 (2) 2-1/2 (1) 1 (1) 2 (2) 2-1/2 (1) 1 (3) 2-1/2 (3) 2-1/2 (1) 2 (1) 1 (4) 2-1/2 125 PSIG HW NO. OF VALVES REQD 1 1 1 1 1 1 1 1 2 2 2 OUTLET SIZE (IN.) 1-1/4 1-1/4 2 2 2 2-1/2 2-1/2 2-1/2 (1) 1 (1) 2-1/2 (1) 1-1/4 (1) 2-1/2 (1) 2-1/2 (1) 2 150 PSIG HW NO. OF VALVES REQD 1 2 2 2 2 2 2 2 2 3 3 OUTLET SIZE (IN.) 2 (1) 1-1/2 (1) 2 (1) 1-1/2 (1) 2 2 (1) 2 (1) 2-1/2 2-1/2 (1) 2-1/2 (1) 3 (1) 2-1/2 (1) 3 3 (2) 3 (1) 2-1/2 3
Firetube Boilers
BOILER HP 100 125 150 200 250 300 350 400 500 600 700, 800
NOTE: Relief valve is Kunkle #537 for 30# & 125#(Section IV) boiler and is Kunkle #927 for 150# HTHW (Section I) boiler.
Table A12-10. Model ICB Recommended Steam Nozzle Size

OPERATING PRESSURE PSIG 15 30 40 50 75 100 125 150 200 250 100 8 6 6 4 4 4 4 2.5 2.5 2 125 8 6 6 6 4 4 4 3 2.5 2.5 150 8 6 6 6 4 4 4 3 3 2.5 200 10 8 6 6 6 6 4 4 4 3 250 10 8 8 6 6 6 6 4 4 4 BOILER HP 300 12 8 8 8 6 6 6 6 4 4 350 12 10 8 8 8 6 6 6 4 4 400 12 10 10 8 8 6 6 6 6 4 500 12 10 10 8 8 8 8 6 6 6 600 12 12 10 10 8 8 8 6 6 6 700 12 12 12 10 10 8 8 8 6 6 800 12 12 12 12 10 10 8 8 6 6
NOTES: 1. Steam nozzle sizes given in inches. 2. Recommended steam nozzle sizes based on 4000 to 5000 fpm steam velocity.
A12-16
12-02
Firetube Boilers
Table A12-11. Model ICB Recommended Non-Return Valve Size
BOILER HP 100 125 150 200 250 300 350 400 500 600 700 800 BOILER CAPACITY (LBS/HR) 3450 4313 5175 6900 8625 10350 12025 13800 17210 20700 24150 27600 OPERATING PRESSURE (PSIG) 50 3 4 4 4 4 6 6 6 6 8 8 8 75 2-1/2 3 4 4 4 4 6 6 6 8 8 8 100 2-1/2 3 3 4 4 4 4 4 6 6 6 6 125 2-1/2 3 3 3 4 4 4 4 6 6 6 6 150 2-1/2 3 3 3 3 4 4 4 4 6 6 6 175 2-1/2 2-1/2 3 3 3 4 4 4 4 4 6 6 200 2-1/2 2-1/2 2-1/2 3 3 4 4 4 4 4 6 6 250 2-1/2 2-1/2 2-1/2 3 3 3 3 4 4 4 6 6
Model ICB
NOTE: Valve sizes (300 psig anges) given in inches.
Table A12-12. Model ICB Blowdown Tank Sizing Information

BOILER HP 100 125 150 200 250 300 350 400 500 600 700 800 WATER (GAL) 75 94 102 135 125 150 174 191 206 248 266 297
Table A12-14. Sound Levels in dBA for 4-Pass ICB Boilers at High Fire
Sound Level dBA BHP 100 125 150 200 250 300 350 400 500 600 700 800 ICB 80.0 84.5 84.5 84.5 84.5 91.0 94.0 91.5 93.5 93.5 93.7 93.7

ALTITUDE (FT) 1000 2000 3000 4000 5000 CORRECTION FACTOR 1.04 1.07 1.11 1.16 1.21 ALTITUDE (FT) 6000 7000 8000 9000 CORRECTION FACTOR 1.25 1.3 1.35 1.4
NOTE: To obtain minimum required gas pressure at altitudes above 700 feet, multiply the pressure by the listed factors: Inches WC x 0.577 = oz/sq-in. oz/sq-in x 1.732 = Inches WC. Inches WC x 0.0361 = psig. oz/sq-in x 0.0625 = psig. psig x 27.71 = Inches WC. psig x 16.0 = oz/sq-in.
A12-17
12-02
Model ICB
Firetube Boilers
Table A12-15. Model ICB, Standard, Minimum Required Gas Pressure at Entrance to Standard, FM & IRI Gas Trains (Upstream of Gas Pressure Regulator)
BOILER HP 100 125 150 200 250 300 350 400 500 600 700 800 STD PIPE SIZE (Inches) 2 2 2 2-1/2 2-1/2 2-1/2 3 3 3 3 3 3 PRESSURE REQUIRED, 3-PASS ("WC) Minimum 8.5 13.5 17 20 32.5 45 46 38 56 120 138.5 86 Maximum 27.7 27.7 27.7 27.7 138.5 138.5 138.5 138.5 138.5 277 277 277 PRESSURE REQUIRED, 4-PASS ("WC) Minimum 10.5 16 21 26 33 45.5 46.5 43.5 56 120 138.5 86 Maximum 27.7 27.7 27.7 138.5 138.5 138.5 138.5 138.5 138.5 277 277 277
NOTE: For undersized or oversized gas trains or altitudes above 700 feet, contact your local Cleaver-Brooks Authorized Representative.
A12-18
12-02
Firetube Boilers
Model ICB
1. Shortest boiler room length (Dwg A) is obtained by allowing for possible future tube replacement (from front or rear of boiler) through a window or doorway. Allowance is only made for minimum door swing at each end of the boiler. This arrangement provides sufcient aisle space at the front of the boiler but a tight space condition at the rear. If space permits, approximately 1.5 additional feet should be allowed at the rear for additional aisle and working space. 2. Next shortest boiler room length (Dwg B) is obtained by allowing for possible future tube replacement from the front of the boiler. Allowance is only made for minimum door swing at the rear. If space permits, approximately 1.5 additional feet should be allowed at the rear for additional aisle and working space.
Figure A12-7. Boiler Room Length (Typical Layouts) Model ICB
BOILER HP DIM. A DIM. B
100 125 84-1/2 115-1/2
150 200 87 120
250 300 93 138
350 400 96 144
500 600 103 170
700 800 110 184
NOTES: 1. Recommended Minimum Distance Between Boiler and Wall. Dimension "A allows for a clear 42" aisle between the water column on the boiler and the wall. If space permits, this aisle should be widened. 2. Recommended Minimum Distance Between Boilers. Dimension B between boilers allows for a clear aisle of: 42" 100-200 hp 48" 250-400 hp 60 500-800 hp If space permits, this aisle should be widened.
Figure A12-8. Boiler Room Width (Typical Layout) Model ICB
A12-19
12-02
Model ICB
Firetube Boilers
The following sample specication is provided by Cleaver-Brooks to assist you in meeting your customers specic needs and application. The Sample Specications are typically utilized as the base template for the complete boiler specication. Contact your local Cleaver-Brooks Authorized Representative for information on special insurance requirements, special code requirements, optional equipment, or general assistance in completing the specication. Model ICB Steam Boiler (100 800 hp, 15 300 psig) 1.0 Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model ICB Hot Water Boiler (100 800 hp, 30 psig, 125 psig) 1.0 Boiler Characteristics (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Hot Water Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model ICB Steam Boiler (100 800 hp, 15 300 psig)
A12-20 A12-20 A12-21 A12-22 A12-25 A12-25 A12-25
A12-26 A12-26 A12-27 A12-27 A12-30 A12-30 A12-30
1.0 Boiler Characteristics (Steam) 1.1 The Steam Boiler shall be Cleaver-Brooks Model ICB, Fuel Series ______ (100, 200, 700), _____ hp designed for _____ psig (15, 150, 200, 250, 300 psig steam). The maximum operating pressure shall be _____ psig. 1.2 The boiler shall have a maximum output of _____ Btu/hr, or _____ horsepower when red with CS 12-48 No. 2 oil and/or natural gas, _____ Btu/cu-ft. Electrical power available will be _____ Volt _____ Phase _____ Cycle and 115/1/60 for the control circuit. 2.0 General Boiler Design 2.1 Number of Passes Select one of the following: A. (Four-Pass) The boiler shall be a four-pass intercooled horizontal retube updraft boiler. It shall be mounted on a heavy steel frame with forced draft burner and burner controls. B. (Three-Pass) The boiler shall be a three-pass intercooled horizontal retube updraft boiler. It shall be mounted on a heavy steel frame with forced draft burner and burner controls. 2.1.1 Approvals: The complete burner/boiler package shall be approved as a unit by Underwriters Laboratories Inc. and bear the UL/cUL label. 2.1.2 The boiler shall be completely preassembled and re tested at the factory. The unit shall be ready for immediate mounting on oor or simple foundation and ready for attachment of water, steam, fuel, electrical, vent and blowdown connections.
A12-20
12-02
Firetube Boilers
2.2 Boiler Shell (Steam)
Model ICB
2.2.1 The boiler shell must be constructed in accordance with ASME Boiler Code and must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser. 2.2.2 Two lifting eyes shall be located on top of the boiler. 2.2.3 Front and rear doors on the boiler shall be davited. 2.2.4 The rear door shall be insulated with a blanket material and a steel covering to give the surface a hard durable nish. 2.2.5 The boiler tubes shall not include turbulators, swirlers or other add-on appurtenances. 2.2.6 The boiler shall be furnished with a manhole and handholes to facilitate boiler inspection and cleaning. 2.2.7 Exhaust Vent Select one of the following: A. (Four-Pass) The exhaust gas vent shall be located near the front of the boiler on the top center line and shall be capable of supporting 2000 lbs. B. (Three-Pass) The exhaust gas vent shall be located at the rear of the boiler on the top center line and shall be capable of supporting 2000 lbs. 2.2.8 Observation ports for the inspection of ame conditions shall be provided at each end of the boiler. 2.2.9 The boiler insulation shall consist of a 2 inch blanket under a sectional preformed sheet metal lagging. This insulation must be readily removable and capable of being reinstalled, if required. 2.2.10 The entire boiler based frame and other components shall be factory painted before shipment using a hard nish enamel coating. 2.2.11 An inner rear turnaround access opening shall swing on a davit, to allow full accessibility to the 2nd pass tubes and furnace. 2.2.12 Tubes shall be removable from either the front or rear of the boiler. 3.0 Steam Boiler Trim 3.1 Water Column A water column shall be located on the right hand side of the boiler complete with gauge glass set and water column blowdown valves. 3.1.1 Feedwater Pump Control The boiler feedwater pump control shall be included as an integral part of the water column to automatically actuate a motor driven feedwater pump maintaining the boiler water level within normal limits. 3.1.2 Low Water Cutoff The low water cutoff shall be included as an integral part of the boiler feedwater control wired into the burner control circuit to prevent burner operation if the boiler water level falls below a safe level. 3.2 Auxiliary Low Water Cutoff The auxiliary low water cutoff shall be included, piped to the vessel, and wired to the burner control circuit. A manual reset device shall be used for this control. 3.3 Steam Pressure Gauge The steam pressure gauge shall be located at the front of the boiler and include cock and test connection. 3.4 Safety Relief Valves Safety valves of a type and size to comply with ASME Code requirements shall be shipped loose. 3.5 Steam Pressure Controls The steam pressure controls to regulate burner operation shall be mounted near the water column.
A12-21
12-02
Model ICB
4.0 Burner and Controls 4.1 Mode of Operation
Firetube Boilers
Burner operation shall be the full modulation principle. The burner shall always return to low re position for ignition. 4.2 Blower 4.2.1 All air for combustion shall be supplied by a forced draft blower mounted on the burner, to eliminate vibration and reduce noise level. 4.2.2 Maximum sound level of the boiler/burner package shall not exceed _____ dBA (when measured in accordance with ABMA Sound Test Standards). 4.2.3 The impeller shall be fabricated aluminum with radial blade, carefully balanced, and directly connected to the blower motor shaft. 4.3 Combustion Air Control Select one of the following: A. (Four-Pass) Combustion air damper and fuel control valve (100 250 hp) or cam operated fuel metering valve (300 800 hp) shall be operated by a single damper control motor that regulates the ame according to load demand. Potentiometer type position controls shall be provided to regulate operation of the damper control motor. B. (Three-Pass) Combustion air damper and fuel control valve (100 350 hp) or cam operated fuel metering valve (400 800 hp) shall be operated by a single damper control motor that regulates the ame according to load demand. Potentiometer type position controls shall be provided to regulate operation of the damper control motor. 4.4 Fuel Specication and Piping Select one of the following fuel types: Fuel series 700 Gas red (para 4.4.1). Fuel series 100 Light oil (No. 2) red (para 4.4.2). Fuel series 200 Light oil or gas red (para 4.4.3). 4.4.1 FUEL SERIES 700 GAS FIRED 4.4.1.1 Burner Type The burner shall be mounted at the front of the boiler and be of high radiant multi-port type for gas. The burner shall be approved for operation on natural gas fuel. 4.4.1.2 Gas Pilot The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include one (1) shut-off valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only). 4.4.1.3 Gas Burner Piping Select one of the following: A. 100 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. B. 125 250 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. C. 300 350 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition.
A12-22
12-02
Firetube Boilers
Model ICB
D. 400 800 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, two (2) motorized gas valves and one (1) valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. 4.4.2 FUEL SERIES 100 LIGHT OIL FIRED 4.4.2.1 Burner Type The burner shall be mounted at the front of the boiler, and shall be approved for operation with CS12-48, Commercial No. 2 oil. 4.4.2.2 Gas Pilot The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include one (1) shut-off valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only). 4.4.2.3 Oil Pump An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Pump shall be motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided. 4.4.2.4 Oil Burner Piping A. Four-Pass Select one of the following: a. 100 150 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, and pressure gauge all integrally mounted on the unit. b. 200 250 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, atomizing air proving switch, low oil pressure switch, and pressure gauge all integrally mounted on the unit. c. 300 800 hp. Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one (1) motorized oil valve with proof of closure switch, pressure relief valve, atomizing air proving switch, and low oil pressure switch all integrally mounted on the unit. B. Three-Pass Select one of the following: a. 100 150 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, and pressure gauge all integrally mounted on the unit. b. 200 350 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, atomizing air proving switch, low oil pressure switch, and pressure gauge all integrally mounted on the unit. c. 400 800 hp. Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one (1) motorized oil valve with proof of closure switch, pressure relief valve, atomizing air proving switch, and low oil pressure switch all integrally mounted on the unit. 4.4.2.5 Oil Atomization Type Select one of the following: A. 100 150 hp. Burner shall include a complete mechanical oil atomizing system and be of the pressure atomizing type. B. 200 800 hp. Burner shall be a low pressure air atomizing type, including a shipped loose air compressor assembly. 4.4.3 FUEL SERIES 200 LIGHT OIL OR GAS FIRED 4.4.3.1 Burner Type Select one of the following: A. 100 150 hp. The burner, mounted at the front of the boiler, shall be a combination pressure atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 oil or natural gas. B. 200 800 hp. The burner, mounted at the front of the boiler, shall be a combination of low pressure air atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 oil or natural gas. 4.4.3.2 Gas Pilot The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary fuel valve cannot open until ame has been established. The pilot train shall include one (1) manual shutoff valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only).
A12-23
12-02
Model ICB
4.4.3.3 Oil Burner
Firetube Boilers
4.4.3.3.1 Oil Pump An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Pump shall be motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided. 4.4.3.3.2 Oil Burner Piping A. Four-Pass Select one of the following: a. 100 150 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, and pressure gauge all integrally mounted on the unit. b. 200 250 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, atomizing air proving switch, low oil pressure switch and pressure gauge all integrally mounted on the unit. c. 300 800 hp. Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one (1) motorized oil valve with proof of closure switch, pressure relief valve, atomizing air proving switch, and low oil pressure switch all integrally mounted on the unit. B. Three-Pass Select one of the following: a. 100 150 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, and pressure gauge all integrally mounted on the unit. b. 200 350 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, atomizing air proving switch, low oil pressure switch and pressure gauge all integrally mounted on the unit. c. 400 800 hp. Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one (1) motorized oil valve with proof of closure switch, pressure relief valve, atomizing air proving switch, and low oil pressure switch all integrally mounted on the unit. 4.4.3.3.3 Oil Atomization Type Select one of the following: A. 100 150 hp. Burner shall include a complete mechanical oil atomizing system and be of the pressure atomizing type. B. 200 800 hp. Burner shall be a low pressure air atomizing type, including a shipped loose air compressor assembly. 4.4.3.4 Gas Burner Piping Select one of the following: A. 100 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. B. 125 150 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. C. 300 350 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. D. 400 800 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, two (2) motorized gas valves and one (1) valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water or any abnormal shutdown condition.
A12-24
12-02
Firetube Boilers
4.5 Control Panel and Flame Safeguard Controller 4.5.1 Control Panel
Model ICB
A factory prewired control panel shall be supplied with the boiler/burner package. Panel may be mounted on the burner or boiler. 4.5.2 The panel will have a NEMA 1A rating and contain the ame safeguard controller, burner motor starter, air compressor motor starter, oil metering pump motor starter, control circuit transformer and fuses, selector switches, indicating lights and terminal strips. Lights shall indicate load demand, ame failure, low water, and fuel valve open. 4.5.3 The panel shall contain fuse protection for the burner motor, air compressor motor, and oil metering pump. 4.5.4 The ame safeguard controller shall be a CB110 ame monitor with EPD170 program module. Flame detector shall be ultraviolet type. 5.0 Efciency Guarantee 5.1 The boiler must be guaranteed to operate at a minimum fuel-to-steam efciency of ____ percent at 100 percent of rating when burning natural gas and ________ fuel-to-steam efciency at 100% ring rate when burning oil (Contact your local CleaverBrooks Authorized Representative for efciency details). 6.0 Warranty 6.1 All equipment is to be guaranteed against defects in materials and/or workmanship for a period of 12 months from date of startup or 18 months from date of shipment, whichever comes rst. 7.0 Execution 7.1 Shop Tests 7.1.1 The packaged boiler must receive factory tests to check the construction, controls, and operation of the unit. All tests may be witnessed by the purchaser, if desired. 7.2 Start-Up Service 7.2.1 After boiler installation is completed, the manufacturer shall provide the services of a eld representative for starting the unit and training the operator at no additional costs. 7.2.1.1 A factory approved and authorized start-up report shall be submitted to the customer/user at the time of start-up.
A12-25
12-02
Model ICB
Model ICB Hot Water Boiler (100 800 hp, 30 psig, 125 psig)
Firetube Boilers
1.0 Boiler Characteristics (Hot Water) 1.1 The Hot Water Boiler shall be Cleaver-Brooks Model ICB, Fuel Series ______ (100, 200, 700), _____ hp designed for _____ psig (30, 125, or other psig hot water). The maximum water temperature will be _____ degree F, and the maximum system temperature drop will be _____ degree F. 1.2 The boiler shall have a maximum output of _____ Btu/hr, or _____ horsepower when red with CS 12-48 No. 2 oil and/or natural gas, _____ Btu/cu-ft. Electrical power available will be _____ Volt _____ Phase _____ Cycle and 115/1/60 for the control circuit. 2.0 General Boiler Design 2.1 Number of Passes Select one of the following: A. (Four-Pass) The boiler shall be a four-pass intercooled horizontal retube updraft boiler. It shall be mounted on a heavy steel frame with forced draft burner and burner controls. B. (Three-Pass) The boiler shall be a three-pass intercooled horizontal retube updraft boiler. It shall be mounted on a heavy steel frame with forced draft burner and burner controls. 2.1.1 Approvals: The complete burner/boiler package shall be approved as a unit by Underwriters Laboratories Inc. and bear the UL/cUL label. 2.1.2 The boiler shall be completely preassembled and re tested at the factory. The unit shall be ready for immediate mounting on oor or simple foundation and ready for attachment of water, steam, fuel, electrical, vent and blowdown connections. 2.2 Boiler Shell (Hot Water) 2.2.1 The boiler shell must be constructed in accordance with ASME Boiler Code and must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser. 2.2.2 The hot water return and outlet connections shall be located on the top center line of the boiler. The boiler shall be designed to rapidly mix the return water with the boiler water. Forced internal circulation shall be used. 2.2.3 A dip tube shall be included as an integral part of the water outlet. 2.2.4 Two lifting eyes shall be located on top of the boiler. 2.2.5 Front and rear doors on the boiler shall be davited. 2.2.6 The rear door shall be insulated with a blanket material and a steel covering to give the surface a hard durable nish. 2.2.7 The boiler tubes shall not include turbulators, swirlers or other add-on appurtenances. 2.2.8 The boiler shall be furnished with a manhole and handholes to facilitate boiler inspection and cleaning. 2.2.9 Exhaust Vent Select one of the following: A. (Four-Pass) The exhaust gas vent shall be located near the front of the boiler on the top center line and shall be capable of supporting 2000 lbs. B. (Three-Pass) The exhaust gas vent shall be located at the rear of the boiler on the top center line and shall be capable of supporting 2000 lbs. 2.2.10 Observation ports for the inspection of ame conditions shall be provided at each end of the boiler. 2.2.11 The boiler insulation shall consist of a 2 inch blanket under a sectional preformed sheet metal lagging. This insulation must be readily removable and capable of being reinstalled, if required. 2.2.12 The entire boiler based frame and other components shall be factory painted before shipment using a hard nish enamel coating. 2.2.13 An inner rear turnaround access opening shall swing on a davit, to allow full accessibility to the 2nd pass tubes and furnace. 2.2.14 Tubes shall be removable from either the front or rear of the boiler.
A12-26
12-02
Firetube Boilers
3.0 Hot Water Boiler Trim 3.1 Hot Water Connections
Model ICB
The hot water outlet and return connections shall be located on the top center line of the boiler. The internal design of these connections shall provide forced internal circulation, mixing return water with the hot water within the boiler. 3.2 Dip Tube The dip tube, an integral part of the hot water outlet, and an air vent tapping in the boiler shell must be provided for removal of air. 3.3 Low Water Cutoff A low water cutoff control shall be mounted on the top centerline of the boiler wired into the burner control circuit to prevent burner operation if boiler water falls below a safe level. A manual reset device shall be used on this control. 3.4 Pressure and Temperature Gauges Pressure and temperature gauges shall be mounted on the boiler with temperature sensing element located adjacent to the hot water outlet. 3.5 Relief Valves Water relief valves of a type and size to comply with ASME Code requirements shall be shipped loose. 3.6 Temperature Controls The temperature controls to regulate burner operation shall be mounted on the unit with temperature sensing elements located adjacent to the hot water outlet. 4.0 Burner and Controls 4.1 Mode of Operation Burner operation shall be the full modulation principle. The burner shall always return to low re position for ignition. 4.2 Blower 4.2.1 All air for combustion shall be supplied by a forced draft blower mounted on the burner, to eliminate vibration and reduce noise level. 4.2.2 Maximum sound level of the boiler/burner package shall not exceed _____ dBA (when measured in accordance with ABMA Sound Test Standards). 4.2.3 The impeller shall be fabricated aluminum with radial blade, carefully balanced, and directly connected to the blower motor shaft. 4.3 Combustion Air Control Select one of the following: A. (Four-Pass) Combustion air damper and fuel control valve (100 250 hp) or cam operated fuel metering valve (300 800 hp) shall be operated by a single damper control motor that regulates the ame according to load demand. Potentiometer type position controls shall be provided to regulate operation of the damper control motor. B. (Three-Pass) Combustion air damper and fuel control valve (100 350 hp) or cam operated fuel metering valve (400 800 hp) shall be operated by a single damper control motor that regulates the ame according to load demand. Potentiometer type position controls shall be provided to regulate operation of the damper control motor. 4.4 Fuel Specication and Piping Select one of the following fuel types: Fuel series 700 Gas red (para 4.4.1). Fuel series 100 Light oil (No. 2) red (para 4.4.2). Fuel series 200 Light oil or gas red (para 4.4.3).
A12-27
12-02
Model ICB
4.4.1 FUEL SERIES 700 GAS FIRED
Firetube Boilers
4.4.1.1 Burner Type The burner shall be mounted at the front of the boiler and of high radiant multi-port type for gas. The burner shall be approved for operation on natural gas fuel. 4.4.1.2 Gas Pilot The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include one (1) shut-off valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only). 4.4.1.3 Gas Burner Piping Select one of the following: A. 100 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. B. 125 250 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. C. 300 350 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. D. 400 800 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, two (2) motorized gas valves and one (1) valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. 4.4.2 FUEL SERIES 100 LIGHT OIL FIRED 4.4.2.1 Burner Type The burner shall be mounted at the front of the boiler, and shall be approved for operation with CS12-48, Commercial No. 2 oil. 4.4.2.2 Gas Pilot The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary fuel valve cannot open until ame has been established. The pilot train shall include one (1) manual shut-off valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only). 4.4.2.3 Oil Pump An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Pump shall be motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided. 4.4.2.4 Oil Burner Piping A. Four-Pass Select one of the following: a. 100 150 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, and pressure gauge all integrally mounted on the unit. b. 200 250 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, atomizing air proving switch, low oil pressure switch, and pressure gauge all integrally mounted on the unit. c. 300 800 hp. Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one (1) motorized oil valve with proof of closure switch, pressure relief valve, atomizing air proving switch, and low oil pressure switch all integrally mounted on the unit. B. Three-Pass Select one of the following: a. 100 150 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, and pressure gauge all integrally mounted on the unit. b. 200 350 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, atomizing air proving switch, low oil pressure switch, and pressure gauge all integrally mounted on the unit.
A12-28
12-02
Firetube Boilers
Model ICB
c. 400 800 hp. Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one (1) motorized oil valve with proof of closure switch, pressure relief valve, atomizing air proving switch, and low oil pressure switch all integrally mounted on the unit. 4.4.2.5 Oil Atomization Type Select one of the following: A. 100 150 hp. Burner shall include a complete mechanical oil atomizing system and be of the pressure atomizing type. B. 200 800 hp. Burner shall be a low pressure air atomizing type, including a shipped loose air compressor assembly. 4.4.3 FUEL SERIES 200 LIGHT OIL OR GAS FIRED 4.4.3.1 Burner Type Select one of the following: A. 100 150 hp. The burner, mounted at the front of the boiler, shall be a combination pressure atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 oil or natural gas. B. 200 800 hp. The burner, mounted at the front of the boiler, shall be a combination of low pressure air atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 oil or natural gas. 4.4.3.2 Gas Pilot The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary fuel valve cannot open until ame has been established. The pilot train shall include one (1) manual shut-off valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only). 4.4.3.3 Oil Burner 4.4.3.3.1 Oil Pump An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Pump shall be motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided. 4.4.3.3.2 Oil Burner Piping A. Four-Pass Select one of the following: a. 100 150 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, and pressure gauge all integrally mounted on the unit. b. 200 250 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, atomizing air proving switch, low oil pressure switch and pressure gauge all integrally mounted on the unit. c. 300 800 hp. Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one (1) motorized oil valve with proof of closure switch, pressure relief valve, atomizing air proving switch, and low oil pressure switch all integrally mounted on the unit. B. Three-Pass Select one of the following: a. 100 150 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, and pressure gauge all integrally mounted on the unit. b. 200 350 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil shut-off valves, atomizing air proving switch, low oil pressure switch and pressure gauge all integrally mounted on the unit. c. 400 800 hp. Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one (1) motorized oil valve with proof of closure switch, pressure relief valve, atomizing air proving switch, and low oil pressure switch all integrally mounted on the unit. 4.4.3.3.3 Oil Atomization Type Select one of the following: A. 100 150 hp. Burner shall include a complete mechanical oil atomizing system and be of the pressure atomizing type. B. 200 800 hp. Burner shall be a low pressure air atomizing type, including a shipped loose air compressor assembly.
A12-29
12-02
Model ICB
4.4.3.4 Gas Burner Piping Select one of the following:
Firetube Boilers
A. 100 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. B. 125 250 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. C. 300 350 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. D. 400 800 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, two (2) motorized gas valves and one (1) valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water or any abnormal shutdown condition. 4.5 Control Panel and Flame Safeguard Controller 4.5.1 Control Panel A factory prewired control panel shall be supplied with the boiler/burner package. Panel may be mounted on the burner or boiler. 4.5.2 The panel will have a NEMA 1A rating and contain the ame safeguard controller, burner motor starter, air compressor starter, oil metering pump motor starter, control circuit transformer and fuses, selector switches, indicating lights and terminal strips. Lights shall indicate load demand, ame failure, low water, and fuel valve open. 4.5.3 The panel shall contain fuse protection for the burner motor, air compressor motor, and the oil metering pump. 4.5.4 The ame safeguard controller shall be a CB110 ame monitor with EPD170 program module. Flame detector shall be ultraviolet type. 5.0 Efciency Guarantee 5.1 The boiler must be guaranteed to operate at a minimum fuel-to-water efciency of ____ percent at 100 percent of rating when burning natural gas and ________ fuel-to-steam efciency at 100% ring rate when burning oil (Contact your local Cleaver-Brooks Authorized Representative for efciency details). 6.0 Warranty 6.1 All equipment is to be guaranteed against defects in materials and/or workmanship for a period of 12 months from date of start-up or 18 months from date of shipment, whichever comes rst. 7.0 Execution 7.1 Shop Tests 7.1.1 The packaged boiler must receive factory tests to check the construction, controls, and operation of the unit. All tests may be witnessed by the purchaser, if desired. 7.2 Start-Up Service 7.2.1 After boiler installation is completed, the manufacturer shall provide the services of a eld representative for starting the unit and training the operator at no additional costs. 7.2.1.1 A factory approved and authorized start-up report shall be submitted to the customer/user at the time of start-up.
A12-30
12-02
Section A13
Model ICB-LN
CONTENTS Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-3 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-3 Dimensions and Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-4 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-13 ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-13 Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-13 Blowdown Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-13 Burner/Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-13 Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-14 Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-14 Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-14 Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-14 Sample Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-20
A13-1
12-02
Model ICB-LN
Firetube Boilers
ILLUSTRATIONS Figure A13-1. Model ICB-LN Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-7 Figure A13-2. Model ICB-LN Hot Water Boiler Dimensions, 4-Pass and 3-Pass (Optional) . . . . . . . . . . . . . . . . . . . . . . . . A13-9 Figure A13-3. Space Required to Open Rear Head on Model ICB-LN Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-11 Figure A13-4. Model ICB-LN Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-11 Figure A13-5. Model ICB-LN Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-12 Figure A13-6. Typical Fuel Oil Supply Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-18 Figure A13-7. Boiler Room Length (Typical Layouts) Model ICB-LN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-19 Figure A13-8. Boiler Room Width (Typical Layout) Model ICB-LN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-19 TABLES Table A13-1. Model ICB-LN Steam Boiler Ratings, 4-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-5 Table A13-2. Model ICB-LN Steam Boiler Ratings, 3-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-5 Table A13-3. Model ICB-LN Hot Water Boiler Ratings, 4-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-6 Table A13-4. Model ICB-LN Hot Water Boiler Ratings, 3-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-6 Table A13-5. Model ICB-LN Steam Boiler Dimensions, 4-Pass and 3-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-8 Table A13-6. Model ICB-LN Hot Water Boiler Dimensions, 4-Pass and 3-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-10 Table A13-7. Model ICB-LN Steam Volume and Disengaging Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-15 Table A13-8. Model ICB-LN Steam Boiler Safety Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-15 Table A13-9. Model ICB-LN Hot Water Boiler Relief Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-16 Table A13-10. Model ICB-LN Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-16 Table A13-11. Model ICB-LN Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-17 Table A13-12. Model ICB-LN Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-17 Table A13-13. Altitude Correction for Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-17 Table A13-14. Sound Pressure Levels in dBA for ICB Boilers at High Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-17 Table A13-15. Model ICB-LN, Standard, Minimum Required Gas Pressure at Entrance to Standard, FM & IRI Gas Trains (Upstream of Gas Pressure Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-18 The following information applies to the Cleaver-Brooks Model ICB-LN Boiler.
A13-2
12-02
Firetube Boilers
Model ICB-LN
Available options include the following (contact your local Cleaver-Brooks Authorized Representative for option details). Boiler Options: Three-pass design. Drain valves. Additional screwed or anged tappings. Blowdown valves. Non-return valves. Feedwater valves and regulators. Surface blowdown systems. Blend pump. Surge load bafes. Seismic design. Burner/Control Options: Flame safeguard controllers. Lead/lag system. High altitude design. Special insurance and code requirements (e.g., IRI, FM, CSD-1). Alarm bell/silence switch. Special motor requirements (TEFC, high efciency). Special indicating lights. Main disconnect. Elapsed time meter. Voltmeter/micro-ammeter. NEMA enclosures. Low-re hold control. Remote emergency shut-off (115V). Circuit breakers. Day/night controls. Special power requirements. Stack thermometer. Fuel Options Air atomizing oil burner, 100 800 hp. Gas strainer. Gas pressure gauge. Future gas conversion. Oversized/undersized gas trains.

The Cleaver-Brooks Model ICB Boiler line provides a quality product utilizing a baseline boiler/burner design. Additionally, the boiler/burner package has the UL/cUL label. The following features apply: Four-Pass Intercooled Design: Four-pass design provides high ue gas velocities and low stack temperatures to maximize efciency. Three-Pass Intercooled Design (optional): Versatile design offered with choice of three or four-pass construction to meet application needs. Intercooled Rear Turnaround: Rear furnace turnaround area is uid cooled and has a davited access opening for full accessibility to 2nd pass tubes and furnace. It eliminates conned space issues and provides for ease of maintenance. All tubes can be removed from either the front or rear of the boiler. Front and Rear Doors: Davit, front and rear doors, all sizes. Provides access to front and rear tube sheet. Rear door completely covers and insulates rear tube sheet. Natural Gas, No. 2 Oil, or Combination Burners Available: Combination gas/oil burners provide quick fuel changeover without burner adjustment.
PRODUCT OFFERING
Cleaver-Brooks Model ICB Boilers are available in low pressure steam, high pressure steam, and hot water designs. Burners are available to re natural gas, No. 2 oil, or a combination of oil and gas. Standard product offering is: 100 800 hp. 30 and 125 psig hot water. 15 300 psig steam. Full modulation, all sizes.
A13-3
12-02
Model ICB-LN
Firetube Boilers

Dimensions and ratings for the Model ICB-LN Boilers are shown in the following tables and illustrations. The information is subject to change without notice. Table A13-1. Model ICB-LN Steam Boiler Ratings, 4-Pass Table A13-2. Model ICB-LN Steam Boiler Ratings, 3-Pass (Optional) Table A13-3. Model ICB-LN Hot Water Boiler Ratings, 4-Pass Table A13-4. Model ICB-LN Hot Water Boiler Ratings, 3-Pass (Optional) Figure A13-1. Model ICB-LN Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional) Table A13-5. Model ICB-LN Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional) Figure A13-2. Model ICB-LN Hot Water Boiler Dimensions, 4-Pass and 3-Pass (Optional) Table A13-6. Model ICB-LN Hot Water Boiler Dimensions, 4-Pass and 3-Pass (Optional) Figure A13-3. Space Required to Open Rear Head on Model ICB-LN Boilers Figure A13-4. Model ICB-LN Boilers Lifting Lug Location Figure A13-5. Model ICB-LN Boiler Mounting Piers
A13-4
12-02
Firetube Boilers
Table A13-1. Model ICB-LN Steam Boiler Ratings, 4-Pass
BOILER H.P. BURNER MODEL 100 125 150 200 250 300 350 400 500 600
Model ICB-LN
700
800
LND54P LND84P LND105P LND125P LND145P LND175P LND210P LND252P LND300P LND315P LND378P LND420P
RATINGS SEA LEVEL TO 700 FT. Rated Capacity (lbs-steam/hr from and at 212F) Btu Output (1000 Btu/hr) 3450 3348 4313 4184 5175 5021 6900 6695 8625 8369 10350 10043 12075 11716 13800 13390 17250 16738 20700 20085 24150 23433 27600 26780
POWER REQUIREMENTS SEA LEVEL TO 700 FT. (60 HZ) Blower Motor hp Separate Compressor Motor hp (Oil only) Integral Oil/Air Motor hp (Oil only) Oil Metering Pump Motor hp (Oil only) Circulating Oil Pump Motor hp (Oil only) BOILER DATA Heating Surface sq-ft. (Fireside) 353 438 555 729 885 1055 1384 1522 1734 2094 3244 3641 5 1 1/2 7-1/2 1 1/2 10 1 1/2 15 1 1/2 15 2 1/2 20 5 1/2 3/4 25 5 3/4 3/4 30 7-1/2 3/4 3/4 40 7-1/2 3/4 3/4 60 7-1/2 3/4 3/4 60 15 1 1 60 15 1 1
NOTE: All fractional hp motors will be single phase voltage except oil metering pump motor (3-phase); integral motors will be 3-phase voltage.
Table A13-2. Model ICB-LN Steam Boiler Ratings, 3-Pass

BOILER H.P. BURNER MODEL 100 125 150 LND84P 200 250 300 350 400 500 600 700 800 LND54P LND63P LND105P LND145S LND145P LND175P LND210P LND252P LND300P LND315P LND378P
RATINGS SEA LEVEL TO 700 FT. Rated Capacity (lbs-steam/hr from and at 212F) Btu Output (1000 Btu/hr) 3450 3348 4313 4184 5175 5021 6900 6695 8625 8369 10350 10043 12075 11716 13800 13390 17250 16738 20700 20085 24150 23433 27600 26780
POWER REQUIREMENTS SEA LEVEL TO 700 FT. (60 HZ) Blower Motor hp Separate Compressor Motor hp (Oil only) Integral Oil/Air Motor hp (Oil only) Oil Metering Pump Motor hp (Oil only) Circulating Oil Pump Motor hp (Oil only) BOILER DATA Heating Surface sq-ft. (Fireside) 353 438 555 729 885 1055 1384 1522 1734 2094 3244 3641 5 1 1/2 5 1 1/2 7-1/2 1 1/2 10 1 1/2 15 2 1/2 15 2 3/4 20 5 1/2 3/4 25 5 3/4 3/4 30 7-1/2 3/4 3/4 40 7-1/2 3/4 3/4 60 7-1/2 3/4 1 60 15 1 1
A13-5
12-02
Model ICB-LN
Table A13-3. Model ICB-LN Hot Water Boiler Ratings, 4-Pass
BOILER H.P. BURNER MODEL 100 125 150 200 250 300 350 400 500
Firetube Boilers
600
700
800
LND54P LND84P LND105P LND125P LND145P LND175P LND210P LND252P LND300P LND315P LND378P LND420P
RATINGS SEA LEVEL TO 700 FT. Btu Output (1000 Btu/hr) 3348 4184 5021 6695 8369 10043 11716 13390 16738 20085 23433 26780
POWER REQUIREMENTS SEA LEVEL TO 700 FT. (60 HZ) Blower Motor hp Separate Compressor Motor hp (Oil only) Integral Oil/Air Motor hp (Oil only) Oil Metering Pump Motor hp (Oil only) Circulating Oil Pump Motor hp (Oil only) BOILER DATA Heating Surface sq-ft. (Fireside) 353 438 555 729 885 1055 1384 1522 1734 2094 3244 3641 5 1 1/2 7-1/2 1 1/2 10 1 1/2 15 1 1/2 15 2 1/2 20 5 1/2 3/4 25 5 3/4 3/4 30 7-1/2 3/4 3/4 40 7-1/2 3/4 3/4 60 7-1/2 3/4 3/4 60 15 1 1 60 15 1 1
Table A13-4. Model ICB-LN Hot Water Boiler Ratings, 3-Pass

BOILER H.P. BURNER MODEL 100 125 150 LND84P 200 250 300 350 400 500 600 700 800 LND54P LND63P LND105P LND145S LND145P LND175P LND210P LND252P LND300P LND315P LND378P
RATINGS SEA LEVEL TO 700 FT. Btu Output (1000 Btu/hr) 3348 4184 5021 6695 8369 10043 11716 13390 16738 20085 23433 26780
POWER REQUIREMENTS SEA LEVEL TO 700 FT. (60 HZ) Blower Motor hp Separate Compressor Motor hp (Oil only) Integral Oil/Air Motor hp (Oil only) Oil Metering Pump Motor hp (Oil only) Circulating Oil Pump Motor hp (Oil only) BOILER DATA Heating Surface sq-ft. (Fireside) 353 438 555 729 885 1055 1384 1522 1734 2094 3244 3641 5 1 1/2 5 1 1/2 7-1/2 1 1/2 10 1 1/2 15 2 1/2 15 2 3/4 20 5 1/2 3/4 25 5 3/4 3/4 30 7-1/2 3/4 3/4 40 7-1/2 3/4 3/4 60 7-1/2 3/4 1 60 15 1 1
A13-6
12-02
Firetube Boilers
4-PASS ICB LOW NOx STEAM BOILERS
Model ICB-LN
3-PASS ICB LOW NOx STEAM BOILERS
Figure A13-1. Model ICB-LN Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional)
A13-7
12-02
Model ICB-LN
Table A13-5. Model ICB-LN Steam Boiler Dimensions, 4-Pass and 3-Pass
BOILER H.P. LENGTHS Overall (3-Pass) Overall (4-Pass) Shell Base Frame Base Frame to Rear Flange Flange to Steam Nozzle WIDTHS Overall (3-Pass) Overall (4-Pass) I.D. Boiler Center to Water Column I I J K 87" 82" 55" 44-1/2" 42-1/2" 37" 6" 6" 30-1/2" 37-1/2" 47-1/2" 39-1/2" 87" 82" 55" 44-1/2" 42-1/2" 37" 6" 6" 30-1/2" 37-1/2" 47-1/2" 39-1/2" 92" 87" 60" 47" 45" 37" 6" 6" 33" 40" 52-1/2" 44-1/2" 92" 87" 60" 47" 45" 37" 6" 6" 33" 40" 52-1/2" 44-1/2" 104" 100" 72" 53" 51" 47" 6" 8" 39" 46" 58-1/2" 50-1/2" 106" 100" 72" 53" 53" 47" 8" 8" 39" 46" 58-1/2" 50-1/2" 112" 109" 78" 56" 56" 53" 8" 8" 42" 49" 64" 56" 112" 109" 78" 56" 56" 53" 8" 8" 42" 49" 64" 56" 126" 122" 92" 63" 63" 59" 8" 10" 49" 56" 68" 55" A A B C D E 173" 173" 199" 201" 199" 199" 240" 240" 215" 215" 241" 244" 247" 252" 268" DIM 100 125 150 200 250 300 350 400 500
Firetube Boilers
600
700
800
257-1/2" 290-1/2" 285-1/2" 290"
312" 312"
270-1/2" 257-1/2" 293-1/2"
127-7/8" 153-7/8" 151-7/8" 192-7/8" 160-7/8" 186-7/8" 189-7/8" 205-7/8" 195-3/4" 228-3/4" 219-7/8" 241-7/8" 124-3/8" 150-3/8" 148-3/8" 189-3/8" 157-3/8" 183-3/8" 184-3/8" 200-3/8" 187-1/4" 220-1/4" 211-3/8" 233-3/8" 9-1/2" 55-7/8" 9-1/2" 61-7/8" 9-1/2" 65-7/8" 9-1/2" 77-7/8" 9-1/2" 68-7/8" 9-1/2" 80-7/8" 9-1/2" 78-7/8" 9-1/2" 94-7/8" 14-1/2" 82-3/4" 14-1/2" 106-3/4" 14-1/2" 98-7/8" 14-1/2" 111-7/8"
128" 122" 92" 63" 65" 59" 10" 10" 49" 56" 68" 55"
142" 133" 106" 70" 72" 59" 10" 10" 56" 63" 74-3/4" 61-3/4"
142" 133" 106" 70" 72" 59" 10" 10" 56" 63" 74-3/4" 61-3/4"
Center to Outside FGR Pipe (3-Pass) KK Center to Outside FGR Pipe (4-Pass) KK FGR Duct Size (3-Pass) FGR Duct Size (4-Pass) Center to Lagging Center to Auxiliary LWCO Base Outside Base Inside HEIGHTS Base to Boiler Centerline Base to Vent Outlet Base to Rear Door Davit Base to FGR Stack Extension (3-Pass Only) Base to Steam Outlet Base Frame Base to Bottom Boiler CONNECTIONS Chemical Feed Feedwater Inlet (Both Sides) Steam Nozzle (15 psig) 150 LB. FLG. Steam Nozzle (150 psig) 300 LB. FLG. Drain Front & Rear (15 psig) Blowdown-Front & Rear(150 psig) Surface Blowoff (150 psig only) Vent Stack Diameter (Flanged) Flange to Center Vent MINIMUM CLEARANCES Rear Door Swing Tube Removal Front Tube Removal Rear DD GG HH G S Y Y W W T BB CC F O OA FF P Q R V V L LL M N
44-1/2" 80-3/4" 82-1/4" 94-3/4" 78-3/8" 12" 16"
44-1/2" 80-3/4" 82-1/4" 94-3/4" 78-3/8" 12" 16"
46" 85" 86-1/2" 99" 82-3/8" 12" 16"
46" 85" 86-1/2" 99" 82-3/8" 12" 16"
54" 101" 101" 118" 96-1/4" 10" 17"
54" 101" 101" 118" 96-1/4" 10" 17"
56" 106" 106" 123"
56" 106" 106" 123"
65-1/2"
65-1/2"
71"
71"
122-1/2" 122-1/2" 135-5/8" 135-5/8" 122-1/2" 122-1/2" 135-5/8" 135-5/8" 142-1/2" 142-1/2" 155-5/8" 155-5/8" 118" 12" 19" 118" 12" 19" 130-5/8" 130-5/8" 12" 17-1/2" 12" 17-1/2"
101-1/2" 101-1/2" 10" 17" 10" 17"
1" 1-1/4" 8" 4" 1-1/2" 1-1/4" 1" 16" 9-1/8"
1" 1-1/2" 8" 4" 1-1/2" 1-1/2" 1" 16" 9-1/8"
1" 1-1/2" 8" 4" 1-1/2" 1-1/2" 1" 16" 9-1/8"
1" 2" 10" 4" 2" 1-1/2" 1" 16" 9-1/8"
1" 2" 10" 6" 2" 1-1/2" 1" 20" 10-5/8"
1" 2" 12" 6" 2" 1-1/2" 1" 20" 10-5/8"
1" 2-1/2" 12" 6" 2" 1-1/2" 1" 20" 10-5/8"
1" 2-1/2" 12" 6" 2" 2" 1" 20" 10-5/8"
1" 2-1/2" 12" 8" 2" 2" 1" 24" 12-5/8"
1" 2-1/2" 12" 8" 2" 2" 1" 24" 12-5/8"
1" 2-1/2" 12" 8" 2" 2" 1" 24" 12-5/8"
1" 2-1/2" 12" 8" 2" 2" 1" 24" 12-5/8"
34" 95" 96-1/2"
34" 121"
36" 119"
36" 160"
43" 122"
43" 148"
46" 149"
46" 165"
53" 146"
53" 179"
60" 170"
60" 192"
122-1/2" 120-1/2" 161-1/2" 126-1/2" 152-1/2" 150-1/2" 166-1/2" 148-1/2" 181-1/2" 172-1/2" 194-1/2"
MINIMUM BOILER ROOM LENGTH ALLOWING FOR DOOR SWING AND TUBE REMOVAL FROM: Front of Boiler Rear of Boiler (3-Pass) Rear of Boiler (4-Pass) Thru Window or Door (3-Pass) Thru Window or Door (4-Pass) WEIGHTS Normal Water Weight Shipping Weight (15psig) Shipping Weight (150psig) 5,140 10,123 10,877 6,515 11,303 12,220 7,184 11,931 13,112 9,612 14,106 15,637 10,175 16,958 17,613 12,278 19,051 20,404 13,192 22,344 25,344 14,593 23,918 27,175 17,870 28,934 31,990 21,780 33,189 36,780 26,638 41,179 45,724 30,026 45,226 50,244 RF 257" 309" 307" 389" 326" 378" 385" 417" 476" 346" 395" 444" 444" 461" 510" 513" 450" 496" 494" 544-1/2" 404" 404" RR 305-1/2" 357-1/2" 355-1/2" 437-1/2" 377-1/2" 429-1/2" 436-1/2" 473-1/2" RR 305-1/2" 359-1/2" 355-1/2" 437-1/2" 377-1/2" 432-1/2" 441-1/2" RD RD 239" 239" 265" 267" 267" 267" 308" 308" 290" 290" 316" 319" 325" 330"
500-1/2" 544-1/2" 382"
342-1/2" 375-1/2" 376-1/2"
348-1/2" 342-1/2" 378-1/2"
A13-8
12-02
Firetube Boilers
4-PASS ICB LOW NOx HOT WATER BOILERS
Model ICB-LN
3-PASS ICB LOW NOx HOT WATER BOILERS
Figure A13-2. Model ICB-LN Hot Water Boiler Dimensions, 4-Pass and 3-Pass (Optional)
A13-9
12-02
Model ICB-LN
Table A13-6. Model ICB-LN Hot Water Boiler Dimensions, 4-Pass and 3-Pass
BOILER H.P. LENGTHS Overall (3-Pass) Overall (4-Pass) Shell Base Frame Base Frame to Rear Flange Flange to Return Flange to Outlet WIDTHS Overall (3-Pass) Overall (4-Pass) I.D. Boiler Center to Control Panel I I J K 87" 81-1/2" 55" 44-1/2" 42-1/2" 37" 6" 6" 30-1/2" 47-1/2" 39-1/2" 87" 81-1/2" 55" 44-1/2" 42-1/2" 37" 6" 6" 30-1/2" 47-1/2" 39-1/2" 92" 84" 60" 47" 45" 37" 6" 6" 33" 52-1/2" 44-1/2" 92" 84" 60" 47" 45" 37" 6" 6" 33" 52-1/2" 44-1/2" 104" 100" 72" 53" 51" 47" 6" 8" 39" 58-1/2" 50-1/2" 106" 100" 72" 53" 53" 47" 8" 8" 39" 58-1/2" 50-1/2" 112" 109" 78" 56" 56" 53" 8" 8" 42" 64" 56" 112" 109" 78" 56" 56" 53" 8" 8" 42" 64" 56" 126" 122" 92" 63" 63" 59" 8" 10" 49" 68" 55" A A B C D E F 173" 173" 199" 201" 199" 199" 240" 240" 215" 215" 241" 244" 247" 252" 268" DIM 100 125 150 200 250 300 350 400 500
Firetube Boilers
600
700
800
257-1/2" 290-1/2" 285-1/2" 290"
312" 312"
270-1/2" 257-1/2" 293-1/2"
127-7/8" 153-7/8" 151-7/8" 192-7/8" 160-7/8" 186-7/8" 189-7/8" 205-7/8" 195-3/4" 228-3/4" 219-7/8" 241-7/8" 124-3/8" 150-3/8" 148-3/8" 189-3/8" 157-3/8" 183-3/8" 184-3/8" 200-3/8" 187-1/4" 220-1/4" 211-3/8" 233-3/8" 9-1/2" 82" 97-1/2" 9-1/2" 98" 123" 9-1/2" 95-5/8" 9-1/2" 9-1/2" 9-1/2" 9-1/2" 9-1/2" 14-1/2" 14-1/2" 175" 14-1/2" 171" 14-1/2" 193" 136-5/8" 101-5/8" 115-5/8" 117-5/8" 132-5/8" 125-1/2" 143-1/2" 139-1/2" 161-1/2"
120-5/8" 161-5/8" 127-5/8" 141-5/8" 143-5/8" 158-5/8" 152-1/2"
128" 122" 92" 63" 65" 59" 10" 10" 49" 68" 55"
142" 129" 106" 70" 72" 59" 10" 10" 56" 74-3/4" 61-3/4"
142" 129" 106" 70" 72" 59" 10" 10" 56" 74-3/4" 61-3/4"
Center to Outside FGR Pipe (3-Pass) KK Center to Outside FGR Pipe (4-Pass) KK FGR Duct Size (3-Pass) FGR Duct Size (4-Pass) Center to Lagging Base Outside Base Inside HEIGHTS Base to Boiler Centerline Base to Vent Outlet Base to Rear Door Davit Base to FGR Stack Extension (3-Pass Only) Base to Return/Outlet Base Frame Base to Bottom Boiler CONNECTIONS Waterll (Both Sides) Water Return Water Outlet Drain Front & Rear Air Vent Vent Stack Diameter (Flanged) Flange to Center Vent MINIMUM CLEARANCES Rear Door Swing Tube Removal Front Tube Removal Rear DD GG HH S U Y W T BB CC H O OA FF P Q R V V L M N
44-1/2" 80-3/4" 82-1/4" 94-3/4" 78-3/8" 12" 16"
44-1/2" 80-3/4" 82-1/4" 94-3/4" 78-3/8" 12" 16"
46" 85" 86-1/2" 99" 82-3/8" 12" 16"
46" 85" 86-1/2" 99" 82-3/8" 12" 16"
54" 101" 101" 118" 96-1/4" 10" 17"
54" 101" 101" 118" 96-1/4" 10" 17"
56" 106" 106" 123"
56" 106" 106" 123"
65-1/2"
65-1/2"
71"
71"
122-1/2" 122-1/2" 135-5/8" 135-5/8" 122-1/2" 122-1/2" 135-5/8" 135-5/8" 142-1/2" 142-1/2" 155-5/8" 155-5/8" 118" 12" 19" 118" 12" 19" 130-5/8" 130-5/8" 12" 17-1/2" 12" 17-1/2"
101-1/2" 101-1/2" 10" 17" 10" 17"
1-1/2" 4" 4" 1-1/2" 1-1/2" 16" 9-1/8"
1-1/2" 6" 6" 1-1/2" 1-1/2" 16" 9-1/8"
1-1/2" 6" 6" 1-1/2" 1-1/2" 16" 9-1/8"
2" 6" 6" 2" 1-1/2" 16" 9-1/8"
2" 8" 8" 2" 1-1/2" 20" 10-5/8"
2" 8" 8" 2" 1-1/2" 20" 10-5/8"
2-1/2" 8" 8" 2" 1-1/2" 20" 10-5/8"
2-1/2" 10" 10" 2" 1-1/2" 20" 10-5/8"
2-1/2" 10" 10" 2" 2" 24" 12-5/8"
2-1/2" 12" 12" 2" 2" 24" 12-5/8"
2-1/2" 12" 12" 2" 2" 24" 12-5/8"
2-1/2" 12" 12" 2" 2" 24" 12-5/8"
34" 95" 96-1/2"
34" 121"
36" 119"
36" 160"
43" 122"
43" 148"
46" 149"
46" 165"
53" 146"
53" 179"
60" 170"
60" 192"
122-1/2" 120-1/2" 161-1/2" 126-1/2" 152-1/2" 150-1/2" 166-1/2" 148-1/2" 181-1/2" 172-1/2" 194-1/2"
MINIMUM BOILER ROOM LENGTH ALLOWING FOR DOOR SWING AND TUBE REMOVAL FROM: Front of Boiler Rear of Boiler (3-Pass) Rear of Boiler (4-Pass) Thru Window or Door (3-Pass) Thru Window or Door (4-Pass) WEIGHTS Normal Water Weight (lbs) Shipping Weight (30psig) (lbs) Shipping Weight (125psig) (lbs) 5,848 10,123 10,238 7,397 11,303 11,418 8,378 11,931 13,153 11,180 14,106 15,679 11,940 16,958 18,609 14,380 19,051 21,270 16,190 22,344 24,522 17,884 23,918 26,631 22,572 28,934 32,175 27,431 33,189 36,972 32,991 41,179 47,122 37,120 45,226 51,782 RF 257" 309" 307" 389" 326" 378" 385" 417" 476" 346" 395" 444" 444" 461" 510" 513" 450" 496" 494" 544-1/2" 404" 404" RR 305-1/2" 357-1/2" 355-1/2" 437-1/2" 377-1/2" 429-1/2" 436-1/2" 473-1/2" RR 305-1/2" 359-1/2" 355-1/2" 437-1/2" 377-1/2" 432-1/2" 441-1/2" RD RD 239" 239" 265" 267" 267" 267" 308" 308" 290" 290" 316" 319" 325" 330"
500-1/2" 544-1/2" 382"
342-1/2" 375-1/2" 376-1/2"
348-1/2" 342-1/2" 378-1/2"
A13-10
12-02
Firetube Boilers
Model ICB-LN
ALL DIMENSIONS IN INCHES BOILER HP 100 125 150 200 250 300 350 400 500 600 700 800 A 31 33 39 42 49 56 B 45 47 53 56 65 74 C 47 52 58 61 69 80 D 70 80 86 92 106 121 E 34 36 43 46 53 60
Figure A13-3. Space Required to Open Rear Head on Model ICB-LN Boilers
ALL DIMENSIONS IN INCHES BOILER HP 100 125 150 200 250 300 350 400 500 600 700 800 A 75-1/4 75-1/4 79-1/2 79-1/2 94 94 99 99 115-1/2 115-1/2 128-1/4 128-1/4 B 21-3/8 21-3/8 25-3/8 25-3/8 32 32 32 32 34 34 34 34 C 81-1/4 107-1/4 96-1/2 137-1/2 96-1/4 122-1/4 123-1/4 139-1/4 125-3/4 158-3/4 151 173 D 10 10 10 10 10 10 10 10 11 11 11 11 E 3 3 3 3 3 3 3 3 3 3 3 3
NOTE: A, B, and C dimensions may vary by 1 inch.
Figure A13-4. Model ICB-LN Boilers Lifting Lug Location
A13-11
12-02
Model ICB-LN
Firetube Boilers
" E"
ALL DIMENSIONS IN INCHES BOILER HP 100 125 150 200 250 300 350 400 500 600 700 800 A 6 6 6 6 6 6 6 6 6 6 6 6 B 9 9 9 9 9 9 9 9 12 12 12 12 C 127-1/2 153-1/2 151-1/2 192-1/2 160-1/2 186-1/2 187-1/2 203-1/2 190-1/2 223-1/2 214-1/2 236-1/2 D 34-1/2 34-1/2 39-1/2 39-1/2 45-1/2 45-1/2 51 51 49-1/2 49-1/2 56-1/4 56-1/4 E 52-1/2 52-1/2 57-1/2 57-1/2 63-1/2 63-1/2 69 69 73-1/2 73-1/2 80-1/4 80-1/4 F 4 4 4 4 4 4 4 4 6-1/2 6-1/2 6-1/2 6-1/2 G 39-1/2 39-1/2 44-1/2 44-1/2 50-1/2 50-1/2 56 56 55 55 61-3/4 61-3/4 X 17-1/2 17-1/2 17-1/2 17-1/2 17-1/2 17-1/2 17-1/2 17-1/2 20-1/2 20-1/2 20-1/2 20-1/2
NOTE: 6-inch high mounting piers recommended for use beneath the boiler base frame. The use of these piers provides increased inspection accessibility to the boiler and added height for washing down the area beneath the boiler.
Figure A13-5. Model ICB-LN Boiler Mounting Piers
A13-12
12-02
Firetube Boilers
Model ICB-LN
Gas-Fired Burners
PERFORMANCE DATA
Contact your local Cleaver-Brooks Authorized Representative for efciencies or additional information.
Table A13-13 lists minimum required gas pressure for altitude correction. Table A13-15 shows minimum and maximum gas pressure requirements for Standard, FM and IRI ICB Boiler gas trains upstream of the gas pressure regulator. For oversized or undersized gas trains or altitude above 700 feet, contact your local Cleaver-Brooks Authorized Representative.
Fuel Connections Gas
ENGINEERING DATA
The following engineering information is provided for Model ICB-LN Boilers. Additional detail is available from your local Cleaver-Brooks Authorized Representative. Boiler Information Table A13-7 shows steam volume and disengaging area for Model ICB-LN Boilers. Table A13-8 lists quantity and outlet size for safety valves supplied on Model ICB-LN Steam Boilers. Table A13-9 lists quantity and outlet size for relief valves supplied on Model ICB-LN Hot Water Boilers. Table A13-10 gives recommended steam nozzle sizes on Model ICB-LN Boilers. Table A13-11 shows recommended non-return valve sizes for Model ICB-LN Boilers. Blowdown Water Requirements Some local codes require blowdown tanks to be constructed in accordance with recommendations of the National Board of Boiler and Pressure Vessel Inspectors. The National Boards recommendations base the size of the blowdown tank on the removal of at least 4 inches of water from the boiler. Table A13-12 lists the approximate quantity of water represented by 4 inches of water at normal operating level for Cleaver-Brooks Model ICB-LN Boilers. Burner/Control Information
Burner Characteristics
The local gas company should be consulted for requirements and authorization for installation and inspection of gas supply piping. Installation of gas supply piping and venting must be in accordance with all applicable engineering guidelines and regulatory codes. All connections made to the boiler should be arranged so that all components remain accessible for inspection, cleaning and maintenance. A drip leg should be installed in the supply piping before the connection to the gas pressure regulator. The drip leg should be at least as large as the inlet tting supplied with the boiler. Consideration must be given to both volume and pressure requirements when choosing gas supply piping size. Refer to the boiler dimension diagram provided by Cleaver-Brooks for the particular installation. Connections to the burner gas train should be made with a union, so that gas train components or the burner may be easily disconnected for inspection or service. Upon completion of the gas piping installation, the system should be checked for gas leakage and tight shutoff of all valves.
Fuel Connections Oil
Burner altitude limits for standard conguration is 700 feet. Contact your local Cleaver-Brooks Authorized Representative for higher altitude availability. Note that higher altitudes may require different congurations, including dimensions, motor hp and gas pressures.
A13-13
12-02
Model ICB-LN
A strainer must be installed in the supply piping upstream of the burner supply pump in order to prevent entry of foreign material into the pump, fuel control valves, or burner nozzle(s). The strainer must be sized for the burner supply pump capacity. A strainer mesh of 150 microns (0.005") is recommended. Install a check valve in the line to prevent draining of the oil suction line when the burner is not in operation. Location of the check valve varies with the system, but usually it is located as close as possible to the storage tank. Installation of a vacuum gauge in the burner supply line between the burner oil pump and the strainer is recommended. Regular observation and recording of the gauge indication will assist in determining when the strainer needs servicing. Upon completion of the oil piping installation, the system should be checked for oil or air leakage and tight shutoff of all valves. Boiler Room Information Figure A13-7 shows typical boiler room length requirements. Figure A13-8 shows typical boiler room width requirements. Stack Support Capabilities 100 800 hp Model ICB-LN Boilers can support up to 2000 lbs without additional support. 100 800 hp Model ICB-LN Boilers can be reinforced to support up to 3000 lbs. Boiler Room Combustion Air When determining boiler room air requirements, the size of the room, air ow, and velocity of air must be reviewed as follows: 1. Size (area) and location of air supply openings in boiler room. A. Two (2) permanent air supply openings in the outer walls of the boiler room are recommended. Locate one (1) at each end of the boiler room, preferably below a height of 7 feet. This allows air to sweep the length of the boiler. B. Air supply openings can be louvered for weather protection, but they should not be covered with ne mesh wire, as this type of covering has poor air ow qualities and is subject to clogging by dust or dirt. C. A vent fan in the boiler room is not recommended, as it could create a slight vacuum under certain conditions and cause variations in the quantity of combustion air. This can result in unsatisfactory burner performance.
Firetube Boilers
D. Under no condition should the total area of the air supply openings be less than one (1) square foot. E. Size the openings by using the formula: Area (sq-ft) = CFM/FPM 2. Amount of air required (cfm). A. Combustion Air = Rated bhp x 8 cfm/bhp. B. Ventilation Air = Maximum bhp x 2 cfm/bhp or a total of 10 cfm/bhp up to 1000 feet elevation. Add 3 percent more per 1000 feet of added elevation. 3. Acceptable air velocity in Boiler Room (fpm). A. From oor to (7) foot height 250 fpm. B. Above (7) foot height 500 fpm. Example: Determine the area of the boiler room air supply openings for (1) 300 hp boiler at 800 feet altitude. The air openings are to be 5 feet above oor level. Air required: 300 x 10 = 3000 cfm (from 2B above). Air velocity: Up to 7 feet = 250 fpm (from 3 above). Area Required: Area = cfm/fpm = 3000/250 = 12 sq-ft total. Area/Opening: 12/2 = 6 sq-ft/opening (2 required).
NOTICE
Consult local codes, which may supersede these requirements. Stack/Breeching Size Criteria The design of the stack and breeching must provide the required draft at each boiler ue gas outlet. Proper draft is critical to burner performance. Although constant pressure at the ue gas outlet of the Model ICB-LN is not required, it is necessary to size the stack/ breeching to limit ue gas pressure variation. The allowable pressure range is 0.25" W.C. to +0.25" W.C. For additional information, please review Section I4, General Engineering Data (Stacks) and Section F, Stacks. Stack and breeching sizes should always be provided by a reputable stack supplier who will design the stack and breeching system based on the above criteria. Your local Cleaver-Brooks Authorized Representative is capable of assisting in your evaluation of the stack/breeching design.
A13-14
12-02
Firetube Boilers
Table A13-7. Model ICB-LN Steam Volume and Disengaging Areas
STEAM VOLUME CU-FT BOILER HP 100 125 150 200 250 300 350 400 500 600 700 800 HIGH PRESSURE (A) 11.2 14 19 25 27.8 33.2 47.9 52.6 74.5 89.6 100.8 112.7 LOW PRESSURE (B) 16.5 20.5 26.3 34.6 41.4 49.4 66.3 72.9 94.9 114.2 127 142 STEAM RELIEVING AREA SQ-IN HIGH PRESSURE (A) 3917 4882 5472 7200 6811 8122 9374 10296 11405 13723 14602 16315 LOW PRESSURE (B) 4363 5443 5990 7891 7618 9072 10238 11246 12168 14630 15538 17381
Model ICB-LN
NOTE: 1. Based on normal water level. A. Based on 150 psig design pressure. B. Based on 15 psig design pressure.
Table A13-8. Model ICB-LN Steam Boiler Safety Valve Outlet Size
VALVE SETTING 15 PSIG STEAM NO. OF VALVES REQD 1 1 1 2 2 2 3 3 3 4 5 OUTLET SIZE (IN.) 2-1/2 3 3 2-1/2 (1) 2-1/2 (1) 3 3 (1) 2 (2) 3 (2) 3 (1) 2-1/2 3 (3) 3 (1) 2-1/2 (3) 3 (2) 2-1/2 150 PSIG STEAM NO. OF VALVES REQD 1 2 2 2 2 2 2 2 2 3 3 OUTLET SIZE (IN.) 1-1/2 (1) 1-1/2 (1) 1-1/4 (1) 1-1/2 (1) 1-1/4 1-1/2 (1) 2 (1) 1-1/2 2 (1) 2-1/2 (1) 2 (1) 2-1/2 (1) 2 2-1/2 (2) 2-1/2 (1) 2 (2) 2-1/2 (1) 2 200 PSIG STEAM NO. OF VALVES REQD 1 2 2 2 2 2 2 2 2 2 2 OUTLET SIZE (IN.) 1-1/2 (1) 1-1/4 (1) 1 1-1/4 (1) 1-1/2 (1) 1-1/4 1-1/2 (1) 2 (1) 1-1/2 2 2 (1) 2-1/2 (1) 2 2-1/2 2-1/2 250 PSIG STEAM NO. OF VALVES REQD 1 2 2 2 2 2 2 2 2 2 2 OUTLET SIZE (IN.) 1-1/4 1 (1) 1 (1) 1-1/4 1-1/4 (1) 1-1/2 (1) 1-1/4 1-1/2 (1) 1-1/2 (1) 2 (1) 1-1/2 (1) 2 2 (1) 2 (1) 2-1/2 2-1/2
BOILER HP 100 125 150 200 250 300 350 400 500 600 700, 800
A13-15
12-02
Model ICB-LN
Table A13-9. Model ICB-LN Hot Water Boiler Relief Valve Outlet Size
VALVE SETTING 30 PSIG HW NO. OF VALVES REQD 1 1 1 2 2 2 3 3 4 4 5 OUTLET SIZE (IN.) 2-1/2 2-1/2 2-1/2 (1) 2-1/2 (1) 1-1/4 (1) 2 (1) 2-1/2 2-1/2 (2) 2-1/2 (1) 1 (1) 2 (2) 2-1/2 (1) 1 (3) 2-1/2 (3) 2-1/2 (1) 2 (1) 1 (4) 2-1/2 125 PSIG HW NO. OF VALVES REQD 1 1 1 1 1 1 1 1 2 2 2 OUTLET SIZE (IN.) 1-1/4 1-1/4 2 2 2 2-1/2 2-1/2 2-1/2 (1) 1 (1) 2-1/2 (1) 1-1/4 (1) 2-1/2 (1) 2-1/2 (1) 2 150 PSIG HW NO. OF VALVES REQD 1 2 2 2 2 2 2 2 2 3 3 OUTLET SIZE (IN.) 2 (1) 1-1/2 (1) 2 (1) 1-1/2 (1) 2 2 (1) 2 (1) 2-1/2 2-1/2 (1) 2-1/2 (1) 3 (1) 2-1/2 (1) 3 3 (2) 3 (1) 2-1/2 3
Firetube Boilers
BOILER HP 100 125 150 200 250 300 350 400 500 600 700, 800
NOTE: Relief valve is Kunkle #537 for 30# & 125#(Section IV) boiler and is Kunkle #927 for 150# HTHW (Section I) boiler.
Table A13-10. Model ICB-LN Recommended Steam Nozzle Size

OPERATING PRESSURE PSIG 15 30 40 50 75 100 125 150 200 250 100 8 6 6 4 4 4 4 2.5 2.5 2 125 8 6 6 6 4 4 4 3 2.5 2.5 150 8 6 6 6 4 4 4 3 3 2.5 200 10 8 6 6 6 6 4 4 4 3 250 10 8 8 6 6 6 6 4 4 4 BOILER HP 300 12 8 8 8 6 6 6 6 4 4 350 12 10 8 8 8 6 6 6 4 4 400 12 10 10 8 8 6 6 6 6 4 500 12 10 10 8 8 8 8 6 6 6 600 12 12 10 10 8 8 8 6 6 6 700 12 12 12 10 10 8 8 8 6 6 800 12 12 12 12 10 10 8 8 6 6
NOTES: 1. Steam nozzle sizes given in inches. 2. Recommended steam nozzle sizes based on 4000 to 5000 fpm steam velocity.
A13-16
12-02
Firetube Boilers
Table A13-11. Model ICB-LN Recommended Non-Return Valve Size
BOILER HP 100 125 150 200 250 300 350 400 500 600 700 800 BOILER CAPACITY (LBS/HR) 3450 4313 5175 6900 8625 10350 12025 13800 17210 20700 24150 27600 OPERATING PRESSURE (PSIG) 50 3 4 4 4 4 6 6 6 6 8 8 8 75 2-1/2 3 4 4 4 4 6 6 6 8 8 8 100 2-1/2 3 3 4 4 4 4 4 6 6 6 6 125 2-1/2 3 3 3 4 4 4 4 6 6 6 6 150 2-1/2 3 3 3 3 4 4 4 4 6 6 6 175 2-1/2 2-1/2 3 3 3 4 4 4 4 4 6 6 200 2-1/2 2-1/2 2-1/2 3 3 4 4 4 4 4 6 6 250 2-1/2 2-1/2 2-1/2 3 3 3 3 4 4 4 6 6
Model ICB-LN
NOTE: Valve sizes (300 psig anges) given in inches.
Table A13-12. Model ICB-LN Blowdown Tank Sizing Information

BOILER HP 100 125 150 200 250 300 350 400 500 600 700 800 WATER (GAL) 75 94 102 135 125 150 174 191 206 248 266 297
Table A13-14. Sound Pressure Levels in dBA for ICB Boilers at High Fire
Sound Level dBA BHP 100 125 150 200 250 300 350 400 500 600 700 800 ICB-LN 83.1 89.5 88.6 90.0 91.0 94.0 91.5 93.5 93.5 93.7 93.7 93.5

NOTE: To obtain minimum required gas pressure at altitudes above 700 feet, multiply the pressure by the listed factors: Inches WC x 0.577 = oz/sq-in. oz/sq-in x 1.732 = Inches WC. Inches WC x 0.0361 = psig. oz/sq-in x 0.0625 = psig. psig x 27.71 = Inches WC. psig x 16.0 = oz/sq-in.
A13-17
12-02
Model ICB-LN
Firetube Boilers
Table A13-15. Model ICB-LN, Standard, Minimum Required Gas Pressure at Entrance to Standard, FM & IRI Gas Trains (Upstream of Gas Pressure Regulator)
BOILER HP 100 125 150 200 250 300 350 400 500 600 700 800 STD PIPE SIZE (Inches) 2 2 2 2-1/2 2-1/2 2-1/2 3 3 3 3 3 3 PRESSURE REQUIRED, 3-PASS ("WC) Minimum 13 19.5 20 27 30 43 45 40.5 53.5 120 138.5 86 Maximum 27.7 27.7 27.7 27.7 138.5 138.5 138.5 138.5 138.5 277 277 277 PRESSURE REQUIRED, 4-PASS ("WC) Minimum 15 17.5 21.5 32.5 35.5 47.5 49.5 42.5 58.5 120 138.5 86 Maximum 27.7 27.7 27.7 138.5 138.5 138.5 138.5 138.5 138.5 277 277 277
NOTE: For undersized or oversized gas trains or altitudes above 700 feet, contact your local Cleaver-Brooks Authorized Representative.
A13-18
12-02
Firetube Boilers
Model ICB-LN
1. Shortest boiler room length (Dwg A) is obtained by allowing for possible future tube replacement (from front or rear of boiler) through a window or doorway. Allowance is only made for minimum door swing at each end of the boiler. This arrangement provides sufcient aisle space at the front of the boiler but a tight space condition at the rear. If space permits, approximately 1.5 additional feet should be allowed at the rear for additional aisle and working space. 2. Next shortest boiler room length (Dwg B) is obtained by allowing for possible future tube replacement from the front of the boiler. Allowance is only made for minimum door swing at the rear. If space permits, approximately 1.5 additional feet should be allowed at the rear for additional aisle and working space.
Figure A13-7. Boiler Room Length (Typical Layouts) Model ICB-LN
BOILER HP DIM. A DIM. B
100 125 84-1/2 115-1/2
150 200 87 120
250 300 93 138
350 400 96 144
500 600 103 170
700 800 110 184
NOTES: 1. Recommended Minimum Distance Between Boiler and Wall. Dimension "A allows for a clear 42" aisle between the water column on the boiler and the wall. If space permits, this aisle should be widened. 2. Recommended Minimum Distance Between Boilers. Dimension B between boilers allows for a clear aisle of: 42" 100-200 hp 48" 250-400 hp 60 500-800 hp If space permits, this aisle should be widened.
Figure A13-8. Boiler Room Width (Typical Layout) Model ICB-LN
A13-19
12-02
Model ICB-LN
Firetube Boilers
The following sample specication is provided by Cleaver-Brooks to assist you in meeting your customers specic needs and application. The Sample Specication is typically utilized as the base template for the complete boiler specication. The LN option includes information on the Low NOx package for 30 ppm NOx (dry volume basis and corrected to 3% O2) when ring natural gas. Contact your local Cleaver-Brooks Authorized Representative for information on special insurance requirements, special code requirements, optional equipment, or general assistance in completing the specication. Model ICB-LN Steam Boiler (100 800 hp, 15 300 psig) 1.0 Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model ICB-LN Hot Water Boiler (100 800 hp, 30 psig, 125 psig) 1.0 Boiler Characteristics (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Hot Water Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model ICB-LN Steam Boiler (100 800 hp, 15 300 psig)
A13-20 A13-20 A13-21 A13-22 A13-24 A13-24 A13-24
A13-25 A13-25 A13-26 A13-26 A13-28 A13-28 A13-28
1.0 Boiler Characteristics (Steam) 1.1 The Steam Boiler shall be Cleaver-Brooks Model ICB-LN, Fuel Series ______ (100, 200, 700), _____ hp designed for _____ psig (15, 150, 200, 250, 300 psig steam). The maximum operating pressure shall be _____ psig. 1.2 The boiler shall have a maximum output of _____ Btu/hr, or _____ horsepower when red with CS 12-48 No. 2 oil and/or natural gas, _____ Btu/cu-ft. Electrical power available will be _____ Volt _____ Phase _____ Cycle and 115/1/60 for the control circuit. 2.0 General Boiler Design 2.1 Number of Passes Select one of the following: A. (Four-Pass) The boiler shall be a four-pass intercooled horizontal retube updraft boiler. It shall be mounted on a heavy steel frame with forced draft burner and burner controls. B. (Three-Pass) The boiler shall be a three-pass intercooled horizontal retube updraft boiler. It shall be mounted on a heavy steel frame with forced draft burner and burner controls. 2.1.1 Approvals: The complete burner/boiler Low NOx package shall be approved as a unit by Underwriters Laboratories Inc. and bear the UL/cUL label. 2.1.2 The boiler shall be completely preassembled and re tested at the factory. The unit shall be ready for immediate mounting on oor or simple foundation and ready for attachment of water, steam, fuel, electrical, vent and blowdown connections. 2.2 Boiler Shell (Steam)
A13-20
12-02
Firetube Boilers
Model ICB-LN
2.2.1 The boiler shell must be constructed in accordance with ASME Boiler Code and must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser. 2.2.2 Two lifting eyes shall be located on top of the boiler. 2.2.3 Front and rear doors on the boiler shall be davited. 2.2.4 The rear door shall be insulated with a blanket material and a steel covering to give the surface a hard durable nish. 2.2.5 The boiler tubes shall not include turbulators, swirlers or other add-on appurtenances. 2.2.6 The boiler shall be furnished with a manhole and handholes to facilitate boiler inspection and cleaning. 2.2.7 Exhaust Vent Select one of the following: A. (Four-Pass) The exhaust gas vent shall be located near the front of the boiler on the top centerline and shall be capable of supporting 2000 lbs. B. (Three-Pass) The exhaust gas vent shall be located at the rear of the boiler on the top centerline and shall be capable of supporting 2000 lbs. 2.2.8 Observation ports for the inspection of ame conditions shall be provided at each end of the boiler. 2.2.9 The boiler insulation shall consist of a 2 inch blanket under a sectional preformed sheet metal lagging. This insulation must be readily removable and capable of being reinstalled, if required. 2.2.10 The entire boiler based frame and other components shall be factory painted before shipment using a hard nish enamel coating. 2.2.11 An inner rear turnaround access opening shall swing on a davit, to allow full accessibility to the 2nd pass tubes and furnace. 2.2.12 Tubes shall be removable from either the front or rear of the boiler. 2.3 Emission Controls 2.3.1 Boiler shall be equipped with a low emission (LN) option for guaranteed NOx performance at 30 ppm, dry volume basis and corrected to 3% O2 when ring natural gas. 2.3.2 The low emission (LN) option shall include a burner and boiler package to provide NOx reduction through an induced ue gas recirculation system using the burner blower assembly, a control valve, a shut-off valve, electrical interlocks, and ue gas recirculation piping. Boiler fuel-to-steam efciency and rated boiler capacity shall be guaranteed while the boiler is operating at the low NOx performance levels. 2.3.3 Burner, boiler and low NOx system shall be manufactured as a package by a single manufacturer. The Low NOx option to the Cleaver-Brooks boiler shall include factory testing as a package, and the burner shall bear the UL, cUL label. 3.0 Steam Boiler Trim 3.1 Water Column A water column shall be located on the right hand side of the boiler complete with gauge glass set and water column blowdown valves. 3.1.1 Feedwater Pump Control The boiler feedwater pump control shall be included as an integral part of the water column to automatically actuate a motor driven feedwater pump maintaining the boiler water level within normal limits. 3.1.2 Low Water Cutoff The low water cutoff shall be included as an integral part of the boiler feedwater control wired into the burner control circuit to prevent burner operation if the boiler water level falls below a safe level. 3.2 Auxiliary Low Water Cutoff The auxiliary low water cutoff shall be included, piped to the vessel, and wired to the burner control circuit. A manual reset device shall be used for this control.
A13-21
12-02
Model ICB-LN
3.3 Steam Pressure Gauge The steam pressure gauge shall be located at the front of the boiler and include cock and test connection. 3.4 Safety Relief Valves Safety valves of a type and size to comply with ASME Code requirements shall be shipped loose. 3.5 Steam Pressure Controls The steam pressure controls to regulate burner operation shall be mounted near the water column. 4.0 Burner and Controls 4.1 Mode of Operation
Firetube Boilers
Burner operation shall be the full modulation principle. The burner shall always return to low re position for ignition. 4.2 Blower 4.2.1 All air for combustion shall be supplied by a forced draft blower mounted on the burner, to eliminate vibration and reduce noise level. 4.2.2 Maximum sound level of the boiler/burner package shall not exceed _____ dBA (when measured in accordance with ABMA Sound Test Standards). 4.2.3 The impeller shall be fabricated aluminum with radial blade, carefully balanced, and directly connected to the blower motor shaft. 4.3 Combustion Air Control Combustion air damper and fuel control valve shall be operated by a single damper control motor that regulates the ame according to load demand. Potentiometer type position controls shall be provided to regulate operation of the damper control motor. 4.4 Fuel Specication and Piping Select one of the following fuel types: Fuel series 700 Gas red (para 4.4.1). Fuel series 100 Light oil (No. 2) red (para 4.4.2). Fuel series 200 Light oil or gas red (para 4.4.3). 4.4.1 FUEL SERIES 700 GAS FIRED 4.4.1.1 Burner Type The burner shall be mounted at the front of the boiler and be of high radiant multi-port type for gas. The burner shall be approved for operation on natural gas fuel. 4.4.1.2 Gas Pilot The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include one (1) shut-off valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only). 4.4.1.3 Gas Burner Piping Select one of the following: A. 100 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. B. 125 250 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition.
A13-22
12-02
Firetube Boilers
Model ICB-LN
C. 300 800 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, two (2) motorized gas valves and one (1) valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. 4.4.2 FUEL SERIES 100 LIGHT OIL FIRED 4.4.2.1 Burner Type The burner shall be mounted at the front of the boiler, and shall be approved for operation with CS12-48, Commercial No. 2 oil. 4.4.2.2 Gas Pilot The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include one (1) shut-off valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only). 4.4.2.3 Oil Pump An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Pump shall be motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided. 4.4.2.4 Oil Burner Piping Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one (1) motorized oil valve with proof of closure switch, pressure relief valve, atomizing air proving switch, and low oil pressure switch all integrally mounted on the unit. 4.4.2.5 Oil Atomization Type Burner shall be a low pressure air atomizing type, including a shipped loose air compressor assembly. 4.4.3 FUEL SERIES 200 LIGHT OIL OR GAS FIRED 4.4.3.1 Burner Type The burner, mounted at the front of the boiler, shall be a combination of low pressure air atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 oil or natural gas. 4.4.3.2 Gas Pilot The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary fuel valve cannot open until ame has been established. The pilot train shall include one (1) manual shutoff valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only). 4.4.3.3 Oil Burner 4.4.3.3.1 Oil Pump An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Pump shall be motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided. 4.4.3.3.2 Oil Burner Piping Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one (1) motorized oil valve with proof of closure switch, pressure relief valve, atomizing air proving switch, and low oil pressure switch all integrally mounted on the unit. 4.4.3.3.3 Oil Atomization Type Burner shall be a low pressure air atomizing type, including a shipped loose air compressor assembly. 4.4.3.4 Gas Burner Piping Select one of the following: A. 100 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. B. 125 150 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. C. 300 800 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, two (2) motorized gas valves and one (1) valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water or any abnormal shutdown condition.
A13-23
12-02
Model ICB-LN
4.5 Control Panel and Flame Safeguard Controller 4.5.1 Control Panel
Firetube Boilers
A factory prewired control panel shall be supplied with the boiler/burner package. Panel may be mounted on the burner or boiler. 4.5.2 The panel will have a NEMA 1A rating and contain the ame safeguard controller, burner motor starter, air compressor motor starter, oil metering pump motor starter, control circuit transformer and fuses, selector switches, indicating lights and terminal strips. Lights shall indicate load demand, ame failure, low water, and fuel valve open. 4.5.3 The panel shall contain fuse protection for the burner motor, air compressor motor, and oil metering pump. 4.5.4 The ame safeguard controller shall be a CB110 ame monitor with EPD170 program module. Flame detector shall be ultraviolet type. 5.0 Efciency Guarantee 5.1 The boiler must be guaranteed to operate at a minimum fuel-to-steam efciency of ____ percent at 100 percent of rating when burning natural gas and ________ fuel-to-steam efciency at 100% ring rate when burning oil (Contact your local CleaverBrooks Authorized Representative for efciency details). 6.0 Warranty 6.1 All equipment is to be guaranteed against defects in materials and/or workmanship for a period of 12 months from date of startup or 18 months from date of shipment, whichever comes rst. 7.0 Execution 7.1 Shop Tests 7.1.1 The packaged boiler must receive factory tests to check the construction, controls, and operation of the unit. All tests may be witnessed by the purchaser, if desired. 7.2 Start-Up Service 7.2.1 After boiler installation is completed, the manufacturer shall provide the services of a eld representative for starting the unit and training the operator at no additional costs. 7.2.1.1 A factory approved and authorized start-up report shall be submitted to the customer/user at the time of start-up.
A13-24
12-02
Firetube Boilers
Model ICB-LN Hot Water Boiler (100 800 hp, 30 psig, 125 psig)
Model ICB-LN
1.0 Boiler Characteristics (Hot Water) 1.1 The Hot Water Boiler shall be Cleaver-Brooks Model ICB-LN, Fuel Series ______ (100, 200, 700), _____ hp designed for _____ psig (30, 125, or other psig hot water). The maximum water temperature will be _____ degree F, and the maximum system temperature drop will be _____ degree F. 1.2 The boiler shall have a maximum output of _____ Btu/hr, or _____ horsepower when red with CS 12-48 No. 2 oil and/or natural gas, _____ Btu/cu-ft. Electrical power available will be _____ Volt _____ Phase _____ Cycle and 115/1/60 for the control circuit. 2.0 General Boiler Design 2.1 Number of Passes Select one of the following: A. (Four-Pass) The boiler shall be a four-pass intercooled horizontal retube updraft boiler. It shall be mounted on a heavy steel frame with forced draft burner and burner controls. B. (Three-Pass) The boiler shall be a three-pass intercooled horizontal retube updraft boiler. It shall be mounted on a heavy steel frame with forced draft burner and burner controls. 2.1.1 Approvals: The complete burner/boiler Low NOx package shall be approved as a unit by Underwriters Laboratories Inc. and bear the UL/cUL label. 2.1.2 The boiler shall be completely preassembled and re tested at the factory. The unit shall be ready for immediate mounting on oor or simple foundation and ready for attachment of water, steam, fuel, electrical, vent and blowdown connections. 2.2 Boiler Shell (Hot Water) 2.2.1 The boiler shell must be constructed in accordance with ASME Boiler Code and must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser. 2.2.2 The hot water return and outlet connections shall be located on the top centerline of the boiler. The boiler shall be designed to rapidly mix the return water with the boiler water. Forced internal circulation shall be used. 2.2.3 A dip tube shall be included as an integral part of the water outlet. 2.2.4 Two lifting eyes shall be located on top of the boiler. 2.2.5 Front and rear doors on the boiler shall be davited. 2.2.6 The rear door shall be insulated with a blanket material and a steel covering to give the surface a hard durable nish. 2.2.7 The boiler tubes shall not include turbulators, swirlers or other add-on appurtenances. 2.2.8 The boiler shall be furnished with a manhole and handholes to facilitate boiler inspection and cleaning. 2.2.9 Exhaust Vent Select one of the following: A. (Four-Pass) The exhaust gas vent shall be located near the front of the boiler on the top centerline and shall be capable of supporting 2000 lbs. B. (Three-Pass) The exhaust gas vent shall be located at the rear of the boiler on the top centerline and shall be capable of supporting 2000 lbs. 2.2.10 Observation ports for the inspection of ame conditions shall be provided at each end of the boiler. 2.2.11 The boiler insulation shall consist of a 2 inch blanket under a sectional preformed sheet metal lagging. This insulation must be readily removable and capable of being reinstalled, if required. 2.2.12 The entire boiler based frame and other components shall be factory painted before shipment using a hard nish enamel coating. 2.2.13 An inner rear turnaround access opening shall swing on a davit, to allow full accessibility to the 2nd pass tubes and furnace. 2.2.14 Tubes shall be removable from either the front or rear of the boiler.
A13-25
12-02
Model ICB-LN
2.3 Emission Controls
Firetube Boilers
2.3.1 Boiler shall be equipped with a low emission (LN) option for guaranteed NOx performance at 30 ppm, dry volume basis and corrected to 3% O2 when ring natural gas. 2.3.2 The low emission (LN) option shall include a burner and boiler package to provide NOx reduction through an induced ue gas recirculation system using the burner blower assembly, a control valve, a shut-off valve, electrical interlocks, and ue gas recirculation piping. Boiler fuel-to-water efciency and rated boiler capacity shall be guaranteed while the boiler is operating at the low NOx performance levels. 2.3.3 Burner, boiler and low NOx system shall be manufactured as a package by a single manufacturer. The Low NOx option to the Cleaver-Brooks boiler shall include factory testing as a package, and the burner shall bear the UL, cUL label. 3.0 Hot Water Boiler Trim 3.1 Hot Water Connections The hot water outlet and return connections shall be located on the top centerline of the boiler. The internal design of these connections shall provide forced internal circulation, mixing return water with the hot water within the boiler. 3.2 Dip Tube The dip tube, an integral part of the hot water outlet, and an air vent tapping in the boiler shell must be provided for removal of air. 3.3 Low Water Cutoff A low water cutoff control shall be mounted on the top centerline of the boiler wired into the burner control circuit to prevent burner operation if boiler water falls below a safe level. A manual reset device shall be used on this control. 3.4 Pressure and Temperature Gauges Pressure and temperature gauges shall be mounted on the boiler with temperature sensing element located adjacent to the hot water outlet. 3.5 Relief Valves Water relief valves of a type and size to comply with ASME Code requirements shall be shipped loose. 3.6 Temperature Controls The temperature controls to regulate burner operation shall be mounted on the unit with temperature sensing elements located adjacent to the hot water outlet. 4.0 Burner and Controls 4.1 Mode of Operation Burner operation shall be the full modulation principle. The burner shall always return to low re position for ignition. 4.2 Blower 4.2.1 All air for combustion shall be supplied by a forced draft blower mounted on the burner, to eliminate vibration and reduce noise level. 4.2.2 Maximum sound level of the boiler/burner package shall not exceed _____ dBA (when measured in accordance with ABMA Sound Test Standards). 4.2.3 The impeller shall be fabricated aluminum with radial blade, carefully balanced, and directly connected to the blower motor shaft. 4.3 Combustion Air Control Combustion air damper and fuel control valve shall be operated by a single damper control motor that regulates the ame according to load demand. Potentiometer type position controls shall be provided to regulate operation of the damper control motor.
A13-26
12-02
Firetube Boilers
4.4 Fuel Specication and Piping Select one of the following fuel types: Fuel series 700 Gas red (para 4.4.1). Fuel series 100 Light oil (No. 2) red (para 4.4.2). Fuel series 200 Light oil or gas red (para 4.4.3). 4.4.1 FUEL SERIES 700 GAS FIRED
Model ICB-LN
4.4.1.1 Burner Type The burner shall be mounted at the front of the boiler and of high radiant multi-port type for gas. The burner shall be approved for operation on natural gas fuel. 4.4.1.2 Gas Pilot The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include one (1) shut-off valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only). 4.4.1.3 Gas Burner Piping Select one of the following: A. 100 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. B. 125 250 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. C. 300 800 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, two (2) motorized gas valves and one (1) valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. 4.4.2 FUEL SERIES 100 LIGHT OIL FIRED 4.4.2.1 Burner Type The burner shall be mounted at the front of the boiler, and shall be approved for operation with CS12-48, Commercial No. 2 oil. 4.4.2.2 Gas Pilot The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary fuel valve cannot open until ame has been established. The pilot train shall include one (1) shut-off valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only). 4.4.2.3 Oil Pump An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Pump shall be motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided. 4.4.2.4 Oil Burner Piping Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one (1) motorized oil valve with proof of closure switch, pressure relief valve, atomizing air proving switch, and low oil pressure switch all integrally mounted on the unit. 4.4.2.5 Oil Atomization Type Burner shall be a low pressure air atomizing type, including a shipped loose air compressor assembly. 4.4.3 FUEL SERIES 200 LIGHT OIL OR GAS FIRED 4.4.3.1 Burner Type The burner, mounted at the front of the boiler, shall be a combination of low pressure air atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 oil or natural gas. 4.4.3.2 Gas Pilot The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the pilot so that the primary fuel valve cannot open until ame has been established. The pilot train shall include one (1) manual shut-off valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only).
A13-27
12-02
Model ICB-LN
Firetube Boilers
4.4.3.3 Oil Burner 4.4.3.3.1 Oil Pump An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Pump shall be motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided. 4.4.3.3.2 Oil Burner Piping Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one (1) motorized oil valve with proof of closure switch, pressure relief valve, atomizing air proving switch, and low oil pressure switch all integrally mounted on the unit. 4.4.3.3.3 Oil Atomization Type Burner shall be a low pressure air atomizing type, including a shipped loose air compressor assembly. 4.4.3.4 Gas Burner Piping Select one of the following: A. 100 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. B. 125 250 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) solenoid and one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shutdown condition. C. 300 800 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, two (2) motorized gas valves and one (1) valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connections, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low water or any abnormal shutdown condition. 4.5 Control Panel and Flame Safeguard Controller 4.5.1 Control Panel A factory prewired control panel shall be supplied with the boiler/burner package. Panel may be mounted on the burner or boiler. 4.5.2 The panel will have a NEMA 1A rating and contain the ame safeguard controller, burner motor starter, air compressor starter, oil metering pump motor starter, control circuit transformer and fuses, selector switches, indicating lights and terminal strips. Lights shall indicate load demand, ame failure, low water, and fuel valve open. 4.5.3 The panel shall contain fuse protection for the burner motor, air compressor motor, and the oil metering pump. 4.5.4 The ame safeguard controller shall be a CB110 ame monitor with EPD170 program module. Flame detector shall be ultraviolet type. 5.0 Efciency Guarantee 5.1 The boiler must be guaranteed to operate at a minimum fuel-to-water efciency of ____ percent at 100 percent of rating when burning natural gas and ________ fuel-to-steam efciency at 100% ring rate when burning oil (Contact your local Cleaver-Brooks Authorized Representative for efciency details). 6.0 Warranty 6.1 All equipment is to be guaranteed against defects in materials and/or workmanship for a period of 12 months from date of start-up or 18 months from date of shipment, whichever comes rst. 7.0 Execution 7.1 Shop Tests 7.1.1 The packaged boiler must receive factory tests to check the construction, controls, and operation of the unit. All tests may be witnessed by the purchaser, if desired. 7.2 Start-Up Service 7.2.1 After boiler installation is completed, the manufacturer shall provide the services of a eld representative for starting the unit and training the operator at no additional costs. 7.2.1.1 A factory approved and authorized start-up report shall be submitted to the customer/user at the time of start-up.
A13-28
12-02
Section B
COMMERCIAL BOILERS
Model FLX Boilers Model 4 Boilers Model 5 Boilers Electric Boilers Truere Boilers Clearre Boilers B1 B2 B3 B4 B5 B6
B-a
02-02
General
Commercial Boilers
B-b
Section B1
FLEXIBLE WATERTUBE BOILERS
CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-3 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-3 Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-4 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-4 DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-5 PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-11 Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-11 Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-11 ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-11 Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-11 Burner/Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1-13 SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1-18 Steam Boiler Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-18 Hot Water Boiler Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-22
B1-1
04-02
Flexible Watertube Boilers

ILLUSTRATIONS
Commercial Boilers
Figure B1-1. Model FLX Hot Water Boiler Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-7 Figure B1-2. Model FLX Steam Boiler Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-9 Figure B1-3. Model FLX Tube Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-13 Figure B1-4. Model FLX Oil Burner Supply Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-15 Figure B1-5. Model FLX Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-16 Figure B1-6.Model FLX Breeching Arrangement - Single or Multiple Boiler Installation . . . . . . . . . . . . . . . . . . . . . . . B1-17 TABLES Table B1-1. Model FLX Watertube Boiler Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-4 Table B1-2. Model FLX Hot Water Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-6 Table B1-3.Model FLX Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-6 Table B1-4. Expected Emissions (ppm, corrected to 3% O2), Natural Gas Fired Boiler . . . . . . . . . . . . . . . . . . . . . . . . . B1-11 Table B1-5. Model FLX Hot Water Boiler Flow Rates and Pressure Drops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-11 Table B1-6. Model FLX Circulating Rates, Hot Water Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-12 Table B1-7. Model FLX Minimum Over Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-12 Table B1-8. Model FLX Boiler Heat Release Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-12 Table B1-9. Model FLX Burner Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-14 Table B1-10. Model FLX Minimum Required Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-14 Table B1-11. Model FLX Sound Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-16 Table B1-12. Model FLX Combustion Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-17
This section contains information on the Flexible Watertube boiler. The product model name is FLX for factory-assembled boilers, and FLE for eld-erectable boilers. It is available in sizes ranging from 1.5 to 12 MMBtu/hr input. Cleaver-Brooks offers the Model FLX bent-tube boiler to meet todays demanding commercial users needs. The exible watertube design has distinct advantages, including resistance to thermal shock and easy boiler maintenance. In addition Model FLX boilers offer high operating efciency. These combined factors equate to a real increase on the return from your boiler room investment.
B1-2
04-02
Commercial Boilers

NOx reduction to 20 ppm available. Meets stringent emission requirements with no loss in operating performance. ASME Construction: Ensures high quality design and manufacturing standards. Ensures safety and reliability. Cleaver-Brooks Forced Draft Burner: Provides high pressure drop for low CO and maximum combustion performance. Reduces stack draft requirements. Optimum fuel and air mixing. Long-life reverse curve impeller. Ensures maximum combustion efciency, as low as 10% excess air. Burner/Boiler by single manufacturer. Removable Side Panels Provides easy access for inspection. Reduces maintenance costs. Ensures containment of furnace gases. Rugged construction for durability. 20-Year Pressure Vessel Warranty: Guaranteed to last. Backed by Cleaver-Brooks. Field Erectable (Optional): Complete package for ease of assembly. Pieces t through standard doorway.

Patented Vessel and Tube Design: Ensures that all tubes are subject to radiant heat from the burner ame. Creates high water-ow-rates at all loads, and increases heat transfer throughout the boiler. Large Downcomer, Located Outside the Fire Zone: Guarantees positive natural internal circulation, minimizing the impact of exterior pumping conditions. True Tangent-Wall Design: No ns or strips to substitute for tubes. Ensures maximum cooling and uniform heat transfer throughout the boiler. Five-Pass Boiler Design: Creates high ue gas velocities to rapidly and efciently transfer heat to the water. Higher efciencies compared to other tangent-tube designs. 1.5-Inch Diameter Tube Design: Eliminates possible damage from thermal shock stresses. Reduces maintenance costs. Prolongs equipment life. Swedge-Fitted Tube Attachment: Eliminates the need for rolling or welding tubes. Lessens repair or replacement requirements. Ease of tube replacement reduces downtime. Burner Supported by the Front Door: No crane/hoist is required to remove burner and components for inspection. Provides easy inspection access. Reduces maintenance costs. Insulated Construction: Reduces thermal losses. Increases efciency. Low NOx Capability:
PRODUCT OFFERING
Information in this section applies to steam and hot water boiler sizes ranging from 1.5 to 12 MMBtu/hr input, as shown in Table B1-1. The Flexible Watertube Boiler is a ve-pass steel boiler with exible tubes formed and arranged to direct the ow of combustion gases through the boiler. The pressure vessel conforms to Section I or Section IV of the ASME Code, and consists of the formed tubes and the external downcomer connected to the top and bottom drums. The heated area of the pressure vessel is contained within a gas-tight, insulated casing that is composed of removable, formed-steel panels. The boiler/burner package
B1-3
04-02

Table B1-1. Model FLX Watertube Boiler Sizes
MODEL FLX-150 FLX-200 FLX-250 FLX-300 FLX-350 FLX-400 FLX-450 FLX-500 FLX-550 FLX-600 FLX-700 FLX-800 FLX-900 FLX-1000 FLX-1100 FLX-1200 CAPACITY INPUT BTU/HR 1,500,000 2,000,000 2,500,000 3,000,000 3,500,000 4,000,000 4,500,000 5,000,000 5,500,000 6,000,000 7,000,000 8,000,000 9,000,000 10,000,000 11,000,000 12,000,000 HEAT OUTPUT BTU/HR 1,200,000 1,600,000 2,000,000 2,400,000 2,800,000 3,200,000 3,600,000 4,000,000 4,400,000 4,800,000 5,600,000 6,400,000 7,200,000 8,000,000 8,800,000 9,600,000 EQUIV HP 36 48 60 72 84 96 108 119 132 143 167 191 215 239 263 287
Commercial Boilers
C. Pressure gauge for steam boilers. D. Operating and limit controls: 1). High limit control - manual reset. 2). Operating limit control - automatic reset. 3). Modulating or proportional controller. E. Low water cutoff: 1). Probe type - hot water. 2). Float type main and probe type auxiliary- steam. F. Pump Control - steam boilers.
NOTICE
Hot water boilers with design pressures up to 150 psig, and with design temperatures less than 250 F, are constructed under Section IV of the ASME Code, and H stamped for low- pressure heating boilers.
NOTES: 1. Design Pressure: 150 psig Hot Water, 15 psig Steam, 150 psig Steam. 2. Also available in Model FLE (eld erectable).
NOTICE
Steam boilers with design pressure of 30 psig, and maximum allowable operating pressure of 15 psig, are constructed under Section IV of the ASME Code, and H stamped for low pressure heating boilers.
is manufactured by Cleaver-Brooks and UL/cUL approved as a package.
Standard Equipment
Equipment described below is for the standard boiler offering. 1. Boiler: A. All boilers are designed and constructed in accordance with the ASME Code and are mounted on an integral frame. All refractories for boiler and burner are installed. B. Factory re test. 2. Cleaver-Brooks ProFire Forced Draft Burner: A. Mounted on a hinged backing plate for easy access to furnace. B. Pressure atomizing type for No. 2 oil burner. This includes the oil pump. C. Stainless steel ame-retention type combustion head for gas, with UV scanner, and gas pressure regulator. D. External access to ame scanner for ease of maintenance. 3. Water/Steam Controls: A. ASME safety relief valve(s). B. Pressure and temperature gauges for hot water boilers.
NOTICE
Steam boilers with design pressure of 150 psig are constructed under Section I of the ASME code and S stamped for high pressure steam boilers. 4. Altitude: Standard boilers attain full ratings at altitudes up to 1,500 feet. Altitude compensation for most models is available for altitudes up to 11,000 ft above sea level.
Optional Equipment
For option details, contact your local Cleaver-Brooks authorized representative. In summary, options include the following: A. Boiler Options Auxiliary low water cut-off (hot water). Stack thermometer. Insulated downcomer(s). Drain valves. Additional screwed tappings.
B1-4
04-02
Commercial Boilers
Packaged for eld erection. B. Burner/Control Options Special burner modulation controls. Low NOx burner. Optional ame safeguard controller. Lead/lag system. High altitude design, up to 11,000 ft. Special insurance and code requirements (e.g., IRI, FM, ASME CSD-1). Alarm bell/silence switch. Special motor requirements (TEFC, high efciency). Remote contacts. Additional relay points and indicator lights. Main disconnect (fusible/circuit breaker). Elapsed time meter. Voltmeter/micro-ammeter. NEMA enclosures. Key lock panel. System pump interlock. Low re hold controls. Assured low re cut-off. Flow switches. High stack temperature cut-off/alarm. Remote emergency shutoff (115V). C. Fuel Options Special gas pressure regulator. Oversized gas trains. Gas strainer. Special fuel shut-off valves. Remote oil pump set. Special pilot. Direct spark oil ignition. Automatic fuel changeover.

Ratings for steam and hot water boilers are shown in Tables B1-2 and B1-3. Dimensions for steam and hot water boilers are shown in Figures B1-1and B1-2.
B1-5
04-02
Commercial Boilers
Table B1-2. Model FLX Hot Water Boiler Ratings

MODEL NO. 150 200 2000 14.3 1600 1660 48 2000 250 2500 17.9 2000 2075 60 2500 300 3000 21.4 2400 2490 72 3000 350 3500 25.0 2800 2905 84 3500 400 4000 28.6 3200 3320 96 4000 450 4500 32.1 3600 3735 108 4500 500 5000 35.7 4000 4150 119 5000 550 5500 39.3 4400 4565 131 5500 600 6000 42.9 4800 4980 143 6000 700 7000 50.0 5600 5810 167 7000 800 8000 57.2 6400 6640 191 8000 900
1000
1100
1200
Fuel Consumption .......Gas (cfh)A 1500 Oil (gph)B 10.7 Output (MBH) ..............Gas Firing 1200 Oil Firing 1245 Approximate bhp Natural Gas Input: CFH (1000 Btu) Natural Gas: Therms/Hour Shipping Weight (lbs) Operating Weight (lbs) Water Content (US gal) Blower Motor hp 36 1500
9000 10000 11000 12000 64.3 71.4 78.6 85.7 7200 7470 215
8000 8300 239
8800 9130 263
9600 9960 287
9000 10000 11000 12000
15 3900 4700 91 1/3A 1/2B
20 3900 4700 91 1/2
25 3900 4700 91 3/4
30 5000 5900 106 1/2A 3/4B
35 5000 5900 106 3/4A 1B
40 6100 7600 174
45 6100 7600 174
50 6100 7600 174 2
55 6100 7600 174 3
60 6100
70 8500
80 8500
90
100
110
120
8500 10000 10000 10000
7600 10500 10500 10500 12300 12300 12300 174 3 228 5 228 5 228
270
270
270 10
1-1/2 1-1/2A 2B
5A 5A 7 1/2 7-1/2B 7-1/2B
NOTES: 212F Feedwater. A. Natural Gas @ 1000 Btu/cu-ft. B. No. 2 Oil @ 140,000 Btu/gal.
Table B1-3. Model FLX Steam Boiler Ratings

MODEL NO. 150 200 250 300 350 400 450 500 550 600 700 800 900 1000 1100 1200
Fuel Consumption ...Gas(h)A 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 7000 8000 9000 10000 11000 12000 78.6 85.7 Oil (gph)B 10.7 14.3 17.9 21.4 25.0 28.6 32.2 35.7 39.3 42.9 50.0 57.2 64.3 71.4 Rated Capacity: lbs steam/hr 1237 1649 2062 2479 2887 3299 3711 4124 4536 4949 5773 6598 7422 8248 8000 8300 239 9072 8800 9130 263 9897 9600 9960 287
Output (MBH) .......Gas Firing 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800 5600 6400 7200 Oil Firing 1245 1660 2075 2490 2905 3320 3735 4150 4565 4980 5810 6640 7470 Approximate bhp Natural Gas Input: CFH (1000Btu) Natural Gas: Therms/Hour Shipping Weight (lbs) Operating Weight (lbs) Operating Water Content (US gal) Blower Motor hp 36 48 60 72 84 96 107 119 131 143 167 191 215
1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 7000 8000 9000 10000 11000 12000 15 20 25 30 35 40 45 50 55 60 70 80 90 100 110 120
5700 5700 5700 6200 6200 7900 7900 7900 7900 7900 10200 10200 10200 11700 11700 11700 6600 6600 6600 7200 7200 9200 9200 9200 9200 9200 12500 12500 12500 14100 14100 14100 85 1/3A 1/2B 85 85 95 1/2A 3/4B 95 3/4A 1B 140 140 140 140 140 210 210 210 252 252 252
1/2
3/4
1-1/2 1-1/2A 2B
5A 5A 7 1/2 7-1/2B 7-1/2B
10
NOTES: 212 F feedwater. A. Natural Gas @ 1000 Btu/cu-ft. B. No. 2 Oil @ 140,000 Btu/gal.
B1-6
04-02
Commercial Boilers
MODEL NO. A - Length Of Base B - Boiler Height (Top of casing)) B1 - Height of Lifting Lug B2 - Height of Flue Gas Outlet C - Boiler Width
150
200
250
300
350
400
450
500
550
600
71-13/16 71-13/16 71-13/16 77-13/16 77-13/16 98-15/16 98-15/16 98-15/16 98-15/16 98-15/16 76 77-3/8 77-1/2 41-1/2 76 77-3/8 77-1/2 41-1/2 56-1/2 8-13/16 25-7/8 16-1/4 8-3/4 28 3 8-5/8 10 4 12-1/2 15 76 77-3/8 77-1/2 41-1/2 56-1/2 8-13/16 25-7/8 16-1/4 8-3/4 28 3 8-5/8 10 4 12-1/2 15 80 81-3/8 81-1/2 45-1/2 60-1/2 8-13/16 31-3/4 16-1/4 8-3/4 32 4 8-5/8 12 4 14-1/2 17 17-7/8 26-1/2 11/2 4 1 80 81-3/8 81-1/2 45-1/2 60-1/2 8-13/16 31-3/4 16-1/4 8-3/4 32 4 8-5/8 12 4 14-1/2 17 17-7/8 26-1/2 1-1/2 4 1 86 87-3/8 87-1/2 47-1/2 63-1/2 9-7/8 35-3/4 18-1/4 8-3/4 34 5 10-3/4 16 6 18-1/2 21 18-3/4 26-1/2 2 5 1-1/4 86 87-3/8 87-1/2 47-1/2 63-1/2 9-7/8 35-3/4 18-1/4 8-3/4 34 5 10-3/4 16 6 18-1/2 21 18-3/4 26-1/2 2 5 1-1/4 86 87-3/8 87-1/2 47-1/2 63-1/2 9-7/8 35-3/4 18-1/4 8-3/4 34 5 10-3/4 16 6 18-1/2 21 18-3/4 33-5/16 2 5 1-1/4 86 87-3/8 87-1/2 47-1/2 63-1/2 9-7/8 35-3/4 18-1/4 8-3/4 34 5 10-3/4 16 6 18-1/2 21 18-3/4 86 87-3/8 87-1/2 47-1/2 63-1/2 9-7/8 35-3/4 18-1/4 8-3/4 34 5 10-3/4 16 6 18-1/2 21 18-3/4
D - Center Lower Drum - Center Upper Drum 56-1/2 E - Center Of Lower Drum To Bottom F - Center Of Burner Opening To Bottom G - Center Of F.G. Outlet To Rear Of Jacket H - Drum Clearance Past Base, Front J - Tube Removal Clearance K - Inlet/Outlet Flange (See Note 5) L - Upper/lower Drum OD M - Flue Gas Outlet ID N - No. Of Holes In Flue Gas Outlet Flange O - Diameter Of Bolt Circle P - Flue Gas Outlet Flange OD R - Drum Clearance Past Base - Rear S - Burner Clearance (See Note 4) T - Drain Connection U - Rear Downcomer (NPS) Size V - Relief Valve Outlet (160 lb) W - Total Length (See Note 4) 8-13/16 25-7/8 16-1/4 8-3/4 28 3 8-5/8 10 4 12-1/2 15
17-15/16 17-15/16 17-15/16 22-9/16 1-1/2 4 1 22-9/16 1-1/2 4 1 22-9/16 1-1/2 4 1
33-5/16 33-5/168 2 5 1-1/4 159-3/4 2 5 1-1/4 159-3/4
121-1/16 121-1/16 121-1/16 130-15/16130-15/16152-15/16152-15/16 159-3/4
NOTES: 1. Measurements in inches. 2. Rear drain connection on Model 600 and larger specication subject to chang without notice. 3. Models 150 thru 350 supplied with one front drain only.
4. Contact your local Cleaver-Brooks authorized representative regarding total length for altitude-compensated boilers. 5. Inlet and outlet anges: Model 150 thru 900 - studded ange. Models 1000 thru 1200 - nozzle ange.
Figure B1-1. Model FLX Hot Water Boiler Dimensions (1 of 2) B1-7

04-02
Commercial Boilers
MODEL NO. A - Length Of Base B - Boiler Height (Top of casing)) B1 - Height of Lifting Lug B2 - Height of Flue Gas Outlet C - Boiler Width D - Center Lower Drum - Center Upper Drum E - Center Of Lower Drum To Bottom F - Center Of Burner Opening To Bottom G - Center Of F.G. Outlet To Rear Of Jacket H - Drum Clearance Past Base, Front J - Tube Removal Clearance K - Inlet/Outlet Flange & Nozzle (NPS) Size. See Note 5. L - Upper/lower Drum OD M - Flue Gas Outlet ID N - No. Of Holes In Flue Gas Outlet Flange O - Diameter Of Bolt Circle P - Flue Gas Outlet Flange OD R - Drum Clearance Past Base - Rear S - Burner Clearance (See Note 4) T - Drain Connection U - Rear Downcomer (NPS) Size V - Relief Valve Outlet (160 lb) W - Total Length (See Note 4)
700
800
900
1000
1100
1200
120-1/16 120-1/16 120-1/16 144-3/16 144-3/16 144-3/16 94 95-3/8 95-1/2 53-1/2 69-1/2 11-7/8 37-3/4 20-1/4 8-5/8 40 6 10-3/4 18 8 20-1/2 23 19-5/16 34-5/16 2 5 1-1/2 94 95-3/8 95-1/2 53-1/2 69-1/2 11-7/8 37-3/4 20-1/4 8-5/8 40 6 10-3/4 18 8 20-1/2 23 19-5/16 34-5/16 2 5 1-1/2 94 95-3/8 95-1/2 53-1/2 69-1/2 11-7/8 37-3/4 20-1/4 8-5/8 40 6 10-3/4 18 8 20-1/2 23 19-5/16 34-5/16 2 5 1-1/2 94 95-3/8 95-1/2 53-1/2 69-1/2 11-7/8 37-3/4 20-1/4 8-5/8 40 8 10-3/4 24 8 26-1/2 29 20 41-1/16 2 5 1-1/2 94 95-3/8 95-1/2 53-1/2 69-1/2 11-7/8 37-3/4 20-1/4 8-5/8 40 8 10-3/4 24 8 26-1/2 29 20 41-1/16 2 5 1-1/2 213-7/8 94 95-3/8 95-1/2 53-1/2 69-1/2 11-7/8 37-3/4 20-1/4 8-5/8 40 8 10-3/4 24 8 26-1/2 29 20 41-1/16 2 5 1-1/2 213-7/8
181-7/16 181-7/16 181-7/16 213-7/8
NOTES: 1. Measurements in inches. 2. Rear drain connection on Model 600 and larger specication subject to change without notice. 3. Models 150 thru 350 supplied with one front drain only. 4. Contact your local Cleaver-Brooks authorized representative regarding total length for altitude-compensated boilers. 5. Inlet and outlet anges: Models 150 thru 900 - studded ange Models 1000 thru 1200 - nozzle ange
Figure1-1. Model FLX Hot Water Boiler Dimensions (2 of2) B1-8

04-02
Commercial Boilers
MODEL NO. A. Length of Base B. Boiler Height (Top of casing) B1 - Top of Lifting Lug C. Boiler Width D. Center of Lower Drum - Center Upper Drum E. Center of Lower Drum to Bottom F. Center of Burner Opening to Bottom G. Center of FG Outlet to Rear of Jacket H. Drum Clearance Past Base - Front J. Tube Removal Clearance K. Steam Nozzle 15psig * K. Steam Nozzle 150psig * L. Lower Drum OD M. Flue Gas Outlet ID N. No. of Holes in Flue Gas Outlet Flange O. Diameter of Bolt Circle (FG Outlet) P. Flue Gas Outlet Flange OD Q. Upper Drum OD R. Drum Clearance Past Base - Rear S. Burner Clearance (See Note 4) T. Drain Connection (15 psig) T. Drain Connection (150 psig) U. Downcomer (NPS) Size W. Height of Steam Nozzle X. Height of Stack Flange Y. Relief Valve Outlet Size (Qty) (15 psig) Y. Relief Valve Outlet Size (Qty) (150 psig) Z. Feed Water Connection Size ZA. Feed Water Location ZZ.Steam Nozzle Location AA. Total Length (See Note) Inspection Handhole Size (Lower)
150
200
250
300
350
400
450
500
550
600
71-13/16 71-13/16 71-13/16 77-13/16 77-13/16 98-15/16 98-15/16 98-15/16 98-15/16 98-15/16 85-3/4 85-3/4 85-3/4 90 90 93-7/8 93-7/8 93-7/8 93-7/8 93-7/8 86-13/16 86-13/16 86-13/16 90-13/16 90-13/16 94-7/8 94-7/8 94-7/8 94-7/8 94-7/8 41-1/2 41-1/2 41-1/2 45-1/2 45-1/2 47-1/2 47-1/2 47-1/2 47-1/2 47-1/2 60 60 60 64 64 67 67 67 67 67 8-13/16 25-7/8 14-11/16 15-1/8 28 4 g. 2 mpt 8-5/8 10 4 12-1/2 15 20 11-1/8 16-3/16 1-1/2 1-1/4 4 86-13/16 87-1/4 2 1-1/4 9-7/8 35-3/4 17-1/8 15-1/2 34 6 g. 3 g. 10-3/4 16 6 18-1/2 21 20 11-9/16 19-3/4 2 1-1/4 5 94-7/8 95-3/8 3 (2) 1-1/4 3/4 3/4 3/4 3/4 3/4 1 38-13/16 38-13/16 38-13/16 42-13/16 42-13/16 46-7/8 36-3/8 36-3/8 36-3/8 39-3/8 39-3/8 50-3/8 114-1/4 114-1/4 114-1/4 124-3/16 124-3/16 145-3/4 4x5 4x5 4x5 4x5 4x5 4x5 8-13/16 25-7/8 14-11/16 15-1/8 28 4 g. 2 mpt 8-5/8 10 4 12-1/2 15 20 11-1/8 16-3/16 1-1/2 1-1/4 4 86-13/16 87-1/4 2 1-1/4 8-13/16 8-13/16 8-13/16 25-7/8 31-3/4 31-3/4 14-11/16 14-5/8 14-5/8 15-1/8 15-1/8 15-1/8 28 32 32 4 g. 5 g. 5 g. 2 mpt 2 mpt 2-1/2 mpt 8-5/8 8-5/8 8-5/8 10 12 12 4 4 4 12-1/2 14-1/2 14-1/2 15 17 17 20 20 20 11-1/8 11-1/8 11-1/8 16-3/16 20-1/8 20-1/8 1-1/2 1-1/2 1-1/2 1-1/4 1-1/4 1-1/4 4 4 4 86-13/16 90-13/16 90-13/16 87-1/4 91-1/2 91-1/2 2 2-1/2 2-1/2 1-1/4 1-1/2 1-1/2 9-7/8 9-7/8 9-7/8 9-7/8 35-3/4 35-3/4 35-3/4 35-3/4 17-1/8 17-1/8 17-1/8 17-1/8 15-1/2 15-1/2 15-1/2 15-1/2 34 34 34 34 6 g. 6 g. 6 g. 6 g. 3 g. 3 g. 3 g. 3 g. 10-3/4 10-3/4 10-3/4 10-3/4 16 16 16 16 6 6 6 6 18-1/2 18-1/2 18-1/2 18-1/2 21 21 21 21 20 20 20 20 11-9/16 11-9/16 11-9/16 11-9/16 19-3/4 26-9/16 26-9/16 26-9/16 2 2 2 2 1-1/4 1-1/4 1-1/4 1-1/4 5 5 5 5 94-7/8 94-7/8 94-7/8 94-7/8 95-3/8 95-3/8 95-3/8 95-3/8 3 3 3 3 (2) (2) (2) (2) 1-1/4 1-1/4 1-1/4 1-1/4 1 1 1 1 46-7/8 46-7/8 46-7/8 46-7/8 50-3/8 50-3/8 50-3/8 50-3/8 145-3/4 152-9/16 152-9/16 152-9/16 4x5 4x5 4x5 4x5
Note: Contact your local Cleaver-Brooks authorized representative regarding total length for altitude-compensated boilers. * g = Class 150# F.F.
Figure B1-2. Model FLX Steam Boiler Dimensions (1 of2) B1-9

04-02
Commercial Boilers
MODEL NO. A. Length of Base B. Boiler Height (Top of casing) B1 - Top of Lifting Lug C. Boiler Width D. Center of Lower Drum - Center Upper Drum E. Center of Lower Drum to Bottom F. Center of Burner Opening to Bottom G. Center of FG Outlet to Rear of Jacket H. Drum Clearance Past Base - Front J. Tube Removal Clearance K. Steam Nozzle 15psig * K. Steam Nozzle 150psig * L. Lower Drum OD M. Flue Gas Outlet ID N. No. of Holes in Flue Gas Outlet Flange O. Diameter of Bolt Circle (FG Outlet) P. Flue Gas Outlet Flange OD Q. Upper Drum OD R. Drum Clearance Past Base - Rear S. Burner Clearance (See Note 4, page B1-7) T. Drain Connection (15 psig) T. Drain Connection (150 psig) U. Downcomer (NPS) Size W. Height of Steam Nozzle X. Height of Stack Flange Y. Relief Valve Outlet Size (Qty) (15 psig) Y. Relief Valve Outlet Size (Qty) (150 psig) Z. Feed Water Connection Size ZA. Feed Water Location ZZ.Steam Nozzle Location AA. Total Length (See Note) Inspection Handhole Size (Lower)
700
800
900
1000
1100
1200
120-1/16 120-1/16 120-1/16 144-3/16 144-3/16 144-3/16 108-5/8 108-5/8 108-5/8 108-5/8 108-7/8 108-7/8 108-7/8 108-7/8 53-1/2 77 11-7/8 37-3/4 17-5/8 17 40 8 g. 4 g. 10-3/4 18 8 20-1/2 23 24 13 2 1-1/4 6 53-1/2 77 11-7/8 37-3/4 17-5/8 17 40 8 g. 4 g. 10-3/4 18 8 20-1/2 23 24 13 2 1-1/4 6 53-1/2 77 11-7/8 37-3/4 17-5/8 17 40 8 g. 4 g. 10-3/4 18 8 20-1/2 23 24 13 2 1-1/4 6 53-1/2 77 11-7/8 37-3/4 20-1/4 17-5/16 40 10 g. 6 g. 10-3/4 24 8 20-1/2 29 24 20-1/2 32-3/8 2 1-1/4 6 108-5/8 108-7/8 53-1/2 77 11-7/8 37-3/4 20-1/4 17-5/16 40 10 g. 6 g. 10-3/4 24 8 20-1/2 29 24 20-1/2 32-3/8 2 1-1/4 6 108-7/8 110-1/8 (2) 3 (2) 2 1 58-7/8 60-3/16 214-3/8 4x5 108-5/8 108-7/8 53-1/2 77 11-7/8 37-3/4 20-1/4 17-5/16 40 10 g. 6 g. 10-3/4 24 8 20-1/2 29 24 20-1/2 32-3/8 2 1-1/4 6 108-7/8 110-1/8 (2) 3 (2) 2 1 58-7/8 60-3/16 214-3/8 4x5
25-1/16 25-1/16 25-1/16
108-7/8 108-7/8 108-7/8 108-7/8 110-1/8 110-1/8 110-1/8 110-1/8 (2) 2-1/2 (2) 2-1/2 (2) 2-1/2 (2) 1-1/2 (2) 1-1/2 (2) 1-1/2 1 58-7/8 60-1/2 4x5 1 58-7/8 60-1/2 4x5 1 58-7/8 60-1/2 4x5 (2) 3 (2) 2 1 58-7/8 60-3/16 4x5
175-1/8 175-1/8 175-1/8 214-3/8
Figure B1-2. Model FLX Steam Boiler Dimensions (2of2) B1-10

04-02
Commercial Boilers

Emissions
Expected emissions for natural gas red FLX boilers are shown in Table B1-4.
PERFORMANCE DATA
Efficiency
Fuel-to-steam (fuel-to-water) efciency is based on specic operating conditions (fuel, pressure, temperature). Nominal efciency on all FLX hot water and low pressure steam boilers is 81% ring natural gas, and 84% ring No. 2 oil. For high pressure steam applications, contact your local CleaverBrooks representative for expected efciencies.
ENGINEERING DATA
Boiler Information
Flow Rates and Pressure Drops Flow rates and pressure drops for the FLX hot water boilers are shown in Table B1-5. This table can be used to determine the boiler pressure drop in relation to full boiler output and system temperature drop. Table B1-6 can be used to determine the maximum gpm circulating rate in relation to full boiler output and system temperature drop. The maximum gpm can be determined by knowing the boiler size and expected system temperature drop. System Operating Parameters (Hot Water) System over pressure requirements are shown in Table B1-7.
Table B1-4. Expected Emissions (ppm, corrected to 3% O2), Natural Gas Fired Boiler
FLUE GAS COMPONENT CO NOx HIGH-FIRE LEVELA LOW-FIRE LEVELB PPMV PPMV 0- 50 40 - 60 0 - 50 30 - 60
NOTE: NOx levels based on standard product offering. A. Based on 12% excess air. B. Based on 15% excess air.
Table B1-5. Model FLX Hot Water Boiler Flow Rates and Pressure Drops
T = 20F
P (PSIG) GPM
MODEL NO.
T = 40F
P (PSIG) GPM
T = 60F
P (PSIG) GPM
T = 80F
P (PSIG) GPM
T = 100F
P (PSIG) GPM
FLX-150 FLX-200 FLX-250 FLX-300 FLX-350 FLX-400 FLX-450 FLX-500 FLX-550 FLX-600 FLX-700 FLX-800 FLX-900 FLX-1000 FLX-1100 FLX-1200
1.14 1.14 1.77 1.85 2.49 1.35 1.71 2.03 2.50 2.99 1.75 2.27 2.85 4.08 4.42 6.20
122.0 162.3 202.8 243.4 284.0 324.5 365.1 405.7 446.3 486.8 567.9 649.1 730.2 811.4 892.6 973.6
0.30 0.30 0.46 0.48 0.65 0.35 0.44 0.54 0.67 0.77 0.45 0.59 0.74 1.02 1.15 1.60
61.1 81.1 101.4 121.7 142.0 162.3 182.6 202.8 223.1 243.4 284.0 324.5 365.1 405.6 446.2 486.8
0.13 0.13 0.21 0.22 0.29 0.16 0.20 0.25 0.31 0.35 0.21 0.27 0.33 0.42 0.48 0.59
41.1 54.1 67.6 81.1 94.7 108.2 121.7 135.2 148.7 162.3 189.3 216.4 243.4 270.4 297.4 324.6
0.08 0.08 0.12 0.12 0.17 0.09 0.11 0.14 0.17 0.20 0.12 0.15 0.19 0.25 0.28 0.31
30.8 40.6 50.7 60.9 71.0 81.1 91.2 101.4 111.5 121.7 142.0 162.3 182.6 202.8 223.0 243.4
0.05 0.05 0.08 0.08 0.11 0.06 0.08 0.09 0.11 0.13 0.08 0.10 0.12 0.15 0.18 0.22
24.4 32.5 40.6 48.7 56.8 64.9 73.0 81.1 89.2 97.4 113.6 129.8 146.0 163.6 178.4 194.8
B1-11
04-02

Table B1-6. Model FLX Circulating Rates, Hot Water Boiler
Commercial Boilers
SYSTEM TEMPERATURE DROP F MODEL NO. (HP) 10 20 30 40 50 60 70 80 90 100
MAXIMUM CIRCULATING RATE - GPM
FLX-150 (36) FLX-200 (48) FLX-250 (60) FLX-300(72) FLX-350 (84) FLX-400 (96) FLX-450 (108) FLX-500 (119) FLX-550 (131) FLX-600 (143) FLX-700 (167) FLX-800 (191) FLX-900 (215) FLX-1000 (239) FLX-1100 (263) FLX-1200 (287)
243 324 404 488 568 648 729 812 893 972 1136 1300 1460 1622 1784 1947
122 162 202 244 284 324 365 406 447 486 568 650 730 811 893 974
81 108 135 162 189 216 243 270 297 325 379 433 487 541 595 649
61 81 101 122 142 162 182 203 223 243 284 325 365 406 446 487
49 65 81 97 114 130 146 162 178 195 227 260 292 324 357 389
41 54 68 81 95 108 122 135 149 162 189 216 243 270 297 325
35 46 58 70 81 93 105 116 128 139 162 185 209 232 255 279
31 41 51 61 71 81 91 101 111 122 142 162 183 203 223 243
27 36 45 54 63 72 81 90 99 108 126 144 162 180 198 216
24 32 41 49 57 65 73 81 89 97 114 130 146 164 178 195
Table B1-8. Model FLX Boiler Heat Release Information

FURNACE PROJECTED AREA (FT2) FURNACE VOLUME (FT3) FURNACE FURNACE HEAT HEAT RELEASE RELEASE BTU/ BTU/HR (FT3) HR (FT2)
MODEL NO.
Table B1-7. Model FLX Minimum Over Pressure Requirements

MAXIMUM MINIMUM SYSTEM OUTLET PRESSURE TEMPERATURE (PSIG) (F)
180 190 200 210 220 230 240
12 15 18 21 24 27 30
38.4 38.4 38.4 48.7 48.7 70.6 70.6 70.6 70.6 70.6 104.6 104.6 104.6 128.9 128.9 128.9
24.2 24.2 24.2 34.9 34.9 54.7 54.7 54.7 54.7 54.7 94.6 94.6 94.6 116.5 116.5 116.5
61,983 82,645 103,306 85,960 100,287 73,126 82,267 91,408 100,548 109,689 73,996 84,567 95,137 85,837 94,421 103,004
39,063 52,083 65,104 61,602 71,869 56,657 63,739 70,822 77,904 84,986 66,922 76,482 86,042 77,580 85,337 93,095
B1-12
04-02
Commercial Boilers
Minimum return water temperature is 120 F; minimum supply (boiler outlet) water temperature is 150 F in order to prevent reside corrosion. System Operating Parameters (Steam Boilers) The following operating limitations must be observed for optimum operation of the boiler: 1. 2. 3. 4. 5. Minimum make-up temperature 60 F. Maximum make-up rate (for on/off make-up control) 2.0 times the evaporation rate. Minimum operating pressure 6 psig. on low pressure steam and 40 psig. on high pressure steam. Maximum operating pressure 12 psig. on low pressure steam. Maximum load tracking rate 0 - 100% load or 100% - 0 load, 30 seconds on low pressure steam and 20% per minute on high pressure steam.

Fuel Connections - Gas The local gas company should be consulted for requirements and authorization for installation and inspection of gas supply piping. Installation of gas supply piping and venting must be in accordance with all applicable engineering guidelines and regulatory codes. All connections made to the boiler should be arranged so that all components remain accessible for inspection, cleaning and maintenance. A drip leg should be installed in the supply piping before the connection to the gas pressure regulator. The drip leg should be at least as large as the inlet tting supplied with the boiler. Consideration must be given to both volume and pressure requirements when choosing gas supply piping size. Refer to the boiler dimension diagram provided by Cleaver-Brooks for the particular installation. Connections to the burner gas train should be made with a union, so that gas train components or the burner may be easily disconnected for inspection or service. Upon completion of the gas piping installation, the system should be checked for gas leakage and tight shutoff of all valves. Fuel Connections - Oil Oil-red burners are equipped with an oil pump, which draws fuel from a storage tank and supplies pressurized oil to the burner nozzle(s). The burner supply oil pump has a greater capacity than the burner requires for the maximum ring rate. Fuel not delivered to the nozzle is returned to the storage tank. A two-pipe (supply and return) oil system is recommended for all installations. Figure B1-4 shows a typical fuel oil supply arrangement. Oil lines must be sized for the burner and burner supply oil pump capacities. The burner supply oil pump suction should not exceed 10" Hg. If a transfer pump is used, it must have a pumping capacity at least equal to that of the burner pump(s). Supply pressure to the burner pump should not exceed 3 psig. A strainer must be installed in the supply piping upstream of the burner supply pump in order to prevent entry of foreign
Maximum boiler water chemistry parameters: Silica: 150 ppm; specic conductance: 3500 mho/cm un-neutralized; total alkalinity: 300 ppm as CaCO3; hardness: 0; oxygen: 7 ppb; pH: 7 - 10; total iron: 0.05 ppm; oil matter: 1 ppm. Boiler Heat Release Information Boiler heat release information is shown in Table B1-8. Tube Attachment Construction of the Flexible Watertube Boiler includes a special tube-to-drum attachment that requires no welding or rolling (see Figure B1-3). The tube is tted with a tapered ferrule, which is press-t into the tube hole in the drum. The ferrule is welded to the tube at the factory for both new and replacement tubes, so no eld welding is required. The tube is held in place with a keeper plate. This tube attachment design reduces repair and maintenance costs, and also reduces the cost of eld erection of new units.
Burner Characteristics Burner information is shown in Table B1-9. Note that the model selection may vary for actual application factors (altitude, gas pressure, etc.). Minimum Required Gas Pressures Approximate gas pressure required at rated input is shown in Table B1-10. For oversized gas trains or altitudes above 1,000 feet, contact your local Cleaver-Brooks authorized representative.
Figure B1-3. Model FLX Tube Attachment
B1-13
04-02

Table B1-9. Model FLX Burner Characteristics
BOILER MAXIMUM INPUT MBH 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 7000 8000 9000 10,000 11,000 12,000
Commercial Boilers
Table B1-10. Model FLX Minimum Required Gas Pressure
STD GAS MIN GAS TRAIN PRESSURE SIZE (IN. WC) (IN.) 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2-1/2 2-1/2 3 3.7 6.3 8.1 8.0 11.0 13.3 16.9 21.4 19.0 17.7 23.8 38.4 48.3 31.2 37.9 37.2
MODEL NO.
BURNER MODEL GP-200-1-1.5 GP-200-1-2.0 GP-200-1-2.5 GP-200-2-3.0 GP-200-2-3.5 GP-200-2-4.0 GP-200-2-4.5 GP-200-3-5.0 GP-200-3-5.5 GP-200-3-6.0 GP-200-3-7.0 GP-200-3-8.0 GP-200-3-9.0 GP-200-4-10.0 GP-200-4-11.0 GP-200-4-12.0
MOTOR 3450 RPM VOLTAGE 120-60-1 120-60-1 120-60-1 120-60-1 240-60-3 240-60-3 240-60-3 240-60-3 240-60-3 240-60-3 240-60-3 240-60-3 240-60-3 240-60-3 240-60-3 240-60-3
MODEL NO. FLX-150 FLX-200 FLX-250 FLX-300 FLX-350 FLX-400 FLX-450 FLX-500 FLX-550 FLX-600 FLX-700 FLX-800 FLX-900 FLX-1000 FLX-1100 FLX-1200
BURNER MODEL GP-700-1-1.5 GP-700-1-2.0 GP-700-1-2.5 GP-700-2-3.0 GP-700-2-3.5 GP-700-2-4.0 GP-700-2-4.5 GP-700-3-5.0 GP-700-3-5.5 GP-700-3-6.0 GP-700-3-7.0 GP-700-3-8.0 GP-700-3-9.0 GP-700-4-10.0 GP-700-4-11.0 GP-700-4-12.0
NOTES: 1. Burner model selection shown is subject to change based on actual application (altitude, gas pressure, etc.). 2. Standard voltage in Canada is 575/3/60. 3. All burners feature full mod operation, with high-low-high available as an option. 4. Burner models shown are for gas/oil burners.
NOTES: 1. Table is based on 1,000 Btu/cu-ft natural gas and elevation up to 1,000 ft. 2. Minimum gas pressure also applies to 200 fuel series burner. 3. Standard regulators suitable for 1 psig maximum inlet pressure.
material into the pump, fuel control valves, or burner nozzle(s). The strainer must be sized for the burner supply pump capacity. A strainer mesh of 150 microns (0.005") is recommended. Install a check valve in the line to prevent draining of the oil suction line when the burner is not in operation. Location of the check valve varies with the system, but usually it is located as close as possible to the storage tank. Installation of a vacuum gauge in the burner supply line between the burner oil pump and the strainer is recommended. Regular observation and recording of the gauge indication will assist in determining when the strainer needs servicing. Upon completion of the oil piping installation, the system should be checked for oil or air leakage and tight shutoff of all valves. Sound Levels (dBA) Refer to Table B1-11 for sound level information. Outdoor Reset Control Cleaver-Brooks does not recommend the use of outdoor conB1-14
trols which reset the boiler water outlet temperature below 150 F, or the utilization of the boiler as a system thermostat. Boiler Room Information The boiler must be installed on a non-combustible oor. If the oor is not level, piers, or a raised pad, slightly larger in length and width than the boiler base dimensions, will make boiler installations and leveling easier. Installation on a raised pad or piers will make boiler drain connections more accessible. The oor, pad, or piers must be of sufcient load bearing strength to safely support the operating weight of the boiler and any additional equipment installed with it. Approximate operating weights for Model FLX series steam and hot water boilers are shown in Dimensions and Ratings. After the boiler is in place it must be leveled. Both side-to-side and front-to-back level can be veried using the vertical connection between the upper and lower drums at the back of the boiler. If shims are required to level the boiler, the weight of the boiler must be evenly distributed at all points of support. The boiler must be installed so that all components remain accessible for inspection, cleaning, or maintenance. Field-
04-02
Commercial Boilers
Figure B1-4. Model FLX Oil Burner Supply Pump Installation installed piping and electrical connections to the burner and boiler must be arranged to allow removal of the casing panels, and swinging of the burner. Minimum clearances to walls or other obstructions and combustible materials are shown in Figure B1-5. The top view shaded sections in Figure B1-5 show areas that must be kept clear of eld installed connections to the boiler for access or maintenance purposes. A positive means of supplying a volume of outside air for complete fuel combustion is required. Proper ventilation of the boiler room must be provided. The amount of air required, and the required duct and air supply opening areas, are determined by the maximum fuel input rating of the burner and the altitude of the installation. Refer to Table B1-12. Air inlets must be sized in accordance with applicable engineering guidelines and regulatory code. Breechings For single boiler installations, use breeching of the same diameter as the vent outlet on the boiler. For multiple boiler installations, and when a number of boilers of the same size (input) are to be connected to a common breeching, use the table on Figure B1-6 to size the breeching diameter. For more information on breechings and stacks, refer to Stacks, Section F. Stack Support Capabilities Flextube boilers can support up to 200 lbs without additional support.
B1-15
04-02
Commercial Boilers
Table B1-11. Model FLX Sound Levels

SOUND LEVEL FIRING RATE MODEL NO. 150 200 250 300 350 400 450 500 550 600 700 800 900 1000 1100 1200
Low Fire (dBA) High Fire (dBA)
75 76
75 76
76 77
75 76
75 76
77 78
78 79
79 80
79 80
79 80
81 82
81 82
83 83
79 81
82 83
88 86
Measurement: Three feet from front center of boiler, and 3-1/2 feet above boiler base. Measurements are decibel ratings on the A-weighted scale, registered without addition of sound attenuators, mufers, or silencers. Sound pressure data taken on combination fuel burners ring oil. Sound pressure levels ring natural gas will be 0.5 dBA lower.
MODEL NO.
SIDES A
TOP B
FRONT C
REAR D
FLX-150 - 250 FLX-300 - 350 FLX-400 - 600 FLX-700 - 1200
28 32 34 40
18 18 18 18
48 48 48 48
24 24 24 24
NOTE: Top Dimension from boiler to top of stack based on stack selection.
Figure B1-5. Model FLX Clearance Requirements
B1-16
04-02
Commercial Boilers
Table B1-12. Model FLX Combustion Air Requirements

MODEL NO. 150 200 250 300 350 400 450 500 550 600 700 800 900 1000 1100 1200
Gas (scfh) 15480 20640 25800 30960 36120 41280 46440 51600 56760 61920 72240 82560 92280 103200 113520 123840 Comb Air (Dry) (lb/hr) 1207 1609 2012 2414 2817 3219 3621 4024 4426 4828 5633 6438 7243 8048 8853 9657
Oil (scfh) 17050 22733 28414 34098 39782 45463 51146 56831 62514 68196 79562 90928 102294 113662 125028 136394 (lb/hr) 1269 1692 2115 2538 2961 3384 3807 4231 4654 5077 5923 6769 7640 8462 9308 10154
Gas (scfh) 17520 23360 29200 35040 40880 46720 52560 58400 64240 70080 81760 93440 105120 116800 128480 140160 Flue Gas (Dry) (lb/hr) 1278 1704 2130 2556 2983 3409 3835 4261 4687 5113 5965 6817 7669 8521 9373 10225
Oil (scfh) 17915 23886 29855 35827 41799 47769 53740 59713 65684 71655 83598 95541 107484 119427 131370 143312 (lb/hr) 1357 1809 2261 2714 3166 3618 4070 4523 4975 5427 6330 7237 8142 9047 9951 10856
NOTES: 1. Natural gas @ 1000 Btu/cu-ft. 2. No. 2 oil @ 140,000 Btu/gal.
Figure B1-6. Model FLX Breeching Arrangement - Single or Multiple Boiler Installation
B1-17
04-02
Commercial Boilers
The following sample specications are provided by Cleaver-Brooks to assist you in specifying your customers specic needs and application. A separate specication is provided for hot water boiler and steam boiler packages. Steam Boiler Package 1.0 Boiler Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Hot Water Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 Field Erectable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hot Water Boiler Package 1.0 Boiler Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 General Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 Field Erectable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-20 B1-20 B1-20 B1-20 B1-23 B1-23 B1-16 B1-16 B1-17 B1-17 B1-19 B1-19
Steam Boiler Package

1.0 Boiler Capacity The _____ (low or high) pressure steam boiler shall be Cleaver-Brooks Model FLX (FLE for eld erected) designed for _______ (15 or 150) psig steam. The boiler shall have a maximum output of __________ lbs/hr at ____ psig when red with No. 2 oil and/or natural gas, ________ Btu/cu-ft. Electrical power available will be ________ Volt, _______ phase, _____ Hz. 2.0 General Design 2.1 The boiler shall be of a two-drum exible watertube design with a tangent tube waterwall furnace mounted on a heavy steel frame. Top, bottom and sides of the furnace shall be water cooled. 2.2 The boiler pressure vessel shall be constructed in accordance with ASME Boiler Code, and must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser. The complete packaged boiler burner unit shall be listed by Underwriters Laboratories, and shall have the UL/cUL label afxed to the front head. 2.2.1 The boiler drums shall be furnished with handholes to facilitate boiler inspection and cleaning. 2.2.2 Boiler tubes shall be 1.5" diameter, 0.095" wall thickness, and shall be easy to remove and replace without expanding or welding the tube attachment to the drums. 2.2.3 The boiler shall have sufciently sized downcomers to provide positive natural internal circulation. 2.2.4 The burner shall be mounted on a hinged backing plate for easy access to furnace. 2.3 Observation ports for the inspection of ame conditions shall be provided at rear end of the boiler and in the burner assembly at the front end. 2.4 The tangent wall tubes shall be covered with 1-1/2 inches of insulation under a gas-tight, 16-gauge inner casing. There shall be 2 inches of insulation between the inner and outer casing. The outer casing shall be 20 gauge. The boiler base frame and other components shall be factory-painted before shipment, using a hard enamel nish.
B1-18
04-02
Commercial Boilers
3.0 Steam Boiler Trim The following items shall be installed on the boiler:
3.1 Low Water Cutoff - A low water cut-off control of the oat-type shall be mounted in a water column to the upper drum. It is to be wired to the burner control circuit to prevent burner operation if the boiler water falls below proper levels. 3.2 Feedwater Pump Control - The boiler feedwater pump control switch shall be included. It shall provide automatic actuation of a motor-driven feedwater pump, or solenoid valve, to maintain the boiler water level within normal limits. 3.3 Steam Pressure Controls - A minimum of three controls shall be provided: one auto reset type for burner on-off control, one for burner ring rate, and one manual reset type for burner cutout in excessive steam pressure conditions. 3.4 Miscellaneous - A pressure gauge shall be mounted to the boiler. Pressure controls (for regulation of burner operation) shall be mounted to the boiler. Steam relief valves shall be of a type and size to comply with ASME Code requirements (shipped loose). 4.0 Burner and Controls The boiler shall be provided with a UL/cUL approved fuel burning system in full accordance with the requirements of state, provincial and local codes, the local gas utility, and other applicable regulatory bodies. The boiler shall be a Cleaver-Brooks Prore burner. Option (specify as required) A. The complete fuel burning system shall further be in full accordance with Factory Mutual (FM) requirements. B. The complete fuel burning system shall further be in full accordance with Industrial Risk Insurers (IRI) requirements. 4.1 Burner Description 4.1.1 Option (specify A, B, or C) A. The burner shall include a gas burner having rated capacity to burn ________ MMBtu/hr of ______ Btu/cu-ft of __________ gas at a pressure of _______ (lbs/sq-inch) (inches of water column) at the inlet of the burner gas control train. B. The burner shall include an oil burner having rated capacity to burn ______ gph of No. 2 fuel oil. C. The burner shall include a combination gas-oil burner having rated capacity to burn _______ MMBtu/hr of _____ Btu/cu-ft gas at a pressure of _________ lbs/sq-inch (inches of water column) at the inlet to the burner gas control train (or _______ gph of No. 2 fuel). 4.1.2 The burner shall be forced draft type with full ring rate modulation. All combustion air shall be furnished by the burner fan, which shall be an integral part of the burner. Each burner motor shall not be larger than ______ hp, ____ phase. 4.1.3 Option (specify A, B, or C) A. The gas burner shall burn the specied quantity of fuel without objectionable vibration, noise, or pulsation, with not more than 15% excess air and less than 50 ppm (corrected to 3% O2) CO in the products of combustion. In addition, when ring gas, the burner shall be guaranteed to produce less than 60 ppm (corrected to 3% O2) NOx emissions. B. The light oil burner shall burn the specied quantity of fuel without objectionable vibration, noise, or pulsation, with not more than 15% excess air and a maximum of No. 1 smoke spot, as measured on the Bacharach Scale. C. The gas-oil burner shall burn the specied quantity of fuel without objectionable vibration, noise, or pulsation, with not more than 15% excess air and less than 50 ppm (corrected to 3% O2) CO in the products of combustion on gas ring, and a maximum of No. 1 smoke, as measured on the Bacharach Scale when burning oil. In addition, when ring gas, the burner shall be guaranteed to produce less than 60 ppm (corrected to 3% O2) NOx emissions. 4.1.4 Primary-secondary air control shall be a design function of the combustion head. Combustion heads requiring an internal adjustment shall not be acceptable. 4.1.5 The burner shall be equipped with an aluminum reverse curve fan for lower fan motor hp requirements and self-cleaning characteristics.
B1-19
04-02
Commercial Boilers
4.1.6 A permanent observation port shall be provided in the burner to allow observation of both the pilot and main ame. Both the pilot and the ame scanner shall be easily accessible without opening or disassembling the burner. 4.1.7 Supply voltage available shall be ______ Volts, ______ phase, 60 Hz. All motors shall be suitable for use on this voltage. All burner controls are to be for use on 120 volts, 1 phase, 60 hz. 4.1.8 The burner shall be factory re-tested to ensure proper operation before shipment. 4.2 Pilot Gas Train for Each Burner (Mounted, Piped, and Wired) A separate pilot gas cock, gas pressure regulator, and pilot safety shutoff gas valve shall be provided for the ignition gas supply. 4.3 Oil Burner 4.3.1 The oil burner shall be of the mechanical pressure atomizing type. 4.3.2 A two-stage oil pump shall be provided for each burner as an integral part of the burner. 4.3.3Two approved automatically operated safety shutoff valve(s) shall be provided in the oil supply line to the burner valves to be piped in series but wired parallel. 4.3.4 Supply an oil pressure gauge to indicate the discharge oil pump pressure. 4.3.5 Install a manual valve, fuel oil lter, or strainer and vacuum gauge on the suction side of the oil pump (optional). 4.3.6 Install a fusible-link-actuated oil safety shutoff valve in the oil supply line between the oil tank and the manual gate valve at the oil pump (optional). 4.3.7 Oil pressure monitoring shall be provided by an approved pressure switch interlocked to accomplish a non-recycling safety shutdown in the event of low oil pressure (optional). 4.4 Gas Valve Train for Each Burner 4.4.1 Provide a pressure gauge to indicate the gas burner manifold pressure (optional). 4.4.2 Furnish and install one manually operated, ________ inch, ball valve upstream of all valves. 4.4.3 Provide one _______ inch, main gas pressure regulator (of tight shutoff type) with vent to outside atmosphere, in accordance with local codes.
NOTICE
Specify a tight shutoff type gas pressure regulator when the inlet gas pressure exceeds 1-1/2 psig. 4.4.4 Provide one ________ inch, automatically operated motorized safety gas valve. One safety shutoff valve shall be proven closed during pre- ignition by proof of valve closure interlock switch on valve. 4.4.5 Provide a second _______ inch, automatically operated gas safety shutoff valve to operate simultaneously with the above gas valve. 4.4.6 A manually operated gas valve shall be located downstream of both automatic gas valves to permit leakage testing of the valves. 4.4.7 Gas pressure monitoring shall be provided by approved pressure switches interlocked to accomplish a non-recycling safety shutdown in the event of either high or low gas pressure (optional on sizes 150-250). 4.5 Burner Controls 4.5.1 The full modulation of the burner shall be controlled by steam pressure by means of a pressure control. 4.5.2 An additional high limit safety pressure control of the manual reset type shall be provided to control the burner. 4.5.3 Pre-purge and post-purge operation of the burner fan shall be provided per current UL/cUL requirements. 4.5.4 The burner shall utilize a Fireye E110 type ame safeguard programmer incorporating 7 LED indicator lights to annunciate the current operating status of the burner. 4.5.5 A manual restart of the burner shall be necessary in the event of shutdown due to ame failure. B1-20
04-02
Commercial Boilers
4.5.6 All three-phase motors shall be controlled and protected by an automatic starter with thermal overload protection. The starter shall be inter-locked to prevent burner operation when over-load relays are tripped out. 4.5.7 Supply a burner-mounted diaphragm air ow switch to prevent the energization of the main fuel valves in the event of insufcient combustion air, or to provide safety shutdown in the event of combustion air interruption. 4.5.8 A factory-wired control cabinet shall be supplied and mounted on the burner. The control cabinet shall house the ame safeguard control, programming timer, burner motor starter, fuses, control circuit transformer, control switches, indicating lamps and relays as required. 4.5.9 Provide four individual lights with nameplates on the control cabinet to indicate call for heat, main fuel valve on, low water, and main ame failure. 4.5.10 Option (specify A or B) A. The changing from one fuel to the other shall be manual by means of a fuel selector switch. No burner adjustments shall be required to switch from one fuel to the other. B. Changing from one fuel to the other shall be automatically controlled by the outdoor temperature switch, or other external device. No burner adjustment shall be required to switch from one fuel to the other. 4.5.11 The burner shall be equipped with suitable fuel and air controls to assure smooth main ame ignition. The burner shall utilize a proportional air ow damper design, including independent low-re and high-re air ow shutter assemblies for ease of adjustment and consistent excess air performance throughout the ring range. 4.5.12 Fuel-air control shall be synchronized. The fuel air drive unit shall be provided with a position indicating switch interlocked with the ame safeguard system to assure starting at the low re position. The ame safeguard system shall further program this drive unit to provide a full open louver of sufcient time to provide a four air change pre-ignition of the combustion chamber, heat exchanger, and ue passages. 4.5.13 Pre-ignition pure air ow rate shall not be less than 60% maximum ring rate air ow. Interlocks shall be provided to monitor and prove 60% air ow purge when air inlet louvers are automatically opened to obtain this rate. 4.5.14 Full modulation of fuel input shall be provided. A modulating pressure control shall be supplied to modulate a burner mounted damper motor controlling both fuel and air supply by means of direct mechanical linkage. 4.5.15 Electronic safety combustion controls shall be supplied, complete with ultra-violet ame scanner to monitor the pilot and main ame. It shall be so utilized as to provide intermittent type gas-electric ignition and pre-ignition timer. Flame rod will not be permitted for proving pilot or main ame. 5.0 Warranty All equipment is to be guaranteed against defects in material and/or workmanship for a period of 12 months from the date of startup or 18 months from the date of shipment, which ever comes rst. In addition the boiler pressure vessel shall be warranted against damage resulting from thermal stress for a period of 20 years from date of shipment provided the boiler is operated and maintained in accordance with the conditions specied in the owners Operator and Maintenance Manual. Refer to the FLX Boiler warranty. 6.0 Field Erectable The specied boiler/burner package shall be shipped disassembled for eld assembly. All pieces and components must t through a standard doorway. Assembly shall be accomplished with ordinary hand tools, with no welding or rolling required. Major casing components are to be shipped with insulation and refractory installed for ease of assembly.
B1-21
04-02

Hot Water Boiler Package
1.0 Boiler Capacity (Hot Water)
Commercial Boilers
1.1 The hot water boiler shall be Cleaver-Brooks Model FLX (FLE for eld erected), designed for 150 psig (hot water). Maximum water temperature shall be _______ F, and maximum system temperature drop shall be _______ F. 1.2 The boiler shall have a maximum output of ____________ Btu/hr when red with No. 2 oil, and/or ________________ Btu/cuft when red with natural gas. Available electrical power will be _____ Volt, _____ phase, ____ Hz. 2.0 General Boiler Design 2.1 The boiler shall be a two-drum, exible watertube design with a tangent-tube waterwall furnace mounted on a heavy steel frame. Top, bottom and sides of the furnace shall be water cooled. 2.2 The boiler pressure vessel must be constructed in accordance with ASME Boiler Code, and must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser. The complete packaged boiler burner unit shall be listed by Underwriters Laboratories, and shall have the UL/cUL label afxed to the front head. 2.2.1 The boiler drums shall be furnished with handholes to facilitate boiler inspection and cleaning. 2.2.2 Boiler tubes shall be 1.5" diameter, with 0.095" wall thickness, and shall be easy to remove and replace without expanding or welding the tube attachment to the drums. 2.2.3 The boiler shall have a sufciently sized downcomer to provide natural internal circulation. 2.2.4 The burner shall be mounted on a hinged backing plate for easy access to the furnace. 2.3 Observation ports for the inspection of ame conditions shall be provided at the rear of the boiler, and in the burner assembly at the front. 2.4 The tangent wall tubes shall be covered with 1-1/2 inches of insulation under a gas-tight, 16-gauge inner casing. There shall be 2 inches of insulation between the inner and outer casing. The outer casing shall be 20 gauge. The boiler base frame and other components shall be factory-painted before shipment, using a hard enamel nish. 3.0 Hot Water Boiler Trim The following items will be installed on the boiler. 3.1 Low Water Cut-Off: A probe-type, low water cut-off control shall be mounted in the upper drum. It is to be wired to the burner control circuit to prevent burner operation if the boiler water falls below a safe level. 3.2 Miscellaneous: A combustion temperature and pressure gauge shall be mounted on the boiler. Temperature controls, for regulation of burner operation, shall be mounted on the boiler and the temperature sensing element shall be located adjacent to the boiler outlet. Water relief valves (shipped loose) shall be of a type and size to comply with ASME Code requirements. 4.0 Burner and Controls The boiler shall be provided with a UL/cUL approved fuel burning system in full accordance with the requirements of state, provincial and local codes, the local gas utility, and other applicable regulatory bodies. The burner shall be a Cleaver-Brooks ProFire burner or approved equal. Option (specify A or B, as required) A. The complete fuel burning system shall be in full accordance with Factory Mutual (FM) requirements. B. The complete fuel burning system shall be in full accordance with Industrial Risk Insurers (IRI) requirements. 4.1 Burner Description 4.1.1 Option (specify A, B, or C) A. The boiler shall include a gas burner having rated capacity to burn ________ MMBtu/hr of ______ Btu/cu-ft of
B1-22
04-02
Commercial Boilers
__________ gas at a pressure of _______ (lbs/sq-in.) (inches of water column) at the inlet of the burner gas control train. B. The boiler shall include an oil burner having rated capacity to burn ______ gph of No. 2 fuel oil. C. The boiler shall include a combination gas-oil burner having rated capacity to burn _______ MMBtu/hr of Btu/cu-ft ______ gas at a pressure of _________ (lbs/sq-in.) (inches of water column) at the inlet to the burner gas control train or _______ gph of No. 2 fuel. 4.1.2 The burner shall be forced draft type with full ring rate modulation. All combustion air shall be furnished by the burner fan, which shall be an integral part of the burner. Each burner motor shall not be larger than ______ hp, ____ phase. 4.1.3 Option (specify A, B, or C)
A. The gas burner shall burn the specied quantity of fuel without objectionable vibration, noise, or pulsation, with not more than 15% excess air and less than 50 ppm (corrected to 3% O2) CO in the products of combustion. In addition, when ring gas, the burner shall be guaranteed to produce less than 60 ppm (corrected to 3% O2) NOx emissions. B. The light oil burner shall burn the specied quantity of fuel without objectionable vibration, noise, or pulsation, with not more than 15% excess air and a maximum of No. 1 smoke spot, as measured on the Bacharach Scale. C. The gas-oil burner shall burn the specied quantity of fuel without objectionable vibration, noise, or pulsation, with not more than 15% excess air and less than 50 ppm (corrected to 3% O2) CO in the products of combustion on gas ring, and a maximum of No. 1 smoke spot, as measured on the Bacharach Scale when burning oil. In addition, when ring gas, the burner shall be guaranteed to produce less than 60 ppm (corrected to 3% O2) NOx emissions. 4.1.4 Primary-secondary air control shall be a design function of the combustion head. Combustion heads requiring an internal adjustment shall not be acceptable. 4.1.5 The burner shall be equipped with an aluminium reverse curve fan for lower fan motor hp requirements and self-cleaning characteristics. 4.1.6 A permanent observation port shall be provided in the burner to allow observation of both the pilot and main ame. Both the pilot and the ame scanner shall be easily accessible without opening or disassembling the burner. 4.1.7 Supply voltage available shall be ______ Volts, ______ phase, 60 Hz. All motors shall be suitable for use on this voltage. All burner controls are to be for use on 120 volts, 1 phase, 60 Hz. 4.1.8 The burner shall be factory re-tested to ensure proper operation before shipment. 4.2 Pilot Gas Train for Each Burner (Mounted, Piped, and Wired) A separate pilot gas cock, gas pressure regulator, and pilot safety shutoff gas valve, shall be provided for the ignition gas supply. 4.3. Oil Burner 4.3.1 The oil burner shall be of the mechanical pressure atomizing type. 4.3.2 A two-stage oil pump shall be provided for each burner as an integral part of the burner. 4.3.3 Two approved automatically operated safety shutoff valve(s) shall be provided in the oil supply line to the burner valves to be piped in series but wired parallel. 4.3.4 Supply an oil pressure gauge to indicate the discharge oil pump pressure. 4.3.5 Install a manual valve, fuel oil lter, or strainer and vacuum gauge on the suction side of the oil pump (optional). 4.3.6 Install a fusible-link-actuated oil safety shutoff valve in the oil supply line between the oil tank and the manual gate valve at the oil pump (optional). 4.3.7 Oil pressure monitoring shall be provided by an approved pressure switch interlocked to accomplish a non-recycling safety shutdown in the event of low oil pressure (optional). 4.4 Gas Valve Train for Each Burner 4.4.1 Provide a pressure gauge to indicate the gas burner manifold pressure (optional).
B1-23
04-02

4.4.2 Furnish and install one manually operated, ________ inch, ball valve upstream of all valves.
Commercial Boilers
4.4.3 Provide one _______ inch, main gas pressure regulator (of tight shutoff type) with vent to outside atmosphere, in accordance with local codes.
NOTICE
Specify a tight shutoff type gas pressure regulator when the inlet gas pressure exceeds 1-1/2 psig. 4.4.4 Provide one ________ inch, automatically operated motorized safety gas valve. One safety shutoff valve shall be proven closed during pre- ignition by proof of valve closure interlock switch on valve. 4.4.5 Provide a second _______ inch, automatically operated gas safety shutoff valve to operate simultaneously with the above gas valve. 4.4.6 A manually operated gas valve shall be located downstream of both automatic gas valves to permit leakage testing of the valves. 4.4.7 Gas pressure monitoring shall be provided by approved pressure switches interlocked to accomplish a non-recycling safety shutdown in the event of either high or low gas pressure (optional on sizes 150-250). 4.5 Burner Controls 4.5.1 The full modulation of the burner shall be controlled by water temperature by means of a temperature control. 4.5.2 An additional high limit safety temperature control of the manual reset type shall be provided to control the burner. 4.5.3 Pre- and post- operation of the burner fan shall be provided per current UL/cUL requirements. 4.5.4 The burner shall utilize a Fireye type ame safeguard programmer, incorporating 7 LED indicator lights to annunciate the current operating status of the burner. 4.5.5 A manual restart of the burner shall be necessary in the event of shutdown due to ame failure. 4.5.6 All three-phase motors shall be controlled and protected by an automatic starter with thermal overload protection. The starter shall be inter-locked to prevent burner operation when over-load relays are tripped out. 4.5.7 Supply a burner-mounted diaphragm air ow switch to prevent energizing the main fuel valves in the event of insufcient combustion air, or to provide safety shutdown in the event of combustion air interruption. 4.5.8 A factory-wired control cabinet shall be supplied and mounted on the burner. The control cabinet shall house the ame safeguard control, programming timer, burner motor starter, fuses, control circuit transformer, control switches, indicating lamps, and relays as required. 4.5.9 Provide four individual lights with nameplates on the control cabinet to indicate call for heat, main fuel valve on, low water, and main ame failure. 4.5.10 Option (specify A or B) A. The changing from one fuel to the other shall be manual by means of a fuel selector switch. No burner adjustments shall be required to switch from one fuel to the other. B. Changing from one fuel to the other shall be automatically controlled by an outdoor temperature switch, or other external device. No burner adjustment shall be required to switch from one fuel to the other. 4.5.11 The burner shall be equipped with suitable fuel and air controls to assure smooth main ame ignition. The burner shall utilize a proportional air ow damper design, including independent low-re and high-re air ow shutter assemblies for ease of adjustment and consistent excess air performance throughout the ring range. 4.5.12 Fuel-air control shall be synchronized. The fuel air drive unit shall be provided with a position indicating switch interlocked with the ame safeguard system to assure starting at the low re position. The ame safeguard system shall further program this drive unit to provide a full open louver of sufcient time to provide a four air change pre-ignition of the combustion chamber, heat
B1-24
04-02
Commercial Boilers
exchanger, and ue passages.
4.5.13 Pre-ignition pure air ow rate shall not be less than 60% maximum ring rate air ow. Interlocks shall be provided to monitor and prove 60% air ow purge when air inlet louvers are automatically opened to obtain this rate. 4.5.14 Full modulation of fuel input shall be provided. A modulating temperature control shall be supplied to modulate a burner mounted damper motor, controlling both fuel and air supply by means of direct mechanical linkage. 4.5.15 Electronic safety combustion controls shall be supplied, complete with ultra-violet ame scanner to monitor the pilot and main ame. It shall be so utilized as to provide intermittent type gas-electric ignition and pre-ignition timer. Flame rod will not be permitted for proving pilot or main ame. 5.0 Warranty All equipment is to be guaranteed against defects in material and/or workmanship for a period of 12 months from the date of startup or 18 months from the date of shipment, which ever comes rst. The boiler pressure vessel shall be warranted against damage resulting from thermal stress for a period of 20 years from date of shipment, provided the boiler is operated and maintained in accordance with the conditions specied in the owners Operating and Maintenance Manual. 6.0 Field Erectable The specied boiler/burner package shall be shipped disassembled for eld assembly. All pieces and components must t through a standard doorway. Assembly shall be accomplished with ordinary hand tools, with no welding or rolling required. Major casing components are to be shipped with insulation and refractory installed for ease of assembly.
B1-25
04-02
Commercial Boilers
NOTES
B1-26
04-02
Section B2
MODEL 4 BOILERS
CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-3 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-3 Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-3 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-4 Special Insurance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-5 Added Equipment for IRI Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-5 Added Equipment for FM Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-5 DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-5 PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-12 Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-12 Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-12 Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-12 ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-12 Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-12 Stack Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-12 SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-17 Steam Boiler Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-17 Hot Water Boiler Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-23
B2-1
04-02
Model 4 Boilers
Commercial Boilers
Figure B2-1. Figure B2-2. Figure B2-3. Figure B2-4.
ILLUSTRATIONS Model 4 Boiler Standard Gas Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-7 Model 4 Hot Water Boiler Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-8 Model 4 Steam Boiler Dimensions Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-10 Model 4 Boiler Over Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-16
TABLES Table B2-1. Model 4 Boiler Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-3 Table B2-2. Model 4 Hot Water Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6 Table B2-3. Model 4 Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2- 6 Table B2-4. Model 4 Boiler Emission Data - Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-12 Table B2-5. Model 4 Boiler Emission Data - No. 2 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-12 Table B2-6. Model 4 Gas Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-13 Table B2-7. Model 4 Steam Boiler Minimum Pressure Vessel Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-14 Table B2-8. Model 4 Boiler Fuel, Air, and Flue Gas Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-14 Table B2-9. Model 4 Hot Water Boiler Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-15 Table B2-10. Model 4 Hot Water Boiler Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-15 Table B2-11. Model 4 Boiler Recommended Steam Nozzle Size at Reduced Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . B2-16 Table B2-12. Model 4 Sound Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-16
This section contains information on the Model 4 Commercial Watertube Boiler product line for low and high pressure steam and hot water applications. Sizes range from 1.5 to 6 MMBtu/hr. The Model 4 Boiler is an excellent choice where high outputs and space limitations exist. The model number designation is 1500 through 6000, representing Btu/hr input (1,500,000 to 6,000,000 Btu/hr). Fuel series designation is as follows: Series 100: No. 2 oil ring. Series 700: Natural gas ring. Series 200: No. 2 oil/natural gas ring. Design pressure designation is stated as 15 psig, 150 psig, and 250 psig for steam, and 140 psig for hot water. For example, an M4W-700-2500-140HW boiler designates a gas-red, 2,500,000 Btu/hr, 140 psig, hot water boiler.
B2-2
04-02
Commercial Boilers
Model 4 Boilers
Steam Design Pressures to 500 psig: High performance in a compact design. Proven vessel design for high design pressure applications. Higher pressures available.

The following features and benets apply to the Model 4 Boiler product line. 33" Cased Width: Boiler ts through most standard doorways. Reduced installation costs. Direct Driven, Vibration-Free Centrifugal Impeller: Quiet operation. Sound levels below 80 dBA. Ideal for noise critical areas such as hospitals, churches, etc. Minimum Refractory: Membrane waterwalls reduce the need for refractory by 95%. Reduced maintenance costs and refractory repair requirements. Membrane Waterwalls: Enhanced heat transfer area in compact design. Sealed combustion chamber improves heat transfer for high efciency. Small Boiler Footprint: Savings of up to 50% in oor space. Weighs up to 40% less than Comparable Boilers: Lower freight and rigging costs. Reduced structural requirements. Standard Built-in Soot Washers: Boiler cleaning without shutdown. Maintains peak boiler performance. Packaged Forced Draft Burner: High pressure drop design. Optimum fuel and air mixing. Improved combustion efciency. Front Door Davit: Easy access to furnace. Reduced maintenance costs.
PRODUCT OFFERING
Information in this section applies to Cleaver-Brooks Model 4 watertube boilers in sizes ranging from 1.5 to 6 MMBtu/hr input, as shown in Table B2-1. Model numbers represent input (1,000 Btu/hr). The Model 4 Boiler is a compact, packaged, all-steel- membraned waterwall watertube boiler. It is a three-pass boiler with watertubes and membranes formed to direct the ow of combustion gases through the boiler. The pressure vessel is constructed to conform with Sections I or IV of the ASME Codes, for hot water, low-pressure steam, and high-pressure steam boilers. The vessel consists of formed membrane tubes and downcomers, connected to the upper and lower drums. The boiler vessel is gas tight, insulated on the outside, and covered by casing constructed of removable, formed steel panels. The standard boiler/burner package is UL approved in hot water, low- pressure steam, and high-pressure steam (150 psig design) when fueled by No. 2 oil and/or natural gas.
Standard Equipment
Equipment described below is for standard boiler offerings. The Cleaver-Brooks Model 4 Boiler is a packaged watertube, steel boiler consisting of pressure vessel, oil or gas burner, burner controls, forced draft fan, and integral air damper control assembly.
Table B2-1. Model 4 Boiler Sizes

MODEL NO. 1500 2000 2500 3000 3500 4000 4500 5000 6000 INPUT MBH 1500 2000 2500 3000 3500 4000 4500 5000 6000 HEAT OUTPUT MBH 1200 1600 2000 2400 2800 3200 3600 4000 4800 EQUIV HP 35 47 59 71 83 95 107 119 143 STEAM SHIPPING OUTPUT WEIGHT LB/HR LBS 1237 1649 2062 2474 2887 3299 3711 4124 4949 3100 3100 3700 3700 4100 4100 4700 4700 5400
NOTE: Steam output from and at 212 F.
B2-3
04-02
Model 4 Boilers
1. Boiler A. Designed, constructed, and hydrostatically tested in accordance with the ASME Boiler and Pressure Vessel Code. B. Refractories for the boiler and burner are installed. C. Fully insulated under a preformed, sectional sheet metal jacket. D. Mounted on an integral steel heavy base frame. E. Factory painted using a hard-nish enamel. 2. Forced Draft Burner A. Integral with front head of boiler (factory mounted and tested). B. Combustion air fan and motor are integral with front head of boiler. C. Pressure atomizing type for No. 2 oil burner includes oil pump. D. High radiant multi-port type burner for gas includes gas train and gas pressure regulator. E. Burner operation uses low-high-low principle. F. Ultra-violet type ame scanner. 3. Hot Water Boiler Control Standard Equipment (140 psig) A. ASME safety relief valve(s). B. Temperature and pressure gauges. C. Temperature controls: High limit control-manual reset. Operating limit control. High-low re rate control. D. Low water cutoff-probe type with manual reset. E. Return water blend pump. F. Low re hold time delay. G. Combustion air proving switch. 4. Steam Boiler Control Standard Equipment (15 to 150 psig) A. ASME safety relief valve(s). B. Steam pressure gauge. C. Pressure controls: High limit control-manual reset. Operating limit control. High-low re control.
Commercial Boilers
D. Low water cutoff with pump control. E. Auxiliary low water cutoff with manual reset. F. Water column gauge glass set and ttings. G. Combustion air proving switch. 5. Electrical Control Panel A. Mounted at eye level on the front head of the boiler. B. NEMA rating 1A with gasket dust seal. C. Contains electronic program relay, switches and four indicating lights (low water, ame failure, load demand, and fuel valve). 6. Miscellaneous A. The boiler is (UL) listed and bears packaged boiler/burner UL listing label. B. Motorized gas valves.
Optional Equipment
For more detailed information on optional equipment, contact your local Cleaver-Brooks authorized representative. In summary, options include the following: 1. Boiler Options Auxiliary low water cut-off (hot water). Pressure gauges and temperature guages. Drain valves. Feed valves. Additional screwed tappings. High pressure designs. Surface blow-off valve. High altitude design. 2. Burner/Control Options Full modulation on gas. Optional ame safeguard controller. Lead/Lag system. Remote emergency shut-off. Day-night controls. Low re hold control. Alarm bell/silence switch. Special motor requirements (TEFC, High efciency). Remote contacts.
B2-4
04-02
Commercial Boilers
Additional relay points and indicator lights. Main disconnect (fusible/circuit breaker). Control circuit transformer. Elapsed time meter. Voltmeter/micro-ammeter. Optional NEMA enclosure. High stack temperature control. 3. Fuel Options Automatic fuel changeover. Special gas pressure regulator. Oversized/undersized gas trains. Gas strainer. Special fuel shut-off valves. Remote oil pump set. Dual pilots (gas and oil). Direct spark oil ignition. Propane fuel ring.
Model 4 Boilers
Added Equipment for FM Compliance 1. Oil Fired Low oil pressure switch. Alarm bell mounted for non-recycling shutdowns. 2. Combination Oil and Gas Fired Low oil pressure switch. Alarm bell mounted for non-recycling shutdowns. High and low gas pressure switches. Sizes 1500-2500. 3. Gas Fired High and low gas pressure switches. Sizes 1500-2500. Alarm bell mounted for non-recycling shutdowns.

Dimension and rating information for Model 4 boilers, is shown in Tables B2-2 and B2-3, and Figures B2-1 through B2-3.
Special Insurance Requirements

Added Equipment for IRI Compliance 1. All fuels Alarm bell mounted for non-recycling shutdowns. High re switch for purge timing. 2. Oil Fired Low oil pressure switch. Gas pilot. 3. Gas red High and low gas pressure switches. Sizes 1500-2500. Two motorized main gas valves with vent valve. Sizes 1500-2500. Second motorized main gas valve with vent valve. Sizes 3000-5000. Main gas vent valve. Size 6000.
B2-5
04-02
Model 4 Boilers
Commercial Boilers
Table B2-2. Model 4 Hot Water Boiler Ratings

BOILER MODEL Rated Capacity Btu Output (1,000 Btu/hr) Boiler Horsepower EDR Water Gross, sq-ft Blower Motor Gas Only (hp) Blower Motor Oil or Combination (hp) Control Circuit Transformer kVA Oil Pump Flooded Water Weight Approximate Shipping Weight NOTE: Ratings are sea level to1000 ft. 908 3100 908 3100 1200 3700 1500 1200 35 8000 3/4 1-1/2 1 2000 1600 47 10667 1 1-1/2 1 2500 2,000 59 13333 1-1/2 2 1 3000 2400 71 16000 2 2 1 3500 2800 83 18667 2 3 1 4000 3200 95 21333 3 5 1 4500 3600 107 24000 3 3 1 5000 4000 119 26667 3 3 1 6000 4,800 143 32000 5 5 1
Belt Driven From Blower Motor 1200 3700 1466 4100 1466 4100 1766 4700 1766 4700 2033 5400
Table B2-3. Model 4 Steam Boiler Ratings

BOILER MODEL Rated Capacity in lbs Steam/hr (212 F) Boiler Horsepower EDR Steam Gross, sq-ft Blower Motor Gas Only (hp) Blower Motor Oil or Combination (hp) Control Circuit Transformer kVA Oil Pump Operating Water Weight Approximate Shipping Weight NOTE: Ratings are at sea level to 1000 ft. 658 3100 658 3100 866 3700 1500 1237 35 5000 3/4 1-1/2 1/2 2000 1649 47 6667 1 1-1/2 1/2 2500 2062 59 8333 1-1/2 2 1/2 3000 2474 71 10000 2 2 1/2 3500 2887 83 11667 2 3 1/2 4000 3299 95 13333 3 5 1/2 4500 3711 107 15000 3 3 1/2 5000 4124 119 16667 3 3 1/2 6000 4949 143 20000 5 5 1/2
B2-6
04-02
Commercial Boilers
Model 4 Boilers
ITEM 1 1 2 3 4 5 6 7 2 3 4 1 2 5 6 7 5 3 4 5 6 7 8 9 1 2 3 6 7 8 9 5 4 5 6 7 8 9 1 2 3 2 3 4 4 5 6 7 8 9 10 5 6 7 8 9 10
PART DESCRIPTION Sizes 1500 TO 2500 Buttery Valve Pilot Shutoff Cock Pilot Gas Regulator Pilot Solenoid Valve Manual Shutoff Valve Main Gas Regulator Motorized Valve with P.O.C. Size 3000 Buttery Valve Pilot Shutoff Cock Pilot Gas Regulator Pilot Solenoid Valve Manual Shutoff Valve Main Gas Regulator Low Gas Pressure Switch Motorized Valve with P.O.C. High Gas Pressure Switch Sizes 3500 to 5000 Buttery Valve Pilot Shutoff Cock Pilot Gas Regulator Pilot Solenoid Valve Manual Shutoff Valve Main Gas Regulator Low Gas Pressure Switch Motorized Valve with P.O.C. High Gas Pressure Switch Size 6000 Buttery Valve Pilot Shutoff Cock Pilot Gas Regulator Pilot Solenoid Valve Manual Shutoff Valve Main Gas Regulator Low Gas Pressure Switch Solenoid Valve Motorized Valve with P.O.C. High Gas Pressure Switch
SIZES INCHES
1-1/2 1/2 1/2 1/2 1-1/2 1-1/2 1-1/2 1-1/2 1/2 1/2 1/2 1-1/2 1-1/2 1/4 1-1/2 1/4 2 1/2 1/2 1/2 2 2 1/4 2 1/4 2 1/2 1/2 1/2 2 2-1/2 1/4 2 2 1/4
Figure B2-1. Model 4 Boiler Standard Gas Train
B2-7
04-02
Model 4 Boilers
Commercial Boilers
Figure B2-2. Model 4 Hot Water Boiler Dimensions - Sheet 1 of 2
B2-8
04-02
Q2
Commercial Boilers
Model 4 Boilers
BOILER MODEL A - Overall B - Cased Boiler C - Base Frame C1 - Base to Front Head C2 - Base Frame Anchor Holes D - Front Head Extension E - Front Casing to Outlet F - Outlet to Relief Valve G - Relief Valve to Relief Valve 30 psig Only H - Rear Casing to Air Vent J - Outside Casing to Ent. Box K - Center to Outside Casing L - Base, Inside M - Base, Outside N - Center to Soot Washer Drain O - Center to Base Center P - Center to Soot Washer QQ - Overall (Base to Vent Outlet) Q - Base to Outlet Q1 - Base to Smoke Box Q2 - Base to Top of Control Box R - Base to Soot Washer S - Height of Base T - Base to Return U - Base to Soot Washer Drain OS - Base to Oil Supply OR - Base to Oil Return BB - Diameter (Sleeve Connection) CC - Rear Casing to Vent CL W - Soot Washers (Two) X - Soot Washer Drains (Two) Y - Bottom Drain (One) HS - Water OutletA HR - Water ReturnA FF - Air Vent GG - Oil Supply and Return HH - Relief Valve Outlet 125 psig Setting DD - Front Door Swing EE - Tube Removal Each Side RF - Allowance for Front Door Swing and 30" Rear Aisle Space RD - Allowance for Tube Removal Each Side and Front Door Swing
1500 91-1/2 60-3/4 54 9-5/8 51-1/2 20-1/8 23-1/4 25-1/2 5-1/2 38-3/16 16-3/8 20 28 5-1/4 12 10-11/16 79 78 77-13/16 83-1/4 55-1/2 4 9-1/4 1-13/16 27-3/4 25-3/4 12 25-13/16 1/4 2 1-1/4 3 3 1 1/2 1 33 30 124 93
2000 91-1/2 60-3/4 54 9-5/8 51-1/2 20-1/8 23-1/4 25-1/2 5-1/2 38-3/16 16-3/8 20 28 5-1/4 12 10-11/16 79 78 77-13/16 83-1/4 55-1/2 4 9-1/4 1-13/16 27-3/4 25-3/4 12 25-13/16 1/4 2 1-1/4 3 3 1 1/2 1 33 30 124 93
2500 107-5/8 76-7/8 69-5/8 9-5/8 67-1/8 20-1/8 32-1/4 32-5/8 5-1/2 38-3/16 16-3/8 20 28 5-1/4 12 10-11/16 79 78 77-13/16 83-1/4 55-1/2 4 9-1/4 1-13/16 27-3/4 25-3/4 12 26-1/4 1/4 2 1-1/4 3 3 1 1/2 1 33 30 140 93
3000 107-5/8 76-7/8 69-5/8 9-5/8 67-1/8 20-1/8 32-1/4 32-5/8 5-1/2 38-3/16 16-3/8 20 28 5-1/4 12 10-11/16 79 78 77-13/16 83-1/4 55-1/2 4 9-1/4 1-13/16 27-3/4 25-3/4 12 26-1/4 1/4 2 1-1/4 3 3 1 1/2 1-1/4 33 30 140 93
3500 123-1/4 92-1/4 85-1/4 9-5/8 82-3/4 21-7/8 32-3/4 47-1/2 5-1/2 38-3/16 16-3/8 20 28 5-1/4 12 10-11/16 79 78 77-13/16 83-1/4 55-1/2 4 9-1/4 1-13/16 27-3/4 25-3/4 12 26-1/4 1/4 2 1-1/2 4 4 1 1/2 1-1/4 33 30 155 93
4000 123-1/4 92-1/4 85-1/4 9-5/8 82-3/4 21-7/8 32-3/4 47-1/2 5-1/2 38-3/16 16-3/8 20 28 5-1/4 12 10-11/16 79 78 77-13/16 83-1/4 55-1/2 4 9-1/4 1-13/16 27-3/4 25-3/4 12 26-1/4 1/4 2 1-1/2 4 4 1 1/2 2 33 30 155 93
4500 142-5/8 108-7/8 100-7/8 10 98-3/8 24-5/8 37-3/8 59-1/2 5-1/2 38-3/16 16-3/8 20 28 5-1/4 12 10-11/16 79 78 77-13/16 83-1/4 55-1/2 4 9-1/4 1-13/16 27-3/4 25-3/4 16 30-3/8 1/4 2 1-1/2 4 4 1 1/2 2 33 30 172 93
5000 142-5/8 108-7/8 100-7/8 10 98-3/8 24-5/8 37-3/8 59-1/2 5-1/2 38-3/16 16-3/8 20 28 5-1/4 12 10-11/16 79 78 77-13/16 83-1/4 55-1/2 4 9-1/4 1-13/16 27-3/4 25-3/4 16 30-3/8 1/4 2 1-1/2 4 4 1 1/2 2 33 30 172 93
6000 158-1/4 124-1/2 116-1/2 10 114 24-5/8 45-1/4 67-1/4 35-7/8 5-1/2 38-3/16 16-3/8 20 28 5-1/4 12 10-11/16 79 78 77-13/16 83-1/4 55-1/2 4 9-1/4 1-13/16 27-3/4 25-3/4 16 30-3/8 1/4 2 1-1/2 4 4 1 1/2 2 33 30 187 93
NOTES: 1. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified prints. 2. Allow sufficient clearance at rear of boiler for soot washer lance removal. 3. Furnace access opening, 13" x 21" located behind front head. 4. Circulating pump standard on ASME Section IV boilers (Max. 250 F and 160 psig). Section I high-temp hot water applications will not include circulator. A. Male pipe thread.
Figure B2-2. Model 4 Hot Water Boiler Dimensions - Sheet 2 of 2 B2-9

04-02
Model 4 Boilers
Commercial Boilers
Figure B2-3. Model 4 Steam Boiler Dimensions Sheet 1 of 2
B2-10
04-02
O2
Commercial Boilers
BOILER MODEL A - Overall B- Cased Boiler C - Base Frame C1 - Base to Front Head C2 - Base Frame Anchor Holes D - Front Head Extension DD - Front Casing to Steam Nozzle CL HH - Steam Nozzle to Safety Valve 15 psig II - Steam Nozzle to Safety Valve 150 psig E - Overall F - Center to Water Column G - Center to Opt. Aux. Water Control H - Center to Outside Casing I - Base Frame Inside J - Base Outside K - Soot Washer Centers L - Center to Soot Washer M - CL Base Rail to Center N - Center to Soot Drain OO - Overall (Base to Vent Outlet) O - Base to Steam Nozzle 150 psig O - Base to Steam Nozzle 15 psig O1 - Base to Smoke Box O2 - Base to Top of Control Box P - Base to Surface Blow Off Q - Base to Feedwater Inlet R - Base to Soot Washer S - Height of Base OS - Base to Oil Supply OR - Base to Oil Return . BB - Diameter (Sleeve Connection) CC - Rear Casing to Vent CL T - Bottom Drum Blow Down 15 # (one) T1 - Bottom Drum Blow Down 150 # (one) U - Steam Nozzle 15 psig V - Steam Nozzle 150 psig W - Soot Washer Drains (Two) X - Surface Blow Off (One) Y - Feedwater Inlet (One) Z - Soot Washers (Two) GG - Oil Supply & Return JJ - Relief Valve Outlet 15 psig JJ - Relief Valve Outlet 150 psig EE - Front Door Swing FF - Tube Removal Each Side RF - Allowance for Front Door Swing and 30" Rear Aisle Space RD - Allowance for Tube Removal Each Side and Front Door Swing 1500 84-1/4 61 54 9-5/8 51-1/2 20-1/8 17-1/4 8 8 59 32-7/16 26-9/16 16-3/8 20 28 21-3/8 10-11/16 12 5-1/4 78-3/4 74-3/4 75 77-13/16 2000 84-1/4 61 54 9-5/8 51-1/2 20-1/8 17-1/4 8 8 59 32-7/16 26-9/16 16-3/8 20 28 21-3/8 10-11/16 12 5-1/4 78-3/4 74-3/4 75 77-13/16 2500 100-1/4 77 69-5/8 9-5/8 67-1/8 20-1/8 25-1/4 12 12 59 32-7/16 26-9/16 16-3/8 20 28 21-3/8 10-11/16 12 5-1/4 78-3/4 74-3/4 75 77-13/16 3000 100-1/4 77 69-5/8 9-5/8 67-1/8 20-1/8 25-1/4 12 12 59 32-7/16 26-9/16 16-3/8 20 28 21-3/8 10-11/16 12 5-1/4 78-3/4 74-3/4 75 77-13/16 3500 117-3/8 92-3/8 85-1/4 9-5/8 82-3/4 21-7/8 30-3/4 11-1/2 17 59 32-7/16 26-9/16 16-3/8 20 28 21-3/8 10-11/16 12 5-1/4 78-3/4 74-3/4 78-1/4 77-13/16 4000 117-3/8 92-3/8 85-1/4 9-5/8 82-3/4 21-7/8 30-3/4 11-1/2 17 59 32-7/16 26-9/16 16-3/8 20 28 21-3/8 10-11/16 12 5-1/4 78-3/4 74-3/4 78-1/4 77-13/16
Model 4 Boilers
4500 136-3/4 109 101 10 98-3/8 24-5/8 37-3/8 13 17 59 32-7/16 26-9/16 16-3/8 20 28 21-3/8 10-11/16 12 5-1/4 78-3/4 78 78-1/4 77-13/16 5000 136-3/4 109 101 10 98-3/8 24-5/8 37-3/8 13 17 59 32-7/16 26-9/16 16-3/8 20 28 21-3/8 10-11/16 12 5-1/4 78-3/4 78 78-1/4 77-13/16 6000 152-3/8 124-5/8 116-1/2 10 114 24-5/8 45-1/4 17 17 59 32-7/16 26-9/16 16-3/8 20 28 21-3/8 10-11/16 12 5-1/4 78-3/4 78 78-1/4 77-13/16
83-1/4
59-1/4 57-1/4 55-1/2 4 27-3/4 25-3/4 12 25-13/16 1-1/4 1-1/4 4A 2-1/2A 2 3/4 1 1/4 1/2 2 1 33 30 124 93
83-1/4
59-1/4 57-1/4 55-1/2 4 27-3/4 25-3/4 12 25-13/16 1-1/4 1-1/4 4A 2-1/2A 2 3/4 1 1/4 1/2 2 1-1/4 33 30 124 93
83-1/4
59-1/4 57-1/4 55-1/2 4 27-3/4 25-3/4 12 26-1/4 1-1/4 1-1/4 4A 3A 2 3/4 1 1/4 1/2 2 1-1/4 33 30 140 93
83-1/4
59-1/4 57-1/4 55-1/2 4 27-3/4 25-3/4 12 26-1/4 1-1/4 1-1/4 4A 3A 2 3/4 1 1/4 1/2 2 1-1/4 33 30 140 93
83-1/4
59-1/4 57-1/4 55-1/2 4 27-3/4 25-3/4 12 26-1/4 1-1/2 1-1/4 6B 3A 2 3/4 1 1/4 1/2 2 1-1/2 33 30 155 93
83-1/4
59-1/4 57-1/4 55-1/2 4 27-3/4 25-3/4 12 26-1/4 1-1/2 1-1/4 6B 3A 2 3/4 1 1/4 1/2 2-1/2 1-1/2 33 30 155 93
83-1/4
59-1/4 57-1/4 55-1/2 4 27-3/4 25-3/4 16 30-3/8 1-1/2 1-1/4 6B 4B 2 3/4 1 1/4 1/2 2-1/2 1-1/2 33 30 172 93
83-1/4
59-1/4 57-1/4 55-1/2 4 27-3/4 25-3/4 16 30-3/8 1-1/2 1-1/4 6B 4B 2 3/4 1 1/4 1/2 2-1/2 1-1/2 33 30 172 93
83-1/4
59-1/4 57-1/4 55-1/2 4 27-3/4 25-3/4 16 30-3/8 1-1/2 1-1/4 6B 4B 2 3/4 1 1/4 1/2 3 2 33 30 187 93
NOTES: 1. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified prints. For 200 psig design pressure or higher, contact factory for certified prints. 2. Allow sufficient space for soot washer lance removal at rear of boiler. 3. Furnace access opening, 13" x 21" located behind front head. A. Female pipe thread. B. Flg 150 psig FF.
Figure B2-3. Model 4 Steam Boiler Dimensions Sheet 2 of 2 B2-11

04-02
Model 4 Boilers
Commercial Boilers
Table B2-11 shows steam nozzle sizes at various operating pressures. Table B2-12 shows maximum sound levels when ring oil or natural gas.
PERFORMANCE DATA
Efficiency
Efciency data provided is based on hot water or low pressure steam operation. Nominal boiler efciency is: Gas - 80 percent. Oil - 83 percent. For high pressure steam applications, contact your local Cleaver-Brooks authorized representative for expected efciency data.

Model 4 Boilers can support up to 200 lbs without additional support.
Stack Breeching Size Criteria

A constant pressure at the ue gas outlet of a Model 4 Boiler is not required. The high static pressure developed in the windbox by the forced draft fan, and high pressure drop type burner, provides a safety margin for pressure changes at the boiler outlet. However, it is necessary to size the stack breeching to limit the ue gas pressure variation. The allowable pressure range is 0.25 WC to +0.25 WC. Table B2-4. Model 4 Boiler Emission Data - Natural Gas
Emissions
The emission data included in this section consist of uncontrolled nitrogen oxides (NOx) and carbon monoxide (CO) for Cleaver-Brooks Model 4 Boilers. The following tables include typical emission levels and a range of actual emissions. Emission data is presented in Table B2-4 for natural gas, and for No. 2 oil in Table B2-5.
NOTICE
The data in these tables represents typical emission levels only. Please contact your local Cleaver-Brooks authorized representative if an emission guarantee is required, or for emission level information not shown in these tables.
CO
POLLUTANT ppm lb/MMBtu ppm NOx lb/MMBtu ppm SOx lb/MMBtu
UNCONTROLLED xx200 0.15 100 0.12 1 0.001 40 0.016 0.01
Fuels
Fuel requirements for the Model 4 Boiler are shown in Table B2-6.
HC/VOCs
ppm lb/MMBtu ppm PM lb/MMBtu
ENGINEERING DATA
Engineering data for Model 4 Boilers are shown in Tables B2- 7 through B2-12. Table B2-7 shows the steam boiler pressure vessel thicknesses, and Table B2-8 shows fuel, combustion air, and ue gas ow rates at rated boiler capacity. Flow rates and pressure drops are shown in Table B2-9. This table can be utilized to determine the boiler pressure drop in relation to the full boiler output and system temperature drop. Table B2-10 can be used to determine the maximum circulating rate in relation to the full boiler output and system temperature drop. The maximum circulation rate can be determined by determining the boiler size and expected system drop. For information on over pressure requirements for Model 4 Boilers refer to Figure B2-4. For more information on hot water boiler over pressure requirements refer to Section I2, Hot Water Systems. B2-12
04-02
Table B2-5. Model 4 Boiler Emission Data - No. 2 Oil

POLLUTANT ppm CO lb/MMBtu ppm NOx lb/MMBtu ppm SOx lb/MMBtu ppm HC/VOCs lb/MMBtu ppm PM lb/MMBtu 0.025 NOTES: Based on fuel oil constituent levels: Fuel bound nitrogen = 0.05% (max) by weight. Sulfur = 0.5% (max) by weight. Ash = 0.01% (max) by weight. 0.025 0.515 50 0.248 270 0.07 187 UNCONTROLLED 90
Commercial Boilers
Model 4 Boilers
Table B2-6. Model 4 Gas Fuel Requirements

NATURAL GAS MINIMUM REQUIRED PRESSURES (INCHES OF WC) STANDARD & FM IRI PROPANE VAPOR MINIMUM REQUIRED PRESSURES (INCHES OF WC) STANDARD & FM IRI
BOILER SIZE
TRAIN SIZE
USAGE SCFH)
USAGE (SCFH)
1500 2000 2500
1.5A 2.0 1.5A 2.0 1.5A 2.0 2.5 1.5A 2.0 2.5 3.0 2.0A 2.5 3.0 2.0A 2.5 3.0 2.0A 2.5 3.0 2.0A 2.5 3.0 4.0 2.0A 2.5 3.0 4.0
4.4 2.3 8.4 4.8 12.9 6.5 5.7 17.1 9.0 6.8 6.0 11.3 9.7 7.1 13.6 11.8 8.5 12.2 9.8 5.6 16.8 12.9 7.1 5.6 21.5 17.5 10.0 7.9
5.3 2.5 10.2 5.0 14.9 6.9 6.0 20.0 9.7 7.3 6.3 12.1 10.3 7.6 14.7 12.6 9.0 13.6 10.8 6.2 18.4 14.1 7.8 6.0 24.0 19.3 11.1 8.4
1500 2000 2500
6.7 5.9 10.5 9.0 13.3 10.8 10.5 17.0 13.8 12.9 12.6 14.3 13.6 12.6 16.5 15.8 14.5 14.8 13.8 12.1 16.4 14.8 12.5 12.0 19.6 18.0 15.0 14.1
7.1 6.0 11.2 9.0 14.1 11.0 10.6 18.2 14.1 13.1 12.7 14.6 13.9 12.8 17.0 16.1 14.7 15.3 14.2 12.4 17.1 15.3 12.8 12.1 20.5 18.7 15.4 14.3
600 800 1000
3000
3000
1200
3500
3500
1400
4000
4000
1600
4500
4500
1800
5000
5000
2000
6000
6000
2400
NOTES: 1. Natural gas pressure based on 1000 Btu/cu-ft @ 0.65 specic gravity. 2. Propane pressures based on 2500 Btu/cu-ft @ 1.6 specic gravity. 3. All pressures given for regulator inlet. A .Standard Gas Train Size.
B2-13
04-02
Model 4 Boilers
Commercial Boilers
Table B2-7. Model 4 Steam Boiler Minimum Pressure Vessel Thickness

PRESSURE (PSIG) 15 150 250 350 500 20" UPPER DRUM 0.375 0.375 0.593 0.812 1.031 8"LOWER DRUM 0.322 0.322 0.322 0.322 0.500 2" TUBES 0.095 0.095 0.095 0.095 0.095
NOTE: All thicknesses are in inches.
Table B2-8. Model 4 Boiler Fuel, Air, and Flue Gas Flow Rates
SIZE & INPUT Gas (cfh)A Fuel Consumption Oil (gph)B,C Gas (scfh) (lb/h) Combustion Air Oil (scfh) (lb/h) Gas (scfh) (lb/h) Flue Gas Oil (scfh) (lb/h) 17914 1357 23886 1809 29855 2261 35827 2714 41799 3166 47769 3618 53741 4070 59713 4523 71655 5427 17049 1269 17520 1278 22733 1692 23360 1704 28414 2115 29200 2130 34098 2538 35040 2556 39782 2961 40880 2983 45463 3384 46720 3409 51147 3808 52560 3835 56831 4231 58400 4261 68196 5077 70080 5113 10.72 15480 1207 14.29 20640 1609 17.86 25800 2012 21.43 30960 2414 25.0 36120 2817 28.57 41280 3219 32.14 46440 3621 35.71 51600 4024 42.85 61920 4828 1500 1500 2000 2000 2500 2500 3000 3000 3500 3500 4000 4000 4500 4500 5000 5000 6000 6000
Notes: A. Gas Consumption based on 1000 Btu/cu-ft. B. Oil consumption based on 140,000 Btu/gal. C. Oil supply lines to be sized for 125 gph pumping rate. Oil pump suction pressure to be -10 Hg to 3 psig.
B2-14
04-02
Commercial Boilers
Table B2-9. Model 4 Hot Water Boiler Pressure Drop
T = 20 BOILER SIZE OUTLET P VELOCITY PSIG FT/S FLOW GPM PSIG P VELOCITY FT/S FLOW GPM PSIG T = 30 OUTLET P VELOCITY FT/S FLOW GPM T = 40 OUTLET
Model 4 Boilers
T = 50 OUTLET P VELOCITY PSIG FT/S FLOW GPM
INLET/OUTLET CONNECTION - 3 NPT 1500 2000 2500 3000 0.54 0.96 1.49 2.13 5.38 7.17 8.96 10.75 123 165 206 248 0.24 0.43 0.67 0.95 3.58 4.79 5.98 7.17 83 110 138 165 0.14 0.24 0.38 0.54 2.69 3.58 4.48 5.38 62 83 103 124 0.09 0.16 0.24 0.343 2.16 2.88 3.60 4.30 50 66 83 99
INLET/OUTLET CONNECTION - 4 NPT 3500 4000 4500 5000 6000 1.32 1.72 2.18 2.68 3.86 7.28 8.34 9.38 10.42 12.50 289 331 372 413 496 0.59 0.77 0.97 1.20 1.72 4.86 5.55 6.26 6.95 8.34 193 220 248 275 330 0.34 0.44 0.55 0.68 0.97 3.65 4.17 4.69 5.21 6.26 145 166 186 207 248 0.22 0.28 0.35 0.43 0.63 2.92 3.34 3.76 4.17 5.01 116 132 149 165 198
NOTE: Based on 200F outlet temperature
Table B2-10. Model 4 Hot Water Boiler Flow Rates

BOILER SIZE (BHP) SYSTEM TEMPERATURE DROP 10 20 30 40 50 60 70 80 90 100
MAXIMUM CIRCULATING RATE - GPM 1500 (35) 2000 (47) 2500 (59) 3000 (71) 3500 (83) 4000 (95) 4500 (107) 5000 (119) 6000 (143) 247 330 413 494 578 661 740 826 992 123 165 206 248 289 331 372 413 496 83 110 138 165 193 220 248 275 330 62 83 103 124 145 166 186 207 248 50 66 83 99 116 132 149 165 198 41 55 69 83 97 110 124 138 166 35 47 59 71 83 95 106 118 142 31 41 52 62 72 83 93 103 124 28 37 46 55 64 74 83 92 110 25 33 41 50 58 66 74 83 99
B2-15
04-02
Model 4 Boilers
Table B2-11. Model 4 Boiler Recommended Steam Nozzle Size at Reduced Pressure
OPERATING PRESSURE (PSIG) 15A 20 40 65 75 95-125B BOILER SIZE 1500 4 3 2-1/2 2-1/2 2-1/2 2-1/2 2000 4 4 3 2-1/2 2-1/2 2-1/2 2500 4 4 3 3 3 3 3000 4 4 4 3 3 3 3500 6 6 4 3 3 3 4000 6 6 4 4 4 3 4500 6 6 6 4 4 4 5000 6 6 6 4 4 4 6000 6 6 6 4 4 4
Commercial Boilers
NOTE: All dimensions are in inches. A. Standard Nozzle Size for 15 lb DP Units. B. Same Nozzle Size as 150 lb DP Units.
Table B2-12. Model 4 Sound Levels

SOUND LEVEL FIRING RATE LFG (dBA) HFG (dBA) LFO (dBA) BOILER SIZE (BHP) 1500 (35) 70 70 69 2000 (47) 70 70 69 2500 (59) 71 72 70 3000 (71) 71 74 71 3500 (83) 72 74 72 4000 (95) 72 76 73 4500 (107) 74 77 74 5000 (119) 75 78 75 6000 (143) 76 79 76
HFO (dBA) 71 71 72 73 74 76 76 77 78 NOTES: 1. Abbreviations: LF=Low Fire, HF=High Fire, O=Oil, G=GAS 2. Measurement: Three (3) feet from front center of boiler and 3-1/2 feet above boiler base. Measurements are decibal ratings on the A-weighted scale, and were registered without the addition of sound attenuators, mufflers, or silencers.
Figure B2-4. Model 4 Boiler Over Pressure Requirements B2-16

04-02
Commercial Boilers
Model 4 Boilers
The following sample specications are provided by Cleaver-Brooks to assist you in specifying your customers specic needs and application. A separate specication is provided for hot water boiler and steam boiler packages. Steam Boiler Specifications 1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-17 2.0 Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-17 3.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-22 Hot Water Boiler Specifications 1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-23 2.0 Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-23 3.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-28
Steam Boiler Specification

1.0 General 1.1 Scope 1.2 Items by Others 1.3 Proposal 1.4 Submittals 1.4.1 The manufacturer shall supply ____ copies of a dimensional drawing indicating all relevant unit dimensions, layout and required clearances. 1.4.2 The manufacturer shall supply ____ copies of a ladder type wiring diagram to include all internal unit wiring, external connections, and power supply requirements. 1.4.3 The manufacturer shall supply a copy of the authorized inspection report, to the purchaser, upon completion and shipment of the unit. 1.5 Codes 1.5.1The boiler shall be designed, constructed, and hydrostatically tested in accordance with the ASME Boiler and Pressure Vessel Code. 1.5.2 The boiler shall be wired in accordance with the rules of the National Electric Code. 1.5.3 All electrical equipment shall be in conformity with the Underwriters Laboratories requirements. 1.5.4 The complete boilerburner package shall be approved by Underwriters Laboratories and shall bear a UL label. 1.5.5 The boiler shall be built to comply with the following insurances _______________. (Factory Mutual, Industrial Risk Insurers, ASME CSD1) 1.6 Guarantees 1.6.1 The complete boiler package shall be warranted from defects in materials and/or workmanship for a period of not less than 18 months from shipment or 12 months from unit startup. 2.0 Product 2.1 Type 2.1.1 The boiler shall be a watertube type steam boiler with all steel membrane walls.
B2-17
04-02
Model 4 Boilers
2.1.2 The boiler shall be a three gas pass type boiler mounted on a heavy duty steel frame. 2.1.3 The boiler shall have an integral forced draft burner and burner controls.
Commercial Boilers
2.1.4 The boiler shall be a Cleaver Brooks Model 4, series ________ (100 = No. 2 oil, 200 = No. 2 oil and gas, 700 = gas) steam boiler. 2.2 Design Criteria 2.2.1 The boiler shall be designed in accordance with the ASME Boiler and Pressure Code Section _____ (IV for low pressure, I for high pressure). 2.2.2 The boiler shall be designed for _____ psig (15, 150, 250, 350, or 500). The maximum operating pressure will be _____ psig. 2.2.3 The boiler shall be designed for a maximum output of ________ lbs/hr of steam, or _________ bhp. The boiler shall develop ________ lbs/hr of steam when operating at ______ psig with a feedwater temperature of ______ F. 2.2.4 Electrical power available will be _______ volts, _______ phase, ______ Hz. 2.2.5 The maximum sound level shall not exceed 80 dBA measured 3 feet in front of the boiler. 2.3 Product Design 2.3.1 Pressure Vessel 2.3.1.1 The upper drum shall have a 20" OD, manufactured from SA53 Gr. B seamless pipe, with a minimum wall thickness of _____". 2.3.1.2 The lower drum shall have an 85/8" OD, manufactured from SA53 Gr. B seamless pipe, with a minimum wall thickness of _____". 2.3.1.3 The generating tubes shall be 2" OD, manufactured from SA178 Gr. A tubing, with a minimum wall thickness of _____". 2.3.1.4 The boiler shall have two downcomers, located at the rear of the boiler, and be totally insulated from the generating tubes. These shall be a minimum of 21/2" OD, manufactured from SA178 Gr. A tubing, with a minimum wall thickness of .105". 2.3.1.5 The upper drum shall have an inspection opening, located at the rear of the unit, to allow internal inspection, and shall be a minimum of 4"x6". 2.3.1.6 The lower drum shall have inspection openings, located at the front and rear of the unit, to allow internal inspection, and shall be a minimum of 47/8"x5 7/8". 2.3.1.7 The boiler shall have inspection openings in the convection area. 2.3.1.8 A feedwater tapping and integral feedwater distribution pipe shall be located in the upper drum. The distribution pipe shall blend the feedwater with the boiler water. 2.3.1.9 A 3/4" surface blowoff connection shall be located in the rear head of the upper drum. 2.3.1.10 A _____" bottom blowoff connection shall be located in the lower drum. 2.3.2 Refractory 2.3.2.1 Refractory shall be limited to the furnace oor to insulate the lower drum, and to the burner throat tile. 2.3.2.2 High temperature insulation shall be installed on the front wall of the furnace. 2.3.3 Insulation and Casing 2.3.3.1 The boiler insulation shall be a minimum of 2" berglass, and shall cover the entire pressure vessel. 2.3.3.2 The insulation shall be covered with a corrugated metal lagging. 2.3.3.3 The metal lagging and insulation shall be arranged for easy removal and installation if required. 2.3.3.4 The front head (windbox) shall be attached with a davit arm, gasket sealed, and bolted. The front head shall swing open to provide full access to the furnace chamber and burner throat tile.
B2-18
04-02
Commercial Boilers
Model 4 Boilers
2.3.3.5 Observation ports shall be provided at each end of the boiler for visual inspection of the pilot and main ame conditions. 2.3.3.6 Two lifting eyes shall be located on top of the boiler. 2.3.3.7 The exhaust gases shall vent at the rear of the boiler, on the top centerline. 2.3.4 Trim 2.3.4.1 The water column shall be located on the left side of the boiler. It shall be piped with unions for easy removal. 2.3.4.2 A gauge glass set, gauge glass blowdown valve, and water column blowdown valves shall be provided. 2.3.4.3 The boiler feedwater control switch shall be included as an integral item of the water column. It shall provide automatic actuation of a motor driven feedwater pump to maintain the boiler water level within normal limits. 2.3.4.4 The low water cutoff switch shall be an integral part of the water column. It shall be wired into the burner control circuit preventing burner operation if the boiler water level falls below the designated safe level. 2.3.4.5 A steam pressure gauge shall be located at the front end of the boiler and shall include a cock and test connection. 2.3.4.6 A safety relief valve shall be provided of a size and type to comply with ASME Code requirements. The safety relief valve set pressure shall be ______ psig. 2.3.4.7 A high limit pressure control shall be provided. It shall be a manual reset type and shall be wired to prevent burner operation and lockout if excessive steam pressure occurs. 2.3.4.8 An operating limit control shall be provided. It shall be wired to provided on off control of the burner at operating set points. 2.3.4.9 A ring rate control shall be provided. It shall control the ring rate of the burner based on the boiler load. 2.3.4.10 An auxiliary low water cutoff shall be provided. It shall be wired into the burner control circuit preventing burner operation if the boiler water level falls below the designated safe level. 2.3.4.11 A stack thermometer shall be shipped loose for eld installation. 2.3.5 Soot Cleaning 2.3.5.1 Soot washer lances shall be provided in the convection area of the boiler measuring the full length of the pressure vessel. 2.3.5.2 Each lance shall be provided with a shutoff valve and the assembly shall be capable of rotating 360 degrees. This shall ensure complete washing of the convection zone while the boiler is operating in the low re mode. 2.3.5.3 Soot washer troughs shall be provided at the bottom of the boiler. These shall be furnished for each convection side and shall measure the full length of the boiler. 2.3.5.4 The soot washer troughs shall be provided with 2" drain connections at the rear of the boiler, and shall have inspection/ cleanout openings at the front of the boiler. 2.3.6 Burner Design General 2.3.6.1 The burner shall be integral to the front head (windbox). 2.3.6.2 All air for combustion shall be supplied by a forced draft blower mounted in the front head (windbox), above the burner, to minimize noise and vibration level. 2.3.6.3 The blower motor shall be an open drip proof type with a minimum service factor of 1.15. 2.3.6.4 The impeller shall be an enclosed centrifugal fan type, properly balanced, and directly connected to the blower motor shaft. 2.3.6.5 The combustion air damper shall be integral to the front head (windbox) and shall be operated by a single damper motor. 2.3.6.6 The burner shall remain in the low re position during ignition and until main ame has been established. 2.3.7 Burner Design Gas 2.3.7.1 The burner shall be the high radiant multiport type approved for operation with natural gas.
B2-19
04-02
Model 4 Boilers
Commercial Boilers
2.3.7.2 The burner shall operate on the _______________ (lowhighlow or full modulation) principle and must return to the low re position prior to ignition. 2.3.7.3 Automatic electric ignition of the premix gas pilot shall be furnished. An electric scanner, of the UV principle, shall monitor the pilot, preventing the primary fuel valve from opening until the pilot ame has been established. 2.3.7.4 The single combustion air damper motor shall operate the gas buttery valve. The damper motor shall regulate the re according to system demand in response to the ring rate control. 2.3.8 Burner Design No. 2 Oil 2.3.8.1 The burner shall be the pressure atomizing type approved for operation with commercial grade No. 2 oil. 2.3.8.2 The burner shall operate on the lowhighlow principle, and must return to the low re position prior to ignition. 2.3.8.3 The burner shall remain in the low re position during ignition and until main ame has been proven. The ignition period shall be monitored with an electric scanner, of the UV principle, to conrm the presence of the low re oil ame. 2.3.8.4 Automatic electric ignition of the low re oil supply shall be provided with a minimum 10,000 volt transformer and heavy duty electrodes.
NOTICE
Optional insurance compliance may require a premix gas pilot in lieu of direct spark ignition.
2.3.8.5 [Optional] Automatic electric ignition of the premix gas pilot shall be furnished. An electric scanner, of the UV principle, shall conrm the pilot prior to the delivery of the low re oil supply. 2.3.8.6 The single combustion air damper motor shall operate the low and high re oil valves. The damper motor shall regulate the re according to system demand in response to the ring rate control. 2.3.9 Burner Design Gas and No. 2 Oil 2.3.9.1 The burner shall be the high radiant multiport type for gas and shall be the pressure atomizing for oil. The burner must be approved for operation with either natural gas or commercial grade No. 2 oil. 2.3.9.2 The burner shall operate on the lowhighlow principle, and must return to the low re position prior to ignition. 2.3.9.3 The burner shall remain in the low re position during ignition and until main ame has been proven. 2.3.9.4 Automatic electric ignition of the premix gas pilot shall be furnished. An electric scanner, of the UV principle, shall monitor the pilot, preventing the primary fuel valve from opening until the pilot ame has been established. 2.3.9.5 The single combustion air damper motor shall operate the low and high re oil valves and the gas buttery valve. The damper motor shall regulate the re according to system demand in response to the ring rate control. 2.3.10 Natural Gas Main Train 2.3.10.1 The gas burner piping shall include a primary gas shutoff valve. It shall be controlled by the programming relay to start or stop the burner and to close automatically in the event of power failure, ame failure, or a low water condition. 2.3.10.2 A manual shutoff valve shall be located ahead of the primary gas valve. 2.3.10.3 A plugged leakage test connection and a second manual shutoff valve shall be provided as a means for a tightness check of the primary shutoff valve. 2.3.10.4 A gas pressure regulator shall be factory mounted and piped for pressure regulation to the burner. 2.3.10.5 Gas Train Components Standard (UL) 2.3.10.5.1 [Sizes 15002500] The primary gas shutoff valve shall be motorized with a proof of closure switch. 2.3.10.5.2 [Sizes 30005000] The primary gas shutoff valve shall be motorized with a proof of closure switch. High and low gas pressure switches shall be provided. B2-20
04-02
Commercial Boilers
Model 4 Boilers
2.3.10.5.3 [Size 6000] The primary gas shutoff valve shall be motorized with a proof of closure switch. A second gas safety shutoff valve and an additional plugged leakage test cock shall be provided. High and low gas pressure switches shall be provided. 2.3.10.6 Gas Train Components Factory Mutual Insurance (FM) 2.3.10.6.1 [Sizes 15005000] The primary gas shutoff valve shall be motorized with a proof of closure switch. High and low gas pressure switches shall be provided. 2.3.10.6.2 Size 6000] The primary gas shutoff valve shall be motorized with a proof of closure switch. A second gas safety shutoff valve and an additional plugged leakage test cock shall be provided. High and low gas pressure switches shall be provided. 2.3.10.7 Gas Train Components Industrial Risk Insurers (IRI) 2.3.10.7.1 [Size 15005000] The gas train piping shall include both primary and secondary motorized gas safety shutoff valves and a second plugged leakage test cock. A vent valve shall be located between the primary and secondary gas shutoff valves. High and low gas pressure switches shall be provided. 2.3.10.7.2 [Size 6000] The primary gas shutoff valve shall be motorized with a proof of closure switch. A second gas motorized shutoff valve and an additional plugged leakage test cock shall be provided. A vent valve shall be located between the primary and secondary gas shutoff valves. High and low gas pressure switches shall be provided. 2.3.11 Natural Gas Pilot Train 2.3.11.1 A pilot gas pressure regulator shall be factory mounted and piped for pressure regulation of the pilot gas to the burner. 2.3.11.2 The pilot gas train shall include a safety shutoff valve. It shall be controlled by the programming relay to start the burner. 2.3.11.3 A manual shutoff valve shall be located ahead of the pilot gas pressure regulator. 2.3.12 Oil System 2.3.12.1 An oil pump shall be provided. The oil pump, integral with the burner, shall include a builtin relief valve and selfcleaning strainer. 2.3.12.2 The oil pump shall be belt driven from the blower motor. 2.3.12.3 The fuel oil system shall include supply and return tubing to a terminal block, an oil pressure gauge, shutoff cock, and four solenoid oil shutoff valves. These items shall be factory mounted and piped on the front head (windbox). 2.4 Burner Management System 2.4.1 Control Panels 2.4.1.1 The control panel shall be a NEMA 1 rated panel and have a key lock. 2.4.1.2 The control panel shall be mounted on the front head of the boiler and shall be conveniently located for the boiler operator. 2.4.1.3 The panel shall contain the blower motor starter, control circuit fuses, control circuit transformer, and control switches. A damper selector switch shall be provided to permit selection of automatic or manual selection of low or high ring. 2.4.1.4 A terminal board shall be provided to which all wires entering or leaving the panel shall be connected. 2.4.1.5 The panel shall include four indicating lights to show operating conditions of: red = low water; red = ame failure; white = load demand; and white = fuel valve open. The lights and switches shall be located on the panel switch ledge. 2.4.1.6 All electrical service connections shall be made to an electrical entrance box to be mounted on the right hand side of the boiler. 2.4.1.7 All electrical wiring shall be oil, heat, and moisture resistant and shall be number coded. 2.4.2 Combustion Safeguard Control 2.4.2.1 A combustion safeguard control (program relay) shall be provided to control ignition, starting, and stopping of the burner. It shall provide precombustion and postcombustion purge periods and shall stop burner operation in the event of ignition, pilot, or main ame failure. Trial for ignition shall be limited to 10 seconds. 2.4.2.2 The boiler shall be provided with a combustion safeguard controller that provides technology and functions equal to the Cleaver Brooks Model CB100. B2-21
04-02
Model 4 Boilers
Commercial Boilers
2.4.2.3 The combustion safeguard control shall be microprocessor based, with selfdiagnostics, nonvolatile memory, and a message center with a vocabulary of 42 different messages. Messages shall scroll across an alphanumeric display and provide sequence status and ame failure mode information. 2.4.2.4 The combustion safeguard control shall have a xed operating sequence incapable of being manually altered. The sequence shall include start, pre purge, pilot and main fuel ignition run, and postpurge cycles. 2.4.2.5 The controller shall be the nonrecycle type for maximum safety that will shut down the burner and indicate as a minimum the following trip functions: pilot failure, main ame failure, high and low re proving switch faults, running interlocks open, false ame signal, and fuel valve open (when proof of closure switch is furnished). 2.4.2.6 The controller shall have a test/run switch. It will allow interruptions to sequence just after prepurge, during pilot ignition trial, and during run cycles, for adjustments to ring rate motor, damper linkages, and pilot ame for turndown tests. 2.4.2.7 The controller shall also have the following functions: display history of operating hours and totals of completed onoff cycles; provide a constant ame signal strength readout; and have provisions for remote display capability. 3.0 Execution 3.1 Shop Tests 3.1.1 The pressure vessel shall be hydrostatically tested in accordance with ASME requirements. 3.1.2 The boiler will be test red by the manufactured, prior to shipment, to verify proper and safe operation. 3.2 Shipment 3.2.1 Painting 3.2.1.1 The entire boiler, base frame, and other components shall be factory painted, before shipment, using a hard nish enamel. 3.2.1.2 The boiler surface shall be cleaned/prepared for painting using manufacturer's specications and standard industrial painting practices. 3.2.2 Preparation 3.2.2.1 All boiler openings shall be plugged/covered prior to shipment. 3.2.2.2 The boiler shall be skid mounted and protected with a weather resistant covering. 3.2.2.3 All shipped loose components shall wrapped in protective material and packaged in a separate container(s). 3.3 Installation 3.4 StartUp 3.4.1 The boiler startup shall be performed by a factory trained representative and will be done in accordance with the manufacturer's recommended procedures. 3.4.2 The boiler startup shall include boiler operator training and shall cover boiler operation, water treatment, and maintenance of the unit. 3.5 Operation and Maintenance Manuals 3.5.1The manufacturer shall supply _____ copies of the Operating & Maintenance Manual.
B2-22
04-02
Commercial Boilers
Hot Water Boiler Specification
1.0 General 1.1 Scope 1.2 Items by Others 1.3 Proposal 1.4 Submittals
Model 4 Boilers
1.4.1 The manufacturer shall supply ____ copies of a dimensional drawing indicating all relevant unit dimensions, layout and required clearances. 1.4.2 The manufacturer shall supply ____ copies of a ladder type wiring diagram to include all internal unit wiring, external connections, and power supply requirements. 1.4.3 The manufacturer shall supply a copy of the authorized inspection report, to the purchaser, upon completion and shipment of the unit. 1.5 Codes 1.5.1 The boiler shall be designed, constructed, and hydrostatically tested in accordance with the ASME Boiler and Pressure Vessel Code. 1.5.2 The boiler shall be wired in accordance with the rules of the National Electric Code. 1.5.3 All electrical equipment shall be in conformity with the Underwriter's Laboratories' requirements. 1.5.4 The complete boilerburner package shall be approved by Underwriter's Laboratories and shall bear a UL label. 1.5.5 The boiler shall be built to comply with the following insurances _______________ (Factory Mutual, Industrial Risk Insurers, ASME CSD1). 1.6 Guarantees 1.6.1 The complete boiler package shall be warranted from defects in materials and/or workmanship for a period of not less than 18 months from shipment or 12 months from unit startup. 2.0 Product 2.1 Type 2.1.1 The boiler shall be a watertube type hot water boiler with all steel membrane walls. 2.1.2 The boiler shall be a three gas pass type boiler mounted on a heavy duty steel frame. 2.1.3 The boiler shall have an integral forced draft burner and burner controls. 2.1.4 The boiler shall be a Cleaver Brooks Model 4, series ________ (100 = No. 2 oil, 200 = No. 2 oil and gas, 700 = gas) hot water boiler. 2.2 Design Criteria 2.2.1 The boiler shall be designed in accordance with the ASME Boiler and Pressure Code Section IV. 2.2.2 The boiler shall be designed for 140 psig. The maximum supply temperature will be _____ F, and the return water temperature will be _____ F. The minimum operating temperature of the boiler shall be 170F. 2.2.3 The boiler shall be designed for a maximum output of ________ BTU/hr, or _____ bhp. 2.2.4 Electrical power available will be _______ volts, _______ phase, ______ Hz. 2.2.5 The maximum sound level shall not exceed 80 dBA measured 3 feet in front of the boiler.
B2-23
04-02
Model 4 Boilers
2.3 Product Design 2.3.1 Pressure Vessel
Commercial Boilers
2.3.1.1 The upper drum shall have a 20" OD, manufactured from SA53 Gr. B seamless pipe, with a minimum wall thickness of .375". 2.3.1.2 The lower drum shall have an 85/8" OD, manufactured from SA53 Gr. B seamless pipe, with a minimum wall thickness of .322". 2.3.1.3 The generating tubes shall be 2" OD, manufactured from SA178 Gr. A tubing, with a minimum wall thickness of .095". 2.3.1.4 The boiler shall have two downcomers, located at the rear of the boiler, and be totally insulated from the generating tubes. These shall be a minimum of 21/2" OD, manufactured from SA178 Gr. A tubing, with a minimum wall thickness of .105". 2.3.1.5 The upper drum shall have an inspection opening, located at the rear of the unit, to allow internal inspection, and shall be a minimum of 4"x6". 2.3.1.6 The lower drum shall have inspection openings, located at the front of the unit, to allow internal inspection, and shall be a minimum of 47/8"x57/8". 2.3.1.7 The boiler shall have inspection openings in the convection area. 2.3.1.8 The hot water outlet shall be located on the top centerline of the boiler and the return water connection shall be located at the rear of the lower drum. The design of the boiler shall provide jet induced circulation which shall mix the return water and the hot water within the boiler. 2.3.1.9 A dip tube shall be included as an integral part of the hot water outlet. An air vent tapping shall be located on the top centerline of the boiler for connection to an expansion tank. 2.3.1.10 A _____" drain connection shall be located in the lower drum. 2.3.2 Refractory 2.3.2.1 Refractory shall be limited to the furnace oor to insulate the lower drum, and to the burner throat tile. 2.3.2.2 High temperature insulation shall be installed on the front wall of the furnace. 2.3.3 Insulation and Casing 2.3.3.1 The boiler insulation shall be a minimum of 2" berglass, and shall cover the entire pressure vessel. 2.3.3.2 The insulation shall be covered with a corrugated metal lagging. 2.3.3.3 The metal lagging and insulation shall be arranged for easy removal and installation if required. 2.3.3.4 The front head (windbox) shall be attached with a davit arm, gasket sealed, and bolted. The front head shall swing open to provide full access to the furnace chamber and burner throat tile. 2.3.3.5 Observation ports shall be provided at each end of the boiler for visual inspection of the pilot and main ame conditions. 2.3.3.6 Two lifting eyes shall be located on top of the boiler. 2.3.3.7 The exhaust gases shall vent at the rear of the boiler, on the top centerline. 2.3.4 Trim 2.3.4.1 The water column shall be the probe type and shall be located on the top centerline of the boiler. It shall be wired into the burner control circuit preventing burner operation if the boiler water level falls below the designated safe level. 2.3.4.2 A pressure gauge and a temperature gauge shall be located at the front end of the boiler. 2.3.4.3 Water relief valves shall be provided of a size and type to comply with ASME Code requirements. The relief valve set pressure shall be ______ psig. 2.3.4.4 A high limit temperature control shall be provided. It shall be a manual reset type and shall be wired to prevent burner operation and lockout if excessive water temperature occurs. The sensing element shall be located adjacent to the outlet connection.
B2-24
04-02
Commercial Boilers
Model 4 Boilers
2.3.4.5 An operating limit control shall be provided. It shall be wired to provided on off control of the burner at operating set points. The sensing element shall be located adjacent to the outlet connection. 2.3.4.6 A ring rate control shall be provided. It shall control the ring rate of the burner based on the boiler load. The sensing element shall be located adjacent to the outlet connection. 2.3.4.7 A hot water circulating pump shall be mounted between the supply and return connections (standard on ASME Section IV heating boilers only). This pump will blend the supply and the system return water. It will ensure a minimum continuous circulation at all times to a level of ten boiler water changes per hour. 2.3.4.8 A stack thermometer shall be shipped loose for eld installation. 2.3.5 Soot Cleaning 2.3.5.1 Soot washer lances shall be provided in the convection area of the boiler measuring the full length of the pressure vessel. 2.3.5.2 Each lance shall be provided with a shutoff valve and the assembly shall be capable of rotating 360 degrees. This shall ensure complete washing of the convection zone while the boiler is operating in the low re mode. 2.3.5.3 Soot washer troughs shall be provided at the bottom of the boiler. These shall be furnished for each convection side and shall measure the full length of the boiler. 2.3.5.4 The soot washer troughs shall be provided with 2" drain connections at the rear of the boiler, and shall have inspection/ cleanout openings at the front of the boiler. 2.3.6 Burner Design General 2.3.6.1 The burner shall be integral to the front head (windbox). 2.3.6.2 All air for combustion shall be supplied by a forced draft blower mounted in the front head (windbox), above the burner, to minimize noise and vibration level. 2.3.6.3 The blower motor shall be an open drip proof type with a minimum service factor of 1.15. 2.3.6.4 The impeller shall be an enclosed centrifugal fan type, properly balanced, and directly connected to the blower motor shaft. 2.3.6.5 The combustion air damper shall be integral to the front head (windbox) and shall be operated by a single damper motor. 2.3.6.6 The burner shall remain in the low re position during ignition and until main ame has been established. 2.3.7 Burner Design Gas 2.3.7.1 The burner shall be the high radiant multiport type approved for operation with natural gas. 2.3.7.2 The burner shall operate on the _______________ (lowhighlow or full modulation) principle and must return to the low re position prior to ignition. 2.3.7.3 Automatic electric ignition of the premix gas pilot shall be furnished. An electric scanner, of the UV principle, shall monitor the pilot, preventing the primary fuel valve from opening until the pilot ame has been established. 2.3.7.4 The single combustion air damper motor shall operate the gas buttery valve. The damper motor shall regulate the re according to system demand in response to the ring rate control. 2.3.8 Burner Design No. 2 Oil 2.3.8.1 The burner shall be the pressure atomizing type approved for operation with commercial grade No. 2 oil. 2.3.8.2 The burner shall operate on the lowhighlow principle, and must return to the low re position prior to ignition. 2.3.8.3 The burner shall remain in the low re position during ignition and until main ame has been proven. The ignition period shall be monitored with an electric scanner, of the UV principle, to conrm the presence of the low re oil ame. 2.3.8.4 Automatic electric ignition of the low re oil supply shall be provided with a minimum 10,000 volt transformer and heavy duty electrodes.
B2-25
04-02
Model 4 Boilers
Commercial Boilers
NOTICE
Optional insurance compliance may require a premix gas pilot in lieu of direct spark ignition. 2.3.8.5 [Optional] Automatic electric ignition of the premix gas pilot shall be furnished. An electric scanner, of the UV principle, shall conrm the pilot prior to the delivery of the low re oil supply. 2.3.8.6 The single combustion air damper motor shall operate the low and high re oil valves. The damper motor shall regulate the re according to system demand in response to the ring rate control. 2.3.9 Burner Design Gas and No. 2 Oil 2.3.9.1 The burner shall be the high radiant multiport type for gas and shall be the pressure atomizing for oil. The burner must be approved for operation with either natural gas or commercial grade No. 2 oil. 2.3.9.2 The burner shall operate on the lowhighlow principle, and must return to the low re position prior to ignition. 2.3.9.3 The burner shall remain in the low re position during ignition and until main ame has been proven. 2.3.9.4 Automatic electric ignition of the premix gas pilot shall be furnished. An electric scanner, of the UV principle, shall monitor the pilot, preventing the primary fuel valve from opening until the pilot ame has been established. 2.3.9.5 The single combustion air damper motor shall operate the low and high re oil valves and the gas buttery valve. The damper motor shall regulate the re according to system demand in response to the ring rate control. 2.3.10 Natural Gas Main Train 2.3.10.1 The gas burner piping shall include a primary gas shutoff valve. It shall be controlled by the programming relay to start or stop the burner and to close automatically in the event of power failure, ame failure, or a low water condition. 2.3.10.2 A manual shutoff valve shall be located ahead of the primary gas valve. 2.3.10.3 A plugged leakage test connection and a second manual shutoff valve shall be provided as a means for a tightness check of the primary shutoff valve. 2.3.10.4 A gas pressure regulator shall be factory mounted and piped for pressure regulation to the burner. 2.3.10.5 Gas Train Components Standard (UL) 2.3.10.5.1 [Sizes 15002500] The primary gas shutoff valve shall be motorized with a proof of closure switch. 2.3.10.5.2 [Sizes 30005000] The primary gas shutoff valve shall be motorized with a proof of closure switch. High and low gas pressure switches shall be provided. 2.3.10.5.3 [Size 6000] The primary gas shutoff valve shall be motorized with a proof of closure switch. A second gas safety shutoff valve and an additional plugged leakage test cock shall be provided. High and low gas pressure switches shall be provided. 2.3.10.6 Gas Train Components Factory Mutual Insurance (FM) 2.3.10.6.1 [Sizes 15005000] The primary gas shutoff valve shall be motorized with a proof of closure switch. High and low gas pressure switches shall be provided. 2.3.10.6.2 [Size 6000] The primary gas shutoff valve shall be motorized with a proof of closure switch. A second gas safety shutoff valve and an additional plugged leakage test cock shall be provided. High and low gas pressure switches shall be provided. 2.3.10.7 Gas Train Components Industrial Risk Insurers (IRI) 2.3.10.7.1 [ Size 15005000] The gas train piping shall include both primary and secondary motorized gas safety shutoff valves and a second plugged leakage test cock. A vent valve shall be located between the primary and secondary gas shutoff valves. High and low gas pressure switches shall be provided. 2.3.10.7.2 [Size 6000] The primary gas shutoff valve shall be motorized with a proof of closure switch. A second gas motorized shutoff valve and an additional plugged leakage test cock shall be provided. A vent valve shall be located between the primary and secondary gas shutoff valves. High and low gas pressure switches shall be provided.
B2-26
04-02
Commercial Boilers
2.3.11 Natural Gas Pilot Train
Model 4 Boilers
2.3.11.1 A pilot gas pressure regulator shall be factory mounted and piped for pressure regulation of the pilot gas to the burner. 2.3.11.2 The pilot gas train shall include a safety shutoff valve. It shall be controlled by the programming relay to start the burner. 2.3.11.3 A manual shutoff valve shall be located ahead of the pilot gas pressure regulator. 2.3.12 Oil System 2.3.12.1 An oil pump shall be provided. The oil pump, integral with the burner, shall include a builtin relief valve and selfcleaning strainer. 2.3.12.2 The oil pump shall be belt driven from the blower motor. 2.3.12.3 The fuel oil system shall include supply and return tubing to a terminal block, an oil pressure gauge, shutoff cock, and four solenoid oil shutoff valves. These items shall be factory mounted and piped on the front head (windbox). 2.4 Burner Management System 2.4.1 Control Panels 2.4.1.1 The control panel shall be a NEMA 1 rated panel and have a key lock. 2.4.1.2 The control panel shall be mounted on the front head of the boiler and shall be conveniently located for the boiler operator. 2.4.1.3 The panel shall contain the blower motor starter, control circuit fuses, control circuit transformer, and control switches. A damper selector switch shall be provided to permit selection of automatic or manual selection of low or high ring. 2.4.1.4 A terminal board shall be provided to which all wires entering or leaving the panel shall be connected. 2.4.1.5 The panel shall include four indicating lights to show operating conditions of: red = low water; red = ame failure; white = load demand; and white = fuel valve open. The lights and switches shall be located on the panel switch ledge. 2.4.1.6 The panel shall include a low re hold timer wired to hold the boiler in a low ring mode, for a minimum of ten minutes, each time the boiler cycles on. This low re hold timer ensures gradual boiler warmup. 2.4.1.7 All electrical service connections shall be made to an electrical entrance box to be mounted on the right hand side of the boiler. 2.4.1.8 All electrical wiring shall be oil, heat, and moisture resistant and shall be number coded. 2.4.2 Combustion Safeguard Control 2.4.2.1 A combustion safeguard control (program relay) shall be provided to control ignition, starting, and stopping of the burner. It shall provide precombustion and postcombustion purge periods and shall stop burner operation in the event of ignition, pilot, or main ame failure. Trial for ignition shall be limited to 10 seconds. 2.4.2.2 The boiler shall be provided with a combustion safeguard controller that provides technology and functions equal to the Cleaver Brooks Model CB100. 2.4.2.3 The combustion safeguard control shall be microprocessor based, with self diagnostics, nonvolatile memory, and a message center with a vocabulary of 42 different messages. Messages shall scroll across an alphanumeric display and provide sequence status and ame failure mode information. 2.4.2.4 The combustion safeguard control shall have a xed operating sequence incapable of being manually altered. The sequence shall include start, pre purge, pilot and main fuel ignition run, and postpurge cycles. 2.4.2.5 The controller shall be the nonrecycle type for maximum safety that will shut down the burner and indicate as a minimum the following trip functions: pilot failure, main ame failure, high and low re proving switch faults, running interlocks open, false ame signal, and fuel valve open (when proof of closure switch is furnished). 2.4.2.6 The controller shall have a test/run switch. It will allow interruptions to sequence just after prepurge, during pilot ignition trial, and during run cycles, for adjustments to ring rate motor, damper linkages, and pilot ame for turndown tests. 2.4.2.7 The controller shall also have the following functions: display history of operating hours and totals of completed onoff cycles; provide a constant ame signal strength readout; and have provisions for remote display capability.
B2-27
04-02
Model 4 Boilers
3.0 Execution 3.1 Shop Tests 3.1.1 The pressure vessel shall be hydrostatically tested in accordance with ASME requirements.
Commercial Boilers
3.1.2 The boiler will be test red by the manufactured, prior to shipment, to verify proper and safe operation. 3.2 Shipment 3.2.1 Painting 3.2.1.1 The entire boiler, base frame, and other components shall be factory painted, before shipment, using a hard nish enamel. 3.2.1.2 The boiler surface shall be cleaned/prepared for painting using manufacturer's specications and standard industrial painting practices. 3.2.2 Preparation 3.2.2.1 All boiler openings shall be plugged/covered prior to shipment. 3.2.2.2 The boiler shall be skid mounted and protected with a weather resistant covering. 3.2.2.3 All shipped loose components shall wrapped in protective material and packaged in a separate container(s). 3.3 Installation 3.4 StartUp 3.4.1 The boiler startup shall be performed by a factory trained representative and will be done in accordance with the manufacturer's recommended procedures. 3.4.2 The boiler startup shall include boiler operator training and shall cover boiler operation, water treatment, and maintenance of the unit. 3.5 Operation and Maintenance Manuals 3.5.1 The manufacturer shall supply _____ copies of the Operating & Maintenance Manual.
B2-28
04-02
Section B3
MODEL 5 BOILERS
CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-3 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-3 Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-4 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-4 Special Insurance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-5 Added Equipment for IRI Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-5 Added Equipment for FM Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-5 DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-5 PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-12 Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-12 Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-12 Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-12 ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-12 SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-16 Steam Boiler Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-16 Hot Water Boiler Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-21
B3-1
10-02
Model 5 Boilers
ILLUSTRATIONS
Commercial Boilers
Figure B3-1. Model 5 Standard Gas Trains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-7 Figure B3-2. Model 5 Steam Boiler Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-8 Figure B3-3. Model 5 Hot Water Boiler Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-10 Figure B3-4. Model 5 Over Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-15 TABLES Table B3-1. Model 5 Boiler Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3- 3 Table B3-2. Model 5 Hot Water Boiler Ratings (N/A to LWV Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6 Table B3-3. Model 5 Emission Data, Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6 Table B3-4. Model 5 Emission Data, No. 2 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-12 Table B3-5. Model 5 Oil Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-12 Table B3-6. Model 5 Gas Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-12 Table B3-7. Model 5 Boiler Reference Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-13 Table B3-8. Model 5 Hot Water Boiler Circulating Rates and Temperature Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-13 Table B3-9. Model 5 Boiler Recommended Steam Nozzle Size at Reduced Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-14 Table B3-10. Model 5 Hot Water Boiler Circulating Rates and Temperature Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-14 Table B3-11. Model 5 Boiler Recommended Steam Nozzle Size at Reduced Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . B3-14 Table B3-12. Model 5 Boiler Sound Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-15 The Model 5 Commercial Watertube Boiler product line is used for low and high pressure steam and hot water applications. Sizes range from 1.5 to 8 MMBtu/hr. The Model 5 Boiler is an excellent choice where high outputs and space limitations exist. The model number designation is 1500 through 8000, representing Btu/hr input (1,500,000 to 8,000,000 Btu/hr). Fuel series designation is as follows: Series 100: No. 2 oil ring. Series 700: Natural gas ring. Series 200: No. 2 oil/natural gas ring. Design pressure designation is stated as 15 psig, 150 psig, and 250 psig for steam, and 140 psig for hot water. For example, a Model M5HW-700-2500-140 boiler designates a gas-red, 2,500,000 Btu/hr, 140 psig, hot water boiler.
B3-2
10-02
Commercial Boilers
Model 5 Boilers

The following features and benefits apply to the Model 5 Boiler product line. 33" Cased Width: Boiler ts through most standard doorways. Reduced installation costs. Direct Driven, Vibration-Free Centrifugal Impeller: Quiet operation. Sound levels below 80 dbA. Ideal for noise critical areas such as hospitals, churches, etc. Minimum Refractory: Membrane waterwalls reduce the need for refractory by 95%. Reduced maintenance costs and refractory repair requirements. Membrane Waterwalls: Enhanced heat transfer area in compact design. Sealed combustion chamber improves heat transfer for high efciency. Small Boiler Footprint: Savings of up to 50% in oor space. Weighs up to 40% less than Comparable Boilers: Lower freight and rigging costs. Reduced structural requirements. Standard Built-in Soot Washers: Boiler cleaning without shutdown. Maintains peak boiler performance. Packaged Forced Draft Burner: High pressure drop design. Optimum fuel and air mixing. Improved combustion efciency.
Low Water Volume Design (optional): Meets various provincial operating engineer codes and regulations. Reduced operating costs. High and low pressure steam. Steam Design Pressures to 500 psig: High performance in a compact design. Proven vessel design for high design pressure applications.
PRODUCT OFFERING
Information in this section applies to Cleaver-Brooks Model 5 watertube boilers in sizes ranging from 1.5 to 8 MMBtu/hr input, as shown in Table B3-1. Model numbers represent input (1,000 Btu/hr). The Model 5 Boiler is a compact, packaged, all-steel membraned waterwall watertube boiler. It is a three-pass boiler with watertubes and membranes formed to direct the ow of combustion gases through the boiler. The pressure vessel is constructed to conform with Sections I or IV of the ASME Codes for hot water, low-pressure steam, and high-pressure steam boilers. The vessel consists of formed membrane tubes and downcomers, connected to the upper and lower drums. The boiler vessel is gas tight, insulated on the outside, and covered by casing constructed of removable, formed steel panels. The standard boiler/burner package is CSA approved in hot water, low- pressure steam, and high-pressure steam (150 psig design) when fueled by No. 2 oil and/or natural gas. The Model 5 Boiler is available with higher pressure designs.
Table B3-1. Model 5 Boiler Sizes

MODEL NO. 1500 2000 2500 3000 3500 4000 4500 5000 6000 8000 LWV INPUT MBH 1500 2000 2500 3000 3500 4000 4500 5000 6000 8000 HEAT OUTPUT MBH 1200 1600 2000 2400 2800 3200 3600 4000 4800 6320 EQUIV HP 35 47 59 71 83 95 107 119 143 194 STEAM SHIPPING OUTPUT WEIGHT LB/HR LBS 1237 1649 2062 2474 2887 3299 3711 4124 4949 65 3100 3100 3700 3700 4100 4100 4700 4700 5400
NOTE: Steam output from and at 212 F. LWV = Low Water Volume.
B3-3
10-02
Model 5 Boilers
Standard Equipment
Equipment described below is for standard boiler offerings. The Cleaver-Brooks Model 5 boiler is a packaged watertube steel boiler consisting of pressure vessel, oil and/or gas burner, burner controls, forced draft fan and integral air damper control assembly. 1. Boiler A. Designed, constructed, and hydrostatically tested in accordance with the ASME Boiler and Pressure Vessel Code. B. Refractories for the boiler and burner are installed. C. Fully insulated under a preformed, sectional sheet metal jacket. D. Mounted on an integral steel heavy base frame. E. Factory painted using a hard-nish enamel. 2. Forced Draft Burner A. Integral with front head of boiler (factory mounted and tested). (Model 8000 LWV uses ProFire.) B. Combustion air fan and motor are integral with front head of boiler. (N/A to Model 8000 LWV.) C. Pressure atomizing type for No. 2 oil burner includes oil pump. D. High radiant multi-port type burner for gas includes gas train and gas pressure regulator. E. Gas burner operates on the full modulation principle. F. Oil burner operation uses low-high-low principle. (Model 8000 LWV is modulated.) G. Ultra-violet type ame scanner. 3. Hot Water Boiler Control Standard Equipment (140 psig) A. ASME safety relief valve(s). B. Temperature and pressure gauges. C. Temperature controls: High limit control-manual reset. Operating limit control. High-low re rate control (full modulation for gas ring). D. Low water cutoff-oat type McDonnell-Miller or approved equal. E. Boiler hot water circulating pump. F. Low re hold time delay. 6. 5. 4.
Commercial Boilers
G. Combustion air proving switch. Steam Boiler Control Standard Equipment (15 to 150 psig) A. ASME safety relief valve(s). B. Steam pressure gauge. C. Pressure controls: High limit control-manual reset. Operating limit control. High-low re control (full modulation for gas ring). D. Low water cutoff with pump control. E. Water column gauge glass set and ttings. F. Auxiliary low water cut-off. G. Combustion air proving switch. Electrical Control Panel A. Mounted at eye level on the front head of the boiler. B. NEMA rating 1A with gasket dust seal. C. Contains electronic program relay and switches. Miscellaneous A. The boiler is Canadian Standards Association (CSA) approved and bears the CSA label.
Optional Equipment
For more detailed information on optional equipment, contact your local Cleaver-Brooks authorized representative. In summary, options include the following: A. Boiler Options Hot water pressure gauge. Drain valves. Additional screwed tappings. Surface blow-off valve. High altitude design. Valves for soot lance. Feedwater control valves. B. Burner/Control Options Optional ame safeguard controller. Lead/Lag system. Light package. Day-night controls.
B3-4
10-02
Commercial Boilers
Alarm bell/silence switch. Special motor requirements (TEFC, High efciency). Remote contacts. Additional relay points and indicator lights. Main disconnect (fusible/circuit breaker). Elapsed time meter. Voltmeter/micro-ammeter. Optional NEMA enclosure. High stack temperature control. C. Fuel Options Special water column.* Guarded plant status equipment. Insulation of upper drum from furnace combustibles. * Note: Not required for low pressure steam applications.
Model 5 Boilers
A. Alarm bell mounted for non-recycling shutdowns. B. High and Low Gas Pressure Switches. C. Second Motorized Gas Valve (Size 6000).

Dimension and rating information for Model 5 boilers, is shown in Table B3-2 and Table B3-3, and Figures B3-1 through B3-3.
PERFORMANCE DATA
Efficiency
Efciency data provided is based on hot water or low pressure steam operation. Nominal boiler efciency is: Gas - 80 percent. Oil - 83 percent. For high pressure steam applications, contact your local Cleaver-Brooks authorized representative for expected efciency data.
Special Insurance Requirements

Added Equipment for IRI Compliance 1. All fuels A. Alarm bell mounted for non-recycling shutdowns. 2. Oil Fired A. Low oil pressure switch. B. Gas pilot. 3. Gas red A. Two motorized main gas valves with vent valve. B. Proof of closure switch (on gas valve). C. High and Low Gas Pressure Switches. Added Equipment for FM Compliance 1. Oil Fired A. Low oil pressure switch. B. Alarm bell mounted for non-recycling shutdowns. 2. Combination Oil and Gas Fired A. Low oil pressure switch. B. Alarm bell mounted for non-recycling shutdowns. C. High and Low Gas Pressure Switches. D. Second Motorized Gas Valve (Size 6000) 3. Gas Fired
B3-5
10-02
Model 5 Boilers
Commercial Boilers
Table B3-2. Model 5 Hot Water Boiler Ratings (N/A to LWV Models)
MODEL NO. Rated Capacity Btu Output (1,000 Btu/hr) Boiler Horsepower EDR Water Gross, Sq-ft. Blower Motor Gas Only (hp) Blower Motor Oil or Combination (hp) Control Circuit Transformer kVA Oil Pump Flooded Water Weight Approximate Shipping Weight NOTE: Ratings are sea level to1000 ft. 794 3100 794 3100 1085 3700 1500 1200 35 8000 2 2 1 2000 1600 47 10667 2 2 1 2500 2,000 59 13333 2 2 1 3000 2400 71 16000 2 2 1 3500 2800 83 18667 2 5 1 4000 3200 95 21333 3 5 1 4500 3600 107 24000 3 5 1 5000 4000 119 26667 3 5 1 6000 4,800 143 32000 5 5 1
Table B3-3. Model 5 Emission Data, Natural Gas

MODEL NO. Rated Capacity in Lbs Steam/hr (212 F) BTU Output (1,000 Btu/hr) Boiler Horsepower EDR Steam Gross, Sq-ft Blower Motor Gas Only (hp) Blower Motor Oil or Combination (hp) Control Circuit Transformer kVA Oil Pump Operating Water Weight Approximate Shipping Weight 543 3100 543 3100 745 3700 1500 1237 1200 35 5000 3/4 2 1/2 2000 1649 1600 47 6667 1 2 1/2 2500 2062 2000 59 8333 1-1/2 2 1/2 3000 2474 2400 71 10000 2 2 1/2 3500 2887 2800 83 11667 2 3 1/2 4000 3299 3200 95 13333 3 5 1/2 4500 3711 3600 107 15000 3 5 1/2 5000 4124 4000 119 16667 3 5 1/2 6000 4949 4800 143 20000 5 5 1/2 8000 LWV 6516 6320 194 26667 10 10 1/2 Direct Drive From Motor 1158 4700 1158 4700 1353 5400 720
Belt Driven From Blower Motor 745 3700 940 4100 940 4100
NOTES: 1. Ratings are at sea level to 1000 ft. 2. Output rating for high pressure steam will be reduced based on operating conditions.
B3-6
10-02
Commercial Boilers
Model 5 Boilers
ITEM
PART SIZE 1500 - 3000 Gas Inlet Shutoff Cock Pilot Regulator Solenoid Valve Lub Shutoff Cock Main Regulator Low Gas Pressure Switch Motorized Gas Valve Plugged Test Port High Gas Pressure Switch Buttery Valve SIZES 3500 TO 5000 Gas Inlet Shutoff Cock Pilot Regulator Solenoid Valve Lub Shutoff Cock Main Regulator Low Gas Pressure Switch Motorized Gas Valve Plugged Test Port High Gas Pressure Switch Buttery Valve SIZE 6000 Gas Inlet Shutoff Cock Pilot Regulator Solenoid Valve Lub Shutoff Cock Main Regulator Low Gas Pressure Switch Motorized Gas Valve (2 reqd) Plugged Test Port High Gas Pressure Switch Buttery Valve
SIZE (IN.)
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11
1-1/2 1/2 1/2 1/2 1-1/2 1-1/2 1/4 1-1/2 1/4 1/4 1-1/2 2 1/2 1/2 1/2 2 2 1/4 2 1/4 1/4 2 2 1/2 1/2 1/2 2 2-1/2 1/4 2 1/4 1/4 2
Figure B3-1. Model 5 Standard Gas Trains
B3-7
10-02
Model 5 Boilers
Commercial Boilers
Figure B3-2. Model 5 Steam Boiler Dimensions - Sheet 1 of 2 B3-8

10-02
OO1
REAR VIEW
FRONT VIEW
Commercial Boilers
MODEL NO. A - Overall B - Pressure Vessel with Casing C - Base Frame C1 - Base to Front Head C2 - Base Frame Anchor Holes D - Front Head Extension DD - Front Casing to Steam Nozzle CL HH - Steam Nozzle to Safety Valve 15# II - Steam Nozzle to Safety Valve 150 # E - Overall F - Center to Water Column G - Center to Aux. Water Control H - Center to Outside Casing I - Base Frame Inside J - Base Outside K - Soot Washer Centers L - Center to Soot Washer M - CL Base Rail to Center N - Center to Soot Drain OO - Overall (Base to Vent Outlet) OO1 - Base to Top of Control Panel O - Base to Steam Nozzle 15# O1 - Base to Steam Nozzle 150# P - Base to Drum CL Q - Base to Feedwater Inlet R - Base to Soot Washer S - Height of Base OS - Base to Oil Supply Conn. OR - Base to Oil Return Conn. BB - Diameter (Sleeve Connection) CC - Rear Casing to Vent CL T - Bottom Drum Blow Down 15 # (one) T1 - Bottom Drum Blow Down 150 # (one) U - Steam Nozzle 15 # V - Steam Nozzle 150 # W - Soot Washer Drains (Two) X - Surface Blow Off (One) Y - Feedwater Inlet (One) Z - Soot Washers (Two) GG - Oil Supply & Return JJ - Relief Valve Outlet 15# JJ - Relief Valve Outlet 150 # EE - Front Door Swing FF - Tube Removal Each Side RF - Allowance for Front Door Swing and 30" Rear Aisle Space 1500 69-11/16 51-1/4 45-1/2 8 43 13 16-3/8 7 8 57-1/2 33 23-1/2 16-1/2 20 28 21-1/2 10-3/4 12 3-1/2 78-1/4 84-1/2 73-1/2 73-1/4 61-3/4 55-3/4 54 4 26-5/8 24-5/8 12 17-3/16 1-1/4 1-1/4 4A 2-1/2 2 3/4 1 1/4 1/2 1-1/2 3/4 33 30 133
A
Model 5 Boilers
2000 69-11/16 51-1/4 45-1/2 8 43 13 16-3/8 7 8 57-1/2 33 23-1/2 16-1/2 20 28 21-1/2 10-3/4 12 3-1/2 78-1/4 84-1/2 73-1/2 73-1/4 61-3/4 55-3/4 54 4 26-5/8 24-5/8 12 17-3/16 1-1/4 1-1/4 4A 2-1/2 2 3/4 1 1/4 1/2 2 1 33 30 133
A
2500 85-13/16 67-3/8 61-1/8 8 58-1/2 13 24-3/8 12 12 57-1/2 33 23-1/2 16-1/2 20 28 21-1/2 10-3/4 12 3-1/2 78-1/4 84-1/2 73-1/2 73-1/4 61-3/4 55-3/4 54 4 26-5/8 24-5/8 12 17-11/16 1-1/4 1-1/4 4A 3
A
3000 85-13/16 67-3/8 61-1/8 8 58-1/2 13 24-3/8 12 12 57-1/2 33 23-1/2 16-1/2 20 28 21-1/2 10-3/4 12 3-1/2 78-1/4 84-1/2 73-1/2 73-1/4 61-3/4 55-3/4 54 4 26-5/8 24-5/8 12 17-11/16 1-1/4 1-1/4 4A 3
A
3500 104-7/16 83 76-3/4 8 74-1/2 16 30-1/8 11-1/2 17 57-1/2 33 23-1/2 16-1/2 20 28 21-1/2 10-3/4 12 3-1/2 78-1/4 84-1/2 76-3/4 73-1/4 61-3/4 55-3/4 54 4 26-5/8 24-5/8 12 17-11/16 1-1/2 1-1/4 6B 3
A
4000 104-7/16 83 76-3/4 8 74-1/2 16 30-1/8 11-1/2 17 57-1/2 33 23-1/2 16-1/2 20 28 21-1/2 10-3/4 12 3-1/2 78-1/4 84-1/2 76-3/4 73-1/4 61-3/4 55-3/4 54 4 26-5/8 24-5/8 12 17-11/16 1-1/2 1-1/4 6B 3
A
4500 121-1/16 99-5/8 92-3/8 8 90 16 36-3/4 13 17 57-1/2 33 23-1/2 16-1/2 20 28 21-1/2 10-3/4 12 3-1/2 78-1/4 84-1/2 76-3/4 76-1/2 61-3/4 55-3/4 54 4 26-5/8 24-5/8 16 21-13/16 1-1/2 1-1/4 6B 4
B
5000 121-1/16 99-5/8 92-3/8 8 90 16 36-3/4 13 17 57-1/2 33 23-1/2 16-1/2 20 28 21-1/2 10-3/4 12 3-1/2 78-1/4 84-1/2 76-3/4 76-1/2 61-3/4 55-3/4 54 4 26-5/8 24-5/8 16 21-13/16 1-1/2 1-1/4 6B 4
B
6000 136-11/16 115-1/4 108 8 105-1/2 16 44-5/8 17 17 57-1/2 33 23-1/2 16-1/2 20 28 21-1/2 10-3/4 12 3-1/2 78-1/4 84-1/2 76-3/4 76-1/2 61-3/4 55-3/4 54 4 26-5/8 24-5/8 16 21-13/16 1-1/2 1-1/4 6B 4B 2 3/4 1 1/4 1/2 3 1-1/2 33 30 200 94
8000LWV
2 3/4 1 1/4 1/2 2 1 33 30 149
2 3/4 1 1/4 1/2 2 1 33 30 149
2 3/4 1 1/4 1/2 2-1/2 1-1/4 33 30 167
2 3/4 1 1/4 1/2 2-1/2 1-1/4 33 30 167 94
2 3/4 1 1/4 1/2 2-1/2 1-1/4 33 30 184 94
2 3/4 1 1/4 1/2 2-1/2 1-1/4 33 30 184 94
RD - Allowance for Tube Removal Each Side and 94 94 94 94 94 Front Door Swing NOTES: 1. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified prints. For 200 psig design pressure or higher, contact factory for certified prints. 2. Allow sufficient space for soot washer lance removal at rear of boiler. 3. Furnace access opening, 15 x 20 located inside rear head. 4. Control panel may be larger due to additional electrical devices accounting for an additional 4 inches in overall height. 5. Subtract 3-1/2 for gas-fired only units. A. Female pipe thread. B. Flg 150 psig FF.
Figure B3-2. Model 5 Steam Boiler Dimensions - Sheet 2 of 2 B3-9

10-02
Model 5 Boilers
Commercial Boilers
Figure B3-3. Model 5 Hot Water Boiler Dimensions - Sheet 1 of 2 B3-10

10-02
REAR VIEW
FRONT VIEW
Commercial Boilers
MODEL NO. A - Overall B - Pressure Vessel with Casing C - Base Frame C1 - Base to Front Head C2 - Base Frame Anchor Holes D - Front Head Extension E - Front Casing to Outlet F - Outlet to Relief Valve G - Rear Drum to Center Line Return H - Rear Casing to Air Vent I - Overall J - Outside Casing to Blend Pump K - Center to Outside Casing L - Base, Inside M - Base, Outside N - Center to Soot Washer Drain O - Center to Base Center P - Center to Soot Washer QQ - Overall (Base to Vent Outlet) Q - Base to Outlet R - Base to Soot Washer S - Height of Base T - Base to Return U - Base to Soot Washer Drain OS - Base to Oil Supply OR - Base to Oil Return BB - Diameter (Sleeve Connection) CC - Rear Casing to Vent CL V - Drain Valve, Low Water Control W - Soot Washers (Two) X - Soot Washer Drains (Two) Y - Bottom Drain (One) Z - Base to Top of Control Box HS - Water Outlet (Male Pipe Thread) HR - Water Return (Female Pipe Thread) FF - Air Vent GG - Oil Supply and Return HH - Relief Valve Outlet 125 # Setting DD - Front Door Swing EE - Tube Removal Each Side RF - Allowance for Front Door Swing and 30" Rear Aisle Space RD - Allowance for Tube Removal Each Side and Front Door Swing 1500 80 51-1/4 45-1/2 8 43 12-7/8 16-1/2 7 4-1/8 5-3/8 46 39 16-9/16 20 28 3-1/2 12 10-3/4 78-1/4 79-7/8 54 4 8-1/4 2-5/8 26-3/4 24-3/4 12 17-3/16 3/4 1/4 2 1-1/4 84-1/2 3 3 1 1/2 3/4 33 30 133 94 2000 80 51-1/4 45-1/2 8 43 12-7/8 16-1/2 7 4-18 5-3/8 46 39 16-9/16 20 28 3-1/2 12 10-3/4 78-1/4 79-7/8 54 4 8-1/4 2-5/8 26-3/4 24-3/4 12 17-3/16 3/4 1/4 2 1-1/4 84-1/2 3 3 1 1/2 3/4 33 30 133 94 2500 96-5/8 67-3/8 61-1/8 8 58-5/8 12-7/8 24-1/2 12 4-5/8 5-3/8 46 39 16-9/16 20 28 3-1/2 12 10-3/4 78-1/4 79-7/8 54 4 8-1/4 2-5/8 26-3/4 24-3/4 12 17-11/16 3/4 1/4 2 1-1/4 84-1/2 3 3 1 1/2 3/4 33 30 149 94 3000 96-5/8 67-3/8 61-1/8 8 58-5/8 15-7/8 24-1/2 12 4-5/8 5-3/8 46 39 16-9/16 20 28 3-1/2 12 10-3/4 78-1/4 79-7/8 54 4 8-1/4 2-5/8 26-3/4 24-3/4 12 17-11/16 3/4 1/4 2 1-1/4 84-1/2 3 3 1 1/2 1 33 30 149 94 3500 115-1/4 83 76-3/4 8 74-1/4 15-7/8 30 10-3/4 4-5/8 5-3/8 46 39 16-9/16 20 28 3-1/2 12 10-3/4 78-1/4 80-5/8 54 4 8-1/4 2-5/8 26-3/4 24-3/4 12 17-11/16 3/4 1/4 2 1-1/4 84-1/2 4 4 1 1/2 1 33 30 167 94 4000 115-1/4 83 76-3/4 8 74-1/4 15-7/8 30 10-3/4 4-5/8 5-3/8 46 39 16-9/16 20 28 3-1/2 12 10-3/4 78-1/4 80-5/8 54 4 8-1/4 2-5/8 26-3/4 24-3/4 12 17-11/16 3/4 1/4 2 1-1/4 84-1/2 4 4 1 1/2 1-1/2 33 30 167 94
Model 5 Boilers
4500 132-7/8 99-5/8 92-3/8 8 89-7/8 15-7/8 36-3/4 13 5-5/8 5-3/8 46 39 16-9/16 20 28 3-1/2 12 10-3/4 78-1/4 80-5/8 54 4 8-1/4 2-5/8 26-3/4 24-3/4 16 21-3/4 3/4 1/4 2 1-1/4 84-1/2 4 4 1 1/2 1-1/2 33 30 184 94 5000 132-7/8 99-5/8 92-3/8 8 89-7/8 15-7/8 36-3/4 13 5-5/8 5-3/8 46 39 16-9/16 20 28 3-1/2 12 10-3/4 78-1/4 80-5/8 54 4 8-1/4 2-5/8 26-3/4 24-3/4 16 21-3/4 3/4 1/4 2 1-1/4 84-1/2 4 4 1 1/2 1-1/2 33 30 184 94 6000 148-11/16 115-1/4 108 8 105-1/2 15-7/8 44-1/2 14 5-5/8 5-3/8 46 39 16-9/16 20 28 3-1/2 12 10-3/4 78-1/4 80-5/8 54 4 8-1/4 2-5/8 26-3/4 24-3/4 16 21-3/4 3/4 1/4 2 1-1/4 84-1/2 4 4 1 1/2 1-1/2 33 30 200 94
NOTES: 1. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified prints. 2. Allow sufficient clearance at rear of boiler for soot washer lance removal. (oil or oil/gas fired units only) 3. Furnace access opening, 15 x 20 located inside rear head. 4. Control panel may be larger due to additional electrical devices accounting for an additional 4 inches in overall height. 5. All Connections are threaded. 6. Subtract 3-1/2 for gas-only fired unit.
Figure B3-3. Model 5 Hot Water Boiler Dimensions - Sheet 2 of 2
B3-11
10-02
Model 5 Boilers
Emissions
The emission data included in this section consist of uncontrolled levels of nitrogen oxides (NOx) and carbon monoxide (CO) for Cleaver-Brooks Model 5 Boilers. The following tables include typical emission levels and a range of actual emissions. Emission data is presented in Table B3-3 for natural gas, and for No. 2 oil in Table B3-4.
Commercial Boilers
ENGINEERING DATA
Engineering data for Model 5 Boilers are shown in Tables B37 through Table B3-12. Table B3-7 shows fuel, combustion air, and ue gas ow rates at rated boiler capacity. Hot water boiler ow rates and pressure drops are shown in Table B3-8. This table can be utilized to determine the boiler pressure drop in relation to the full boiler output and system temperature drop. Table B3-10 can be used to determine the maximum water circulating rate in a hot water boiler in relation to the full boiler output and system temperature drop. The maximum circulating rate can be determined from the boiler size and expected system temperature drop. See Figure B3-4 for minimum operating pressure, based on the maximum temperature in a Model 5 hot water boiler. For more information, refer to Section 12, Hot Water Systems. Table B3-11 shows recommended steam nozzle sizes at various operating pressures. Table B3-12 shows maximum sound levels when ring oil or natural gas.
NOTICE
The data in these tables represents typical emission levels only. Please contact your local Cleaver-Brooks authorized representative if an emission guarantee is required, or for emission level information not shown in these tables.
Fuels
Fuel requirements for the Model 5 Boiler are shown in Tables B3-5 and B3-6. Table B3-4. Model 5 Emission Data, No. 2 Oil
POLLUTANT CO NOx SOx HC/VOCs PM ppmA lb/MMBtu ppmA lb/MMBtu ppmA lb/MMBtu ppmA lb/MMBtu ppmA lb/MMBtu UNCONTROLLED 200 0.15 100 0.12 1 0.001 40 0.016 0.01
A. ppm levels corrected to 3% O2 dry basis.
Table B3-5. Model 5 Oil Fuel Requirements

POLLUTANT CO NOx SOx HC/VOCs PM ppmA lb/MMBtu ppmA lb/MMBtu ppmA lb/MMBtu ppmA lb/MMBtu ppmA lb/MMBtu UNCONTROLLEDB 90 0.07 187 0.248 278 0.515 50 0.025 0.025 BOILER MODEL OIL USAGEA (GPH) NOTES:
Table B3-6. Model 5 Gas Fuel Requirements

1500 2000 2500 3000 3500 4000 4500 5000 6000 8000 LWV
10.7 14.3 17.9 21.4 25.0 28.6 32.7 35.7 42.8
NOTES: A. ppm levels corrected to 3% O2 dry basis. B. Based on the following fuel oil constituents. Fuel-bound nitrogen = 0.05% (max) by weight. Sulfur = 0.5% (max) by weight. Ash = 0.01% (max) by weight.
1.Oil supply lines to be sized for 125 gph pumping rates. 2.Oil pump suction pressure -10 Hg to 3 psig. A.Usage Based on #2 Fuel @ 140,000 Btu/gal.
B3-12
10-02
Commercial Boilers
Table B3-7. Model 5 Boiler Reference Data
NATURAL GAS BOILER SIZE TRAIN SIZE MINIMUM REQUIRED PRESSURES (INCHES OF WC) STANDARD & FM 1500 2000 2500 1.5 2.0
A
Model 5 Boilers
PROPANE VAPOR MINIMUM REQUIRED PRESSURES (INCHES OF WC) STANDARD & FM 1500 2000 2500 6.4 5.4 9.8 8.0 11.7 9.1 8.8 14.8 11.6 10.7 10.4 12.9 12.2 11.2 14.7 14.0 12.7 14.1 13.1 11.5 15.6 14.0 11.7 11.1 18.4 16.8 13.8 13.0 N/A IRI 7.1 6.0 11.2 9.0 14.1 11.0 10.6 18.2 14.1 13.1 12.7 14.6 13.9 12.8 17.0 16.1 14.7 15.3 14.2 12.4 17.1 15.3 12.8 12.1 20.5 18.7 15.4 14.3 N/A 600 800 1000 USAGE (SCFH)
USAGE (SCFH)
IRI 5.3 2.5 10.2 5.0 14.9 6.9 6.0 20.0 9.7 7.3 6.3 12.1 10.3 7.6 14.7 12.6 9.0 13.6 10.8 6.2 18.4 14.1 7.8 6.0 24.0 19.3 11.1 8.4 19.9 17 13
4.3 1.8 8.4 3.8 11.3 4.9 4.1 14.9 6.8 4.5 3.7 10.0 8.3 5.8 11.9 10.0 6.8 11.5 9.1 4.9 16.0 12.1 6.3 4.8 20.4 16.3 8.8 6.7 -
1.5A 2.0 1.5A 2.0 2.5 1.5A 2.0 2.5 3.0 2.0A 2.5 3.0 2.0A 2.5 3.0 2.0A 2.5 3.0 2.0A 2.5 3.0 4.0 2.0A 2.5 3.0 4.0 2.5A 3.0 4.0
3000
3000
1200
3500
3500
1400
4000
4000
1600
4500
4500
1800
5000
5000
2000
6000
6000
2400
8000 LWV
8000 N/A
NOTES: 1. Natural gas pressure based on 1000 Btu/cu-ft @ 0.65 specic gravity. 2. Propane pressures based on 2500 Btu/cu-ft @ 1.6 specic gravity. 3. All pressures given for regulator inlet. A.Standard Gas Train Size.
Table B3-8. Model 5 Hot Water Boiler Circulating Rates and Temperature Drop
SIZE & INPUT Gas (cfh) Fuel Consumption Oil (gph) Hot Water Output Steam Rated Cap. (psig) 1000 Btu/hr Stm/h (212) Gas (scfh) (lb/hr) Combustion Air Oil (scfh) (lb/hr) Gas (scfh) (lb/hr) Flue Gas Oil (scfh) lb/hr) 10.72 1200 1237 15480 1207 17049 1269 17520 1278 17914 1357 14.29 1600 1649 20640 1609 22733 1692 23360 1704 23886 1809 17.86 2000 2062 25800 2012 28414 2115 29200 2130 29855 2261 21.43 2400 2474 30960 2414 34098 2538 35040 2556 35827 2714 25.0 2800 2887 36120 2817 39782 2961 40880 2983 41799 3166 28.57 3200 3299 41280 3219 45463 3384 46720 3409 47769 3618 32.14 3600 3711 46440 3621 51147 3808 52560 3835 53741 4070 35.71 4000 4124 51600 4024 56831 4231 58400 4261 59713 4523 42.85 4800 4949 61920 4828 68196 5077 70080 5113 71655 5427 57.14 N/A 6516 82560 6437 90816 7081 93438 6817 102782 5970 1500 1500 2000 2000 2500 2500 3000 3000 3500 3500 4000 4000 4500 4500 5000 5000 6000 6000 8000 LWV 8000
B3-13
10-02
Model 5 Boilers
Commercial Boilers
T = 20 BOILER SIZE OUTLET P PSI VELOCITY FT/S FLOW GPM P PSI T = 30 OUTLET VELOCITY FT/S FLOW GPM P PSI T = 40 OUTLET VELOCITY FT/S FLOW GPM P PSI T = 50 OUTLET VELOCITY FT/S FLOW GPM
INLET/OUTLET CONNECTION - 3 NPT 1500 2000 2500 3000 0.54 0.96 1.49 2.13 5.38 7.17 8.96 10.75 123.8 165.2 206.5 247.6 0.24 0.43 0.67 0.95 3.58 4.79 5.98 7.17 82.6 110.4 137.8 165.2 0.14 0.24 0.38 0.54 2.69 3.58 4.48 5.38 61.9 82.6 103.2 123.9 0.09 0.16 0.24 0.343 2.16 2.88 3.60 4.30 49.8 66.4 83.0 99.2
INLET/OUTLET CONNECTION - 4 NPT 3500 4000 4500 5000 6000 1.32 1.72 2.18 2.68 3.86 7.28 8.34 9.38 10.42 12.50 289.0 330.8 372.1 413.4 496.0 0.59 0.77 0.97 1.20 1.72 4.86 5.55 6.26 6.95 8.34 193.0 220.4 248.2 275.6 330.8 0.34 0.44 0.55 0.68 0.97 3.65 4.17 4.69 5.21 6.26 145.0 165.6 186.3 206.9 248.2 0.22 0.28 0.35 0.43 0.63 2.92 3.34 3.76 4.17 5.01 115.8 132.4 149.0 165.6 198.8
NOTE: Based on 200F outlet temperature
Table B3-10. Model 5 Hot Water Boiler Circulating Rates and Temperature Drop
BOILER SIZE (BHP) SYSTEM TEMPERATURE DROP 10 20 30 40 50 60 70 80 90 100
MAXIMUM CIRCULATING RATE - GPM 1500 (35) 2000 (47) 2500 (59) 3000 (71) 3500 (83) 4000 (95) 4500 (107) 5000 (119) 6000 (143) 247 330 413 494 578 661 740 826 992 123 165 206 248 289 331 372 413 496 83 110 138 165 193 220 248 275 330 62 83 103 124 145 166 186 207 248 50 66 83 99 116 132 149 165 198 41 55 69 83 97 110 124 138 166 35 47 59 71 83 95 106 118 142 31 41 52 62 72 83 93 103 124 28 37 46 55 64 74 83 92 110 25 33 41 50 58 66 74 83 99
OPERATING PRESSURE (PSI) 15A 20 40 65 75 95-125
B
BOILER SIZE 1500 4 3 2-1/2 2-1/2 2-1/2 2-1/2 2000 4 4 3 2-1/2 2-1/2 2-1/2 2500 4 4 3 3 3 3 3000 4 4 4 3 3 3 3500 6 6 4 3 3 3 4000 6 6 4 4 4 3 4500 6 6 6 4 4 4 5000 6 6 6 4 4 4 6000 6 6 6 4 4 4 8000 LWV 8 8 8 6 6 6
NOTE: All dimensions are in inches. A. Standard Nozzle Size for 15 psig DP Units. B. Same Nozzle Size as 150 psig DP Units.
B3-14
10-02
Commercial Boilers
Model 5 Boilers
Table B3-12. Model 5 Boiler Sound Levels

BOILER SIZE (BHP) SOUND LEVEL / FIRING RATE LFG (dBA) HFG (dBA) LFO (dBA) HFO (dBA) 1500 (35) 70 70 69 71 2000 (47) 70 70 69 71 2500 (59) 71 72 70 72 3000 (71) 71 74 71 73 3500 (83) 72 74 72 74 4000 (95) 72 76 73 76 4500 (107) 74 77 74 76 5000 (119) 75 78 75 77 6000 (143) 76 79 76 78
NOTES: 1. Abbreviations: LF=Low Fire, HF=High Fire, O=Oil, G=GAS 2. Measurement: Three (3) feet from front center of boiler and 3-1/2 feet above boiler base. Measurements are decibel ratings on the A-Weighted scale, and were registered without the addition of sound attenuators, mufflers, or silencers. 3. N/A to 8000 LWV.
Figure B3-4. Model 5 Over Pressure Requirements
B3-15
10-02
Model 5 Boilers
Commercial Boilers
The following sample specications are provided by Cleaver-Brooks to assist you in specifying your customers specic needs and application. A separate specication is provided for hot water boiler and steam boiler packages. Steam Boiler Specifications 1.0 Boiler Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-16 2.0 Boiler Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-16 3.0 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-18 Hot Water Specifications 1.0 Boiler Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-21 2.0 Boiler Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-21 3.0 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-22
Steam Boiler Specification

1.0 Boiler Capacity The steam boiler shall be Cleaver-Brooks Model 5, Series ______ (100, 200, 700), _______lbs/hr or ________ bhp, designed for _______ psig (15, 150, 250, 350, or 500 psig) steam. The maximum operating pressure will be ________ psig. (Series 100 - No. 2 oil; 200 - No. 2 oil and gas; 700 - gas.) The boiler shall have a maximum output of _______ Btu/hr, or ____ horsepower, when red with No.2 oil and/or natural gas ______ Btu/cu-ft. The boiler shall develop _______ lbs/hr when operating at _______ psig with feedwater temperature at ______ F. Safety relief valves shall be set at ________ psig. Electrical power available will be _______ volts, _______ phase, _______ Hz. All electrical service connections shall be made to an electrical entrance box mounted on the right hand side of the boiler. 2.0 Boiler Description The boiler shall be an all steel membrane wall watertube boiler with 3-pass gas travel. It shall be mounted on a heavy duty steel frame with integral forced draft burner and burner controls. The complete packaged boiler-burner unit shall be approved by Canadian Standards Association and shall have the CSA label afxed to the front head. The boiler shall be completely assembled and re tested at the factory. The boiler shell must be constructed and hydrostatically tested in accordance with the ASME Boiler and Pressure Vessel Code Section I or IV. It must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser. Two lifting eyes shall be located on top of the boiler. Two downcomers shall be located at the rear of the boiler and totally insulated from the generating tubes. The generating tubes shall be 2" OD SA-178 Grade A with .095" wall thickness. The downcomers shall be 2-1/2" OD for 35 and 47 hp; 3" OD for 59 to 83 hp and 4" for 95 to 143 hp. Material shall be SA-178-A and the 2-1/2" and 3" downcomers shall have a 0.105" wall. The 4" downcomers shall have a 0.135" wall. The upper drum shall be 20" OD Schedule 20, SA-53-B seamless pipe with .375" wall. The lower drum shall be 6" nominal pipe size, SA-53-B seamless pipe with .312" wall (up through 150 psig). Refractory shall be limited to the furnace oor, insulating the lower drum, the burner throat tile, and to the formed rear access door which unbolts for ease of entry and/or inspection. High-temperature insulation shall be installed on the front wall of the furnace. Observation ports shall be provided at each end of the boiler for visual inspection of the pilot and main ame conditions. The exhaust gas vent shall be located at the rear of the boiler on the top centerline. A stack thermometer shall be shipped loose for eld installation.
B3-16
10-02
Commercial Boilers
Inspection openings shall be provided in the convection area.
Model 5 Boilers
The boiler insulation shall be a minimum of 2" ber glass blanket. This insulation shall be covered with a corrugated sheet metal lagging. The lagging and insulation shall be arranged for easy removal and reinstallation if required. The entire boiler, base frame, and other components shall be factory painted before shipment using a hard nish enamel. 2.1 Soot Cleaning Soot washer lances shall be provided in the convection area of the boiler measuring full length of the pressure vessel. Each lance assembly shall be capable of rotating 360 degrees. This shall ensure complete washing of the convection zone while the boiler is operating in the low re mode. Soot washer troughs shall be provided at the bottom of the boiler. These shall be furnished for each convection side running the full length of the boiler with 2" drain connections at the boiler rear. Inspection/cleanout openings for each trough shall be located at the front of the boiler. 2.2 Boiler Connections A feedwater tapping and an integral feedwater distribution pipe shall be located in the upper drum. This distribution pipe shall blend the feedwater with the boiler water. A 3/4" surface blowoff connection shall be located in the rear head of the upper drum. Handholes shall be provided at each end of the lower drum and in the rear of the upper drum for inspection of the water side surfaces. 2.3 Boiler Trim The water column shall be located on the left side of the boiler. It shall be piped with union connections for easy removal. A gauge glass set, and gauge glass water column blowdown valves shall be provided. The boiler feedwater pump control switch shall be included as an integral item of the water column. It shall provide automatic actuation of a motor driven feedwater pump to maintain the boiler water level within normal limits. The low water cutoff switch shall be an integral part of the water column. It shall be wired into the burner control circuit preventing burner operation if the boiler water falls below the designated safe level. An auxiliary low water cut-off shall be located on the right hand side of the boiler and shall be wired into the control circuit so as to prevent burner operation in the event the primary cut-off fails and shall include a drain valve. A minimum of three controls shall be provided: one auto reset type for burner on-off control, one for burner ring rate, and one manual reset type for burner cutout on excessive steam pressure. A steam pressure gauge shall be located at the front end of the boiler and shall include a cock and test connection. Safety relief valves shall be provided of a type and size to comply with ASME Code requirements. 2.3.1 Low Water Volume Design, 150 psig The water level control and water level cut-offs shall be installed at a level that limits the water content in the boiler to 75 gallons or less at full operating capacity. The water column shall be a McDonnell-Miller 193-7 or approved equal, located on the left side of the boiler. It shall be piped with union connections for easy removal. A gauge glass set and gauge glass water column blowdown valves shall be provided. Feedwater shall be controlled by means of a electric proportional feedwater valve, Worchester or approved equal, complete with stop valve, check valve, and 3-valve by-pass. Controls shall be provided to comply with Guarded Plant status requirements. Provisions (insulation/wetpack) shall be made to ensure no combustibles within the boiler furnace, come in direct contact with the upper or lower drum.
B3-17
10-02
Model 5 Boilers
2.3.2 Low Water Volume Design, 15 psig Controls shall be provided to comply with Guarded Plant status requirements.
Commercial Boilers
Provisions (Insulation/Wetpack) shall be made to ensure no combustibles within the boiler furnace come in direct contact with the upper or lower drum. 3.0 Burner 3.1 Burner Description All air for combustion shall be supplied by a forced draft blower mounted in the front head (windbox), above the burner, to minimize vibration and noise level. The impeller shall be an enclosed centrifugal fan type, properly balanced and directly connected to the blower motor shaft. The maximum sound level shall not exceed 80 dBA measured 3 feet in front of the boiler. The oil burner shall operate on the low-high-low principle and must return to the low re position prior to ignition. The gas burner shall operate on the full modulation system and must return to the low re position prior to ignition. The burner shall remain in the low re position during ignition and until main ame has been proven. 3.2 Gas Fired Burner 3.2.1 General The burner shall be integral with the front head of the boiler and shall be the high radiant multi-port type approved for operation with natural gas. Automatic electric ignition of the premix gas pilot shall be furnished. A UV ame detector shall monitor the pilot, preventing the primary fuel valve from opening until the pilot ame has been established. A single damper motor shall control the combustion air damper and the buttery gas valve. The damper motor shall regulate the re according to system demand in response to the boiler mounted temperature/pressure control. The gas burner piping system on the unit shall include a primary gas shutoff valve. It shall be controlled by the programming relay to start or stop the burner and to close automatically in the event of power failure, ame failure, excessive pressure or temperature, high or low gas pressure, or a low water condition. A lubricated shutoff cock shall be located ahead of the primary valve for manual shutoff. A plugged leakage test connection and a lubricated plug cock are provided as a means for a tightness check of the primary shutoff valve. A gas pressure regulator shall be factory mounted and piped for proper pressure regulation to the burner. 3.2.2 Gas Train Components The primary shutoff valve shall be a motorized type. High and low gas pressure switches shall be provided. 3.3 No. 2 Oil Fired Burner 3.3.1 General The burner shall be integral with the front head of the boiler. It shall be the pressure atomizing type approved for operation with commercial grade No. 2 oil. The burner shall operate on the low-high-low principle, and must return to the low-re position prior to ignition. The burner shall remain in the low-re position during ignition and until low re and main ames have been proven. Automatic electric ignition of the low-re oil supply shall be provided with a 10,000 volt transformer and heavy duty electrodes. The ignition period shall be monitored with an electric scanner of the UV principle to conrm the presence of the low re oil ame.
B3-18
10-02
Commercial Boilers
Model 5 Boilers
NOTICE
Optional insurance compliance may require a premix gas pilot in lieu of electric ignition. The combustion air damper, low-re, and high-re oil valves shall be operated by a single damper control motor. This motor shall regulate the re according to system demand in response to the boiler-mounted high-low re pressure control. 3.3.2 Oil System: An oil pump shall be provided. The oil pump, integral with the burner, shall include a built-in relief valve and self- cleaning strainer. The pump shall be belt driven from the blower motor. The fuel oil system shall include supply and return tubing to a terminal block, oil pressure gauge, shutoff cock, and four solenoid oil shutoff valves. These items shall be factory mounted on the front head. 3.4 No.2 Oil and Gas Burner 3.4.1 General The burner shall be integral with the front head of the boiler. It shall be the pressure atomizing type for oil and high radiant multiport type for gas. The burner must be approved for operation with either commercial grade No.2 oil or natural gas. The oil burner shall operate on the low-high-low principle, the gas burner shall operate on the full modulation principle, and must return to the low-re position prior to ignition. The burner shall remain in the low-re position during ignition and until main ame has been proven. Automatic electric ignition of the premix gas pilot shall be provided. A UV ame detector shall monitor the pilot to prevent the primary fuel valve from opening until the pilot ame has been established. A single damper motor shall control the combustion air damper, high and low re oil valves, and the buttery gas valve. The damper motor shall regulate the re according to system demand in response to the boiler-mounted pressure control. 3.4.2 Oil System An oil pump shall be included. The oil pump, integral with the burner, shall include a built-in relief valve and self-cleaning strainer. The pump shall be belt-driven from the blower motor. The fuel oil system shall include supply and return tubing to a terminal block, oil pressure gauge, shutoff cock, and four solenoid oil shutoff valves. These items shall be factory mounted on the front head. 3.4.3 Gas System The gas burner piping system on the unit shall include a primary gas shutoff valve. It shall be controlled by the programming relay to start or stop the burner and to close automatically in the event of power failure, ame failure, excessive pressure or temperature, high or low gas pressure, or a low water condition. A lubricated shutoff cock shall be located ahead of the primary valve for manual shutoff. A plugged leakage test connection and a lubricated plug cock are provided as a means for a tightness check of the primary shutoff valve. A gas pressure regulator shall be factory-mounted and piped for proper pressure regulation to the burner. 3.4.4 Gas Train Components The primary shutoff valve shall be a motorized type. High and low gas pressure switches shall be provided. 3.5 Burner and Flame Failure Controller A combustion safeguard control shall be provided to control ignition, starting and stopping the burner and provide precombustion and postcombustion purge periods. It shall stop burner operation in the event of ignition, pilot or main ame failure. Trial for ignition shall be limited to 10 seconds.
B3-19
10-02
Model 5 Boilers
3.6 Control Panel
Commercial Boilers
The control panel shall be mounted on the front head of the boiler and shall be conveniently located for the operator. It shall be a NEMA 1A rated enclosure and have a key lock. Each boiler shall be factory-equipped with a ame safeguard controller that provides technology and functions equal to the Cleaver-Brooks Model CB 100. Flame safeguard controller shall be microprocessor based, with self-diagnostics, non-volatile memory, and a message center with a vocabulary of 42 different messages. Messages shall scroll across an alpha-numeric display and provide sequence status and failure mode information. The controller shall have a xed operating sequence incapable of being manually altered. The sequence will include start, pre-purge, pilot and main fuel ignition run and post-purge cycles. Controller shall be the non-recycle type for maximum safety that will shutdown the burner and indicate as a minimum the following trip functions: pilot and main ame failure, high and low re proving switch faults, running interlocks open, false ame signal and fuel valve open. The controller shall have a run/test switch. It will allow interruptions to sequence just after pre-purge, during pilot ignition trial, and during run cycles for adjustments to ring rate motor, damper linkages, and pilot ame for turndown tests. In addition to the above functions, the controller shall: Display history of operating hours and totals of completed on-off cycles. Provide a constant ame signal strength read-out. Have provisions for a remote display capability. The panel shall contain the blower motor starter, control circuit fuses, control circuit transformer, and control switches. A damper positioning switch shall be provided to permit selection of automatic ring or manual selection of low or high re. A terminal board shall be provided to which all wires entering or leaving the panel shall be connected. All electrical equipment shall be in conformity with the Canadian Standards Association requirements. Oil, heat and moisture resistant wire shall be used and shall be number coded.
B3-20
10-02
Commercial Boilers
Hot Water Boiler Specification
1.0 Boiler Capacity
Model 5 Boilers
The hot water boiler shall be Cleaver-Brooks Model 5, Series ______ (100, 200, 700), _______ bhp, designed for 140 psig hot water. The maximum supply temperature will be ______ F, and the minimum return water temperature will be _______ F. The minimum operating temperature of the boiler shall be 170 F. (Series 100 - No. 2 oil; 200 - No. 2 oil and gas; 700 - gas.) The boiler shall have a maximum output of ______ Btu/hr, or _____ hp, when red with No.2 oil and/or natural gas _______ Btu/ cu-ft. Safety relief valves shall be set at _______ psig. Electrical power available will be ______ volts, _______ phase, _______ Hz. All electrical service connections shall be made to an electrical entrance box mounted on the right hand side of the boiler. 2.0 Boiler Description The boiler shall be an all steel membrane wall watertube boiler with 3-pass gas travel. It shall be mounted on a heavy duty steel frame with integral forced draft burner and burner controls. The complete packaged boiler-burner unit shall be approved by Canadian Standard Association and shall have the CSA label afxed to the front head. The boiler shall be completely assembled and re tested at the factory. The boiler shell must be constructed and hydrostatically tested in accordance with the ASME Boiler and Pressure Vessel Code. It must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser. Two lifting eyes shall be located on top of the boiler. Two downcomers shall be located at the rear of the boiler and totally insulated from the generating tubes. The generating tubes shall be 2" OD SA-178 Grade A with .095" wall thickness. The downcomers shall be 2-1/2" OD for 35 and 47 hp; 3" OD for 59 to 83 hp and 4" OD for 95 to 143 hp. Material shall be SA-178-A and the 2-1/2" and 3" downcomers shall have a 0.105" wall. The 4" downcomers shall have a 0.135" wall. The upper drum shall be 20" OD schedule 20, SA-53-B seamless pipe with .375" wall. The lower drum shall be 6" nominal pipe size, SA-53-B seamless pipe with .312" wall. Refractory shall be limited to the furnace oor, insulating the lower drum, the burner throat tile, and to the formed rear access door which unbolts for ease of entry and/or inspection. High-temperature insulation shall be installed on the front wall of the furnace. Observation ports shall be provided at each end of the boiler for visual inspection of the pilot and main ame conditions. The exhaust gas vent shall be located at the rear of the boiler on the top centerline. A stack thermometer shall be shipped loose for eld installation. Inspection openings shall be provided in the convection area. The boiler insulation shall be a minimum of 2" ber glass blanket. This insulation shall be covered with a corrugated sheet metal lagging. The lagging and insulation shall be arranged for easy removal and reinstallation if required. The entire boiler, base frame, and other components shall be factory painted before shipment using a hard nish enamel. 2.1 Soot Cleaning Soot washer lances shall be provided in the convection area of the boiler measuring full length of the pressure vessel. Each lance shall be provided with a shutoff valve and the assembly shall be capable of rotating 360 F. This shall ensure complete washing of the convection zone while the boiler is operating in the low re mode. Soot washer troughs shall be provided at the bottom of the boiler. These shall be furnished for each convection side running the full length of the boiler with 2" drain connections at the boiler rear. Inspection/cleanout openings for each trough shall be located at the front of the boiler. 2.2 Boiler Connections The hot water outlet connection shall be located on the top centerline of the boiler and the return connection shall be located at the rear of the lower drum. The design of the boiler shall provide jet induced circulation, which shall mix the return water with the hot water within the boiler.
B3-21
10-02
Model 5 Boilers
Commercial Boilers
A dip tube shall be included as an integral part of the hot water outlet. An air vent tapping shall be located on the top centerline of the boiler for connection to an expansion tank. Handholes shall be provided at the end of the lower drum and in the rear of the upper drum for inspection of the water side surfaces. 2.3 Boiler Trim The low water cutoff switch shall be a probe type, mounted in the top center-line of the boiler. It shall be wired into the burner control circuit to prevent burner operation if the boiler water falls below a proper level. A minimum of three controls shall be provided: one auto reset type for burner on-off control, one for burner ring rate, and one manual reset type for burner cutout on excessive water temperature. The sensing elements shall be located adjacent to the outlet connection. A hot water circulating pump shall be mounted between the supply and return water connections (standard on ASME Section IV heating boilers only). This pump will blend the supply and the system return water. It will ensure a minimum continuous circulation at all times to a level of 10 boiler water changes per hour. A combination pressure-temperature gauge shall be located on the boiler. Water relief valves shall be provided of a type and size to comply with ASME Code requirements. 3.0 Burner 3.1 Burner Description All air for combustion shall be supplied by a forced draft blower mounted in the front head (windbox), above the burner, to minimize vibration and noise level. The impeller shall be an enclosed centrifugal fan type, properly balanced and directly connected to the blower motor shaft. The maximum sound level shall not exceed 80 dBA measured 3 feet in front of the boiler. The oil burner shall operate on the low-high-low principle and must return to the low re position prior to ignition. The gas burner shall operate on the full modulation system and must return to the low re position prior to ignition. The burner shall remain in the low re position during ignition and until main ame has been proven. 3.2 Gas Fired Burner 3.2.1 General The burner shall be integral with the front head of the boiler and shall be the high radiant multi-port type approved for operation with natural, manufactured, or mixed gas. Automatic electric ignition of the premix gas pilot shall be furnished. A UV ame detector shall monitor the pilot, preventing the primary fuel valve from opening until the pilot ame has been established. A single damper motor shall control the combustion air damper and the buttery gas valve. The damper motor shall regulate the re according to system demand in response to the boiler mounted temperature/pressure control. The gas burner piping system on the unit shall include a primary gas shutoff valve. It shall be controlled by the programming relay to start or stop the burner and to close automatically in the event of power failure, ame failure, excessive pressure or temperature, high or low gas pressure, or a low water condition. A lubricated shutoff cock shall be located ahead of the primary valve for manual shutoff. A plugged leakage test connection and a lubricated plug cock are provided as a means for a tightness check of the primary shutoff valve. A gas pressure regulator shall be factory mounted and piped for proper pressure regulation to the burner. 3.2.2 Gas Train Components The primary shutoff valve shall be a motorized type. High and low gas pressure switches shall be provided.
B3-22
10-02
Commercial Boilers
3.3 No. 2 Oil Fired Burner 3.3.1 General
Model 5 Boilers
The burner shall be integral with the front head of the boiler. It shall be the pressure atomizing type approved for operation with commercial grade No.2 oil. The burner shall operate on the low-high-low principle, and must return to the low-re position prior to ignition. The burner shall remain in the low-re position during ignition, and until low re and main ames have been proven. Automatic electric ignition of the low-re oil supply shall be provided with a 10,000 volt transformer and heavy duty electrodes. The ignition period shall be monitored with an electric scanner of the UV principle to conrm the presence of the low re oil ame.
NOTICE
Optional insurance compliance may require a premix gas pilot in lieu of electric ignition. The combustion air damper, low-re, and high-re oil valves shall be operated by a single damper control motor. This motor shall regulate the re according to system demand in response to the boiler mounted high-low re temperature/pressure control. 3.3.2 Oil System An oil pump shall be provided. The oil pump, integral with the burner, shall include a built-in relief valve and self- cleaning strainer. The pump shall be belt driven from the blower motor. The fuel oil system shall include supply and return tubing to a terminal block, oil pressure gauge, shutoff cock, and four solenoid oil shutoff valves. These items shall be factory mounted on the front head. 3.4 No.2 Oil and Gas Burner 3.4.1 General: The burner shall be integral with the front head of the boiler. It shall be the pressure atomizing type for oil and high radiant multiport type for gas. The burner must be approved for operation with either commercial grade No.2 oil or natural gas. The oil burner shall operate on the low-high-low principle, and must return to the low-re position prior to ignition. The gas burner shall operate on the full modulation system and must return to the low re position prior to ignition. The burner shall remain in the low-re position during ignition and until main ame has been proven. Automatic electric ignition of the premix gas pilot shall be provided. A UV ame detector shall monitor the pilot to prevent the primary fuel valve from opening until the pilot ame has been established. A single damper motor shall control the combustion air damper, high and low re oil valves, and the buttery gas valve. The damper motor shall regulate the re according to system demand in response to the boiler mounted high-low re temperature/pressure control. 3.4.2. Oil System An oil pump shall be included. The oil pump, integral with the burner, shall include a built-in relief valve and self-cleaning strainer. The pump shall be belt-driven from the blower motor. The fuel oil system shall include supply and return tubing to a terminal block, oil pressure gauge, shutoff cock, and four solenoid oil shutoff valves. These items shall be factory mounted on the front head. 3.4.3 Gas System The gas burner piping system on the unit shall include a primary gas shutoff valve. It shall be controlled by the programming relay to start or stop the burner and to close automatically in the event of power failure, ame failure, excessive pressure or temperature, high or low gas pressure, or a low water condition. A lubricated shutoff cock shall be located ahead of the primary valve for manual shutoff. A plugged leakage test connection and a lubricated plug cock are provided as a means for a tightness check of the primary shutoff valve. B3-23
10-02
Model 5 Boilers
Commercial Boilers
A gas pressure regulator shall be factory-mounted and piped for proper pressure regulation to the burner. 3.4.4 Gas Train Components The primary shutoff valve shall be a motorized type. High and low gas pressure switches shall be provided. 3.5 Burner and Flame Failure Controller A combustion safeguard control shall be provided to control ignition, starting and stopping the burner and provide precombustion and postcombustion purge periods. It shall stop burner operation in the event of ignition, pilot or main ame failure. Trial for ignition shall be limited to 10 seconds. 3.6 Control Panel The control panel shall be mounted on the front head of the boiler and shall be conveniently located for the operator. It shall be a NEMA 1A rated enclosure and have a Yale key lock. Each boiler shall be factory-equipped with a ame safeguard controller that provides technology and functions equal to the Cleaver-Brooks Model CB100. Flame safeguard controller shall be microprocessor based, with self-diagnostics, non-volatile memory, and a message center with a vocabulary of 42 different messages. Messages shall scroll across an alpha-numeric display and provide sequence status and failure mode information. The controller shall have a xed operating sequence incapable of being manually altered. The sequence will include start, pre-purge, pilot and main fuel ignition run and post-purge cycles. Controller shall be the non-recycle type for maximum safety that will shutdown the burner and indicate as a minimum the following trip functions: pilot and main ame failure, high and low re proving switch faults, running interlocks open, false ame signal and fuel valve open. The controller shall have a run/test switch. It will allow interruptions to sequence just after pre-purge, during pilot ignition trial, and during run cycles for adjustments to ring rate motor, damper linkages and pilot ame for turndown tests. In addition to the above functions, the controller shall: Display history of operating hours and totals of completed on-off cycles. Provide a constant ame signal strength read-out. Have provisions for a remote display capability. The panel shall contain the blower motor starter, control circuit fuses, control circuit transformer, and control switches. A damper positioning switch shall be provided to permit selection of automatic ring or manual selection of low or high re. A terminal board shall be provided to which all wires entering or leaving the panel shall be connected. All electrical equipment shall be in conformity with the Canadian Standard Association requirements. Oil, heat and moisture resistant wire shall be used and shall be number coded. A low re hold timer shall be mounted in the panel and wired to hold the boiler in a low ring mode, for a minimum of 10 minutes, each time the boiler cycles on. This low re hold timer ensures gradual boiler warm up.
B3-24
10-02
Section B4
ELECTRIC BOILERS
CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-3 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-3 Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-4 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4 DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-5 PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-5 Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-5 Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-5 ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-5 SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-25 ILLUSTRATIONS Figure B4-1. Figure B4-2. Figure B4-3. Figure B4-4. Figure B4-5. Figure B4-6. Models HW and CWB Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-7 Model S Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-8 Model CR Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-9 Model CSB Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-10 Models TWH and TWV Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-11 Model IWH Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-12
B4-1
04-02
Electric Boilers
TABLES
Commercial Boilers
Table B4-1. Cleaver-Brooks Electric Boilers Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-3 Table B4-2. Power Supply Wire Lug Sizing Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6 Table B4-3. Model HW Ratings - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-13 Table B4-4. Model CWB Ratings - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-15 Table B4-5. Model S/CR Ratings - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-18 Table B4-6. Model CSB Ratings - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-20 Table B4-7. Model TWH/TWV Vessel Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-22 Table B4-8. Model TWH/TWV Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-23 Table B4-9. Model IWH Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-24 Power Supply Wire Lug Sizing Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-24 This section contains information on the complete line of Cleaver-Brooks electric boilers with kilowatt output ratings from 9 to 3,375 kW. Electric boilers are typically utilized for applications where stringent environmental regulations and boiler space requirements are critical.
B4-2
04-02
Commercial Boilers
Electric Boilers
High Turndown/Input Control: By individually controlling the heating elements with solid state digital step controllers, a high degree of input control is achievable. Virtually unlimited input control is available with optional solid state SCR power controllers. Quiet Operation: Elimination of combustion noise and minimal moving parts results in extremely quiet operation. Low Return Water Temperatures: Electric boilers are able to withstand virtually any return water temperature. With combustion by-products and high temperature differentials eliminated, condensation and thermal shock do not limit return water temperatures.

In applications where electric power is more economically available than fossil fuels, or where fossil fuel combustion and the handling of combustion by-products are unacceptable, electric boilers offer a viable alternative. Reduced Maintenance: The absence of high maintenance combustion equipment and the use of solid state control devices reduce the complexity and number of moving parts. Electric elements are easily accessible and replaceable either individually or in ange mounted groups. Pressure vessel components are not subjected to thermal stresses induced by high temperature differentials and cycling encountered with fossil fuel combustion. Compact Size: Electric boilers are typically one-quarter to one-half the size of fossil fuel boilers with similar Btu output. No Emissions: Because there is no combustion, electric boilers are 100% emission free. This may be benecial in meeting total plant emission requirements. No Stack Requirements: With no products of combustion to contend with, installation costs are reduced by the elimination of stack requirements.
PRODUCT OFFERING
Information in this section applies directly to Cleaver-Brooks Electric Boilers. See Table B4-1 for description of the various models in the electric boiler line. Hot Water Boilers Hot water boilers are available in heating or process applications with ow rates of 10 to 1840 gpm. Steam Boilers
Table B4-1. Cleaver-Brooks Electric Boilers Product Offering

PRODUCT TYPE Hot Water Boilers MODEL HW CWB Steam Boilers S CR CSB Hot Water Storage Heaters TWV TWH Instantaneous Water Heaters Notes: IWH OUTPUT (KW) 9-2520 12-3360 12-1944 12-480 540-3375 30-360 30-360 75 15-360 50/75 13-360 A 150 1, 2 ELEMENT DENSITY (W/SQ-IN.) 50 75 67 67 75 75 WATER CONTENT (GALLONS) 16-500 16-500 16-595 16-115 180-790 150-1500 500-2500 DESIGNB PRESSURE (PSIG) 150 150 15/50/125 15/50/125 15/50/125 125/150 125/150 NOTES 1 1 2 2,3 2 2 2
1. Heating elements are of copper construction. 2. Heating elements are of Incoloy construction. 3. CR identical to Model S but has integral condensate return tank and pump. A. Water content not applicable. Flow rate in GPM is listed. B. Some boiler combinations that have vessel sizes above 42, or above 600 gallons, will have additional design pressure limitations. Contact your local Cleaver-Brooks authorized representative for final design pressure and model selection.
B4-3
04-02
Electric Boilers
Steam boilers are available for use in steam heating or process applications requiring 42 to 10,080 pounds of steam per hour. Hot Water Storage Heaters Hot water storage heaters are typically used for domestic hot water heating or high surge volume applications. Model TWV uses vertical storage tanks. Model TWH uses horizontal storage tanks. Instantaneous Hot Water Heaters Instantaneous hot water heaters are typically used in standby or on-demand hot water applications where hot water storage is not acceptable. High delta T and high ow applications can be achieved by linking multiple units in series or in parallel respectively.
Commercial Boilers
2 Step: One 2-stage temperature switch. 3 Step: One 3-stage time delay sequencer. 4 Step: One 4-stage time delay sequencer. 5 Step and above: Solid state proportional linear sequence step control with adjustable span and interstage time delay. All Steam Boilers: Manual reset high pressure cut-off. Auxiliary auto-reset high pressure cut-off. Combination low-water cut-off and pump control. Pilot light to indicate high pressure alarm. Bottom and water column blowdown valves. Feedwater stop and check valves. Pressure gauge. Sight gauge with drain and guards Inspection opening. Pressure controls as follows: 1 Step: One On-Off pressure switch. 2 Step: Two On-Off pressure switches. 3 Step and above: Solid state proportional linear sequence step control with adjustable span and interstage time delay. Models TWV and TWH: Magnesium anode. Lined tank. Model IWH: Flow switch.
Standard Equipment
The equipment described below applies to standard boilers. All Boilers: ASME Code carbon steel vessel with glass ber insulation. UL listing. Heavy gauge steel enclosure. Electrical lugs for primary power supply. 200,000 amp interrupting capacity fusing. Contactors rated for 500,000 cycles. 120 V control transformer with primary fusing and power switch with integral breaker. Pilot lights to indicate control power on and low water alarm (except model IWH). ASME relief/safety valves. All Hot Water Boilers and Heaters: Manual reset high-temperature cut-off. Auxiliary auto-reset high temperature cut-off. Auto-reset probe, low-water cut-off (except model IWH which includes ow switch). High temperature alarm with pilot light. Drain valve. Pressure and temperature gauges. Inspection opening. Temperature controls as follows: 1 Step: On-off temperature switch.
Optional Equipment
All Boilers: This is a partial list of boiler options and accessories. Contact your local Cleaver-Brooks authorized representative for a complete list of all available options and accessories. Output step enable/disable toggle switches. Additional pilot lights. Alarm relays and terminal strips. Audible alarm. Alarm silencer. Safety door interlock. Time clock.
B4-4
04-02
Commercial Boilers
Ammeter. Voltmeter. Kilowatt hour meter. Ground fault detector. Outdoor reset control. Progressive sequence step controls. Auxiliary low-water cut-off. Flow switch. Preheat switch. Unfused manual disconnect. Fused manual disconnect. Molded case disconnect. Molded case circuit breaker. Shunt trip for molded case disconnect/circuit breaker. Main-power door interlock (standard with disconnects 600 amps and below).
Electric Boilers
PERFORMANCE DATA
Efficiency
All Cleaver-Brooks Electric Boilers are virtually 100% efcient, excluding radiant losses. These losses are minimized due to insulation supplied as standard.
Emissions
Since electric boilers have no combustion, there are no emissions. This eliminates the need for stacks, pollution controls, and emission permits.
ENGINEERING DATA
Calculations: The following formula can be used to correctly size a hot water boiler: kW = gph x delta T (in F)/410, or kW = 1 gph x delta T (in C)/862 Where: kW is the boiler output rating. gph is the hot water ow rate. delta T is the temperature rise of water. For conversion of pounds of steam to kW, the following can be used: 10 kW = 34 lbs steam/hr = 1.02 BHP

This section contains all of the dimensions and ratings for the electric boiler product line. The gures are arranged by boiler models. Dimensions for electric boilers are shown in Figures B4-1 through B4-6.
NOTICE
Ratings information for Model TWV and Model TWH is split into two tables. Since this model is used for hot water storage as well as heating, the boiler vessel capacity in gallons and the heating rate must be selected to meet specific application needs. Table B4-6 gives the vessel capacity and boiler base models. Table B4-7 gives the heating or kilowatt rating of the units. For example, if a large storage capacity is needed, from Table B4-6 and the base model TWV100, which gives a 1000 gallon capacity, from Table B4-7 the suffix of - 90, which would add a 90 KW heater, the full model number would be TWV-100-90. Ratings for electric boilers are shown in tables B4-3 though B4-9.
Finally, the following formula can be used to determine amperage of three phase power to size power line feeds to the boiler: Amps (3 ph) = Watts/(Volts x 1.73) Power Supply: The information in Table B4-2 can be used to correctly size power lugs when designing power supply lines for the boilers. Ground Fault Detection: Available on all boilers, this equipment monitors the supply circuit for ground current in the boiler. In the event of a ground fault, a signal opens the control circuit or trips the supply circuit breaker. This equipment can prevent excessive boiler damage from arcing faults to ground when used with a supply circuit breaker with shunt trip. Per NEC, ground fault interruption (GFI) is required on all wye power supplies rated 1000 amps or more.
B4-5
04-02
Electric Boilers
Disconnect: A manual disconnect (safety switch), a non-auto circuit breaker, or an automatic circuit breaker can be installed integral with the boiler. If specied, the devices can also include such features as a mechanical door interlock and, for circuit breakers, an automatic trip coil. The capacity of fused or automatic disconnects must not be less than 125 percent of the maximum rated amp draw of the boiler; manual disconnects may be rated at 100% of the maximum boiler draw.
Commercial Boilers
Table B4-2. Power Supply Wire Lug Sizing Guide
SUPPLY WIRE LUG QTY/PH/SIZE GROUND LUG SIZE
MAX KW
208V, 240V/3-PH/60 HZ 1 @ SLU70 SLU35 1 @ SLU350 SLU70 1 @ SLU500 SLU70 2 @ TA500 SLU125 4 @ TA500 SLU225 6 @ TA500 SLU300 480V/3-PH/60 HZ 36 1 @ SLU70 SLU35 180 1 @ SLU350 SLU70 105 1 @ SLU500 SLU70 360 2 @ TA500 SLU125 1000 4 @ TA500 SLU225 1480 6 @ TA500 SLU300 NOTE: Contact your local Cleaver-Brooks authorized representative for information on 600 volt supply lugs. 18 90 105 180 420 540
B4-6
04-02
Commercial Boilers
Electric Boilers
MODEL NO.
CONNECTION SIZES INLET & OUTLET DRAIN (NPT) 3/4 3/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2 3/4 3/4 3/4
B
DIMENSIONS (IN.) WIDTH A 28 28 36 36 46 46 50 50 62 62 62 68 68 28 28 28 46 46 50 50 50 62 62 62 68 68 DEPTH B 28 28 36 36 36 36 42 42 54 54 54 72 72 28 28 28 36 36 42 42 42 54 54 54 72 72 HEIGHT C 39 39 66 66 66 66 72 80 72 88 100 86 100 39 39 54 66 66 72 72 80 72 88 100 86 100 INLET D 8 8 14 14 14 14 18 19 20 23 23 24 24 8 8 8 14 14 18 18 18 20 23 23 24 24
MINIMUM RECOMMENDED CLEARANCES (IN.) TOP E 12 12 18 18 18 18 18 18 24 24 24 24 24 12 12 12 18 18 18 18 18 24 24 24 24 24 SIDE F 15 15 18 18 18 18 21 21 24 24 24 30 30 15 15 15 18 18 21 21 21 24 24 24 30 30 REAR G 12 12 18 18 18 18 18 18 24 24 24 24 24 12 12 12 18 18 18 18 18 24 24 24 36 36
APPROXIMATE WEIGHTS (LBS.) SHIPPING 450 550 800 1050 1350 1550 2450 2850 3300 3700 4200 6100 6700 450 500 800 1400 1500 2200 2400 2800 3300 3600 4200 5800 6500 OPERATE 580 680 1410 1660 1990 2190 3450 4020 5230 6280 7230 9600 10800 580 630 1005 2040 2140 3200 3400 3980 5260 6220 7280 9300 10500
HW-120 HW-121 HW-201 HW-202 HW-203 HW-204 HW-241 HW-242 HW-361 HW-362 HW-363 HW-421A HW-422A CWB-120 CWB-121 CWB-122 CWB-201 CWB-202 CWB-241 CWB-242 CWB-243 CWB-361 CWB-362 CWB-363 CWB-421A CWB-422A
2 3 4FB 4F 4F 4F 6F 6F 6F 8F 8F 10F 10F 2 3 3 4F
1-1/4 1-1/4 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2
4F 6F 6F 6F 6F 8F 8F 10F 10F
NOTE: Heights are for boiler only. Control panel size varies based on the number of steps. A. Normally supplied with 2 control cabinets for 2 power supplies. B. Flanged connection (150 psig ANSI).
Figure B4-1. Models HW and CWB Dimensions B4-7

04-02
Electric Boilers
Commercial Boilers
MODELS S-120 THRU S-200
MODELS S-241 THRU S-480
CONNECTION SIZE (NPT) MODEL NO. FW 15 PSIG 125 PSIG 15 PSIG 125 PSIG BLOWDOWN STEAM OUTLET WIDTH A
DIMENSIONS (IN.) DEPTH B HEIGHT C LWCO D
CLEARANCES TOP E SIDES F
APPROXIMATE WEIGHTS (LBS) SHIPPING OPERATE
S-120 S-161 S-162 S-200 S-241 S-242 S-301 S-302 S-361 S-362 S-421 S-480
1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4 3/4 3/4 1 1
3/4 3/4 3/4 1 1-1/4 1-1/4 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 2
3/4 3/4 3/4 1 1 1 1 1 1 1 1 1-1/4
1 1-1/2 2 2-1/2 3 3 4FA 4FA 4FA 6FA 6FA 8FA
3/4 1 1 1-1/4 1-1/2 1-1/2 2 2-1/2 2-1/2 3FA 3FA 4FA
28 32 32 36 50 50 56 56 62 62 68 74
28 32 32 36 42 42 48 48 54 54 60 66
38 54 54 66 72 72 72 88 72 86 72 92
20 34 34 41 41 41 40 50 42 52 41 53
12 12 12 12 12 12 15 15 18 18 18 18
18 18 18 18 18 18 21 21 24 24 27 27
600 750 800 1150 1400 1600 2100 2200 2900 3200 4150 5450
675 880 930 1480 1900 2000 3000 3300 4000 4800 5800 8000
NOTE: Heights are for boiler only. Control panel size will vary based on the number of steps A. Flanged connection (150 psig ANSI)
Figure B4-2. Model S Dimensions B4-8

04-02
Commercial Boilers
Electric Boilers
CONNECTION SIZE (NPT) MODEL NO. BLOWDOWN 15 PSIG STEAM OUTLET COND. RETURN OVERFLOW WIDTH A
DIMENSIONS (IN.) DEPTH B HEIGHT C LWCO
APPROXIMATE WEIGHTS (LBS.) SHIPPING D OPERATE
125 PSIG 15 PSIG 125 PSIG
CR-120 CR-161 CR-162 CR-200 CR-241 CR-242
3/4 3/4 3/4 1 1-1/4 1-1/4
3/4 3/4 3/4 1 1 1
1 1-1/2 2 2-1/2 3 3
3/4 1 1 1-1/4 1-1/2 1-1/2
3/4 1 1 1-1/4 1-1/2 1-1/2
3/4 1 1 1-1/4 1-1/2 1-1/2
28 32 32 36 50 50
38 42 42 48 52 52
38 54 54 66 72 72
20 28 34 41 41 41
850 1050 1150 1650 2000 2200
950 1200 1280 2030 2600 2700
NOTE: Heights are for boiler only. Control panel size will vary based on the number of steps.
Figure B4-3. Model CR Dimensions B4-9

04-02
Electric Boilers
Commercial Boilers
CONNECTION SIZE (NPT) MODEL NO. FW 15 PSIG 125 PSIG CSB-301 CSB-302 CSB-361 CSB-362 CSB-421 CSB-422 CSB-423 CSB-424 CSB-425 3/4 3/4 3/4 3/4 1 1 1 1 1 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2 1 1 1 1 1 1 1-1/2 1-1/2 1-1/2 15 PSIG 125 PSIG 4FA 4FA 4FA 6FA 6FA 6FA 8FA 8FA 8FA 2 2-1/2 2-1/2 3FA 3F
A
DIMENSIONS (IN.) WIDTH A 56 56 62 62 68 68 130 140 150 DEPTH B 48 48 54 54 60 60 68 68 68 HEIGHT C 72 88 72 88 72 88 62 62 62 LWCO D 40 50 42 52 41 51 34 34 34
CLEARANCES TOP E 15 15 18 18 18 18 24 24 24 SIDES F 21 21 24 24 27 27 36 36 36
APPROXIMATE WEIGHTS (LBS) SHIPPING OPERATE 2400 2650 2900 3300 4250 4600 5700 6400 7100 3200 3700 4000 4800 5800 6700 8000 9300 10600
BLOWDOWN
STEAM OUTLET
3FA 4FA 4FA 4FA
NOTE: Heights are for boiler only. Control panel size will vary based on the number of steps A. Flanged connection (150 psig ANSI)
Figure B4-4. Model CSB Dimensions B4-10

04-02
Commercial Boilers
Electric Boilers
CONNECTION SIZE (NPT) MODEL NO. INLET & OUTLET TWV-015 TWV-020 TWV-025 TWV-030 TWV-035 TWV-040 TWV-050 TWV-060 TWV-075 TWV-100 TWV-125 TWV-150 TWH-050 TWH-060 TWH-075 TWH-100 TWH-125 TWH-150 TWH-175 TWH-200 TWH-225 TWH-250 1 1 1-1/4 1-1/4 1-1/4 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2 1-1/2 1-1/2 2 2 2 2 2 3 3 3 DRAIN 1 1 1 1 1 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2 2 2 WIDTH A 34 34 40 40 40 46 46 52 52 64 64 64 94 110 108 140 172 164 194 178 198 220
DIMENSIONS (IN.) DEPTH B 44 44 50 50 50 56 56 62 62 72 72 72 46 46 52 52 52 58 58 64 64 64 HEIGHT C 64 80 72 84 96 84 100 92 110 100 120 140 52 52 58 58 58 66 66 72 72 72
APPROXIMATE WEIGHTS (LBS.) SHIPPING 1250 1400 1525 1700 1900 2100 2500 3000 3800 4600 5300 6000 2700 3100 4000 4900 5800 6700 7500 7700 8500 9300 OPERATE 2500 3050 3600 4200 4800 5400 6700 8000 10000 12900 15700 18500 6800 8100 10200 13200 16200 19200 22000 24300 27200 30000
NOTE: Heights are for boiler only. Control panel size will vary based on the number of steps.
Figure B4-5. Models TWH and TWV Dimensions B4-11

04-02
Electric Boilers
Commercial Boilers
INLET B E 3
REIEF VALVE A
OUTLET RR
12 MIN
RL D TYP
DRAIN
1-1/2
B + 1-1/2 END FRONT
* MINIMUM CLEARANCE FOR MAINTENANCE OR ELEMENT REMOVAL ** C-C OF 5/8 MOUNTING HOLES
MODEL NO.
CONNECTION SIZE (NPT) INLET & OUTLET WIDTH DRAIN A 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 30 50 50 82 50 50 82 82
DIMENSIONS (INCHES) DEPTH B 20 20 20 20 22 22 22 26 HEIGHT C 18 18 18 18 22 22 22 30 INLET D 8-1/2 8-1/2 8-1/2 8-1/2 9-1/2 9-1/2 9-1/2 10 INLET E 6 6 6 6 8 8 8 9
MINIMUM RECOMMENDED CLEARANCES (IN.) LEFT RL 20 20 36 36 20 36 36 36 RIGHT FRONT RR 12 20 12 36 20 12 36 36 36 36 36 36 36 36 36 36
APPROXIMATE WEIGHTS (LBS) SHIPPING 250 400 300 450 450 350 500 600 OPERATE 295 440 340 525 252 425 630 810
IWH-611 IWH-612 IWH-621 IWH-622 IWH-812 IWH-821 IWH-822 IWH-022
2 2 2 2 3 3 3 3A
NOTE: Heights are for Boiler only. Control panel size will vary based on the number of steps. A. For flow rates above 240 gpm, specify 4" flanged connections.
Figure B4-6. Model IWH Dimensions
B4-12
04-02
Commercial Boilers
Table B4-3. Model HW Ratings - Sheet 1 of 2
MODEL NO. HW-120 VES CAP GAL. 16 MAX FLOW GPM 80 RATED KW 9 12 18 24 27 36 48 HW-121 16 80 60 72 84 96 HW-201 74 230 90 105 120 HW-202 74 230 135 150 165 180 195 210 225 240 HW-203 78 300 270 300 330 360 HW-204 78 300 390 420 450 480 HW-241 122 670 468 504 540 576 HW-242 142 670 612 648 684 720 HW-361 235 900 750 780 810 840 870 900 930 960 ELEMENTS NO. OF CONT MBTU/HR QTY 31 41 61 82 92 123 164 205 246 287 328 307 358 409 461 512 563 614 665 717 768 819 921 1024 1126 1228 1331 1433 1535 1638 1597 1720 1842 1965 2088 2211 2334 2457 2559 2661 2764 2866 2968 3071 3173 3276 3 3 6 6 9 9 12 15 18 21 24 18 21 24 27 30 33 36 39 42 45 48 54 60 66 72 78 84 90 96 78 84 90 96 102 108 114 120 75 78 81 84 87 90 93 96 KW 3 4 3 4 3 4 4 4 4 4 4 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 6 6 6 6 6 6 6 6 10 10 10 10 10 10 10 10 <250V >250V 1 1 1 2 2 2 4 5 6 7 8 6 7 8 9 10 11 12 13 14 15 16 18 20 22 24 1 1 1 1 1 1 2 2 2 3 3 3 4 4 5 5 6 6 7 7 8 8 9 10 11 12 13 14 15 16 13 14 15 16 17 18 19 20 25 26 27 28 29 30 31 32 208-240V 1@9 1@12 1@18 2@12 1@18,1@9 2@18 2@24 2@24,1@12 3@24 3@24,1@12 4@24 3@30 3@30,1@15 4@30 4@30,1@15 5@30 5@30,1@15 6@30 6@30,1@15 7@30 7@30,1@15 8@30 6@45 4@45,4@30 6@45,2@30 8@45 480-600V 1@9 1@12 1@18 1@24 1@27 1@36 2@24 1@36,1@24 2@36 1@36,2@24 2@36,1@24 3@30 3@30,1@15 4@30 4@30,1@15 5@30 5@30,1@15 6@30 6@30,1@15 7@30 7@30,1@15 8@30 4@60,1@30 5@60 5@60,1@30 6@60 6@60,1@30 7@60 7@60,1@30 8@60 5@72,3@36 6@72,2@36 7@72,1@36 8@72 7@72,3@36 8@72,2@36 9@72,1@36 10@72 5@90,5@60 6@90,4@60 7@90,3@60 8@90,2@60 9@90,1@60 10@90 7@90,5@60 8@90,4@60 208 26 34 51 68 76 101 134 168 201 234 267 251 292 334 376 417 459 501 542 584 626 667 750 834 917 1000 NO. AND KW OF STEPS
Electric Boilers
3- PHASE AMPS VS VOLTAGE 240 23 30 44 59 66 88 116 145 174 203 232 218 254 290 326 362 398 434 470 506 542 578 651 723 795 867 480 12 15 23 30 33 44 59 73 88 102 116 109 127 145 163 181 199 218 236 254 272 290 326 362 398 434 470 506 542 578 564 607 651 694 737 780 824 867 903 939 975 1011 1047 1084 1120 1156 600 10 13 18 24 27 36 47 59 70 82 93 88 102 116 131 145 160 174 189 203 218 232 261 290 319 347 376 405 434 463 451 486 521 555 590 625 659 694 723 752 780 809 838 867 896 925
B4-13
04-02
Electric Boilers
Table B4-3. Model HW Ratings - Sheet 2 of 2
MODEL NO. VES CAP GAL. MAX FLOW GPM RATED KW 990 1020 1050 1080 HW-362 315 900 1110 1140 1170 1200 1230 1260 1290 1320 1350 1380 1410 1440 HW-363 370 1170 1470 1500 1530 1560 1590 1620 1650 1680 1710 1740 1770 1800 HW-421 425 1560 1830 1860 1890 1920 1950 1980 HW-422 500 1840 2101 2040 2070 2100 2130 2160 2190 2220 2250 2280 2310 2340 2370 2400 2520 ELEMENTS NO. OF CONT MBTU/HR QTY 3378 3480 3583 3685 3787 3890 3992 4094 4197 4299 4401 4504 4606 4709 4811 4913 5016 5118 5220 5323 5425 5527 5630 5732 5835 5937 6039 6142 6244 6346 6449 6551 6653 6756 6858 6960 7063 7165 7268 7370 7472 7575 7677 7779 7882 7984 8086 8189 8598 99 102 105 108 111 114 117 120 123 126 129 132 135 138 141 144 147 150 153 156 159 162 165 168 171 174 177 180 183 186 189 192 195 198 201 204 207 210 213 216 219 222 225 228 231 234 237 240 252 KW 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 <250V >250V 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 84 208-240V 480-600V 9@90,3@60 10@90,2@60 11@90 12@90 9@90,5@60 10@90,4@60 11@90,3@60 12@90,2@60 13@90,1@60 14@90 10@90,6@60 12@90,4@60 13@90,3@60 14@90,2@60 15@90,1@60 16@90 13@90,5@60 14@90,4@60 15@90,3@60 16@90,2@60 17@90,1@60 18@90 15@90,5@60 16@90,4@60 17@90,3@60 18@90,2@60 19@90,1@60 20@90 1@120,19@90 2@120,18@90 3@120,17@90 4@120,16@90 5@120,15@90 6@120,14@90 7@120,13@90 8@120,12@90 9@120,11@90 NO. AND KW OF STEPS
Commercial Boilers
3- PHASE AMPS VS VOLTAGE 208 240 480 1192 1228 1264 1300 1336 1372 1408 1444 1480 1517 1553 1589 1625 1661 1697 1733 1769 1805 1841 1877 1913 1950 1986 2022 2058 2094 2130 2166 2202 2238 2274 2310 2346 2383 2528 2455 2491 2527 2563 2599 2635 2671 2707 2743 2779 2816 2852 2888 3032 600 954 982 1011 1040 1069 1098 1127 1156 1185 1213 1242 1271 1300 1329 1358 1387 1416 1444 1473 1502 1531 1560 1589 1618 1646 1675 1704 1733 1762 1791 1820 1849 1877 1906 2023 1964 1993 2022 2051 2079 2108 2137 2166 2195 2224 2253 2282 2310 2426
10@120,10@90 11@120,9@90 12@120,8@90 13@120,7@90 14@120,6@90 15@120,5@90 16@120,4@90 17@120,3@90 18@120,2@90 19@120,1@90 20@120 4@150,16@120
B4-14
04-02
Commercial Boilers
Table B4-4. Model CWB Ratings - Sheet 1 of 3
MODEL NO. CWB-120 VES CAP. GAL. 16 MAX FLOW GPM 80 ELEMENTS RATED KW 12 18 24 30 36 45 54 60 72 CWB-121 16 160 90 108 126 144 CWB-122 25 160 162 180 198 216 234 252 270 288 CWB-201 78 300 324 360 396 432 CWB-202 78 300 468 504 540 576 CWB-241 122 670 600 630 660 690 720 CWB-242 122 670 750 780 810 840 870 900 930 960 CWB-243 142 670 990 1020 MBTU/HR QTY 41 61 82 102 123 154 184 205 246 307 368 430 491 553 614 676 737 798 860 921 983 1105 1228 1350 1474 1597 1720 1842 1965 2047 2150 2252 2354 2457 2559 2661 2764 2866 2968 3071 3173 3276 3378 3481 3 3 6 6 6 9 9 12 12 15 18 21 24 27 30 33 36 39 42 45 48 54 60 66 72 78 84 90 96 60 63 66 69 72 75 78 81 84 87 90 93 96 99 102 KW 4 6 4 5 6 5 6 5 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 NO. OF CONT. 208240V 1 1 2 2 2 3 3 4 4 5 6 7 8 9 10 11 12 13 14 15 16 18 20 22 24 480600V 1 1 1 1 1 2 2 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 10 11 12 13 14 15 16 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 NO. AND KW OF STEPS 208-240V 1@12 1@18 1@24 1@30 1@36 1@30,1@15 1@36,1@18 2@30 2@36 2@36,1@18 3@36 3@36,1@18 4@36 4@36,1@18 5@36 5@36,1@18 6@36 6@36,1@18 7@36 7@36,1@18 8@36 6@54 4@54,4@36 6@54,2@36 8@54 480-600V 1@12 1@18 1@24 1@30 1@36 1@45 1@54 2@30 2@36 2@36,1@18 3@36 3@36,1@18 4@36 3@36,1@54 5@36 5@36,1@18 6@36 6@36,1@18 7@36 7@36,1@18 8@36 3@72,3@36 2@72,6@36 3@72,5@36 4@72,4@36 5@72,3@36 6@72,2@36 7@72,1@36 8@72 10@60 1@90,9@60 2@90,8@60 3@90,7@60 4@90,6@60 5@90,5@60 6@90,4@60 7@90,3@60 8@90,2@60 9@90,1@60 10@90 7@90,5@60 8@90,4@60 9@90,3@60 10@90,2@60
Electric Boilers
3-PHASE AMPS VS VOLTAGE 208 34 51 68 84 101 126 151 168 201 251 301 351 401 451 501 551 601 651 700 750 800 900 1000 1100 1200 240 30 44 59 73 88 109 131 145 174 218 261 304 347 391 434 477 521 564 607 651 694 780 867 954 1040 480 15 23 30 37 44 55 66 73 88 109 131 153 174 196 218 239 261 282 304 326 347 391 434 477 521 564 607 651 694 723 759 795 831 867 903 939 975 1011 1047 1084 1120 1156 1192 1228 600 13 18 24 30 36 44 53 59 70 88 105 122 140 157 174 192 209 226 243 261 278 313 347 382 417 451 486 521 555 578 607 636 665 694 723 752 780 809 838 867 896 925 954 982
B4-15
04-02
Electric Boilers
MODEL NO. VES CAP. GAL. MAX FLOW GPM ELEMENTS RATED KW 1080 1110 1140 1170 1200 CWB-361 235 900 1224 1260 1296 CWB-362 315 1170 1332 1368 1404 1440 1476 1512 1548 1584 1620 1656 1692 1728 CWB-363 370 1170 1764 1800 1836 1872 1908 1944 1980 2016 2052 2088 2124 2160 CWB-421 425 1840 2200 2240 2280 2320 2360 2400 2440 2480 2520 2560 2600 2640 MBTU/HR QTY 3685 3787 3890 3992 4094 4176 4299 4422 4545 4668 4790 4913 5036 5159 5282 5405 5527 5650 5773 5896 6019 6142 6264 6387 6510 6633 6756 6879 7001 7124 7247 7370 7506 7643 7779 7916 8052 8189 8325 8462 8598 8735 8871 9008 108 111 114 117 120 102 105 108 111 114 117 120 123 126 129 132 135 138 141 144 147 150 153 156 159 162 165 168 171 174 177 180 165 168 171 174 177 180 183 186 189 192 195 198 KW 10 10 10 10 10 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 NO. OF CONT. 208240V 480600V 36 37 38 39 40 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 55 56 57 58 59 60 61 62 63 64 65 66 NO. AND KW OF STEPS 208-240V 480-600V 12@90
Commercial Boilers
3-PHASE AMPS VS VOLTAGE 208 240 480 1300 1336 1372 1408 1444 1473 1517 1560 1603 1646 1690 1733 1776 1820 1863 1906 1950 1993 2036 2079 2123 2166 2209 2253 2296 2339 2383 2426 2469 2512 2556 2599 2647 2695 2743 2792 2840 2888 2936 2984 3032 3080 3128 3176 600 1040 1069 1098 1127 1156 1179 1213 1248 1283 1317 1352 1387 1421 1456 1491 1525 1560 1594 1629 1664 1698 1733 1768 1802 1837 1872 1906 1941 1976 2010 2045 2079 2118 2156 2195 2233 2272 2310 2349 2387 2426 2464 2503 2541
9@90,5@60 10@90,4@60 11@90,3@60 12@90,2@60 10@108,2@72 11@108,1@72 12@108 9@108,5@72 10@108,4@72 11@108,3@72 12@108,2@72 13@108,1@72 14@108 11@108,5@72 12@108,4@72 13@108,3@72 14@108,2@72 15@108,1@72 16@108 13@108,5@72 14@108,4@72 15@108,3@72 16@108,2@72 17@108,1@72 18@108 15@108,5@72 16@108,4@72 17@108,3@72 18@108,2@72 19@108,1@72 20@108 15@120,5@80 16@120,4@80 17@120,3@80 18@120,2@80 19@120,1@80 20@120 1@160,19@120 2@160,18@120 3@160,17@120 4@160,16@120 5@160,15@120 6@160,14@120
B4-16
04-02
Commercial Boilers
MODEL NO. CWB-422 VES CAP. GAL. 500 MAX FLOW GPM 1840 ELEMENTS RATED KW 2680 2720 2760 2800 2840 2880 2920 2960 3000 3040 3080 3120 3160 3200 3240 3280 3320 3360 MBTU/HR QTY 9144 9281 9417 9554 9690 9827 9963 10100 10236 10372 10509 10645 10782 10918 11055 11191 11328 11464 201 204 207 210 213 216 219 222 225 228 231 234 237 240 243 246 249 252 KW 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 NO. OF CONT. 208240V 480600V 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 NO. AND KW OF STEPS 208-240V 480-600V 7@160,13@120 8@160,12@120 9@160,11@120 10@160,10@120 11@160,9@120 12@160,8@120 13@160,7@120 14@160,6@120 15@160,5@120 16@160,4@120 17@160,3@120 18@160,2@120 19@160,1@120 20@160 9@160,15@120 10@160,14@120 11@160,13@120 12@160,12@120
Electric Boilers
3-PHASE AMPS VS VOLTAGE 208 240 480 3225 3273 3321 3369 3417 3465 3513 3561 3609 3658 3706 3754 3802 3850 3898 3946 3994 4042 600 2580 2618 2657 2695 2734 2772 2811 2849 2888 2926 2965 3003 3042 3080 3119 3157 3196 3234
B4-17
04-02
Electric Boilers
Table B4-5. Model S/CR Ratings - Sheet 1 of 2
MODEL NO. S/CR-120 WATER VOL GAL 9 STEAM SPACE GAL 7 RATED KW 12 24 36 48 S/CR-161 23 16 60 80 S/CR-162 23 16 100 120 140 160 S/CR-200 48 26 160 180 200 220 240 S/CR-241 62 53 260 280 300 320 S/CR-242 62 53 340 360 380 400 420 440 460 480 S-301 110 70 440 460 480 S-302 140 90 500 520 540 560 580 600 620 640 660 680 700 720 S-361 150 100 756 792 828 864 ASME RATING LBS STM 42 84 126 168 210 280 350 420 490 560 560 630 700 770 840 910 980 1050 1120 1190 1260 1330 1400 1470 1540 1610 1680 1540 1610 1680 1750 1820 1890 1960 2030 2100 2170 2240 2310 2380 2450 2520 2646 2772 2898 3024 ELEMENTS QTY 3 6 9 12 9 12 15 18 21 24 24 27 30 33 36 39 42 45 48 51 54 57 60 63 66 69 72 66 69 72 75 78 81 84 87 90 93 96 99 102 105 108 63 66 69 72 KW 4 4 4 4 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 6.7 12 12 12 12 NO. OF CONT. 208240V 1 2 3 4 3 4 5 6 7 8 8 9 10 11 12 13 14 15 16 17 18 19 20 480V 1 1 1 2 2 2 3 3 4 4 4 5 5 6 6 7 7 8 8 9 9 10 10 10 11 11 12 11 11 12 13 13 13 14 14 15 15 16 16 17 17 18 21 22 23 24
Commercial Boilers
NO. AND KW OF STEPS 208/240V 1@12 1@24 1@36 2@24 1@40,1@20 2@40 2@40,1@20 3@40 3@40,1@20 4@40 4@40 4@40,1@20 5@40 5@40,1@20 6@40 6@40,1@20 7@40 7@40,1@20 8@40 8@40,1@20 2@60,6@40 3@60,5@40 4@60,4@40 480V 1@12 1@24 1@36 2@24 1@40,1@20 2@40 2@40,1@20 3@40 3@40,1@20 4@40 4@40 4@40,1@20 5@40 5@40,1@20 6@40 6@40,1@20 7@40 7@40,1@20 8@40 8@40,1@20 1@80,7@40 1@80,6@40,1@60 2@80,6@40 2@80,5@40,1@60 3@80,5@40 3@80,4@40,1@60 4@80,4@40 3@80,5@40 3@80,4@40,1@60 4@80,4@40 4@80,3@40,1@60 5@80,3@40 5@80,2@40,1@60 6@80,2@40 6@80,1@40,1@60 7@80,1@40 7@80,1@60 8@80 6@80,3@40,1@60 7@80,3@40 7@80,2@40,1@60 8@80,2@40 9@72,3@36 10@72,2@36 11@72,1@36 12@72
3-PHASE AMPS 208V 34 68 101 134 168 223 279 334 390 445 445 501 556 612 667 723 778 834 889 945 1000 1056 1111 240V 30 59 88 116 145 193 242 290 338 386 386 434 482 530 578 626 675 723 771 819 867 915 963 480V 15 30 44 59 73 97 121 145 169 193 193 218 242 266 290 314 338 362 386 410 434 458 482 506 530 554 578 530 554 578 602 626 651 675 699 723 747 771 795 819 843 867 910 954 997 1040
B4-18
04-02
Commercial Boilers
Table B4-5. Model S/CR Ratings - Sheet 2 of 2
MODEL NO. WATER VOL GAL STEAM SPACE GAL RATED KW 936 972 1008 1044 1080 S-421 210 140 1044 1080 1116 1152 1188 1224 1260 1296 S-422 270 180 1332 1368 1404 1440 1476 1512 S-480 360 235 1440 1476 1512 1548 1584 1620 1656 1692 1728 1764 1800 1836 1872 1908 1944 ASME RATING LBS STM 3276 3402 3528 3654 3780 3654 3780 3906 4032 4158 4284 4410 4536 4662 4788 4914 5040 5166 5292 5040 5166 5290 5418 5540 5670 5790 5922 6050 6174 6300 6426 6550 6678 6800 ELEMENTS QTY 78 81 84 87 90 87 90 93 96 99 102 105 108 111 114 117 120 123 126 120 123 126 129 132 135 138 141 144 147 150 153 156 159 162 KW 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 NO. OF CONT. 208/ 240V 480V 26 27 28 29 30 29 30 31 32 33 34 35 36 37 38 39 40 41 42 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 NO. AND KW OF STEPS 208/240V 480V 13@72 13@72,1@36 14@72 14@72,1@36 15@72 15@72,1@36 15@72 15@72,1@36 16@72 16@72,1@36 17@72 17@72,1@36 18@72 18@72,1@36 19@72 19@72,1@36 20@72 1@108,19@72 2@108,18@72 20@72 9@108,7@72 10@108,6@72 11@108,5@72 12@108,4@72 13@108,3@72 14@108,2@72 15@108,1@72 16@108 13@108,5@72 14@108,4@72 15@108,3@72 16@108,2@72 17@108,1@72 18@108
Electric Boilers
3-PHASE AMPS 208V 240V 480V 1127 1170 1213 1257 1300 1257 1300 1343 1387 1430 1473 1517 1560 1603 1646 1690 1733 1776 1820 1733 1776 1820 1863 1906 1950 1993 2036 2079 2123 2166 2209 2253 2296 2339
NOTE: Contact your local Cleaver-Brooks authorized representative for model availability at 600 Volts.
B4-19
04-02
Electric Boilers
Table B4-6. Model CSB Ratings - Sheet 1 of 2
MODEL NO. WATER VOL GAL STEAM SPACE GAL RATED KW ASME RATING LBS STM ELEMENTS QTY KW NO. OF CONT. 480V
Commercial Boilers
NO. AND KW OF STEPS 480V
3-PH AMPS 480V
CSB-301
110
70
540 570 600 630 660 690 720
1890 1995 2100 2205 2310 2415 2520 2625 2730 2835 2940 2660 2800 2940 3080 3220 3360 3500 3640 3780 3920 4060 4200 3920 4060 4200 4340 4480 4620 4760 4900 5040 5180 5320 5460 5600 5740 5880 5460 5600 5740 5880 6020
54 57 60 63 66 69 72 75 78 81 84 57 60 63 66 69 72 75 78 81 84 87 90 84 87 90 93 96 99 102 105 108 111 114 117 120 123 126 117 120 123 126 129
10 10 10 10 10 10 10 10 10 10 10 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3
18 19 20 21 22 23 24 25 26 27 28 19 20 21 22 23 24 25 26 27 28 29 30 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 39 40 40 42 43
8@60,2@30 9@60,1@30 10@60 5@90,3@60 6@90,2@60 7@90,1@60 8@90 5@90,5@60 6@90,4@60 7@90,3@60 8@90,2@60 9@80,1@40 10@80 9@80,3@40 10@80,2@40 11@80,1@40 12@80 12@80,1@40 13@80 13@80,1@40 14@80 14@80,1@40 15@80 14@80 14@80,1@40 15@80 15@80,1@40 16@80 1@120,15@80 2@120,14@80 3@120,13@80 4@120,12@80 5@120,11@80 6@120,10@80 7@120,9@80 8@120,8@80 9@120,7@80 10@120,6@80 7@120,9@80 8@120,8@80 9@120,7@80 10@120,6@80 11@120,5@80
651 687 723 759 795 831 867 903 939 975 1011 915 963 1011 1059 1108 1156 1204 1252 1300 1348 1396 1444 1348 1396 1444 1492 1541 1589 1637 1685 1733 1781 1829 1877 1926 1974 2022 1877 1926 1974 2022 2070
CSB-302
140
90
750 780 810 840
CSB-361
150
100
760 800 840 880 920 960
CSB-362
200
130
1000 1040 1080 1120 1160 1200
CSB-421
210
140
1120 1160 1200 1240 1280 1320 1360 1400 1440
CSB-422
270
180
1480 1520 1560 1600 1640 1680
CSB-423
300
200
1560 1600 1640 1680 1720
B4-20
04-02
Commercial Boilers
Table B4-6. Model CSB Ratings - Sheet 2 of 2
MODEL NO. WATER VOL GAL STEAM SPACE GAL RATED KW ASME RATING LBS STM ELEMENTS QTY KW NO. OF CONT. 480V
Electric Boilers
NO. AND KW OF STEPS 480V
3-PH AMPS 480V
1800 1840 1880 1920 CSB-424 385 260 1960 2000 2040 2080 2120 2160 2200 2240 2280 2320 2360 2400 CSB-425 470 320 2440 2480 2520 2560 2600 2640 2680 2720 2760 2800 2840 2880
6300 6440 6580 6720 6860 7000 7140 7280 7420 7560 7700 7840 7980 8120 8260 8400 8540 8680 8820 8960 9100 9240 9380 9520 9660 9800 9940 10080
135 138 141 144 147 150 153 156 159 162 165 168 171 174 177 180 183 186 189 192 195 198 201 204 207 210 213 216
13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3 13.3
45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
13@120,3@80 14@120,2@80 15@120,1@80 16@120 1@160,15@120 2@160,14@120 3@160,13@120 4@160,12@120 5@160,11@120 6@160,10@120 7@160,9@120 8@160,8@120 9@160,7@120 10@160,6@120 11@160,5@120 12@160,4@120 13@160,3@120 14@160,2@120 15@160,1@120 16@160 11@160,7@120 12@160,6@120 13@160,5@120 14@160,4@120 15@160,3@120 16@160,2@120 17@160,1@120 18@160
2166 2214 2262 2310 2359 2407 2455 2503 2551 2599 2647 2695 2743 2792 2840 2888 2936 2984 3032 3080 3128 3176 3225 3273 3321 3369 3417 3465
NOTE: Contact your local Cleaver-Brooks authorized representative for model availability at 600 volts.
B4-21
04-02
Electric Boilers
Table B4-7. Model TWH/TWV Vessel Sizes
Commercial Boilers
MODEL BASE (1) TWV-015 TWV-020 TWV-025 TWV-030 TWV-035 TWV-040 TWV-050 TWV-060 TWV-075 TWV-100 TWV-125 TWV-150 TWH-050 TWH-060 TWH-075 TWH-100 TWH-125 TWH150 TWH-175 TWH-200 TWH-225 TWH-250
TANK SIZE GAL. 150 200 250 300 350 400 500 600 750 1000 1250 1500 500 600 750 1000 1250 1500 1750 2000 2250 2500
VESSEL DIMENSIONS (INCHES) DIAMETER 30 30 36 36 36 42 42 48 48 60 60 60 42 42 48 48 48 54 54 60 60 60 OVER ALL LENGTH 54 70 62 74 86 74 90 82 100 90 110 130 90 106 104 136 168 160 190 174 194 216
NOTES: 1. Add recovery heater kw size to complete model number (see below) recovery heaters for TWV-015 cannot exceed 240 kW 2. Note: Use this table in conjunction with Table B4-7.
B4-22
04-02
Commercial Boilers
Table B4-8. Model TWH/TWV Ratings
Electric Boilers
MODEL NO SUFFIX
.A
RATED KW
GPH@ 100 F RISE
OUTPUT MBH
ELEMENTS NO. OF CONT. 208-240V QTY KW 480-600V QTY KW 208240V 480600V 208-240V 480V NO. AND KW OF STEPS
3-PHASE AMPS VS VOLTAGE 208 240 480
TWV/TWH-030 -060 -090 -120 -150 -180 -210 -240 -270 -300 -330 -360
30 60 90 120 150 180 210 240 270 300 330 360
123 246 369 443 615 738 861 984 1107 1230 1353 1476
61 123 205 409 512 614 717 819 921 1024 1126 1228
6 12 18 24
5 5 5 5
3 6 9 12 15 18 21 24 27 30 33 36
10 10 10 10 10 10 10 10 10 10 10 10
2 4 6 8
1 2 2 4 5 6 7 8 9 10 11 12
1@30 2@30 3@30 4@30
1@30 2@30 3@30 4@30 2@60, 1@30 3@60 3@60, 1@30 4@60 4@60, 1@30 5@60 5@60, 1@30 6@60
84 168 251 334
73 145 218 290
37 73 109 145 181 218 254 290 326 362 398 434
A. Storage tank must be specified with a properly sized recovery heater to complete the model number (e.g., TWV-030-120 is a 300 gallon vertical storage tank with a 120 kW recovery heater).
NOTICE
Ratings information for Model TWV and Model TWH is split into two tables. Since this model of electric boiler is used for hot water storage as well as heating, the boiler vessel capacity in gallons and the heating rate must be selected to meet specific application needs. Table B4-6 gives the vessel capacity and boiler base models. Table B4-7 gives the heating or kilowatt rating of the units. For example, if a large storage capacity is needed, for instance, 1000 gal with a vertical tank, from Table B4-6, the base model is TWV-100, and if 90 kW recovery is required, from Table B4-7 the suffix is -90, which would add a 90 KW heater, the full model number would be TWV-100-90.
B4-23
04-02
Electric Boilers
Table B4-9. Model IWH Ratings
Commercial Boilers
MODEL NO.
MAX FLOW GPMA
RATED KW
MBTU /HR
ELEMENTS QTY KW
NO. OF CONT <250V >250V
NO. AND KW OF STEPS 208-240 480-600
3- PHASE AMPS VS VOLTAGE 208 240 480 600
IWH-611
135
15 30
51 102 154 205 102 205 307 409 256 307 358 409 307 409 512 614 717 819 717 819 921 1024 1126 1228
3 6 9 12 3 6 9 12 15 18 21 24 9 12 15 18 21 24 21 24 27 30 33 36
5 5 5 5 10 10 10 10 5 5 5 5 10 10 10 10 10 10 10 10 10 10 10 10
1 2 3 4
1 1 2 2 1 2 3 4
1@15 1@30 1@45 2@30
1@15 1@30 1@45 1@60 1@30 1@60 1@ 30,1@ 60 2@ 60
43 84 126 168
37 73 109 145
19 37 55 73 37 73 109 145
15 30 44 59 30 59 88 116 73 88 102 116 88 116 145 174 203 232 203 232 261 290 319 347
IWH-612
135
45 60
IWH-621
135
30 60
IWH-622
135
90 120
IWH-812
240
75 90 105 120
5 6 7 8
3 3 4 4 3 4 5 6 7 8 7 8 9 10 11 12
1@30,1@45 2@45 1@45,2@30 4@30
1@30,1@45 3@30 1@45, 2@30 4@ 30 3 @ 30 4 @ 30 3@30,1@60 2@30,2@60 1@30,3@60 4@60 1@30,3@60 4@60 3@30,3@60 2@30,4@60 1@30,5@60 6@60
209 251 292 334
181 218 254 290
91 109 127 145 109 145 181 218 254 290 254 290 326 362 398 434
IWH-821
240
90 120
IWH-822
240
150 180 210 240
IWH-022
360
210 240 270 300 330 360
A. Maximum flow rate is based on a maximum velocity of 1.5 fps through the heater; Minimum flow rate should not be less than 10% of the maximum flow rate listed.
B4-24
04-02
Commercial Boilers
Electric Boilers
The following sample specications are provided by Cleaver-Brooks to assist you in meeting your customers specic needs and application. 1.0 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-25 2.0 Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-25 3.0 Heating Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-25 4.0 Trim and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-26 5.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-26 1.0 Capacities 1.1 Boiler Capacity - Hot Water The ____ gallon _____ capacity hot water boiler shall be Cleaver-Brooks Model ___________ rated ____ kW at ____ V, ____ ph, 60 Hz, ____ MBtu/hr. Unit shall be suitable to operate under the following conditions: system ow rate ____ gpm; outlet water temperature ____ F; return water temperature ____F; system operating pressure ____ psig. Boiler Capacity - Steam The _____ gallon ______ capacity steam boiler shall be Cleaver-Brooks Model ______________ rated _____ kW at ____ V, _____ ph, 60 Hz. Unit shall produce ______ lbs steam/hr (from and at 212 F) at a nominal pressure of ____ psig. Water Heater Capacity - Instantaneous The horizontal circulation water heater shall be Cleaver-Brooks Model IWH ___________ rated _____ kW at ____ V, ____ ph, 60 Hz. 1.2 Storage Tank Heater Capacity The _____ gallon capacity (horizontal or vertical) shall be Cleaver-Brooks Model ___________ rated kW at _____ V, _____ ph, 60 Hz, and shall recover ____ gpm at 100 F rise. 2.0 Boiler The vessel shall be constructed in accordance with ASME Boiler Code. The vessel shall be designed for ____ psig. The relief valve shall be per ASME Code, set at ____ psig. The vessel shall be insulated with a double wrap of 2-inch ber blanket insulation having 1-1/2 PCF density. The boiler shall be UL listed, and bear the Underwriters Laboratories label. The boiler shall be of the packaged type, factory assembled, wired, and tested. The boiler shall be mounted on a full size structural steel base. The boiler enclosure shall be 16-gauge steel. The entire enclosure shall be nished in light blue enamel paint. The overall dimensions of the boiler shall be _____ inches long, ______ inches wide, and _____ inches high. For CR Models, the boiler shall include built-in condensate receiver and feed pump, with make-up valve mounted on common base with boiler, factory wired and piped, and enclosed in boiler casing. For TWV and TWH models, the vessel interior shall be lined with Epoxy, cement or sprayed copper or nickel and have magnesium anode protection. 3.0 Heating Elements The heating elements shall be individually mounted, rod type, and eld replaceable with standard tools.
B4-25
04-02
Electric Boilers
The heating watt density shall not exceed _______ (50 or 75) W/sq-in. The heating elements shall be _________ (copper or Incoloy) sheathed. 4.0 Trim and Controls The units shall be complete with the following: Main lugs for supply circuits.
Commercial Boilers
Supplemental internal branch circuit fuses, current limiting, rated at 200,000 amps interrupting capacity. Fused 120 V control circuit transformer. Magnetic contactors rated at 500,000 cycles. Integral high temperature limit (hot water boilers). High pressure limit (steam boilers). Low water cutoff (oat-type with gauge glass for steam) on all models except IWH which is supplied with a ow switch. Pressure-temperature gauge (hot water boilers). Pressure gauge (steam boilers)). Pilot switch. Pilot lights for power on, low water, high temperature or pressure. Relief valve. Drain valve (hot water boilers). Bottom and water column blowdown valves (steam boilers). Feedwater stop and check valves (steam boilers). All models (except IWH, TWV, and TWH) shall be supplied with modulating step controls to gradually apply the load in ____ steps. All models (except IWH, TWV, and TWH) shall be supplied with proportioning temperature (hot water units) or pressure (steam units) control to balance power input to match system demand.
NOTICE
Temperature control on IWH, TWV, and TWH is one of the following methods (select A or B or C). A. Thermostats - The heating elements shall be staged by control thermostats. (Standard for one and two step heaters). B. Sequencer - The heating elements shall be staged by a time delay sequencer, to energize heating elements in ____ stages with an adjustable 1 to 15 second time delay between stages. (Standard for 3 or 4 step heaters.) C Modulating Step Control - (Standard for heaters above 4 steps). 5.0 Warranty 1. The Cleaver-Brooks unit shall be warranted against defective workmanship and materials for a period of one year from the date of start- up or 18 months from shipment. 2. The TWH and TWV models shall include a 5 year warranty against vessel leakage.
B4-26
04-02
Section B5 TRUEFIRE BOILERS
Table of Contents
TrueFire Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-2 Three-Pass Wetback Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-2 Optimal Boiler Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-2 High Boiler Fuel-to-water Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-2 Advanced Insulated Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-2 Quality Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-2 Hinged Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-2 Designed for Heating Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-2 TrueFire Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-3 Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-3 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-3 Boiler Room Combustion Air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-3 Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-4 System Operating Parameters: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-4
B5-1
02-03
TrueFire Boilers
Commercial Boilers
LIST OF FIGURES Figure B5-1. Model MTF Hot Water Boiler Dimensions (Page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-6 Figure B5-2.Model MTF Minimum Room Clearance Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-8 LIST OF TABLES Table B5-1. Model MTF Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-5 Table B5-2. Model MTF Minimum Over Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-9 Table B5-3. Model MTF Circulation & Temperature Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-9 Table B5-4. Model MTF Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-10 Table B5-5. Model MTF Minimum Required Gas Pressure Altitude Conversion . . . . . . . . . . . . . . . . . . . B5-10 Table B5-6. Model MTF Boilers Minimum and Maximum Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . B5-11 Table B5-7. TrueFire Furnace Dimensions and Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-11
TrueFire Features and Benefits

Three-Pass Wetback Design
Three-pass wetback design provides excellent boiler efciency with minimal refractory. Dimpled tubes on the third pass provide high ue-gas velocities and exceptional heat transfer. Unique wetback design provides access to boiler tubes, tube sheet, and furnace for ease of maintenance.
Quality Construction
ASME construction ensures high quality design, safety, and reliability. ISO 9001 certied manufacturing process ensures the highest degree of manufacturing standards are always followed.
Hinged Front Door

Provides access to all tubes and the furnace section for easy inspection and maintenance. No crane or hoist is required to access the burner and components for inspection.
Optimal Boiler Sizing

Ten boiler sizes with capacity range of 300,000 Btu/hr through 3,000,000 Btu/hr provides the exibility for optimal boiler sizing on every heating application under 60 PSI.
Designed for Heating Applications

Pressure vessel is warranted for 20 years against thermal shock. Corrosion risk is minimized due to the tube arrangement at the hottest point of the boiler, which guarantees an even gas ow and heat distribution through the boiler.
High Boiler Fuel-to-Water Efficiency

The advanced boiler design guarantees an efciency of up to 84% on gas operation and up to 88% on oil operation.
Advanced Insulated Construction

All non-heat transfer pressure vessel surfaces are completely insulated to reduce the radiation losses and increase efciency.
B5-2
02-03
Commercial Boilers
TrueFire Boilers
6 dial pressure gauge (New York code). IRI gas train and FM gas train. Lead/lag systems for up to 6 boilers. Gas-Fired Burners Table B5-5 shows correction factors for gas pressure at elevations over 700 ft above sea level. Table B5-6 shows minimum and maximum gas pressure requirements for Standard, FM and IRI Boiler gas trains upstream of the gas pressure regulator. For oversized or undersized gas trains or altitude above 2,000 feet, contact your local Cleaver-Brooks Authorized Representative. Fuel Connections - Gas The local gas company should be consulted for requirements and authorization for installation and inspection of gas supply piping. Installation of gas supply piping and venting must be in accordance with all applicable engineering guidelines and regulatory codes. All connections made to the boiler should be arranged so that all components remain accessible for inspection, cleaning and maintenance. A drip leg should be installed in the supply piping before the connection to the gas pressure regulator. The drip leg should be at least as large as the inlet tting supplied with the boiler. Consideration must be given to both volume and pressure requirements when choosing gas supply piping size. Refer to the boiler dimension diagram provided by Cleaver-Brooks for the particular installation. Connections to the burner gas train should be made with a union, so that gas train components or the burner may be easily disconnected for inspection or service. Upon completion of the gas piping installation, the system should be checked for gas leakage and tight shutoff of all valves.
TrueFire Product Offering

Information in this section applies to hot water boiler sizes ranging from 300,000 Btu input to 3,000,000 Btu input. The TrueFire boiler is a three-pass wetback retube boiler. The boiler/burner package is UL/cUL approved. The pressure vessel conforms to Section IV of the ASME Code. The pressure vessel is wrapped in blanket insulation and contained inside a casing that is composed of removable steel panels.
Standard Equipment
Equipment described below is for the standard boiler offering. 1. Boiler: A. All boilers are designed and constructed in accordance with the ASME Code. B. Boiler is mounted on a base, insulated, and cased. 2. Forced draft burner: A. Burner is mounted on the hinged front door. Door can be hinged from either side. B. The burner has UL/cUL approval. C. Burner Controls: Natural Gas: Series 700 Light Oil: Series 100 Combination: Series 200 MTF-300, On-Off burner. MTF-500 through MTF-750, Low-High-Off burner. MTF-1000 through MTF-3000, full modulation burner. 3. Water Controls: A. Pressure and temperature gauges. B. Operating and limit controls. C. Low water cutoff probe control.

When determining boiler room air requirements, the size of the room, air ow, and velocity of air must be reviewed as follows: 1. Size (area) and location of air supply openings in boiler room. A. Two (2) permanent air supply openings in the outer walls of the boiler room are recommended. Locate one (1) at each end of the boiler room, preferably below a height of 7 feet. This allows air to sweep the length of the boiler.
Optional Equipment
Options include the following: 30# safety relief valve. Drain valve. Probe type auxiliary low water cutoff.
B5-3
02-03
TrueFire Boilers
B. Air supply openings can be louvered for weather protection, but they should not be covered with ne mesh wire, as this type of covering has poor air ow qualities and is subject to clogging by dust or dirt. C. A vent fan in the boiler room is not recommended, as it could create a slight vacuum under certain conditions and cause variations in the quantity of combustion air. This can result in unsatisfactory burner performance. D. Under no condition should the total area of the air supply openings be less than one (1) square foot. E. Size the openings by using the formula: Area (sq-ft) = cfm/fpm 2. Amount of air required (cfm). A. Combustion Air = Rated bhp x 8 cfm/bhp. B. Ventilation Air = Maximum bhp x 2 cfm/bhp or a total of 10 cfm/bhp - up to 1000 feet elevation. Add 3 percent more per 1000 feet of added elevation. 3. Acceptable air velocity in Boiler Room (fpm). A. From oor to (7) foot height - 250 fpm. B. Above (7) foot height - 500 fpm. Example: Determine the area of the boiler room air supply openings for (1) 300 hp boiler at 800 feet altitude. The air openings are to be 5 feet above oor level. Air required: 300 x 10 = 3000 cfm (from 2B above). Air velocity: Up to 7 feet = 250 fpm (from 3 above). Area Required: Area = cfm/fpm = 3000/250 = 12 sq-ft total. Area/Opening: 12/2 = 6 sq-ft/opening (2 required).
Commercial Boilers
System Operating Parameters:
System over-pressure requirements are shown on Table B5-2. Minimum return water temperature = 130 F. Minimum supply water temperature (boiler outlet)= 150 F. Maximum design temperature = 250 F. Maximum operating temperature = 240 F.
NOTICE

The design of the stack and breeching must provide the required draft at each boiler ue gas outlet. Proper draft is critical to burner performance. Although constant pressure at the ue gas outlet is not required, it is necessary to size the stack/breeching to limit ue gas pressure variation. The allowable pressure range is 0.25 W.C. to +0.25 W.C.
B5-4
02-03
Commercial Boilers
TrueFire Boilers
Table B5-1: Model MTF Boiler Ratings

MTF300 MTF500 MTF750 MTF1000 MTF1250 MTF1500 MTF1750 MTF2000 MTF2500 MTF3000
MODEL NO.
RATINGS - SEA LEVEL TO 2000 FT Btu Input (1000 Btu/hr) 300 500 750 1000 1250 1500 1750 2000 2500 3000
APPROXIMATE FUEL CONSUMPTION AT RATED CAPACITY Light Oil gph (140,000 Btu/gal) Natural Gas CFH (1000 Btu/cu-ft) Gas (Therm/hr) 2.1 300 3.0 3.6 500 5.0 5.4 750 7.5 7.1 1000 10.0 8.9 1250 12.5 10.7 1500 15.0 12.5 1750 17.5 14.3 2000 20.0 17.9 2500 25.0 21.4 3000 30.0
POWER REQUIREMENTS - SEA LEVEL TO 2000 FT, 60 HZ Blower Motor hp 3/4 3/4 1/2 1/2 3/4 3/4 1 1 1-1/2 1-1/2
Note: Pressure atomized burners. Integral oil pump. For altitude above 2000 ft contact your local Cleaver-Brooks Authorized Representative.
B5-5
02-03
TrueFire Boilers
Commercial Boilers
FF
B S X F
GG S E
R K
U G Z
D J
O
P W T H
Q
C A N
MODEL NO.
MTFDIM MTF-300 MTF-500 MTF-750 1000 LENGTHS
MTF1250
MTF1500
MTF1750
MTF2000
MTF2500
MTF3000
Gas Overall Length Oil/Comb. Shell Length Base Frame Length Front Head Extension Front Flange To Water Supply Rear Lag. To Return Base Frame To Rear Head Rear Lag. To Vent Rear Lag. To Drain B C E F G H X Z 39-3/4 35-1/4 9 10 1-3/4 8-1/4 3-1/2 1-3/4 52-3/4 48 9 12 1-3/4 8-1/4 3-1/2 1-3/4 57-1/2 52-3/4 9-1/4 15-3/4 1-3/4 8 3-1/2 1-3/4 61-1/2 56-3/4 10 15-3/4 1-3/4 9-1/4 4-1/2 1-3/4 WIDTHS Overall Width Base Outside Base Inside I M N 31-1/4 28 23-3/4 33-1/2 29-1/4 25 34-1/4 31-1/4 27 38-1/4 33-1/2 29-1/4 38-1/4 33-1/2 29-1/4 38-1/4 33-1/2 29-1/4 47 41-3/4 37-1/2 47 41-3/4 37-1/2 47 41-3/4 37-1/2 51-3/4 46-1/2 42-1/2 61-1/2 56-3/4 10 15-3/4 1-3/4 9-1/4 4-1/2 1-3/4 70 65-1/2 10 15-3/4 1-3/4 9 4-1/2 1-3/4 74-1/2 69-3/4 11-3/4 18-1/3 2-1/4 9 4-1/4 2-1/4 74-1/2 69-3/4 11-3/4 18-1/4 2-1/4 9 4-1/4 2-1/4 74-1/2 69-3/4 11-3/4 18-1/4 2-1/4 9 4-1/4 2-1/4 84 80-1/2 11-3/4 17-3/4 2-1/4 7-1/2 4-1/4 2-1/4 A 75 88 93 112 112 120-1/2 130-1/2 130-1/2 130-1/2 140
Figure B5-1. Model MTF Hot Water Boiler Dimensions (Page 1 of 2)
B5-6
02-03
Commercial Boilers
TrueFire Boilers
MODEL NO.
DIM MTF-300 MTF-500 MTF-750
MTF1000 HEIGHTS
MTF1250
MTF1500
MTF1750
MTF2000
MTF2500
MTF3000
O.A. Height Base To Top Of Lagging Base To Vent Outlet Base To Controls Base To Supply Port Base To Return Port Base Frame Base To Lifting Lug Base To Drain
D J K L O P Q R T
49-1/2 34-3/4 27-3/4 41-1/4 40-3/4 13-1/2 4-3/4 39 7
50-1/2 35 27-3/4 41-3/4 41-1/4 13-1/2 4-3/4 39-1/4 6-1/2
54 37-3/4 28-3/4 44-1/4 44-1/4 12-1/4 4-3/4 42 6
57-1/4 41-1/2 31-1/2 48 47-3/4 16-1/2 4-3/4 45-1/4 7
57-1/4 41-1/2 31-1/2 48 47-3/4 16-1/2 4-3/4 45-1/4 7
57-1/4 41-1/2 31-1/2 48 47-3/4 16-1/2 4-3/4 45-1/4 7
75-1/4 48-1/2 37-1/2 55 60-3/4 14 4-3/4 53 7
76-1/4 48-1/2 37-1/2 55 60-3/4 14 4-3/4 53 7
76-1/4 48-1/2 37-1/2 55 60-3/4 14 4-3/4 53 7
83-1/4 53-1/4 41-1/2 59-3/4 66-3/4 21-3/4 4-3/4 57-1/2 6-3/4
CONNECTIONS Supply Return Drain Vent Outlet S U W Y 1-1/2 1-1/2 1-1/2 6 2 2 1-1/2 6 2-1/2 2-1/2 1-1/2 8 2-1/2 2-1/2 1-1/2 10 2-1/2 2-1/2 1-1/2 10 2-1/2 2-1/2 1-1/2 10 4 4 1-1/2 12 4 4 1-1/2 12 4 4 1-1/2 12 5 5 1-1/2 14
MISCELLANEOUS Tube Removal Rear Front Clearance Burner Aisle* FF GG 28-1/4 47-1/4 40-1/4 47-1/4 45-3/46 47-1/4 49-3/4 63-1/2 49-3/4 63-1/2 58 63-1/2 62-1/2 67 62-1/2 67 62-1/2 67 74-3/4 67
WEIGHTS Normal Water Weight (Lbs) Shipping Weight 304 1095 463 1384 619 1657 802 1964 771 2188 926 2299 1217 2786 1146 2992 1146 3107 2067 4801
* Dimensions given exceed front tube removal requirements.
Figure B5-1. Model MTF Hot Water Boiler Dimensions ( Page 2 of 2)
B5-7
02-03
TrueFire Boilers
Commercial Boilers
Distance Between Boilers (Hinged Side) C
Burner Hinged Side B
D Stack & Smokebox Removal
Distance Between Boilers (Hinged Side)
MODEL NO.
DIM MTF-300 MTF-500 MTF-750 MTF-1000 MTF-1250 MTF-1500 MTF-1750 MTF-2000 MTF-2500 MTF-3000 LENGTHS (in)
Door, Aisle Hinged Side Between Boilers (Hinged Side) Stack, Smokebox
A B C D
47-1/4 25 56 36 6
47-1/4 25 56 36 6
47-1/4 25 56 40 6
63-1/2 41-1/2 89 44 6
63-1/2 41-1/2 89 44 6
63-1/2 41-1/2 89 44 6
67 45-1/2 97 48 6
67 45-1/2 97 48 6
67 45-1/2 97 48 6
67 43 92 52 6
Between Boilers (Non-Hinged Side) E
Door Swing (LH or RH) is Interchangable Customer to apply B & C Dimensions Appropriately Figure B5-2. Model MTF Minimum Room Clearance Dimensions
B5-8
02-03
Commercial Boilers
TrueFire Boilers
Table B5-2: Model MTF Minimum Over Pressure Requirements

MAXIMUM OUTLET TEMPERATURE (F) MINIMUM SYSTEM PRESSURE (PSI)
180 190 200 210 220 230 240
12 15 18 21 24 27 30
Table B5-3: Model MTF Circulation & Temperature Drop

SYSTEM TEMPERATURE DROP (DEGREES F) MODEL NO. 10 20 30 40 50 60 70 80 90 100 110
Circulation Rate (GPM) MTF-300 MTF-500 MTF-750 MTF-1000 MTF-1250 MTF-1500 MTF-1750 MTF-2000 MTF-2500 MTF-3000 51.5 86.5 131.3 176.1 217.6 259.6 304.6 350.1 435.2 531.2 25.8 43.3 65.7 88.0 108.8 129.8 152.3 175.1 217.6 265.6 17.2 28.8 43.8 58.7 72.5 86.5 101.5 116.7 145.1 177.1 12.9 21.6 32.8 44.0 54.4 64.9 76.2 87.5 108.8 132.8 10.3 17.3 26.3 35.2 43.5 51.9 60.9 70.0 87.0 106.2 8.6 14.4 21.9 29.3 36.3 43.3 50.8 58.4 72.5 88.5 7.4 12.4 18.8 25.2 31.1 37.1 43.5 50.0 62.2 75.9 6.4 10.8 16.4 22.0 27.2 32.5 38.1 43.8 54.4 66.4 5.7 9.6 14.6 19.6 24.2 28.8 33.8 38.9 48.4 59.0 5.2 8.7 13.1 17.6 21.8 26.0 30.5 35.0 43.5 53.1 4.7 7.9 11.9 16.0 19.8 23.6 27.7 31.8 39.6 48.3
B5-9
02-03
TrueFire Boilers
Commercial Boilers
Table B5-4: Model MTF Boiler Safety Valve Openings

VALVE SETTING MODEL NO. MTF-300 MTF-500 MTF-750 MTF-1000 MTF-1250 MTF-1500 MTF-1750 MTF-2000 MTF-2500 MTF-3000 60 psig NO. OF VALVES REQD 1 1 1 1 1 1 1 1 1 1 OUTLET SIZE (IN) 1 1 1 1 1 1 1 1 1/4 1 1/4 1 1/4
Note: Valve manufacturer is Kunkle, #537
Table B5-5: Model MTF Minimum Required Gas Pressure Altitude Conversion
CORRECTION FACTOR 1.04 1.07 1.11 1.16 1.21 CORRECTION FACTOR 1.25 1.3 1.35 1.4
ALTITUDE (FT) 1000 2000 3000 4000 5000
ALTITUDE (FT) 6000 7000 8000 9000
To obtain minimum required gas pressure at altitudes above 700 feet, multiply the pressure by the listed factors: Inches WC x0.577 = oz/sq.in. oz/sq.in x 1.732 = Inches WC Inches WC x 0.0361 = psig psig x 27.71 = Inches WC psig x 16.0 =oz/sq-in.
B5-10
02-03
Commercial Boilers
TrueFire Boilers
Table B5-6: Model MTF Boilers Minimum and Maximum Gas Pressure
STD PIPE SIZE (IN) UL MTF-300 MTF-500 MTF-750 MTF-1000 MTF-1250 MTF-1500 MTF-1750 MTF-2000 MTF-2500 MTF-3000 1 1 1 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 2 2 1.8 4.2 4.1 9.6 10.8 6.8 7.0 9.5 11.7 8.9 MINIMUM BURNER PRESSURE (W.C.) IRI/FM 1.8 4.0 3.7 9.8 11.1 7.3 7.6 10.4 11.5 8.9 MAXIMUM BURNER PRESSURE (W.C.) MAX. PRESS. 14 14 14 14 14 14 14 14 14 14
MODEL NO.
Minimum and maximum gas pressure at the entrance to UL and IRI gas trains (upstream of gas pressure regulator .
Table B5-7: TrueFire Furnace Dimensions and Pressures

FURNACE INNER DIA. (IN.) 15-1/4 15-1/4 17-1/4 19-1/4 19-1/4 19-1/4 23-3/4 23-3/4 23-3/4 27 FURNACE LENGTH (IN.) 29-1/2 42-1/2 48 51 51 59-3/4 64 64 64 74-1/2 FURNACE PRESSURE (IN. WC) 0.3 0.5 0.7 0.9 1.2 1.9 2.0 2.1 2.1 2.3
MODEL NO. MTF-300 MTF-500 MTF-750 MTF-1000 MTF-1250 MTF-1500 MTF-1750 MTF-2000 MTF-2500 MTF-3000
B5-11
02-03
TrueFire Boilers
Commercial Boilers
Notes
B5-12
02-03
Commercial Boilers
CLEAVER-BROOKS TRUEFIRE FIRETUBE BOILER SUGGESTED SPECIFICATION
TrueFire Boilers
1.0 BOILER CAPACITY 1.1 The hot water boiler shall be Cleaver-Brooks Model MTF designed for 60 psig (hot water). Maximum water temperature shall be _______ F, and maximum system temperature drop shall be _______ F. 1.2 The boiler shall have a maximum output of ____________ Btu/hr when red with No. 2 oil, and/or ________________ Btu/cuft when red with natural gas. Available electrical power will be _____ Volt, _____ phase, ____ Hz. 2.0 GENERAL BOILER DESIGN 2.1 Boiler shall be a compact retube type, three pass, wet back, updraft design with high efciency heat transfer technology and efciency herein listed. The boiler shall be designed for natural gas ring (and/or No. 2 oil ring). Gas supply pressure to the boiler gas pressure regulating valve shall be ____ psig minimum and ___ psig maximum. Boilers shall attain full rating at an elevation of ___ feet. The burner shall be forced draft multiport type for gas (and pressure atomizing type for oil). The boiler and burner must be supplied or approved by the boiler manufacturer to assure compatibility and single source responsibility for the package's performance. The boilers shall be constructed in accordance with ASME Section IV Code. The complete packaged boiler/burner unit shall be listed by Underwriters Laboratories, and shall have the UL/cUL label afxed to the unit. 2.2 Front door shall be hinged and be easily converted to allow door swing to either side for easy access. Front tube sheet along with all three ue gas passes must be fully accessible for inspection and cleaning when the door is swung open without the need for a conned entry space permit. Rear tube sheet shall be accessed through inspection access panel. 2.3 Other factory furnished and installed items for each boiler shall include: 2.3.1 Two lifting eyes on top center line of boiler. 2.3.2 Two (2) inch berglass blanket insulation and readily removable steel jacket. 2.3.3 Burner observation port. 2.3.4 Automatic to manual ring switch for manual control of the ring rate plus all operating controls (Models MTF 500 MTF 3000). 2.3.5 Factory painting using a hard nish enamel. 2.3.6 Dial type hot water temperature gauge. 2.3.7 Hot water pressure gauge. 2.3.8 ASME Code relief valve(s) with side outlet set for 60 psig. 2.3.9 A probe-type, low water cut-off control. 2.4 Each boiler shall be rated at ___ MBH output (___BHP) for 60 psig hot water design pressure. Controls shall include HighLow temperature control on larger units, operating limit temperature control and high limit temperature control of the manual reset type. Controls shall be adjusted for ___oF operating temperature. 3.0 BOILER CONNECTIONS 3.1 Hot water Boiler(s) shall be specically designed for bottom inlet and top outlet with necessary internal bafing. Inlet connection shall be ___". Outlet connection shall be ___". 4.0 BURNER AND CONTROLS 4.1 The boiler shall be provided with a UL/cUL approved fuel burning system in full accordance with the requirements of state, provincial and local codes, the local gas utility, and other applicable regulatory bodies. The burner shall be a Cleaver-Brooks ProFire burner or approved equal.
B5-13
02-03
TrueFire Boilers
4.2 Option (specify A or B, as required)
Commercial Boilers
A. The complete fuel burning system shall be in full accordance with Factory Mutual (FM) requirements. B. The complete fuel burning system shall be in full accordance with Industrial Risk Insurers (IRI) requirements. 4.3 Burner Description 4.3.1 Option (specify A, B, or C) A. The boiler shall include a gas burner having rated capacity to burn ________ MMBtu/hr of ______ Btu/cu-ft of __________ gas at a pressure of _______ (lbs/sq-in.) (inches of water column) at the inlet of the burner gas control train. B. The boiler shall include an oil burner having rated capacity to burn ______ gph of No. 2 fuel oil. C. The boiler shall include a combination gas-oil burner having rated capacity to burn _______ MMBtu/hr of Btu/cu-ft ______ gas at a pressure of _________ (lbs/sq-in.) (inches of water column) at the inlet to the burner gas control train or _______ gph of No. 2 fuel. 4.3.2 The burner shall be forced draft type with (specify A, B, or C) ring rate. All combustion air shall be furnished by the burner fan, which shall be an integral part of the burner. Each burner motor shall not be larger than ______ hp, ____ phase. A. On-Off for Model MTF-300. B. Low-High-Off for Models MTF-500 and MTF-750. C. Full modulation for Models MTF-1000 through MTF-3000. 4.3.3 Option (specify A, B, or C)
A. The gas burner shall burn the specied quantity of fuel without objectionable vibration, noise, or pulsation, with not more than 15% excess air and less than 40 ppm (corrected to 3% O2) CO in the products of combustion. B. The light oil burner shall burn the specied quantity of fuel without objectionable vibration, noise, or pulsation, with not more than 15% excess air and a maximum of No. 1 smoke spot, as measured on the Bacharach Scale. C. The gas-oil burner shall burn the specied quantity of fuel without objectionable vibration, noise, or pulsation, with not more than 15% excess air and less than 40 ppm (corrected to 3% O2) CO in the products of combustion on gas ring, and a maximum of No. 1 smoke spot, as measured on the Bacharach Scale when burning oil. 4.3.4 Primary-secondary air control shall be a design function of the combustion head. Combustion heads requiring an internal adjustment shall not be acceptable. 4.3.5 The burner shall be equipped with an aluminium reverse curve fan for lower fan motor hp requirements and self-cleaning characteristics. 4.3.6 A permanent observation port shall be provided in the burner to allow observation of both the pilot and main ame. Both the pilot and the ame scanner shall be easily accessible without opening or disassembling the burner. 4.3.7 Supply voltage available shall be ______ Volts, ______ phase, 60 Hz. All motors shall be suitable for use on this voltage. All burner controls are to be for use on 120 volts, 1 phase, 60 Hz. 4.3.8 The burner shall be factory re-tested to ensure proper operation before shipment. 4.4 Pilot Gas Train for Each Burner (Mounted, Piped, and Wired) 4.4.1 A separate pilot gas cock, gas pressure regulator, and pilot safety shutoff gas valve, shall be provided for the ignition gas supply. 4.5 Oil Burner 4.5.1 The oil burner shall be of the mechanical pressure atomizing type. 4.5.2 A two-stage oil pump shall be provided for each burner as an integral part of the burner. 4.5.3 Two approved automatically operated safety shutoff valve(s) shall be provided in the oil supply line to the burner valves to be piped in series but wired parallel.
B5-14
02-03
Commercial Boilers
4.5.4 Supply an oil pressure gauge to indicate the discharge oil pump pressure.
TrueFire Boilers
4.5.5 Install a manual valve, fuel oil lter, or strainer and vacuum gauge on the suction side of the oil pump (optional). 4.5.6 Install a fusible-link-actuated oil safety shutoff valve in the oil supply line between the oil tank and the manual gate valve at the oil pump (optional). 4.5.7 Oil pressure monitoring shall be provided by an approved pressure switch interlocked to accomplish a non-recycling safety shutdown in the event of low oil pressure (optional). 4.6 Gas Valve Train for Each Burner 4.6.1 Provide a pressure gauge to indicate the gas burner manifold pressure (optional). 4.6.2 Furnish and install one manually operated, ________ inch, ball valve upstream of all valves. 4.6.3 Provide one _______ inch, main gas pressure regulator (of tight shutoff type) with vent to outside atmosphere, in accordance with local codes.
NOTICE
Specify a tight shutoff type gas pressure regulator when the inlet gas pressure exceeds 1-1/2 psig. 4.6.4 Provide one ________ inch, automatically operated motorized safety gas valve. One safety shutoff valve shall be proven closed during pre- ignition by proof of valve closure interlock switch on valve. 4.6.5 Provide a second _______ inch, automatically operated gas safety shutoff valve to operate simultaneously with the above gas valve. 4.6.6 A manually operated gas valve shall be located downstream of both automatic gas valves to permit leakage testing of the valves. 4.6.7 Gas pressure monitoring shall be provided by approved pressure switches interlocked to accomplish a non-recycling safety shutdown in the event of either high or low gas pressure (optional on Models MTF-300 through MTF-2000). 4.7 Burner Controls 4.7.1 An additional high limit safety temperature control of the manual reset type shall be provided to control the burner. 4.7.2 Pre- and post- operation of the burner fan shall be provided per current UL/cUL requirements. 4.7.3 The burner shall utilize a Cleaver-Brooks ame safeguard programmer, incorporating 7 LED indicator lights to annunciate the current operating status of the burner. 4.7.4 A manual restart of the burner shall be necessary in the event of shutdown due to ame failure. 4.7.5 All three-phase motors shall be controlled and protected by an automatic starter with thermal overload protection. The starter shall be inter-locked to prevent burner operation when over-load relays are tripped out. 4.7.6 Supply a burner-mounted diaphragm air ow switch to prevent energizing the main fuel valves in the event of insufcient combustion air, or to provide safety shutdown in the event of combustion air interruption. 4.7.7 A factory-wired control cabinet shall be supplied and mounted on the burner. The control cabinet shall house the ame safeguard control, programming timer, burner motor starter, fuses, control circuit transformer, control switches, indicating lamps, and relays as required. 4.7.8 Provide four individual lights with nameplates on the control cabinet to indicate call for heat, main fuel valve on, low water, and main ame failure. 4.7.9 The changing from one fuel to the other shall be manual by means of a fuel selector switch. No burner adjustments shall be required to switch from one fuel to the other. 4.7.10 The burner shall be equipped with suitable fuel and air controls to assure smooth main ame ignition. The burner shall utilize a proportional air ow damper design, including independent low-re and high-re air ow shutter assemblies for ease of
B5-15
02-03
TrueFire Boilers
adjustment and consistent excess air performance throughout the ring range.
Commercial Boilers
4.7.11 Fuel-air control shall be synchronized. The fuel air drive unit shall be provided with a position indicating switch interlocked with the ame safeguard system to assure starting at the low re position. The ame safeguard system shall further program this drive unit to provide a full open louver of sufcient time to provide a four air change pre-ignition of the combustion chamber, heat exchanger, and ue passages. 4.7.12 Pre-ignition pure air ow rate shall not be less than 60% maximum ring rate air ow. Interlocks shall be provided to monitor and prove 60% air ow purge when air inlet louvers are automatically opened to obtain this rate. 4.7.13 Full modulation of fuel input shall be provided on Models MTF-1000 through MTF-3000. A modulating temperature control shall be supplied to modulate a burner mounted damper motor, controlling both fuel and air supply by means of direct mechanical linkage. 4.7.14 Electronic safety combustion controls shall be supplied, complete with ultra-violet ame scanner to monitor the pilot and main ame. It shall be so utilized as to provide intermittent type gas-electric ignition and pre-ignition timer. Flame rod will not be permitted for proving pilot or main ame. 5.0 EFFICIENCY 5.1 The boiler(s) will have a guaranteed efciency of up to 84% on gas and up to 88% on #2 oil at 100% of rating. 6.0 OPERATING TESTS, START-UP AND ON-SITE SERVICES 6.1 The boiler system and accessories shall be furnished by a single vendor to assure proper installation and service design interface, and to provide in-warranty and post-warranty unied responsibility for the owner and consulting engineer. 6.2 Boiler/burner vendor's service organization shall employ service technicians having experience in all aspects of troubleshooting, corrective service, and preventive maintenance O&M reporting. Service personnel shall be full-time employees of the vendor's organization, and shall be available 24 hrs/day, 365 days per year. 6.3 Boiler/burner vendor shall be covered by a general liability insurance policy in the minimum amount of $________. Boiler/ burner vendor shall provide the owner with a certicate of insurance specifying amounts and types of coverage. All personnel involved in start-up, service, adjustment, or testing of the equipment must be covered by this insurance. 6.4 Boiler/burner vendor shall provide a factory trained service engineer for periodic supervision during installation, eld start-up service to supervise starting, adjusting and testing of the boiler, training of operating personnel in the proper operation and maintenance. 7.0 WARRANTY 7.1 All equipment is to be guaranteed against defects in materials and/or workmanship for a period of 12 months from date of startup or 18 months from date of shipment, whichever comes rst. The warranty shall include parts only to repair or replace all defective parts and material. In addition the pressure vessel shall have a seven (7) year warranty against failure caused by low water ow or burner ame impingement on any heating surface. The boiler will be additionally warranted for 20 years against thermal shock. The warranty will not include damage caused by corrosion, operation at low water level, accumulation of scale, sludge or dirt or other improper service, operation, or neglect.
B5-16
02-03
Section B6
CLEARFIRE BOILERS
Table of Contents Clearfire Features and Benefits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-2 Compact Firetube Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-2 High Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-2 Advanced Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-2 Ease of Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-2 Quality Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-2 Full Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-2 Premix Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-2 Designed For Heating Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-2 Clearfire Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-3 Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-3 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-3 Gas-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-3 Fuel Connections - Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-3 Boiler Room Combustion and Ventilation Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-3 Indoor Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-3 Direct Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-4 Conventional Combustion Air Supply (For U.S. Installation only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-4 Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-4 System Operating Parameters: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-4 SUGGESTED SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-13
B6-1
04-8-03
Clearfire Boilers
Commercial Boilers
List of Figures AluFer Firetubes for Extended Heat Transfer Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-2 Ratio of Return Water Temperature to Efficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-5 Comparison of Return Water Temperature to Heat exchanger Temperature and Fluegas Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-5 Model MCF Hot Water Boiler Dimensions (Page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-7 Model MCF Minimum Room Clearance Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-9 List of Tables Table B6-1. Model MCF Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-5 Table B6-2. Model MCF Minimum Over Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-9 Table B6-3. Model MCF Circulation & Temperature Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-9 Table B6-4. Model MCF Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-10 Table B6-5. Model MCF Minimum Required Gas Pressure Altitude Conversion . . . . . . . . . . . . . . . . . B6-10 Table B6-6. Model MCF Boilers Minimum and Maximum Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . B6-11 Table B6-7. Clearfire Furnace Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-11
Clearfire Features and Benefits

Compact Firetube Design
The Clearfire boiler is a single pass, down fired durable Firetube boiler. The internal extended-heating surface tubes provide very high levels of performance in a compact space.
Ease of Maintenance
The steel casing is easily accessible and a drop down platform and hinged burner assembly provide access to all key components.
Quality Construction
ASME construction ensures high quality design, safety, and reliability. Supported with a 20 year thermal shock warranty. ISO 9001:2001 certified manufacturing process ensures the highest degree of manufacturing standards is always followed.
High Efficiency
With the extended heating surface tubes the Clearfire can produce fuel to water efficiency of up to 98% depending upon operating conditions.
Full Modulation
The burner and variable speed combustion fan modulate to provide only the amount of heat required, reduced cycling, low sound levels, and reduced fuel costs.
Premix Technology
The Clearfire Boiler utilizes Premix technology to mix both fuel and combustion air prior to entering the firing chamber. Combined with the variable speed fan, this technology provides very low emission levels and exceptionally safe operation.
Designed For Heating Applications

Figure B6-1. AluFer Firetubes for Extended Heat Transfer Capabilities The pressure vessel is designed for 60 psig and is constructed of durable ASTM Graded Steel and Stainless Steel materials to provide years of operation. The counter Flow Heat Exchanger provides optimal heat transfer. The vessel is designed to prevent hot spots and has no minimum flow requirements and no mininum return water requirements.
Advanced Construction
Construction from ASME steel, 316Ti stainless steel tubes with AluFer tube inserts provide optimal heat transfer. The Clearfire Boiler will provide many years of trouble-free operation.
B6-2
04-8-03
Commercial Boilers
3.
Clearfire Boilers
Controller option for communication device to computer interface. Condensate treatment tank assembly. Outside air intake for sealed combustion.
Clearfire Product Offering

Information in this section applies to hot water boiler sizes ranging from 750,000 Btu input through 1,800,000 Btu input.
4. 5.
Standard Equipment
Equipment described below is for the standard boiler offering: 1.
Gas-Fired Burners Table 6-5 shows correction factors for gas pressure at elevations over 700 feet above sea level. Table 6-6 shows minimum and maximum gas pressure requirements for standard gas trains upstream of gas pressure regulator. For oversize or undersize gas trains or altitudes above 2,000 feet, contact your local authorized Cleaver-Brooks Representative. Fuel Connections - Gas The local gas company should be consulted for requirements and authorization for installation and inspection of gas supply piping. Installation of gas supply piping and venting must be in accordance with all applicable engineering guidelines and regulatory codes. All connections made to the boiler should be arranged so that all components remain accessible for inspection, cleaning and maintenance. A drip leg should be installed in the supply piping before the connection to the gas pressure regulator. The drip leg should be at least as large as the inlet fitting supplied with the boiler. Consideration must be given to both volume and pressure requirements when choosing gas supply piping size. Refer to the boiler dimension diagram provided by Cleaver-Brooks for the particular installation. Connections to the burner gas train should be made with a union, so that gas train components or the burner may be easily disconnected for inspection or service. Upon completion of the gas piping installation, the system should be checked for gas leakage and tight shutoff of all valves.
Boiler
A. All boilers are designed for 60 psig and constructed in accordance with ASME Code. B. Boiler is mounted on a base, insulated, and casing provided.
2.
Forced Draft Burner A. Burner shall be a unitized Venturi, gas valve, blower, and burner head design. B. Burner shall incorporate a variable speed DC combustion air fan capable of modulating 5:1. C. Burner head shall be constructed of a Fecralloy-metal fiber for solid body radiation of the burner flame. D. The whisper quiet burner shall produce no more than 70-dBA sound power reading at full firing rate. E. Burner design shall have provision for induction of outside combustion air for sealed combustion.
3.
Control Boiler/burner controls shall be an integrated, digital modulating controller that controls the following functions: Heating loops. Burner sequencing with safe start check, pre-purge, direct spark ignition and post purge. Electronic ignition. Flame supervision. Safety shutdown with display of error. Modulating combustion fan. Circulating pump. Low gas pressure, air proving, high limit, and frost protection.
Boiler Room Combustion and Ventilation Air

Indoor Units The boiler must be supplied with sufficient quantities of noncontaminated air to support proper combustion and equipment ventilation. Combustion air can be supplied via conventional venting, where combustion air is drawn from the area immediately surrounding the boiler, or via direct vent, where combustion air is drawn directly from outside. All installations must comply with the requirements of NFGC for U.S., CAN\CGA B 149.1 and.2 for Canada, and all local codes.
Optional Equipment
1. 2. Controller options for multiple boiler sequencing. Outside temperature reset.
B6-3
04-8-03
Clearfire Boilers
2. 3.
Commercial Boilers
The openings must communicate either directly or by ducts with the outdoors. Each opening must have a minimum free area of one(1) square inch per 4,000 Btu/Hr of total input rating of all equipment in the room when the opening is communicating directly with the outdoors or through vertical ducts. The minimum free area required for horizontal ducts is one (1) square inch per 2,000 Btu/Hr of total input rating to all the equipment in the room. Refer to NFGC, Part 5, for additional information.
Direct Combustion Air If outside air is drawn through a vent pipe directly to the unit for combustion: 1. 2. 3. Install combustion air direct vent in accordance with manufacturer s instructions Provide for adequate ventilation. In cold climates, and to mitigate potential freeze-up, it is highly recommended that a motorized sealed damper be used to prevent the circulation of cold air through the boiler during non-operating hours. 4.
NOTICE

The design of the stack and breeching must provide the required draft at each boiler flue gas outlet. Proper draft is critical to burner performance. Although constant pressure at the flue gas outlet is not required, it is necessary to size the stack/breeching to limit flue gas pressure variation. The allowable pressure range is 0.25 (-60Pa) W.C. to +0.5 W.C. (120 Pa)
Conventional Combustion Air Supply (For U.S. Installation only) All air from Inside the Building. If all combustion air is drawn from inside the building (the mechanical equipment room does not receive air from outside): 1. The mechanical equipment room must be provided with two permanent openings communicating directly with additional room(s) of sufficient volume so that the combined volume of all spaces meet the criteria for an unconfined space. (An unconfined space is defined as a space whose volume is more that 50 cubic feet per 1,000 Btu/H of aggregate input rating of all appliances installed in that space.) Each opening must have a minimum free area of one (1) square inch per 1,000 Btu/Hr of the total input rating of all gas utilization equipment in the mechanical equipment room. One opening must commence within twelve (12) inches of the top, and one opening must commence within twelve (12) inches of the bottom of the room Refer to NFGC, Part 5, for additional information.
System Operating Parameters:

System over pressure requirements are shown on Table B6-2.
No minimum return water temperature. No minimum supply water temperature (boiler outlet). Maximum design temperature: 210 F (99C). Maximum operating temperature: 195 F (90C).
2.
3.
4.
All Air from Outdoors. If all combustion air is received from the air outside the building, (the mechanical equipment room directly communicates with the outdoors), the following method can be used: 1. The mechanical equipment room must be provided with two permanent openings, one commencing within twelve (12) inches of the top, and one opening commencing within twelve (12) inches of the bottom of the room.
B6-4
04-8-03
Commercial Boilers
Clearfire Boilers
50% Firing Rate 100% Firing Rate
Figure B6-2. Ratio of Return Water Temperature to Efficiency
100% Load 50% Load 25% Load
Figure B6-3. Comparison of Return Water Temperature to Heat Exchanger Temperature and Fluegas Temperature
B6-5
04-8-03
Clearfire Boilers
Commercial Boilers
Table B6-1: Model MCF Boiler Ratings

MODEL NO. Btu Input (1000 Btu/hr) Natural Gas CFH (1000 Btu/cu-ft) Gas (Therm/hr) Amperage (220/60/1) Heating Surface sq-ft (Fireside) MCF-750 750 625 7.5 3 BOILER DATA 276 344 479 547 Note: For altitude above 2000 ft contact your local Authorized Cleaver-Brooks Representative. MCF-1000 1000 900 10.0 3 MCF-1500 1500 1350 15.0 4 MCF-1800 1800 1620 18.0 4
RATINGS - SEA LEVEL TO 2000 FT APPROXIMATE FUEL CONSUMPTION AT RATED CAPACITY
POWER REQUIREMENTS - SEA LEVEL TO 2000 FT, 60 HZ
B6-6
04-8-03
Commercial Boilers
Clearfire Boilers
B I H G Z V U DD O T S U X Q C M V J CC DD A F P W BB E
N AA
MODEL NO.
DIM
MCF-750
MCF-1000
MCF-1500
MCF-1800
Overall Length Front of Boiler to Casing Control Panel Projection Vent Projection from Rear of Casing
C M N P
LENGTHS 62-3/4 50 4-1/4 7-1/2 WIDTHS
62-3/4 50 4-1/4 7-1/2
66-3/4 50 4-1/4 8
66-3/4 50 4-1/4 8
Overall Width Width Less Side Casing Boiler Centerline to Centerline of Air Intake Spacing Between Left & Right Stack Stubs Side of Casing to Gas Connection Casing to Centerline of Boiler Connections
B D I K G H
36-3/4 31-1/4 4 17 5-3/4 18-1/4
36-3/4 31-1/4 4 17 5-3/4 18-1/4
43-3/4 38-1/4 7 21 5-3/4 21-3-4
43-3/4 38-1/4 7 21 5-3/4 26
Figure B6-4. Model MCF Hot Water Boiler Dimensions (Page 1 of 2)
B6-7
04-8-03
Clearfire Boilers
Commercial Boilers
MODEL NO.
DIM
MCF-750
MCF-1000
MCF-1500
MCF-1800
Overall Height Floor to Top of Stack Stub Rear of Boiler to Centerline of Stack Stub Casing Height Floor to Centerline of Return Floor to Centerline of Outlet Floor to Centerline of Vent Gas Connection to top of Casing Gas Connection to Floor
HEIGHTS A 76-1/4 J L O Q S T E F 19 7-1/2 60 20 56-3/4 63-1/2 9 67-1/2
76-1/4 19 7-1/2 60 20 56-3/4 63-1/2 9 67-1/2
82-1/2 20 8-1/4 65-1/2 21-1/2 58-1/2 64-1/2 10 72-1/2
82-1/2 20 8-1/4 65-1/2 21-1/2 58-1/2 64-1/2 10 72-1/2
CONNECTIONS Connection (Supply and Return) Vent Electrical Connection, Left or Right Side (Optional) Drain Flue Gas Connection (Left or Right Side (Optional) Air Inlet Connection Boiler Adjustment Foot Gas Inlet Condensate Connection Waterside Inspection Port U V W X Y Z AA BB CC DD WEIGHTS Normal Water Weight (lbs) Shipping Weight (lbs) 747 1477 722 1554 895 1940 871 2061 2-1/2 (NPT) 1-1/2 (NPT) 1-1/2 10 4 3-1/4 1-1/2 3/4 (NPT) 2-1/2 (NPT) 1-1/2 (NPT) 1-1/2 10 4 3-1/4 1-1/2 3/4 (NPT) 3 (Flg) 1-1/2 (NPT) 1-1/2 12 6 3-1/4 2 3/4 (NPT) 3 (Flg) 1-1/2 (NPT) 1-1/2 12 6 3-1/4 2 3/4 (NPT)
Figure B6-1. Model MCF Hot Water Boiler Dimensions ( Page 2 of 2)
B6-8
04-8-03
Commercial Boilers
Clearfire Boilers
MODEL NO.
DIM
MCF-750 LENGTHS
MCF-1000
MCF-1500
MCF-1800
Top Clearance Side Clearance Backway Front Between Boilers
A B C D E
12 20 8 36 3
12 20 8 36 3
12 20 8 36 3
12 20 8 36 3
Figure B6-5. Model MCF Minimum Room Clearance Dimensions
B6-9
04-8-03
Clearfire Boilers
Commercial Boilers
Table B6-2: Model MCF Minimum Over Pressure Requirements

MAXIMUM OUTLET TEMPERATURE (F) MINIMUM SYSTEM PRESSURE (PSI)
180 190 195
12 15 18
Table B6-3: Model MCF Circulation & Temperature Drop

SYSTEM TEMPERATURE DROP (DEGREES F) MODEL NO. MCTF-750 MCF-1000 MCF-1500 MCF-1800 10 20 30 40 50 60 70 80 90 100 110
CIRCULATION RATE (GPM) 131.1 175.7 260.3 351.0 65.6 87.8 130.2 175.5 43.7 58.6 86.8 117.1 32.8 43.9 65.1 87.8 26.2 35.1 52.1 70.2 21.9 29.3 43.4 58.5 18.7 25.1 37.2 50.1 16.4 22.0 32.5 43.9 14.6 19.5 28.9 39.0 13.1 17.6 26.0 35.1 11.9 16.0 23.7 31.9
B6-10
04-8-03
Commercial Boilers
Clearfire Boilers
Table B6-4: Model MCF Boiler Safety Valve Openings

Safety Valve Opening (in) VALVE SETTING 60 psig NO. OF VALVES REQ D 1 1 1 1 OUTLET SIZE (IN.) 3/4 3/4 3/4 3/4
MBH
Minimum Release Valve Capacity 750 1000 1500 1800
MODEL NO. MCF-750 1-1/2 1-1/2 MCF-1000 MCF-1500 MCF-1800
Table B6-5: Model MCF Minimum Required Gas Pressure Altitude Conversion
To obtain minimum required gas pressure at altitudes above 700 feet, multiply the pressure by the listed factors: Inches WC x0.577 = oz/sq.in. oz/sq.in x 1.732 = Inches WC Inches WC x 0.0361 = psig psig x 27.71 = Inches WC psig x 16.0 =oz/sq-in.
B6-11
04-8-03
Clearfire Boilers
Commercial Boilers
Table B6-6: Model MCF Boilers Minimum and Maximum Gas Pressure
MODEL NO. STD PIPE SIZE (IN) 1 1 1-1/4 1-1/4 GAS BURNER MIN. PRESSURE UL MCF-750 MCF-1000 MCF-1500 MCF-1800 4.1 5 5.3 7.2 IRI 4.6 6.3 6.4 8.5 MAX. PRESS. 14 14 14 14
Minimum and maximum gas pressure at the entrance to UL and IRI Gas Trains (Upstream of Gas Pressure Regulator).
Table B6-7: Clearfire Furnace Dimensions

MODEL NO. MCF-750 MCF-1000 MCF-1500 MCF-1800 FURNACE INNER DIA. (IN.) 28.6 28.6 34.17 34.17 FURNACE LENGTH (IN.) 15.86 15.86 16.06 16.06
B6-12
04-8-03
Commercial Boilers
CLEAVER-BROOKS CLEARFIRE FIRETUBE BOILER
Clearfire Boilers
SUGGESTED SPECIFICATION
1.0 BOILER CAPACITY 1.1 Furnish and install in accordance with plans and specifications including manufacturers recommendations, state and local code _____ hot water boiler(s). The hot water boiler(s) shall be Cleaver-Brooks Model MCF Clearfire rated at 60 psig design pressure and capacity as scheduled on the drawing and specifications. 2.0 BOILER DESIGN 2.1 Boiler shall be a compact Firetube type, single pass, and down-fired design with ultra low emission and high efficiency condensing technology herein listed. The boiler shall be designed for natural gas firing. Gas supply pressure to the boiler gas pressureregulating valve shall be ____psig minimum and ____psig maximum. Boiler shall attain full rating at an elevation of ____feet. The burner shall be a forced draft design with gas and combustion air premixed prior to the burner head. The boiler, and burner, shall be supplied by the same manufacturer to assure compatibility and single source responsibility for the package performance. The boilers shall be constructed in accordance with ASME Section IV Code. Boiler to be manufactured within an ISO 9001 certified facility. 2.2 The boiler shall be constructed with a minimum of 10 square-feet of fireside heating surface per 33,475 Btu s of input. 2.3 The pressure vessel shall be constructed with titanium stabilized stainless steel boiler tubes with aluminum extended internal heating surface (AluFer). Firetube internal surface shall be a minimum of 4 times the external waterside surface area. The pressure vessel shall be of a counter flow design with no minimum return water temperature requirements and no minimum flow requirements. 2.4. Other 2" fiberglass blanket insulation and easily removable casing. Burner observation port. Factory paint with durable powder coat paint finish for corrosion protection. ASME Code relief valves with side outlet set for 60 psig. 3.0 BOILER CONNECTIONS 3.1 Hot Water Boiler(s) shall be specifically designed for top water outlet and bottom water inlet. Inlet connections shall be _____. Outlet connections shall be_____. 4.0 COMPUTERIZED BURNER CONTROL 4.1 Boiler Burner controls shall be an integrated, digital modulating controller. 4.2 Controller shall provide the following functions: 2 Heating loops. Burner sequencing with safe start check, pre-purge, direct spark ignition and post purge. Electronic ignition. Flame supervision. Safety shutdown with display of error. Modulating combustion fan. Circulating pump operation. Low gas pressure, air proving, high limit, and frost protection. 4.3 Controller shall have an option for multiple boiler sequencing. (Up to five boilers.) B6-13
04-8-03
Clearfire Boilers
4.4 Controller shall have an option for communication device to computer interface. 5.0 BURNER DESIGN 5.1 Burner shall be a unitized Venturi, gas valve, blower, and burner head design.
Commercial Boilers
5.2 Burner shall incorporate a variable speed DC combustion air fan capable of modulating the burner at a 5:1 ratio from high fire to low fire. 5.3 Burner head shall be constructed of a Fecralloy-metal fiber for solid body radiation of the burner flame. 5.4 Burner shall produce less than 70-dBA sound reading at full firing rate. 5.5 Burner design shall have provision for induction of outside combustion air for sealed combustion. 6.0 ELECTRICAL REQUIREMENTS 6.1 Power available will be 220-1-60 phase with option for 115-1-60. 6.2 All wiring shall be in compliance with National Electrical Code. 7.0 EFFICIENCY 7.1 The boiler(s) will have a guaranteed efficiency of up to 98% based on return water temperatures of 80 degrees Fahrenheit at full firing rate. 8.0 EMISSIONS 8.1 Burner Boiler design shall produce NOx emission levels of no more than 20 PPM at full firing rate. 9.0 OPERATING TESTS, STARTUP AND ON SITE SERVICES 9.1 A single vendor to assure proper installation and service design interface, and to provide in-warranty and post-warranty unified responsibility for the owner and consulting engineer, as well as shall furnish the boiler system and accessories. 9.2 Boiler vendor s service organization shall employ service technicians having experience in all aspects of troubleshooting, corrective service, and preventative maintenance O&M reporting. Service personnel shall be full-time employees of the vendors organization and shall be available 24 hours per day and 365 days per year. 9.3 Boiler vendor shall be covered by a general liability insurance policy in the minimum amount of $__________. Boiler vendor shall provide the owner with a certificate of insurance specifying amounts and types of coverage. All personnel involved in start-up service, adjustment, or testing of the equipment must be covered by this insurance. 9.4 Boiler vendor shall provide a factory trained service engineer for periodic supervision during installation, field start-up service to supervise starting, adjusting and testing of the boiler, training of the operating personnel in the proper operations and maintenance. 10.0 MANUFACTURER S WARRANTY 10.1 All equipment shall be guaranteed against defects in materials and or workmanship for a period of 12 months from the date of startup, or 18 months from the date of shipment, whichever comes first. The warranty shall include parts only to repair or replace all defective parts and material. 10.2 The pressure vessel shall be warranted for 20 years against thermal shock.
B6-14
04-8-03
Section C
INDUSTRIAL WATERTUBE BOILERS
CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4 Boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4 Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-5 Flue Gas Recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-5 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5 Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6 Optional Equipment (Partial Listing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-7 DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-7 EMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-32 ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-34 Steam Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-34 Lower Drum (Mud Drum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-34 Drum Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-35 Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-35 Convection Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-37 Casing and Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-39 Structural Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-41 Burner/Controls Information (A, BR, CN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-41 Flame Safeguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-41 Burner/Controls Information (CT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-44 Flame Safeguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-45 Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-46 Breeching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-47 SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-55 ILLUSTRATIONS Figure C-1. Model D Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-16 Figure C-2. Models DL and DLD Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-18 Figure C-3. Model DLDH Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-20 Figure C-4. Model DFE Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-22 Figure C-5. Model DW Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-24 Figure C-6. Model DLW Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-26 Figure C-7. General A Burner Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-28 C-1
02-02
Industrial Watertube Boilers

Figure C-8. General BR Burner Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-29 Figure C-9. General CN Burner Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-30 Figure C-10 General CT Burner Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-31 Figure C-11. Drum Internals and Steam Purifiers for 1, 3, and 7 ppm Solids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-36 Figure C-12. Drum Internals and Separator for 99.5% Dry Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-36 Figure C-13. D Series Boiler Tube Cut-Away . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-37 Figure C-14. Convection Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-38 Figure C-15. D Series Boiler Enclosure Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-39 Figure C-16. Series Skid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-40 Figure C-17. Support Drum in Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-40 Figure C-18. Forced FGR System, Industrial Watertube Boiler (A, BR, CB Burners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-44 Figure C-19. Induced FGR System, Industrial Watertube Boiler (CT Burner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-47 Figure C-20. Recommended Pier Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-48 Figure C-21. Right Hand Boiler Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-48 Figure C-22. Left Hand Boiler Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-48 Figure C-23. RH and LH Boiler Arrangement With Separate Stacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-49 Figure C-24. LH and RH Boiler Arrangement With Common Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-49 Figure C-25. Two-Boiler Arrangement With Separate Stacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-50 Figure C-26. Breeching,; Top Outlet Transition Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-51 Figure C-27. Breeching; Gas Outlet Transition (Direct-to-Stack) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-52 Figure C-28. Breeching, Gas Outlet Transition (Connection to horizontal breeching) . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-53 TABLES Table C-1. Industrial Watertube Steam Boiler Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C- 6 Table C-2. Standard Trim (Model D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8 Table C-3. Standard Trim (Models DL and DLD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9 Table C-4. Standard Trim (Model DLDH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10 Table C-5. Standard Trim (Model DFE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-11 Table C-6. 300 psig Steel Trim (Model D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12 Table C-7. 300 psig Steel Trim (Models DL and DLD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13 Table C-8. 300 psig Steel Trim (Model DLDH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-14 Table C-9. 300 psig Steel Trim (Model DFE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-15 Table C-10. Industrial Watertube Emission Data - Natural Gas (A, B, CN Burners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-32 Table C-11. Industrial Watertube Emission Data - No. 2 Oil (A, BR, CN Burner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-32 Table C-12. Industrial Watertube Emission Data - Heavy Oils (A, BR, CN Burners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-32 Table C-13. Industrial Watertube Emission Data - Natural Gas (CT Burner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-33 Table C-14. Industrial Watertube Emission Data - No. 2 Oil (CT Burner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-33 Table C-15. Industrial Watertube Emission Data - Heavy Oils (CT Burner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-33 Table C-16. Heating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-34 Table C-17. Maximum Heat Output (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-35 Table C-18. Maximum Heat Output (Steam). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-35 Table C-19. Burner Data (Model A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-42 Table C-20. Burner Data (Model BR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-42 Table C-21. Burner Data (Model CN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-42 Table C-22. Standard Offering (A, BR, and CN Burners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-43 Table C-23. Burner Data (Model CT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-45 Table C-24. Standard Offering (Model CT Burner). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-46 Table C-25. Industrial Watertube Boiler Stack Size Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-54
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This section contains information on the Cleaver-Brooks D Series Industrial Watertube Boiler product line. The D Series is named after its design. Tubes are assembled between the steam drum and mud drum forming the furnace in the shape of a D, which provides maximum circulation and high steam quality. The D Series consists of ve Models: D, DL, DLD, DLDH and DFE. The models differ according to the size of their steam and mud drums, the height and width of the boiler, and capacities. Cleaver-Brooks Industrial Watertube Boilers range from 10,000 to 150,000 lbs/hr steam. Design pressure to 1000 psig. Super heat temperature to 750 F. High temperature hot water boilers range from 13.4 MMBtu/hr to 62.5 MMBtu/hr output. Model designations for the high temperature hot water boilers are DW and DLW.
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The following features and benets apply to Cleaver-Brooks Industrial Watertube Boiler Products.
10 Gauge Double Casing: Provides static zone to prevent ue gas entrapment and acidcorroding of the casing. Allows higher furnace pressures required to minimize NOx formations when utilizing ue gas recirculation technologies. Rugged and suitable for outdoor installation. Heavy Base Frame: Permits easy lifting, jacking, or skidding during initial installation. Allows placement of piers, facilitating visual underside inspections and simplifying general housekeeping. Provides maximum support for boiler vessel.
Boilers
Six Furnace Wall Cooling: Ensures minimal refractory maintenance and extends boiler life. Ensures proper circulation with tiles to protect furnace oor tubes to. Tangent Tube Design, 2" Tubes on 2" Centers Provides greater uniform heat transfer. Minimizes thermal stress with non-welded water-cooled, heating surfaces. Provides cooler furnace temperature minimizing the formation of thermally-produced NOx emissions. Membrane Inner Furnace Wall, 2" Tubes on 4" Centers: Eliminates by-pass of furnace gases into the convection section. Minimizes both CO and NOx emissions. Rear Furnace Wall: Maximizes heat transfer area and minimizes refractory maintenance with 80% wall coverage with tubes m. Allows stressless pressure vessel/tube expansion because of oating rear wall with positive end wall seals. Convection Section Design: Enables easy tube removal with wide and narrow spacing between rows of tubes. Eliminates abrasion of tubes from sootblower action by locating sootblower nozzle within the wide space area of tubes. Maximizes heat transfer with even distribution of ue gases through the utilization of vertical bafes. Patented Drum Internals: Eliminates, in many applications, the need for expensive two-or-three-element feedwater control systems through use of Cleaver-Brooks patented system of bafes to ensure stable water levels under dynamic load conditions.
Burners
High Turndown Capability: Reduces burner cycling. Reduces maintenance costs. Reduces fuel costs. Is available for gas, oil or combination. Integral Forced Draft Fan: Eliminates need for special ducting or breeching. Creates smaller overall package and an integral part of the burner windbox. Reduces motor horsepower requirements. Assures proper sizing for combustion air requirements. Steam or Air Atomazation: Provides clean, efcient ring of oil fuels. Provides low steam consumption. Provides packaged air compressor with air atomized burners. Patented Fuel Oil Controller: Consolidates function of four valves. Eliminates need for up to 35 separate pipe ttings. Provides ease of maintenance and operation. Furnished completely piped and assembled.
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Low NOx Capability: Guaranteed NOx levels to 10 ppm available. Provides ease of operation and installation. Meets or exceeds EPA air quality regulations. Assures high fuel-to-steam efciency (no loss in efciency over standard package). Offers synchronized FGR operation with boiler modulation. Ensurer simplied control and safe and reliable operation with single-point-positioning of fuel, air and FGR. Is engineered specically for CB Boilers. Assures reliable, trouble-free operation with integrated safety controls. Patented Dual Canister Burner Housing Design (Model A Burner) - Extended Burner Drawer (Model BR & Model CN Burners): Guarantees NOx emission control on natural gas and #2 oilutilizing forced FGR system conguration. Improves CO performance. Maintains ame stability and combustion control. Assure complete mixing of ame and recirculating ue gases for excellent NOx and CO control. Proven Venturi-Type Burner Design CT Burner venturi design allows for low NOx emissions through utilization of induced FGR. Mechanical Linkage Assembly Minimizes complex controls. Allows for single-point-positioning to synchronize fuel, air and FGR ow rates. Manual Shutoff Valve: Allows for isolation of FGR system during maintenance periods while allowing boiler to operate and maintain load.
Controls
Microprocessor-Based Flame Safeguard System: Provides diagnostic capability with alpha-numeric display. Is UL, FM, IRI, and CSA approved. Retains last fault/lockout condition with non-volatile memory (refer to Boiler Controls, Section 8 for more information on optional ame safeguard systems). Full Modulation Combustion Controls System: Features single-point positioning for safety, simplicity, reliability, and ease of start-up. Maintains pressure or temperature setpoint automatically. Features built-in low-re hold. Enables single switch quick changeover from gas ring to oil ring. Cleaver-Brooks Water Column: Comes with ve probes for high and low water alarm conditions (audio-visual alarm provided in boiler control panel) and dual redundant low water cutoffs. Complete Controls Package Includes: All controls piped and wired. Custom control systems (optional). All wiring conforms to NEC and industry standards.
PRODUCT OFFERING
Atomizing Air Compressor (Optional): Pre-piped (A and BR Burner) or mounted in a convenient console (CN Burner). Automatically-controlled and interlocked through ame safeguard system. Cleaver-Brooks Industrial Watertube Boilers range from 10,000 to 150,000 lbs/hr steam. Design pressure to 1000 psig. Super heat temperature to 750 F. High temperature hot water boilers range from 13.4 to 62.5 MMBtu/hr output.
Flue Gas Recirculation

Integrated Boiler/Burner/FGR Control Package Satises FM/IRI requirements.
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Table C-1. Industrial Watertube Steam Boiler Models
MODEL NO. 26 34 42 52 D 60 68 76 86 94 52 60 68 DL 76 86 94 68 76 DLD 86 94 60 68 76 86 DLDH 94 102 110 118 85 98 DFE 110 121 132 106.2 115.6 124.9 134.1 81.3 101.5 111.5 121.6 151.7 78.14 85.54 63.4 76.3 85.6 97 70.3 79.91 87.41 60.15 68.87 MAX OUTA LBS/HR (STEAM) 16 21.4 26.8 37.41 43.92 50.22 57.17 65.12 72.62 45.47 53.31 61.47
materials and equipment: Inner and outer 10-gauge casing. Packaged burner assembly. Electric single-point positioning full modulating combustion controls. Forced draft fan and motor drive. Sootblowers for heavy oil ring. 240 psig trim package. Membrane inner furnace wall. IRI requirements. 2. Each burner is furnished with a standard Cleaver-Brooks electric positioning combustion control system designed to operate in conjunction with the burner and fuel control valves provided. The system includes the following major components: Master pressure control. Limiting pressure control. Electric drive motor. Control shaft and linkages. Gas control valve (for gas or combination burners). Fuel oil controller (for oil or combination burners). Forced draft fan control. The combustion control system is mounted on the unit at the plant and is shipped as a completely integrated system. 3. The boiler is built in accordance with the following requirements: American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section I, Power Boilers. American Boiler Manufacturers Association (ABMA) Manual of Industry Standards. National Fire Protection Association (NFPA), 8501 Prevention of Furnace Explosions in Fuel Oil and Natural Gas-Fired Single Burner Boiler Furnaces. Steel Structures Painting Council (SSPC), Surface Preparation SP-l.
A. DLDH with Economizer.
Table C-1 shows Models D, DL, DLD, DLDH and DFE steam boilers and the associated outputs. An FGR system can be purchased with a new boiler or retrot.
National Electric Code (NEC) National Electrical Manufacturers Association (NEMA). Insurance Requirements: Safety equipment and combustion controls described above, which are Cleaver-Brooks standard, can be modied to meet Factory Mutual, Military, or other
Standard Equipment
1. Included with each standard packaged unit are the following C-6
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requirements. Industrial Risk Insurers: Equipment is furnished in compliance with published requirements of the Industrial Risk Insurers as given in the latest IRI information Single Burner Boiler Furnaces. Tables (C-2, C-3, C-4 and C-5) show boiler trim packages included with standard design pressure of 260 psig. Tables (C-6, C7, C-8 and C-9) show boiler trim installed at 300 psig design pressure. Fuel Options Low re fuel change-over. Special gas train sizes. Gas strainer. Special fuel shut-off values. Special oil pump sets. Alternate fuel ring. For information on the following options please refer to the referenced section: Economizers (selected for specic job site conditions), Section G. Optional Controls, Section D.
Optional Equipment (Partial Listing)

The following options are available: Boiler Options Design pressure up to 1000 psig. Superheaters. Hinged manway covers in steam drum. Clean out ports in front and rear convection wall. Multiple 12" x 24" convection side access doors. Warm up coil in lower drum. Platforms and ladders. Various steam quality drum internals. Special blowdown valves. Weatherproong. Wash drains. Rear furnace access door. Burner/Control Options Special motors (TEFC, high efciency, etc.). NEMA enclosures. Special combustion control systems: Single-point, parallel positioning, full metering, cross-limited systems. Cleaver-Brooks oxygen trim system. Plant master, lead-lag, day-night controls, etc. Feed water control systems (one, two, or three element). Special burner packages. Special insurance or code requirements.

The following illustrations (Figures C-1 thru C-8) show dimensions for the Industrial Watertube Product offering. Figure C-1. Model D Dimensions Figure C-2. Model DL and DLD Dimensions Figure C-3. Model DLDH Dimensions Figure C-4. Model DFE Dimensions Figure C-5. Model DW Dimensions Figure C-6. Model DLW Dimensions Figure C-7. General A Burner Dimensions Figure C-8. General BR Burner Dimensions Figure C-9. General CN Burner Dimensions Figure C-10. General CT Burner Dimensions FGR sytems for Industrial Watertube boiler applications are custom engineered to meet specic application requirements. Specic information regarding dimensions, ratings, and performance data will be provided on a job-by-job basis. Contact your local Cleaver-Brooks authorized representative for assistance.
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Table C-2. Standard Trim (Model D)

VALVES SERVICE QUANTITY MFG. TYPE VALVE SIZES Safety Feed Stop Feed Stop Feed Check Drum Blow-off Tandem Air Vent Continuous Blowdown Soot Blower Control Soot Blower Drain Soot Blower Drain Code 1 1 1 1 Set 1 1 1 1 1 Kunkle Velan Velan Lunk. Edw. Velan Velan Velan Velan Velan 252 S-2054B F-2054B 624 848-849 S-2074B S-2074B S-2054B S-2074B S-2074B Code 1-1/2 1-1/2 1-1/4 1/2 1 2 3/4 Code 1-1/2 1-1/2 1-1/4 1/2 1 2 3/4 Code 2 2 1-1/4 1/2 1 2 3/4 Code 2-1/2 2-1/2 1-1/4 1/2 1 2 3/4 3/4 Code 2-1/2 2-1/2 1-1/4 1/2 1 2 3/4 3/4 26 34-42 MODEL D 52-76 86 94
FEEDWATER REGULATOR ASSEMBLY Feedwater Regulator Regulator By-pass (Throttle) Regulator By-pass (Shut-off) Regulator By-pass (Shut-off) Liquid Level Control (Shut-off) Control Drain 1 1 2 2 2 1 Fisher Velan Velan Velan Velan Velan 667 EZ S-2074B S-2074B S-2074B S-2054B S-2054B 1 1-1/4 1-1/2 1-1/2 3/8 1 1-1/4 1-1/2 1-1/2 3/8 1-1/2 1-1/2 2 1-1/2 3/8 2 2 2-1/2 1-1/2 3/8 2 2 2-1/2 1-1/2 3/8
WATER COLUMN ASSEMBLY Water Column Water Gauge Gauge Cocks Column Drain Gauge Drain Hi-Low Alarm Low Water Cut-off 1 1 3 1 1 1 2 C-B Rel. Rel. Velan Velan Warr. Warr. Steel 404-RS GC-451 S-2054B S-2054B Probe Probe 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 -
Note: Valve manufacturers listed are for reference only. Actual manufacturer may vary.
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Table C-3. Standard Trim (Models DL and DLD)

VALVES SERVICE QUANTITY MFG TYPE VALVE SIZES Safety Feed Stop Feed Stop Feed Check Drum Blow-off Tandem Air Vent Continuous Blowdown Soot Blower Control Soot Blower Drain Soot Blower Drain Code 1 1 1 1 Set 1 1 1 1 1 Kunkle Velan Velan Lunk. Edw. Velan Velan Velan Velan Velan 252 S-2054B F-2054B 624 848-849 S-2074B S-2074B S-2054B S-2074B S-2074B Code 2 2 1-1/4 1/2 1 2 3/4 Code 2 2 1-1/4 1/2 1 2 3/4 Code 2-1/2 2-1/2 1-1/4 1/2 1 2 3/4 Code 2-1/2 2-1/2 1-1/4 1/2 1 2 3/4 3/4 Code 2-1/2 2-1/2 1-1/4 1/2 1 2 3/4 3/4 Code 2-1/2 2-1/2 1-1/4 1/2 1 2 3/4 3/4 52 60 MODELS DL & DLD 68 76 86 94
FEEDWATER REGULATOR ASSEMBLY Feedwater Regulator Regulator By-pass (Throttle) Regulator By-pass (Shut-off) Regulator By-pass (Shut-off) Liquid Level Control (Shut-off) Control Drain 1 1 2 2 2 1 Fisher Velan Velan Velan Velan Velan 667 EZ S-2074B S-2074B S-2074B S-2054B S-2054B 1-1/2 1-1/2 2 1-1/2 3/8 1-1/2 1-1/2 2 1-1/2 3/8 2 2 2-1/2 1-1/2 3/8 2 2 2-1/2 1-1/2 3/8 2 2 2-1/2 1-1/2 3/8 2 2 2-1/2 1-1/2 3/8
WATER COLUMN ASSEMBLY Water Column Water Gauge Gauge Cocks Column Drain Gauge Drain Hi-Low Alarm Low Water Cut-off 1 1 3 1 1 1 2 C-B Rel. Rel. Velan Velan Warr. Warr. Steel 404-RS GC-451 S-2054B S-2054B Probe Probe 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 -
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Table C-4. Standard Trim (Model DLDH)

VALVES SERVICE QTY MFG TYPE 60 VALVE SIZES Safety Feed Stop Feed Stop Feed Check Drum Blow-off Tandem Air Vent Continuous Blowdown Soot Blower Control Soot Blower Drain Soot Blower Drain Code 1 1 1 1 Set 1 1 1 1 1 Kunkle Velan Velan Lunk. Edw. Velan Velan Velan Velan Velan 252 S-2054B F-2054B 624 848-849 S-2074B S-2074B S-2054B S-2074B S-2074B Code 2-1/2 2-1/2 1-1/4 1/2 1 2 3/4 3/4 Code 2-1/2 2-1/2 1-1/4 1/2 1 2 3/4 3/4 Code 3 3 1-1/4 1/2 1 2 3/4 3/4 Code 3 3 1-1/4 1/2 1 2 3/4 3/4 Code 3 3 1-1/2 1/2 1-1/2 2 3/4 3/4 Code 3 3 1-1/2 1/2 1-1/2 2 3/4 3/4 Code 3 3 1-1/2 1/2 1-1/2 2 3/4 3/4 Code 3 3 1-1/2 1/2 1-1/2 2 3/4 3/4 68 76 MODEL DLDH 86 94 102 110 118
FEEDWATER REGULATOR ASSEMBLY Feedwater Regulator Regulator By-pass (Throttle) Regulator By-pass (Shut-off) Regulator By-pass (Shut-off) Liquid Level Control (Shut-off) Control Drain 1 1 2 2 2 1 Fisher Velan Velan Velan Velan Velan 667 EZ S-2074B S-2074B S-2074B S-2054B S-2054B 2 2 2-1/2 1-1/2 3/8 2 2 2-1/2 1-1/2 3/8 2 2-1/2 3 1-1/2 3/8 2 2-1/2 3 1-1/2 3/8 2 2-1/2 3 1-1/2 3/8 3 2-1/2 3 1-1/2 3/8 3 3 3 1-1/2 3/8 3 3 3 1-1/2 3/8
WATER COLUMN ASSEMBLY Water Column Water Gauge Gauge Cocks Column Drain Gauge Drain Hi-Low Alarm Low Water Cut-off 1 1 3 1 1 1 2 C-B Rel. Rel. Velan Velan Warr. Warr. Steel 404-RS GC-451 S-2054B S-2054B Probe Probe 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 -
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Table C-5. Standard Trim (Model DFE)

VALVES SERVICE QTY MFG TYPE 85 98 MODEL DFE 110 121 132
VALVE SIZES Safety Feed Stop Feed Stop Feed Check Drum Blow-off Tandem Air Vent Continuous Blowdown Soot Blower Control Soot Blower Drain Soot Blower Drain Code 1 1 1 1 Set 1 1 1 1 1 Kunkle Velan Velan Lunk. Edw. Velan Velan Velan Velan Velan 252 S-2054B F-2054B 624 848-849 S-2074B S-2074B S-2054B S-2074B S-2074B Code 3 3 1-1/2 1/2 1-1/2 2 3/4 3/4 Code 3 3 1-1/2 1/2 1-1/2 2 3/4 3/4 Code 3 3 1-1/2 1/2 1-1/2 2 3/4 3/4 Code 4 4 1-1/2 1/2 1-1/2 2 3/4 3/4 Code 4 4 1-1/2 1/2 1-1/2 2 3/4 3/4
FEEDWATER REGULATOR ASSEMBLY Feedwater Regulator Regulator By-pass (Throttle) Regulator By-pass (Shut-off) Regulator By-pass (Shut-off) Liquid Level Control (Shut-off) Control Drain 1 1 2 2 2 1 Fisher Velan Velan Velan Velan Velan 667 EZ S-2074B S-2074B S-2074B S-2054B S-2054B 2 2-1/2 3 1-1/2 3/8 2 2-1/2 3 1-1/2 3/8 3 2-1/2 3 1-1/2 3/8 3 3 4 1-1/2 3/8 3 3 4 1-1/2 3/8
C-11
02-02
Table C-6. 300 psig Steel Trim (Model D)

VALVES SERVICE QTY MFG TYPE 26 BOILER MODEL - D 34-42 52-76 86 94
VALVE SIZES Safety Feed Stop Feed Stop Feed Check Feed Check Drum Blow-off Tandem Air Vent Continuous Blowdown Soot Blower Control Soot Blower Drain Soot Blower Drain Code 1 1 1 1 1 Set 1 1 1 1 1 Kunkle Velan Velan Edw. Lunk. Edw. Velan Velan Velan Velan Velan 300 S-2054B F-1064C 838 3072-C 848-849 S-2074B S-2074B S-2054B S-2074B S-2074B Code 1-1/2 1-1/2 1-1/4 1/2 1 2 3/4 Code 1-1/2 1-1/2 1-1/4 1/2 1 2 3/4 Code 2 2 1-1/4 1/2 1 2 3/4 Code 2-1/2 2-1/2 1-1/4 1/2 1 2 3/4 3/4 Code 2-1/2 2-1/2 1-1/4 1/2 1 2 3/4 3/4
FEEDWATER REGULATOR ASSEMBLY Feedwater Regulator Regulator By-pass (Throttle) Regulator By-pass (Shut-off) Regulator By-pass (Shut-off) Liquid Level Control (Shut-off) Control Drain 1 1 2 2 2 1 Fisher Velan Velan Velan Velan Velan 667 EZ S-2074B S-2054B F-1064C S-2054B S-2054B 1 1-1/4 1-1/2 1-1/2 3/8 1 1-1/4 1-1/2 1-1/2 3/8 1-1/2 1-1/2 2 1-1/2 3/8 2 2 2-1/2 1-1/2 3/8 2 2 2-1/2 1-1/2 3/8
C-12
02-02
Table C-7. 300 psig Steel Trim (Models DL and DLD)

VALVES SERVICE QTY MFG TYPE VALVE SIZES Safety Feed Stop Feed Stop Feed Check Feed Check Drum Blow-off Tandem Air Vent Continuous Blowdown Soot Blower Control Soot Blower Drain Soot Blower Drain Code 1 1 1 1 1 Set 1 1 1 1 1 Kunkle Velan Velan Edw. Lunk. Edw. Velan Velan Velan Velan Velan 300 S-2054B F-1064C 838 3072-C 848-849 S-2074B S-2074B S-2054B S-2074B S-2074B Code 2 2 1-1/4 1/2 1 2 3/4 Code 2 2 1-1/4 1/2 1 2 3/4 Code 2-1/2 2-1/2 1-1/4 1/2 1 2 3/4 Code 2-1/2 2-1/2 1-1/4 1/2 1 2 3/4 3/4 Code 2-1/2 2-1/2 1-1/4 1/2 1 2 3/4 3/4 Code 2-1/2 2-1/2 1-1/4 1/2 1 2 3/4 3/4 52 BOILER MODELS - DL AND DLD 60 68 76 86 94
FEEDWATER REGULATOR ASSEMBLY Feedwater Regulator Regulator By-pass (Throttle) Regulator By-pass (Shut-off) Regulator By-pass (Shut-off) Liquid Level Control (Shut-off) Control Drain 1 1 2 2 2 1 Fisher Velan Velan Velan Velan Velan 667 EZ S-2074B S-2054B F-1064C S-2054B S-2054B 1-1/2 1-1/2 2 1-1/2 3/8 1-1/2 1-1/2 2 1-1/2 3/8 2 2 2-1/2 1-1/2 3/8 2 2 2-1/2 1-1/2 3/8 2 2 2-1/2 1-1/2 3/8 2 2 2-1/2 1-1/2 3/8
WATER COLUMN ASSEMBLY Water Column Water Gauge Gauge Cocks Column Drain Gauge Drain Hi-Low Alarm Low Water Cut-off 1 1 3 1 1 1 2 C-B Rel. Rel. Velan Velan Warr. Warr. Steel 404-RS GC-451 S-2054B S-2054B Probe Probe 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 -
C-13
02-02
Table C-8. 300 psig Steel Trim (Model DLDH)

VALVES SERVICE QTY MFG TYPE 60 VALVE SIZES Safety Feed Stop Feed Stop Feed Check Feed Check Drum Blow-off Tandem Air Vent Continuous Blowdown Soot Blower Control Soot Blower Drain Soot Blower Drain Code 1 1 1 1 1 Set 1 1 1 1 1 Kunkle Velan Velan Edw. Lunk. Edw. Velan Velan Velan Velan Velan 300 S-2054B F-1064C 838 3072-C 848-849 S-2074B S-2074B S-2054B S-2074B S-2074B Code 2-1/2 2-1/2 1-1/4 1/2 1 2 3/4 3/4 Code 2-1/2 2-1/2 1-1/4 1/2 1 2 3/4 3/4 Code 3 3 1-1/4 1/2 1 2 3/4 3/4 Code 3 3 1-1/4 1/2 1 2 3/4 3/4 Code 3 3 1-1/4 1/2 1 2 3/4 3/4 Code 3 3 1-1/4 1/2 1 2 3/4 3/4 Code 3 3 1-1/4 1/2 1 2 3/4 3/4 Code 3 3 1-1/4 1/2 1 2 3/4 3/4 68 BOILER MODEL - DLDH 76 86 94 102 110 118
FEEDWATER REGULATOR ASSEMBLY Feedwater Regulator Regulator By-pass (Throttle) Regulator By-pass (Shut-off) Regulator By-pass (Shut-off) Liquid Level Control (Shut-off) Control Drain 1 1 2 2 2 1 Fisher Velan Velan Velan Velan Velan 667 EZ S-2074B S-2054B F-1064C S-2054B S-2054B 2 2 2-1/2 1-1/2 3/8 2 2 2-1/2 1-1/2 3/8 2 2-1/2 3 1-1/2 3/8 2 2-1/2 3 1-1/2 3/8 2 2-1/2 3 1-1/2 3/8 3 2-1/2 3 1-1/2 3/8 3 3 3 1-1/2 3/8 3 3 3 1-1/2 3/8
WATER COLUMN ASSEMBLY Water Column Water Gauge Gauge Cocks Column Drain Gauge Drain Hi-Low Alarm Low Water Cut-off 1 1 3 1 1 1 2 C-B Rel. Rel. Velan Velan Warr. Warr. Steel 404-RS GC-451 S-2054B S-2054B Probe Probe 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 3/4 3/4 3/4 3/8 -
C-14
02-02
Table C-9. 300 psig Steel Trim (Model DFE)
VALVES SERVICE QTY MFG TYPE 85 98
MODEL DFE 110 121 132
VALVE SIZES Safety Feed Stop Feed Stop Feed Check Feed Check Drum Blow-off Tandem Air Vent Continuous Blowdown Soot Blower Control Soot Blower Drain Soot Blower Drain Code 1 1 1 1 1 Set 1 1 1 1 1 Kunkle Velan Velan Edw. Lunk. Edw. Velan Velan Velan Velan Velan 300 S-2054B F-2064C 838 307-C 848-849 S-2074B S-2074B S-2054B S-2074B S-2074B Code 3 3 1-1/2 1/2 1 2 3/4 3/4 Code 3 3 1-1/2 1/2 1 2 3/4 3/4 Code 3 3 1-1/2 1/2 1 2 3/4 3/4 Code 4 4 1-1/2 1/2 1 2 3/4 3/4 Code 4 4 1-1/2 1/2 1 2 3/4 3/4
FEEDWATER REGULATOR ASSEMBLY Feedwater Regulator Regulator By-pass (Throttle) Regulator By-pass (Shut-off) Regulator By-pass (Shut-off) Liquid Level Control (Shut-off) Control Drain 1 1 2 2 2 1 Fisher Velan Velan Velan Velan Velan 667 EZ S-2074B S-2074B F-1064C S-2054B S-2054B 2 2-1/2 3 1-1/2 3/8 2 2-1/2 3 1-1/2 3/8 3 2-1/2 3 1-1/2 3/8 3 3 4 1-1/2 3/8 3 3 4 1-1/2 3/8
C-15
02-02
Figure C-1. Model D Dimensions - Sheet 1 of 2
C-16
02-02
MODEL D 26 34 42 52 60 68 76 86 94
DIMENSIONS (IN.) A. Length, Over Casing B. Length, Over Skid C. Width, Gas Outlet D. Height, Gas Outlet E. Front to CL Gas Outlet F. Skid to CL Gas Outlet G. Skid to CL of Sootblower Flange H. Distance Between Sootblowers I. Shipping Height (.375) J. Overall Width K. Upper Drum Diameter L. Lower Drum Diameter M. No. of Piers/CL to CL spacing N. Burner
A
113.75 144 15 54 12.5 91 74 153.25 127 36 24 (2) 48
142.75 173 18 54 14 91 74 153.25 127 36 24 (2) 60
171.75 202 27 54 18.5 91 74 153.25 127 36 24 (2) 76
208 238 30 54 19.875 91 74 153.25 127 36 24 (2) 94
237 267 30 66 20 85 74 153.25 127 36 24 (2) 108
266 296 33 66 22 85 74 153.25 127 36 24 (3) 82
295 325 36 66 23 85 74 153.25 127 36 24 (3) 92
331.25 361.5 36 66 23 85 74 153.25 127 36 24 (3) 104
360.25 390.25 42 75 25.875 80.5 74 153.25 127 36 24 (3) 114
Refer to Figures C-7 thru C-10 for dimensions WEIGHTS (LBS)
Weight, Dry
35200 41900 44400
40700 49350 52540
45870 56470 60340
52580 65610 70340
57970 72970 78380
66330 83280 89380
72490 91310 98200
79640 100990 108630
85250 108550 116865
Weight, Filled to Oper LevelB Weight, FloodedB
DRUM CONNECTION SIZES (IN.) (1) Main Steam Outlet (1) Feedwater Inlet (2) Safety Valves
C C
4 2 Code 1
A
4 2 Code 1 2 1 1 0.5 1 1.25
6 2 Code 1 2 1 1 0.5 1 1.25
6 2 Code 1 2 1 1 0.5 1 1.25
6 2 Code 1 2 1 1 0.5 1 1.25
8 2 Code 1 2 1 1 0.5 1 1.25
8 2.5 Code 1 2 1 1 0.5 1 1.25
8 2.5 Code 1 2 1 1 0.5 1 1.25
8 2.5 Code 1 2 1 1 0.5 1 1.25
(1) Blowdown (Surface) Sootblower (if applicable) (2) Water Column (2) Level Control (1) Chemical Feed (1) Vent (1) Blowdown (Mud drum)
2 1 1 0.5 1 1.25
NOTES: 1. 12x16 manhole in each end of upper and lower drum. All tubes are 2 OD. 2. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension prints. A. Boiler Model D, 76 thru 94, may use sootblowers on front and rear. All others may use one sootblower. B. Weights do not include burner or accessories. C. Steam outlet number and size of safety valves are based on a 150 psig operating pressure. Steam outlet and safety valve sizes may vary with pressure increase and the actual steam outlet. For sizes with different operating pressure, and/or non-return valves, contact your local Cleaver-Brooks authorized representative.
Figure C-1. Model D Dimensions - Sheet 2 of 2
C-17
02-02
Figure C-2. Models DL and DLD Dimensions - Sheet 1 of 2
C-18
02-02
DL MODELS 52 60 68 76 86 94 68
DLD MODELS 76 86 94
DIMENSIONS (IN.) A. Length, Over Casing B. Length, Over Skid C. Width, Gas Outlet D. Height, Gas Outlet E. Front to CL Gas Outlet F. Skid to CL Gas Outlet G. Skid to CL of Sootblower FlangeA H. Distance Between Sootblowers I. Shipping Height (.375) J. Overall Width K. Upper Drum Diameter L. Lower Drum Diameter M. No. of Piers/CL to CL spacing N. Burner 208 238 30 66 19.875 105 84 173.25 136.5 36 24 (2) 94 237 267 33 66 21.5 105 84 173.25 136.5 36 24 (2) 108 266 296 36 66 23 105 84 173.25 136.5 36 24 (3) 82 295 325 42 75 26 100.5 84 173.25 136.5 36 24 (3) 92 331.25 361.5 42 75 26 100.5 84 173.25 136.5 36 24 (3) 104 360.25 390.25 42 84 25.875 96 84 173.25 136.5 36 24 (3) 114 266 296 36 66 23 105 84 177 136.5 42 24 (3)82 295 325 42 75 26 100.5 84 177 136.5 42 24 (3) 92 331.25 361.5 42 75 26 100.5 84 177 136.5 42 24 (3) 104 360.25 390.25 42 84 25.875 96 84 177 136.5 42 24 (3) 114
Refer to Figures C-7 thru C-10 for Dimensions WEIGHTS (LBS)
Weight, Dry
62700 78700 83430
68200 86200 91610
77550 96990 103090
83600 105220 111830
91300 115600 122900
96800 131300 137200
78900 98700 107500
85000 107000 117800
93000 117700 129700
98600 133700 144200
Weight, Filled to Oper LevelB Weight, FloodedB
DRUM CONNECTION SIZES (IN.) (1) Main Steam OutletC (1) Feedwater Inlet (2) Safety ValvesC (1) Blowdown (Surface) Sootblower (if applicable)A (2) Water Column (2) Level Control (1) Chemical Feed (1) Vent 8 2 Code 1 2 1 1 0.5 1 8 2 Code 1 2 1 1 0.5 1 8 2.5 Code 1 2 1 1 0.5 1 8 2.5 Code 1 2 1 1 0.5 1 10 2.5 Code 1 2 1 1 0.5 1 10 2.5 Code 1 2 1 1 0.5 1 8 2.5 Code 1 2 1 1 0.5 1 8 2.5 8 2.5 10 2.5
(3) Code (3) Code (3) Code 1 2 1 1 0.5 1 1 2 1 1 0.5 1 1 2 1 1 0.5 1
(1) Blowdown (Mud drum) 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 NOTES: 1. 12 x 16 manhole in each end of upper and lower drum. All tubes are 2 OD. 2. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension prints. A. Boiler Models DL and DLD, 76 thru 94, may use sootblowers on front and rear. All others may use one sootblower. B. Weights do not include burner or accessories. C. Steam outlet number and size of safety valves are based on 150 psig operating pressure. Steam outlet and safety valve sizes may vary with pressure increase and actual steam outlet. For sizes with different operating pressure, and/or non-return valves, contact your local Cleaver-Brooks authorized representative.
Figure C-2. Models DL and DLD Dimensions - Sheet 2 of 2
C-19
02-02
Figure C-3. Model DLDH Dimensions - Sheet 1 of 2
C-20
02-02
MODEL DLDH 60 68 76 86 94 102 110 118
DIMENSIONS (IN.) A. Length, Over Casing B. Length, Over Skid C. Width, Gas Outlet D. Height, Gas Outlet E. Front to CL Gas Outlet F. Skid to CL Gas Outlet G. Skid to CL of Sootblower FlangeA H. Distance Between Sootblowers I. Shipping Height (.375) J. Overall Width K. Upper Drum Diameter L. Lower Drum Diameter M. No. of Piers/CL to CL spacing N. Burner 237 267 36 66 23 107 67.5 40 187 144 42 30 (3) 54 266 296 36 82 23 99 67.5 40 187 144 42 30 (3) 82 295 325 40 82 25 99 67.5 40 187 144 42 30 (4) 62 331.25 361.5 42 89 26 95.5 67.5 40 187 144 42 30 (4) 70 360.25 390.25 45 90 24.375 95 67.5 40 187 144 42 30 (4) 76 389.25 419.25 50 90 30 95 67.5 40 187 144 42 30 (4) 87 418.25 448.25 55 90 32.5 95 67.5 40 187 144 42 30 (4) 96 447.25 477.25 55 90 32.5 95 67.5 40 187 144 42 30 (4) 105
Weight, DryB Weight, Filled to Oper LevelB Weight, FloodedB
83500 105400 112100
93503 118027 125997
101247 127801 135925
108106 138079 147813
111666 144330 155051
119611 154966 166674
127596 178337 165642
135581 176318 190000
DRUM CONNECTION SIZES (IN.) (1) Main Steam OutletC (1) Feedwater Inlet (2) Safety ValvesC (1) Blowdown (Surface) Sootblower (if applicable)A (2) Water Column (2) Level Control (1) Chemical Feed (1) Vent (1) Blowdown (Mud drum) 8 3 (3) Code 1 2.5 1 2.5 0.5 1 1.25 8 3 (3) Code 1 2.5 1 2.5 0.5 1 1.25 10 3 (3) Code 1 2.5 1 3 0.5 1 1.25 10 3 (3) Code 1 2.5 1 3 0.5 1 1.25 10 3 (3) Code 1.5 2.5 1 3 0.5 1 1.5 10 3 (3) Code 1.5 2.5 1 3 0.5 1 1.5 12 3 (3) Code 1.5 2.5 1 3 0.5 1 1.5 12 3 (3) Code 1.5 2.5 1 3 0.5 1 1.5
NOTES: 1. 12x 16 manhole in each end of upper and lower drum. All tubes are 2 OD. 2. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension prints. A. Boiler Model DLHD, 60 & 68, may use two sootblowers on rear, and Models DLDH, 76 thru 118, may use two sootblowers on front and rear. B. Weights do not include burner or accessories. C. Steam outlet number and size of safety valves are based on 150 psig operating pressure. Steam outlet and safety valve sizes may vary with pressure increase and actual steam outlet. For sizes with different operating pressure, and/or non-return valves, contact your local Cleaver-Brooks authorized representative.
Figure C-3. Model DLDH Dimensions - Sheet 2 of 2
C-21
02-02
Figure C-4. Model DFE Dimensions - Sheet 1 of 2
C-22
02-02
MODEL DFE 85 98 110 121 132
DIMENSIONS (IN.) A. Length, Over Casing B. Length, Over Skid C. Width, Gas Outlet D. Height, Gas Outlet E. Front to CL Gas Outlet F. Skid to CL Gas Outlet G. Skid to CL of Sootblower FlangeA H. Distance Between Sootblowers I. Shipping Height (.375) J. Overall Width K. Upper Drum Diameter L. Lower Drum Diameter M. No. of Piers/CL to CL spacing N. Burner 327 357 40 90 25 95 67.5 113.5 200.25 151.375 48 I.D. 30 O.D. (4) 72 374.75 404.75 45 90 27.5 95 67.5 113.5 200.25 151.375 48 I.D. 30 O.D (4) 88 418.25 448.25 50 90 30 95 67.5 113.5 200.25 151.375 48 I.D. 30 O.D (4) 104 457.75 487.75 55 90 32.5 95 67.5 113.5 200.25 151.375 48 I.D. 30 O.D (4) 104 498 528 60 90 35 95 67.5 113.5 200.25 151.375 48 I.D. 30 O.D (4) 120
Weight, DryB Weight, Filled to Oper LevelB Weight, FloodedB
117,250 154,300 163,450
130,750 170,400 184,400
143,350 188,050 203,800
154,750 204,100 221,400
166,350 220,450 239,350
DRUM CONNECTION SIZES (IN.) (1) Main Steam OutletC (1) Feedwater Inlet (2) Safety ValvesC (1) Blowdown (Surface) Sootblower (if applicable)A (2) Water Column (2) Level Control (1) Chemical Feed (1) Vent (1) Blowdown (Mud drum) 10 3 Code 1.5 2.5 1 1 0.5 1 1.5 10 3 Code 1.5 2.5 1 1 0.5 1 1.5 10 3 Code 1.5 2.5 1 1 0.5 1 1.5 12 4 Code 1.5 2.5 1 1 0.5 1 1.5 12 4 Code 1.5 2.5 1 1 0.5 1 1.5
NOTES: 1. 12x 16 manhole in each end of upper and lower drum. All tubes are 2 OD. 2. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension prints. A. Boiler Model DFE 85 thru 132, may use two sootblowers on front and rear. B. Weights do not include burner or accessories. C. Steam outlet number and size of safety valves are based on a 150 psig operating pressure. Steam outlet and safety valve sizes may vary with pressure increase and actual steam outlet. For sizes with different operating pressure, and/or non-return valves, contact your local CleaverBrooks authorized representative.
Figure C-4. Model DFE Dimensions - Sheet 2 of2 C-23

02-02
Figure C-5. Model DW Dimensions - Sheet 1 of 2
C-24
02-02
MODEL DW 26 34 42 52 60 68 76 86 94
DIMENSIONS (IN.) A. Length, Over Casing B. Length, Over Skid C. Width, Gas Outlet D. Height, Gas Outlet E. Front to CL Gas Outlet F. Skid to CL Gas Outlet G. Skid to CL of Sootblower FlangeA H. Shipping Height (.375) I. Overall Width J. Upper Drum Diameter K. Lower Drum Diameter L. No. of Piers/CL to CL spacing M. Burner 113 144 15 54 125 91 74 153.25 127 36 24 (2) 48 142 173 18 54 14 91 74 153.25 127 36 24 (2) 60 171 202 27 54 18.5 91 74 153.25 127 36 24 (2) 76 207 238 30 54 19.875 91 74 153.25 127 36 24 (2) 94 236 267 30 66 20 85 74 153.25 127 36 24 (2) 108 265 296 33 66 22 85 74 153.25 127 36 24 (3) 82 294 325 36 66 23 85 74 153.25 127 36 24 (3) 92 330.5 361.5 36 66 23 85 74 153.25 127 36 24 (3) 104 359.5 390.25 42 75 25.875 80.5 74 153.25 127 36 24 (3) 114
Weight, DryB Weight, FloodedB
35200 44400
40700 52540
45870 60340
52580 70340
57970 78380
66330 89380
72490 98200
79640 108630
85250 116865
DRUM CONNECTION SIZES (IN.) (1) Water Inlet/OutletC (2) Safety/ Relief ValvesC Sootblower (if applicable)A (2) Water Column (1) Vent (1) Blowdown (lower drum) Code 2 1 1 1.25 Code 2 1 1 1.25 Code 2 1 1 1.25 Code 2 1 1 1.25 Code 2 1 1 1.25 Code 2 1 1 1.25 Code 2 1 1 1.25 Code 2 1 1 1.25 Code 2 1 1 1.25
NOTES: 1. 12x 16 manhole in each end of upper and lower drum. All tubes are 2 OD. 2. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension prints. A. Boiler Model DW, 76 thru 94, may use sootblowers on front and rear. All others may have one sootblower. B. Weights do not include burner or accessories. C.Water inlet/outlet size and number and size of safety/relief valve are variable, due to operating temperatures and pressures. Contact your local Cleaver-Brooks authorized representative for job-specific information.
Figure C-5 Model DW Dimensions - Sheet 2 of 2
C-25
02-02
Figure C-6. Model DLW Dimensions - Sheet 1 of 2
C-26
02-02
MODEL DLW 52 60 68 76 86 94
DIMENSIONS (IN.) A. Length, Over Casing B. Length, Over Skid C. Width, Gas Outlet D. Height, Gas Outlet E. Front to CL Gas Outlet F. Skid to CL Gas Outlet G. Skid to CL of Sootblower FlangeA H. Shipping Height (.375) I. Overall Width J. Upper Drum Diameter K. Lower Drum Diameter L. No. of Piers/CL to CL spacing M. Burner 207 238 30 66 19.875 105 84 173.25 136.5 36 24 (2) 94 236 267 33 66 21.5 105 84 173.25 136.5 36 24 (2) 108 265 296 36 66 23 105 84 173.25 136.5 36 24 (3) 82 294 325 42 75 26 100.5 84 173.25 136.5 36 24 (3) 92 330.5 361.5 42 75 26 100.5 84 173.25 136.5 36 24 (3) 104 359.5 390.25 42 84 25.875 96 84 173.25 136.5 36 24 (3) 114
Refer to Figure C-7 thru C-10 for dimensions WEIGHTS (LBS)
Weight, DryB Weight, FloodedB
62700 83430
68200 91610
77550 103090
83600 111830
91300 122900
96800 13720
DRUM CONNECTION SIZES (IN.) (1) Water Inlet/OutletC (2) Safety/ Relief ValvesC Sootblower (if applicable)A (2) Water Column (1) Vent (1) Blowdown (lower drum) Code 2 1 1 1.25 Code 2 1 1 1.25 Code 2 1 1 1.25 Code 2 1 1 1.25 Code 2 1 1 1.25 Code 2 1 1 1.25
NOTES: 1. 12x 16 manhole in each end of upper and lower drum. All tubes are 2 OD. 2. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension prints. A. Boiler Model DLW, 76 thru 94, may use sootblowers on front and rear. All others may have one sootblower.( B. Weights do not include burner or accessories. C. Water inlet/outlet size and number and size of safety/relief valve are variable, due to operating temperatures and pressures. Contact your local Cleaver-Brooks authorized representative for job-specific information.
Figure C-6. Model DLW Dimensions - Sheet 2 of 2
C-27
02-02
BURNER MODEL A
STANDARD A 66 B 60 C 67 D 24-1/4 E 54 F 70 G 115-1/8 H 52-1/8 I 21-3/4 J 33
NOTES: 1. Fuel train shipped loose and not included in above weights. 2. Weight includes forced draft fan and drive. 3. Accompanying dimensions, while sufciently accurate for layout purposes, must be conrmed for construction by certied dimension prints. 4. All dimensions in inches.
Figure C-7. General A Burner Dimensions
C-28
02-02
BURNER MODEL BR1 BR2 BR3
STANDARD A 51-1/2 53-1/4 53-3/4 B 32 32 32 C 73 73 73 D 21-1/2 21-1/2 21-1/2 E 54-1/2 54-1/2 54-1/2 F 64 64 64 G 126-1/2 126-1/2 126-1/2 H 34-1/2 34-1/2 34-1/2 I 22 22 22 J 23 23 23
NOTES: 1. Fuel train shipped loose and not included in above weights. 2. Weight includes forced draft fan and drive. 3. Accompanying dimensions, while sufciently accurate for layout purposes, must be conrmed for construction by certied dimension prints. 4. All dimensions in inches.
Figure C-8. General BR Burner Dimensions
C-29
02-02
BURNER MODEL CN1 CN2 CN3 CN4 CN5 CN7 CN8
STANDARD A 56-3/4 58-3/4 58-3/4 58-3/4 61-1/4 65-1/4 71-3/4 B 60-1/2 60-1/2 60-1/2 60-1/2 60-1/2 60-1/2 60-1/2 C 80-1/4 80-1/4 80-1/4 80-1/4 80-1/4 82 82 D 30-1/4 30-1/4 30-1/4 30-1/4 30-1/4 30-1/4 30-1/4 E 52 52 52 52 52 52 52 F 65 65 65 65 65 65 65 G 140-1/2 140-1/2 140-1/2 140-1/2 140-1/2 142 142 H 37-1/4 37-1/4 37-1/4 37-1/4 37-1/4 40-3/4 40-3/4 I 21-1/2 21-1/2 21-1/2 21-1/2 21-1/2 21-7/8 21-7/8 J 37-1/2 37-1/2 37-1/2 37-1/2 37-1/2 37-1/2 37-1/2
NOTES: 1. Fuel train shipped loose and not included in above weights. 2. Weight includes forced draft fan and drive. 3. Approx CN console weight: 1200 lbs (oil and gas unit) (not shown). Approx CN console weight 500 lbs (gas unit only) (not shown). 4. Accompanying dimensions, while sufciently accurate for layout purposes, must be conrmed for construction by certied dimension prints. 5. All dimensions in inches.
Figure C-9. General CN Burner Dimensions C-30

02-02
BURNER MODEL CT-1 CT-2 CT-3 CT-4 CT-5 CT-6 CT-7 CT-8 CT-9 CT-10 CT-11 CT-12 CT-13 CT-14 CT-15 CT-16 CT-17 CT-18 CT-19 CT-20
A 54 54 60-3/4 66-3/4 66-3/4 66-3/4 66-3/4 66-3/4 74 74 74 74 74 74 74 74 81-1/4 81-1/4 81-1/4 91-1/4
B 60 60 60 60 60 60 72 72 72 72 72 72 72 72 72 72 72 72 72 72
C 60 60 60 60 60 60 72 72 72 72 72 72 72 72 72 72 72 72 72 72
D 49 49 53-1/2 58-1/4 58-1/4 58-1/4 58-1/4 58-1/4 63-1/4 63-1/4 63-1/4 63-1/4 63-1/4 63-1/4 63-1/4 63-1/4 70 70 70 76
E 59 59 59 59 59 59 59 59 59 59 59 59 59 59 65 65 65 65 65 65
F 83 86 89 95 95 95 95 95 95 96 96 100 100 100 100 100 102 102 102 102
G 138 138 142-1/2 147-1/4 147-1/4 147-1/4 153-1/4 153-1/4 158-1/4 158-1/4 158-1/4 158-1/4 158-1/4 158-1/4 164-1/4 164-1/4 171 171 171 177
H 66 66 66 66 66 66 78 78 78 78 78 78 78 78 78 78 78 78 78 78
NOTES: 1. The accompanying dimensions, while sufciently accurate for layout purposes, must be conrmed for construction by certied dimension prints. 2. All dimensions in inches. 3. Burner Models CT-21 through CT-27 have the forced draft fan located remote from the burner/windbox assembly. Please contact your local Cleaver-Brooks authorized representative for burner applications involving these models.
Figure C-10. General CT Burner Dimensions C-31

02-02
EMISSIONS
The emission data included in this section consists of uncontrolled and controlled levels of nitrogen oxides (NOX) and carbon monoxide (CO) for Cleaver-Brooks D, DL, DLD, DLDH and DFE Industrial Watertube Boilers equipped with CleaverBrooks Model A, BR, CN or CT burners. The following tables include typical emission levels. Because individual boiler performance can vary, contact your local Cleaver-Brooks authorized representative for specic levels of performance for your application. Emission data for natural gas, No. 2 oil, and No. 6 oil are presented in Tables C-9 through C14.
Cleaver-Brooks Industrial Watertube Boilers are available with a standard burner package or optional ue gas recirculation (FGR) package. The Cleaver-Brooks FGR packages are integrated boiler/ burner/control packages designed specically for CleaverBrooks boilers.
Table C-10. Industrial Watertube Emission Data - Natural Gas (A, BR, CN Burners)
TYPICAL UNCONTROLLED EMISSIONS POLLUTANT < 65,000 pph CO ppm lb/MMBtu NOx ppm lb/MMBtu 200 .146 110 .13 < 65,000 pph 200 .146 40 .05 TYPICAL EMISSIONS CONTROLLED W/FGR
NOTE: The emission information provided is for reference only and should not be utilized for permitting purposes without the expressed written consent of Cleaver-Brooks Division of Aqua-Chem, Inc. All information is based on 3% O2.
Table C-11. Industrial Watertube Emission Data - No. 2 Oil (A, BR, CN Burner)
TYPICAL UNCONTROLLED EMISSIONS POLLUTANT < 65,000 pph CO ppm lb/MMBtu NOx ppm lb/MMBtu 200 .155 185 .25 < 65,000 pph 200 .155 130 .17 TYPICAL EMISSIONS CONTROLLED W/FGR
NOTES: 1. NOx Emissions for No. 2 oil are dependent upon fue-bound nitrogen content of oil. Emission levels indicated assume a fuel bound nitrogen content of.01% by weight. 2. The emission information provided is for reference only and should not be utilized for permitting purposes without the expressed written consent of Cleaver-Brooks Division of Aqua-Chem, Inc. All information is based on 3% O2.
Table C-12. Industrial Watertube Emission Data - Heavy Oils (A, BR, CN Burners)
TYPICAL UNCONTROLLED EMISSIONS POLLUTANT < 65,000 pph CO ppm lb/MMBtu NOx ppm lb/MMBtu 200 .158 435 .58
NOTES: 1. NOx Emissions from heavy oils are dependent upon fuel-bound nitrogen content of oil. Emission levels indicated assume a fuel bound nitrogen content of.4% by weight. 2. The emission information is for reference only and should not be utilized for permitting purposes without the expressed written consent of Cleaver-Brooks Division of Aqua-Chem, Inc. All information is based on 3% O2.
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Table C-13. Industrial Watertube Emission Data - Natural Gas (CT Burner)
TYPICAL UNCONTROLLED EMISSIONS POLLUTANT <85,000 pph CO ppm lb/MMBtu NOx ppm lb/MMBtu 200 .15 85 .10 86,000-105,000 pph 200 .15 93 .11 106,000-150,000 pph 200 .15 101 .12 15,000-150,000 pph 200 .15 30 .035 TYPICAL EMISSIONS CONTROLLED W/FGR
NOTE: The emission information provided is for reference only and should not be utilized for permitting purposes without the expressed written consent of Cleaver-Brooks Division of Aqua-Chem, Inc. All information is based on 3% O2.
Table C-14. Industrial Watertube Emission Data - No. 2 Oil (CT Burner)
TYPICAL UNCONTROLLED EMISSIONS POLLUTANT <85,000 pph CO ppm lb/MMBtu NOx ppm lb/MMBtu 200 .155 150 .20 86,000-105,000 pph 106,000-150,000 pph 200 .155 157 .21 200 .155 165 .22 15,000-150,000 pph 200 .155 75 .10 TYPICAL EMISSIONS CONTROLLED W/FGR
NOTES: 1. NOx Emissions for No. 2 oil are dependent upon fue-bound nitrogen content of oil. Emission levels indicated assume a fuel bound nitrogen content of.01% by weight. 2. The emission information provided is for reference only and should not be utilized for permitting purposes without the expressed written consent of Cleaver-Brooks Division of Aqua-Chem, Inc. All information is based on 3% O2.
Table C-15. Industrial Watertube Emission Data - Heavy Oils (CT Burner)
TYPICAL UNCONTROLLED EMISSIONS POLLUTANT 15,000-150,000 pph CO ppm lb/MMBtu NOx ppm lb/MMBtu 200 .158 380 .51 15,000-150,000 pph 200 .158 260 .35 TYPICAL EMISSIONS CONTROLLED W/FGR
NOTES: 1. NOx Emissions from heavy oil are dependent upon fuel bound nitrogen content of oil. Emission levels indicated assume a fuel bound nitrogen content of.4% by weight. 2. The emission information provided is for reference only and should not be utilized for permitting purposes without the expressed written consent of Cleaver-Brooks Division of Aqua-Chem, Inc. All information is based on 3% O2.
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ENGINEERING DATA
The following engineering data will assist in selecting and specifying Cleaver-Brooks Industrial Watertube Boilers. Table C-16 shows heating surfaces for the IWT Boilers. Tables C-17 and C-18 show temperature and pressure information for selection of high temperature hot water boilers.
MODEL NO.
Table C-16. Heating Surface

CONV HEATING SURFACE (SQ-FT) FURNACE HEATING SURFACE (PROJ) (SQ-FT) TOTAL HEATING SURFACE (SQ-FT) FURNACE VOLUME (CU-FT)
26 34 42 52 D 60 68 76 86 94 52 60 68 DL 76 86 94 68 76 DLD 86 94 60 68 76 86 DLDH 94 102 110 118 85 98 DFE 110 121 132
1120 1517 1911 2407 2806 3206 3595 4087 4470 2912 3393 3870 4346 4947 5418 3774 4248 4825 5284 4000 4564 5126 5806 6368 6930 7495 8056 5707 6622 7461 8223 9000
241 302 369 449 511 580 634 726 793 518 593 676 751 848 923 673 747 842 919 650 737 818 923 1004 1089 1172 1253 923 1063 1187 1305 1416
1361 1819 2280 2856 3317 3786 4229 4313 5263 3430 3986 4546 5097 5795 6341 4447 4995 5667 6203 4650 5301 5944 6729 7372 8019 8667 9309 6663 7685 8648 9528 10416
317 425 527 654 754 855 951 1081 1184 903 1048 1194 1328 1510 1654 1188 1321 1502 1645 1111 1261 1411 1599 1750 1900 2050 2200 1750 2024 2274 2501 2733
Steam Drum
Model D and DL boilers have 36" ID steam drums, constructed of SA-515 Grade-70 steel plate. Models DLD and DLDH boilers have 42" ID steam drums; the DFE has a 48 Drum constructed of SA- 515 Grade-70 steel plate. All drums are of welded construction in strict conformance with the ASME Power Boiler Code. All drums are stress-relieved, and welded seams are radiographed and hydrostatically tested at 1-1/2 times design pressure. The drum incorporates elliptical heads with 12" x 16" manholes on each end, and is wholly supported by the tubes, so no extra supporting steel is required. All tubes are expanded into the drums. The steam drum has the following external connections: One main steam outlet, anged. Two 12" x 16" manways. One feedwater inlet. Two or three safety valve anged connections (as required). One blowdown connection, screwed. One soot blower connection, screwed. Two water column connections, screwed. Two feedwater regulator connections, screwed. One chemical feed connection, screwed. Two lifting Lugs. The steam drum is tted with an internal feed pipe, chemical feed pipe, and blowdown piping. Water level control bafing is installed to ensure that all steam released from the generating tubes is released behind the bafes and not through the water level. Standard patented drum internals consist of steam separators or dryers that are installed to ensure the steam leaving the drum will contain not more than 1/2 of 1 percent moisture when boiler water concentrations are maintained in accordance with ABMA recommendations. Special drum internals for more stringent moisture content are available. See Figures C-11 and C-12 for illustration of drum internals.
Lower Drum (Mud Drum)

The lower drum is 24" OD of SA-53 Grade-B seamless pipe, and is of fusion-welded construction, or 30" OD of SA-515,
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Table C-17. Maximum Heat Output (Hot Water)
HOT WATER GENERATORS MODEL NO. 26 34 42 52 DW 60 68 76 86 94 52 60 68 DLW 76 86 94 50.3 57.1 62.5 MAX OUT MM BTU/HR 13.4 17.9 22.5 28.2 32.7 37.5 41.7 47.5 51.9 33.8 39.3 44.8 DL 76 86 94 68 70.3 79.91 87.41 60.15 68.87 78.14 85.54 63.4 76.3 85.6 97 106.2 115.6 124.9 134.1 81.3 101.5 111.5 121.6 151.7 D
Table C-18. Maximum Heat Output (Steam)

STEAM BOILER MODEL NO. 26 34 42 52 60 68 76 86 94 52 60 68 MAX OUTA MMBTU/HR (STEAM) 16 21.4 26.8 37.41 43.92 50.22 57.17 65.12 72.62 45.47 53.31 61.47
Grade-70, welded plate (DLDH and DFE boiler). The lower drum is stress relieved, seams are radiographed, and hydrostatically tested at 1-1/2 times design pressure. The drum incorporates two 12" x 16" manways - one at each end - and required blow-drum connections. Internally, the drum has a blowdown guide bafe to ensure effective blowdown of the lower drum without disturbing water circulation in the unit. The drum is supported by the structural steel frame (skid) and has welded guide lugs that t into the base frame, permitting expansion of the drum within the skid, thereby eliminating potential expansion stresses.
76 DLD 86 94 60 68 76 86 DLDH 94 102 110 118 85 98 DFE 110 121 132 A. DLDH with economizer.
Drum Enclosure
The steam drum is shop-insulated with mineral wool block and enclosed in a welded 10-gauge steel casing. All drum heads are shop-insulated and enclosed in a 10-gauge steel casing. No further insulation is required in the eld.
Furnace
The furnace (combustion chamber) employs 2" OD, SA-178A electric resistance welded tubes, arranged for maximum coverage of all six furnace walls. In a D type watertube boiler, the furnace tubes generate more than half of the steam produced by the boiler, although the furnace represents only about 15% of the reported surface. Due to the high heat absorption rates present in the furnace, D tubes are placed in a tangent spacing arrangement to provide as much water-cooled surface as possible. With the exception of the inner furnace wall, which is
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Figure C-11. Drum Internals and Steam Puriers for 1, 3, and 7 ppm Solids
Figure C-12. Drum Internals and Separator for 99.5% Dry Steam
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MEMBRANE
Figure C-13. D Series Boiler Tube Cut-Away membrane construction, extended metallic surfaces are not used. See Figure C-13. All tubes in the furnace are accessible for mechanical tube cleaners. No headers are employed in the boiler, and all tubes terminate in the upper and lower drums. Both oor and roof tubes are designed with adequate pitch to ensure drainage and proper circulation without swedging ends of tubes. The six-wall furnace cooling is arranged as follows: Front wall - Tubes closely spaced around burner. Tangent outer side wall - 2" tubes spaced on 2" centers. Membrane sealed inner wall - 2" tubes spaced on 4" centers. Tangent oor - 2" tubes spaced on 2" centers. Tangent roof - 2" tubes spaced on 2" centers. Rear wall - Triple row of tubes. Furnace exit - Double row of screen tubes. Access: Access to furnace is through burner opening in front wall or optional rear access door. Observation: Two air-cooled observation ports, with Pyrex eye shields, provided in rear wall. Air Pressure Test: Inner seal-welded 10-gauge casing, subjected to an air pressure test of 8" WC. It is considered tight if air pressure drop does not exceed 2" WC in 5 minutes. Flue Gas Outlet: One anged rectangular ue gas outlet, sized for desired ue gas velocity and arranged for eld welding, will be provided. Top gas outlet is also available on the D, DL and DLD models
Convection Tubes
Definition The convection section, or boiler section, of a D type boiler are those tubes to which heat is transmitted mainly by convection from the products of combustion. Tubes The convection section consists of 2" OD, wall tubes. The tubes are SA-178 electric resistance-welded construction in accordance with ASME standards. Tube Arrangement The tubes are arranged with longitudinal rows of tubes in alternate wide and narrow spacing to ensure proper and effective arrangement of soot-blowing equipment. This arrangement
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also allows removal of any tube without the necessity of removing adjacent tubes. All tubes in the boiler section are expanded into the upper and lower drums. No swaged or nned tubes are used in the convection section, thereby allowing heating surface to be reported based on actual tube surface, not extended metal surfaces or ns. Baffling The convection bank is designed to eliminate the need for longitudinal bafes. A vertical steel deector bafe is placed immediately in front of the ue gas outlet connection in order to prevent any short-circuiting of ue gas at the outlet. The boiler incorporates vertical bafes located to maintain gas velocities and transfer rates.(Figure C-14). Soot Blowers On heavy oil red units, soot blowers are installed to provide the operator with a means of cleaning the boiler while it is in operation. The soot blower element is installed on the outside row of tubes, and blows an approximate 180 arc using steam piped from the steam drum. Where the length of the convection bank requires a blower in excess of 20 feet, two soot blowers are provided - one entering from the rear of the unit and one from the front. Tube Removal The use of the alternate wide-and-narrow spacing of boiler tube rows makes it possible to remove and replace individual tubes in the convection section without the necessity of cutting and removing adjacent tubes. In other staggered convection bank designs, it is often necessary to remove many good tubes in order to provide physical clearance to remove a damaged tube. Soot blower bearings are of the welded-type, which eliminates problems of misalignment associated with bolted bearings. The soot blower is a valve-in-head type and arranged for manual operation by means of a chain. Purging air is piped to the soot blower from the burner windbox to provide continuous cleaning of the inside of the element, and to prevent combustion gases from leaking back to the valve mechanism in the soot blower head. On boilers without sootblowers, wall boxes and bearing are provided. Internal Cleaning The internal surfaces of all tubes, both convection and furnace types, can be mechanically cleaned using either electric or pneumatic driven tube cleaners. Acid cleaning procedures are also available.
Inner furnace wall
Outer furnace and convection wall with membrane design.
Membrane Design The inner furnace wall separating the furnace from the convection section incorporates welded extended surfaces on each side of the tube. After the tubes are installed the adjacent surface ns are seal-welded forming a gas tight membrane inner wall. Membrane construction for the outer furnace wall and the outer convection wall is available as an option. Figure C-14. Tubes with Membrane design for Inner furnace. C-38
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MEMBRANE 2-1/2 BLOCK (LOW DENSITY)
Figure C-15. D Series Boiler Enclosure Construction
Casing and Insulation

Design The unit is enclosed by a double panel casing, with that portion of the casing exposed to the products of combustion completely seal-welded to form an air and gas tight enclosure. The outer casing panels are skip-welded and are suitable for indoor installation (seal-welded for outdoor optional). The casing is supported off the structural steel frame and is not welded or attached to tubing, thereby ensuring free expansion of pressure parts within the casing enclosure. Casing and Wall Design Construction of the boiler enclosure is as follows (Figure C15): 1. Front Wall - Furnace Area: 3", 4-way interlocking tile. 4" Hi-temperature block insulation. 10-gauge inner seal welded casing.
2-1/2 low density block insulation. 1/4 burner front plate. 2. Rear Wall: 3", 4-way interlocking tile. 4" Hi-temperature block insulation. 10-gauge inner seal welded casing. 2-1/2 low density block insulation, 1/4 outer casing. 3. Convection Section and Furnace Side Wall and Roof: 10-gauge inner seal welded casing. 4-3/8 low-density mineral wool block. 10-gauge outer steel casing. 4. Casing Finish: Painted with high-temperature enamel paint prior to shipment.
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Figure C-16. Series Skid Assembly
Figure C-17. Support Drum in Skid
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Furnace Floor Furnace oor tubes are covered with 1-1/2 square edge tile. positioning controls. A switch is provided to permit changeover from automatic, fully-modulated ring, to continuous ring at any desired rate between minimum and maximum. Control safeguards assure that the burner always returns to the minimum ring position for ignition. For air-atomized oil-red boilers (air atomazation is optional), ltered primary air for atomizing the fuel oil is provided independent of the combustion air by a motor-driven air compressor. The fuel oil pump may be mounted near the boiler, or at a remote location. For burning heavy oil, the burner is equipped with a combination steam-electric heater, each controlled by a thermostat. Both heaters are installed in a single compact shell, and are mounted, piped, and wired on the burner. The thermostatic controls are set to cut out the electric heater when steam is available. A metering valve permits circulation of hot oil to the burner at all times. An automatic purge pump system back-purges the burner drawer oil piping and nozzle upon shut-down and returns any unburned oil to the storage tank. The FGR system used with the A, BR and CN burner and controls, is shown in Figure C-18.
Structural Frame
Models D, DL, DLD, DLDH and DFE boilers (see Figure C16 and C-17) are supported by a heavy structural steel frame skid assembly. The skid assembly consists of two 14" wide ange beams running parallel to the drum. The beams are attached by means of heavy steel plates that form the saddle and support for the lower drum. The skid assembly also incorporates 10 ga. oor plate of the boiler beneath the furnace area and convection section. The skid assembly is fabricated as a complete structure prior to assembly of the unit. This method of support, using saddle plates and guide lugs, permits the lower drum to ride in the saddle plates, thus permitting expansion of the pressure parts in the structural frame and casing enclosure of the boiler. Stops are provided during assembly to limit movement of the drum within the expected expansion limits. To facilitate lifting and handling of the boiler, lifting lugs are welded to the upper drum. In addition, the main beams of the skid are coped and reinforced to provide space beneath the end of the beam for jacking of the unit as required during installation. Holes are provided in the main beams for use by riggers to drag or lift the unit by its base frame.
Flame Safeguard
The boiler is equipped with a fully automatic ame safeguard system to ensure pre-purge, proper light-off, shutdown upon ame failure, and post purge on shutdown. The system is designed to meet Factory Mutual or Industrial Risk Insurers requirements. The control system includes safety interlocks to shut down the unit in the event of any of the following, as required for the fuel or fuels being red: Flame failure. High steam pressure. Low drum water level. Low atomizing pressure (oil or combination burners). Low fuel oil pressure (oil or combination burners). Low fuel oil temperature (oil or combination burners). High fuel oil temperature (oil or combination burners - IRI only). Low fuel gas pressure (gas or combination burners). High fuel gas pressure (gas or combination burners). Forced draft fan failure.
Burner/Controls Information (Models A, BR, CN)

Each application requires burner selection based on boiler and overall project requirements. Tables C-19, C-20, and C-21 show the standard Cleaver-Brooks burners and associated inputs and fuel requirements. Once the boiler has been selected, the burner is matched based on the input requirements for the boiler. Table C-22 shows the standard offering for each burner package. The burner assembly is attached to the front wall of the boiler with all components readily accessible for inspection and maintenance. The oil burner is either low pressure air or steam atomized ignited by gas pilot. The main gas burner is also ignited by a gas pilot. The gas burner is designed for a 8:1 turndown when supplied with 10 psig gas pressure, turndown on oil is 6:1 when supplied with 125 psig oil pressure. The burner operates with full modulation through single point
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Table C-19. Burner Data (Model A)
GAS PRESSURE (INCHES H2O) 4 GAS LINE W/4 GC VALVES BURNER MODEL A-1 A-2 A-3 A-4 A-5 A-6 A-7 A-8 MAX INPUT (MBTU) 13.8 16.9 16.6 18.6 19.7 22.2 22.9 26.5 HP (OIL)A 10 15 15 15 20 25 25 30 HP (GAS) 10 10 10 10 15 20 20 25 FM 10.5 15.7 15.0 18.8 21.0 26.1 27.8 36.8 IRI 12.3 18.4 17.6 22.0 24.7 30.7 32.7 43.3 4 GAS LINE W/4 MAXON VALVES FM 8.9 13.3 12.6 15.9 17.7 22.0 23.4 31.0 IRI 9.1 13.6 13.0 16.3 18.2 22.5 24.0 31.8 100 100 100 100 100 100 100 100 OIL PRESSURE (PSIG)
A. Air compressor for atomizing air belt driven from FD fan motor. 25 CFM required.
Table C-20. Burner Data (Model BR)

GAS PRESSURE (INCHES H2O) BURNER MODEL BR-1 BR-2 BR-3 BR-4 MAX INPUT (MBTU) 31.0 36.0 40.2 42.4 HP (OIL)A 15 20 25 30 HP (GAS) 15 20 25 30 4 GAS LINE W/4 GC VALVES FM 45.8 60.7 75.1 83.0 IRI 56.6 74.9 92.5 102.1 4 GAS LINE W/4 MAXON VALVES FM 36.4 48.4 60.0 66.4 IRI 38.3 50.8 63.0 69.7 6 GAS LINE W/4 MAXON VALVES FM 26.3 34.9 43.3 47.9 IRI 28.0 37.1 46.1 51.0 100 100 100 100 OIL PRESSURE (PSIG)
A. BR Burner (if air-atomized) has separate 7.5 hp motor to drive atomizing air compressor. 35 cfm required.
Table C-21. Burner Data (Model CN)

GAS PRESSURE IN INCHES H2O 4 GAS LINE W/4 MAXON VALVES BURNER MODEL CN-1 CN-2 CN-3 CN-4 CN-5 CN-7 CN-8 MAXIMUM INPUT (MBTU) 46.5 49.8 63.5 66.0 77.1 75.0 81.3 HP (OIL)A 20 30 40 50 60 60 75 HP (GAS) 20 30 40 50 60 60 75 FM 61.5 70.3 108.8 117.0 134.6 148.9 IRI 65.4 74.8 115.5 124.2 142.8 157.8 6 GAS LINE W/4 MAXON VALVES FM 39.6 45.5 70.4 75.9 87.8 97.6 113.8 IRI 43.3 49.7 76.9 82.9 95.8 106.4 123.9 100 100 100 100 125 125 125 OIL PRESSURE (PSIG)
NOTES: 1. All horsepower requirements shown are for altitudes up to 1500 feet above sea level. A. CN Burner (if air-atomized) has separate 15 hp motor to drive atomizing air compressor. 70 cfm required.
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Table C-22. Standard Offering (A, BR, and CN Burners)

BURNER MODEL AND SIZE A 1-8 BR 1-4 CN 1-8 FORCED DRAFT FAN 1 2 3 X 4 X X X X X x X x X x X Fan driven by open drip-proof motor. Damper at FD fan outlet. Type of damper: a. Rotary (as used on Firetube Boiler Product Line). b. Characterized Quadrant (Rotary), NOT a Butterfly Type Damper. Combustion air-proving switch (CAPS) mounted and wired. ATOMIZING MEDIUM 5 6 X 7 X X X X X X X X C-B low pressure air or steam-atomized. Type of air compressor drive (if air-atomized): a. Belt driven from FD fan motor. b. Motor driven module mounted on burner. c. Motor driven module mounted in CN console, remote from burner (field piping and wiring required). Atomizing air proving switch (AAPS) mounted and wired on compressor. CONTROLS & ELECTRICAL 8 9 10 11 12 13 14 15 16 17 X X X X X X X X X X X X X X X X X X X Cleaver-Brooks standard electric positioning controls. C-B 100 flame safeguard control with lead sulfide scanner. Controls remote from control enclosure have NEMA 1 housing. Control enclosure: controls are mounted in NEMA 1A panel, mounted on burner. NEMA 12 panel, mounted on burner. NEMA 1A compartment of CN console for Model CN-100 thru CN-600 (oil fired). NEMA 1A panel mounted on burner for Model CN-700 (gas-fired only). Steam pressure controls (HLPC, OLPC, LFPC and MPC) and 8-1/2 steam gauge all on a common manifold assembly, shipped separate from burner (field piping and wiring required). Fuses and starters for FD fan motor, air compressor motor and fuel oil heater all mounted and wired on burner. Fuses and starters for air compressor motor and fuel oil heater all mounted and wired in CN console (field wiring required between console and burner). Starter only for F.D. fan motor, shipped loose (field mounting and wiring required). Electric current characteristics 230-460V/3-phase/60Hz. Control circuit transformer mounted and wired on burner. MISCELLANEOUS: 22 X X X Turndown ratio of burner - 6:1 for oil firing, 8:1 for gas firing. FUEL 24 X X X Gas pilot for all fuel series. STANDARD EQUIPMENT
18 19
X X
X X
X X
NOTE: Standard equipment listed here is included only with burner model indicated by an X HLPC - High-Limit Pressure Control OCPC - Operating Limit Pressure Control LFPC - Low-Fire Pressure Switch MPC - Modulating Pressure Control
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FGR INLET PIPING AND SUPPORT STEEL (BY OTHERS)
Figure C-18. Forced FGR System, Industrial Watertube Boiler (A, BR, CB Burners)
Burner/Controls Information (Model CT)

Each application requires burner selection based on boiler and overall project requirements. Table C-23 shows the Model CT burner selections and the associated inputs and fuel requirements. Burner selection is based upon input requirements for the boiler. Table C-24 shows standard non FGR offerings for the Model CT burner equipment package. The burner assembly is seal-welded to the front wall of the boiler, with all components readily accessible for inspection and maintenance. The windbox is non-insulated for ambient combustion air, and is fabricated of ASTM A-36 plate, com-
plete with structural framing, support legs, access door, and splitter vanes and bafes for equalizing air ow distribution to the burner. A forced draft fan of centrifugal-type construction, arrangement four, with downblast discharge provides combustion air for the burner system. The fan is mounted directly on top of the windbox for applications up to 80,000 pph of steam (may be less than 80,000 lbs/hr with certain FGR conditions). In applications exceeding 80,000 pph of steam, the forced draft fan is mounted remote from the windbox. The combustion air fan is supplied with a variable inlet vane-type damper, inlet screen, and silencer to reduce fan noise to 85 dBA at a distance of
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Table C-23. Burner Data (Model CT)

BURNER MODEL NOMINAL LOAD REFERENCE LB/HR
15,000 20,000 25,000 29,000 32,000 35,000 38,000 42,000 45,000 48,000 51,000 54,000 57,000 60,000 63,000 66,000 69,000 72,000 75,000 79,000 82,000 85,000 96,000 105,000 115,000 124,000 134,000
FD FAN MOTOR HP
15 20 20 25 30 30 40 40 50 50 50 60 60 60 75 75 75 75 75 100 100 100 125 125 150 150 200
NATURAL GAS FIRING HEAT INPUT MMBTU/HR

20 26 32 38 42 46 50 54 58 62 66 70 74 78 82 86 90 94 98 102 106 110 123 133 146 157 168
NO. 2 FUEL OIL FIRING HEAT INPUT MMBTU/HR

19 25 31 37 41 45 49 52 56 60 64 68 72 76 79 83 87 91 95 99 103 107 119 129 141 152 163
CT-1 CT-2 CT-3 CT-4 CT-5 CT-6 CT-7 CT-8 CT-9 CT-10 CT-11 CT-12 CT-13 CT-14 CT-15 CT-16 CT-17 CT-18 CT-19 CT-20 CT-21 CT-22 CT-23 CT-24 CT-25 CT-26 CT-27
NOTES -Minimum required gas supply pressure to main gas pressure regulator is 15 psig. -Minimum required oil pump supply pressure to oil fuel train is 175 psig. -With fuel supply pressures listed, the turndown is 10:1 on gas 8:1 on oil. -Nominal load reference and FD fan motor hp are for non-FGR applications.
three (3) feet from the fan. The combustion air fan utilizes a 240V or 480V, 3-phase, 60 Hz, electric motor drive. Special voltages and frequencies are available. The gas burner is of multi-spud injector-type design, utilizing fuel staging within the ame envelope for reduction in thermal NOx formation. The burner is designed to provide 10:1 turndown on natural gas when supplied with constant 15 psig gas pressure at the inlet to the gas pressure regulator. The oil burner is of the low-pressure, steam-atomizing type, and is designed to provide 8:1 turndown when supplied with constant 175 psig oil pressure at the inlet to the fuel oil train. Both the gas and oil burners utilize a spark-ignited, gas-pilot
ignition system. The burner operates with full modulation through single-pointpositioning controls. A switch is provided to permit changeover from automatic, fully modulated ring, to continuous ring at any desired rate between minimum and maximum. Control safeguards assure that the burner always returns to the minimum ring position for ignition.
Flame Safeguard
The burner is equipped with a fully automatic ame safeguard system to ensure pre-purge, proper light-off, shutdown on ame failure, and post-purge on shutdown. The system is designed to meet FM, IRI, and CSA requirements.
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Table C-24. Standard Offering (Model CT Burner).
BURNER MODEL AND SIZE CT 1-20 CT 21-27 STANDARD EQUIPMENT ON CT BURNER
FORCED DRAFT FAN 1 2 3 X X 4 5 6 7 8 9 10 11 X X X X X X X X X X X X X X X X X X Fan driven by open drip proof motor. Damper at FD fan inlet. FD Fan Location: a. On windbox. b. Remote from burner. Combustion air proving switch (CAPS) mounted and wired. ATOMIZING MEDIA (OIL-FIRED UNITS) Steam atomization standard. CONTROLS & ELECTRICAL Cleaver-Brooks standard electric positioning controls. Cleaver-Brooks parallel positioning controls. C-B 100 ame safeguard control with lead sulde scanner. Controls remote from control enclosure have NEMA 1 housing. NEMA 12 panel, mounted on boiler. Steam pressure controls (High Limit Pressure Control, Operating Limit Pressure Control, Low-Fire Pressure Control and Modulating Pressure Control) and 8-1/2 steam gauge all on a common manifold assembly, shipped separate from burner (eld piping and wiring required). Starter for FD fan motor. X X X X X X Electric current characteristics 230-460V, 3-phase, 60-Hz. Control circuit transformer mounted and wired on burner. FUEL 15 Gas pilot for all fuel series. NOTE: Standard equipment listed here is included only with burner model indicated by an X.
12 13 14
The control system includes safety interlocks to shut down the system in the event of any of the following, as required for the fuel or fuels being red: Flame failure. High steam pressure. Low drum water level. Low atomizing steam pressure (oil or combination gas/oil burners). Low fuel oil pressure (oil or combination gas/oil burners).
Low fuel oil temperature (oil or combination gas/oil burners). High fuel oil temperature (oil or combination gas/oil burners, IRI only). Low or high fuel gas pressure. Forced draft fan failure. In forced FGR applications, the FGR fan can be mounted on the boiler as shown in Figure C-19, mounted on a separate pedestal, or mounted on the oor.
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Figure C-20 shows the recommended pier arrangement for industrial watertube boilers. Figures C-21, C-22, C-23, C-24, and C-25 show different boiler and stack arrangements for industrial watertube boilers.
Breeching
If more than one boiler is connected to a common stack or breeching, an outlet damper and damper regulator is required unless otherwise noted. Refer to Figure C-26 through C-28 for breeching transition dimensions, and to Table C-25 for stack size selection.
FGR DUCT (BY OTHERS)
(by others)
Figure C-19. Induced FGR System, Industrial Watertube Boiler (CT Burner)
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Figure C-20. Pier Arrangement
Figure C-21. Right Hand Boiler Arrangement
Figure C-22. Left Hand Boiler Arrangement
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Figure C-23. RH and LH Boiler Arrangement With Separate Stacks
Figure C-24. LH and RH Boiler Arrangement With Common Stack
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Figure C-25. Two-Boiler Arrangement With Separate Stacks
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DIMENSIONS IN INCHES BOILER MODEL A 26 34 42 52 60 68 76 86 94 52 60 68 76 86 94 15 18 27 30 30 33 36 36 42 30 33 36 42 42 42 B 36 36 36 36 39 39 39 39 42 39 39 39 39 42 42 C 86-3/4 86-3/4 86-3/4 86-3/4 98-3/4 98-3/4 98-3/4 98-3/4 107-3/4 86-3/4 98-3/4 98-3/4 107-3/4 107-3/4 116-3/4
DL
NOTES: 1. Dimensions vary per stack size and velocity. 2. Must be shipped loose for eld installation. 3. For DLD-DLDH, contact your local Cleaver-Brooks authorized representative.
Figure C-26. Breeching,; Top Outlet Transition Piece
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DIMENSIONS IN INCHES BOILER MODEL A 26 34 42 52 60 68 76 86 94 68 76 86 94 54 54 54 54 66 66 66 66 75 66 75 75 84 B 15 18 27 30 30 33 36 36 42 36 42 42 42 C 36 36 36 36 36 36 36 36 36 36 36 36 36
DL
NOTES 1. Dimensions vary per stack size and velocities. 2. Must be shipped loose for eld installation. 3. For DLD-DLDH, contact your local Cleaver-Brooks authorized representative.
Figure C-27. Breeching; Gas Outlet Transition (Direct-to-Stack)
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DIMENSIONS IN INCHES BOILER MODEL A 26 34 42 52 60 68 76 86 94 52 60 68 76 86 94 54 54 54 54 66 66 66 66 75 66 66 66 75 75 84 B 15 18 27 30 30 33 36 36 42 30 33 36 42 42 42 C 36 36 36 36 39 39 39 39 42 39 39 39 39 42 42 D 35 35-1/2 35-1/2 35-1/2 41-1/2 41-1/2 41-1/2 41-1/2 46 41-1/2 41-1/2 41-1/2 46 46 50-1/2 E 24 24 24 24 25-1/2 25-1/2 25-1/2 25-1/2 27 25-1/2 25-1/2 25-1/2 25-1/2 27 27
DL
NOTES: 1. Dimensions vary per stack size and velocity. 2. Must be shipped loose for eld installation. 3. For DLD-DLDH, contact your local Cleaver-Brooks authorized representative.
Figure C-28. Breeching; Gas Outlet Transition (Connection to horizontal breeching)
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02-02
Table C-25. Industrial Watertube Boiler Stack Size Selection Chart

FLUE GAS FLOW TO STACK LBS/HR MINIMUM 12,910 15,510 21,210 24,410 32,010 36,010 43,010 50,010 57,010 66,010 75,010 84,010 94,010 104,010 115,010 126,010 137,510 150,010 162,510 178,010 192,010 206,010 221,010 237,010 255,010 271,010 MAXIMUM 15,500 21,200 24,400 32,000 36,000 43,000 50,000 57,000 66,000 75,000 84,000 94,000 104,000 115,000 126,000 137,500 150,000 162,500 178,000 192,000 206,000 221,000 237,000 255,000 271,000 287,000 24 28 30 34 36 39 42 45 48 51 54 57 60 63 66 69 72 75 78 81 84 87 90 93 96 99 3.012 4.125 4.747 6.121 6.874 8.296 9.621 11.045 12.566 14.186 15.904 17.720 19.635 21.647 23.758 25.967 28.274 30.680 33.183 35.785 38.484 41.282 44.179 47.173 50.265 53.456 STACK DIAMETER IN.* FLUE GAS VELOCITY FPM AT 560 F GAS TEMP MINIMUM 1840 1620 1920 1710 1995 1860 1920 1940 1945 1990 2020 2030 2050 2060 2080 2085 2090 2100 2100 2130 2140 2145 2150 2155 2170 2180 MAXIMUM 2200 2200 2200 2240 2245 2220 2225 2220 2250 2260 2260 2270 2270 2270 2270 2270 2270 2270 2300 2300 2300 2300 2310 2310 2310 2310 0- 500 501-1000 1001-1500 1501-2000 2001-2500 2501-3000 3001-3500 3501-4000 4501-4500 4501-5000 5001-5500 5501-6000 6001-6500 6501-7000 1.0 1.025 1.05 1.07 1.085 1.105 1.12 1.15 1.17 1.19 1.22 1.24 1.26 1.28
FREE AREA SQ-FT
ELEVATION FT
MULTIPLICATION FACTOR
* Dimensions vary per stack size and ue gas velocities. If boiler is more than 500 feet above sea level, multiply the actual gas ow to stack by factor given and select the stack diameter that corresponds to the corrected gas ow. Based on a 25 ft high steel stack, the following weight will apply for estimating purposes. the above stack diameters apply, dependent upon the ue gas ow to the stack as determined from the performance sheet.
STACK DIAMETER IN. 24 27 30 33 36 39 42
WEIGHT (LBS) 3/16 PLATE 1305 1460 1632 1787 1959 2113 2268 1/4 PLATE 1749 1956 2187 2394 2623 2830 3037
STACK DIAMETER IN. 45 48 51 54 57 60 63
WEIGHT (LBS) 3/16 PLATE 2439 2593 2765 2940 3080 3220 3400 1/4 PLATE 3267 3474 3705 3910 4140 4350 4570
The stack weights shown include the base ring, clean-out door, and connection for breeching.
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02-02
The following sample specications are provided by Cleaver-Brooks to assist you in specifying your customers specic needs and application. A separate specication is provided for steam boiler packages and high temperature hot water packages. Steam Boiler 1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-51 2.0 Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-53 3.0 Economizer (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-57 4.0 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-57 5.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-59 Hot Water Generator 1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-61 2.0 Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-62 3.0 Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-66 4.0 Instrumentation and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-66 5.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-67 FGR System (A, BR and CN Burners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-69 FGR System (CT Burner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-70
Steam Boiler
1.0 General 1.1 Shop-Assembled Steam Boiler This specication shall govern the construction features, materials, fabrication, inspection, and preparation for shipment of packaged-type, shop-assembled, watertube steam generating equipment with burner assembly, all necessary appurtenances, controls and auxiliary equipment mounted to the maximum practical extent, as an integral unit on a steel base so as to make a complete selfcontained assembly. 1.2 General Requirements 1.2.1 Proposal Complete description, drawings, and material specications and performance shall accompany each proposal. 1.2.2 Guarantee Steam will contain not more than 1/2 of 1% moisture when boiler water concentrations are maintained in accordance with ABMA recommendations. The boiler manufacturer shall guarantee the steam generating capacity and thermal efciency as stated herein, while the unit is being red with the primary fuel at the specied operating conditions. Performance and efciency tests shall be conducted immediately after completion of start-up. The manufacturer must have a representative in attendance at the time the test is conducted. All equipment is to be guaranteed against defective design, workmanship, or material for one year from the date of initial operation, not to exceed eighteen (18) months from shipment. 1.2.3 Standards and Codes The following regulatory codes and standards, publication issue in effect at date of invitation for bids, form a part of this specication. All applicable components shall be designed and constructed in accordance with these codes with additions or modications as required by this specication. American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section I, Power Boilers. American Boiler Manufacturers Association (ABMA) Manual of Industry Standards. C-55
02-02

Underwriters Laboratories (UL), UL 795 Commercial-Industrial Gas-Fired Heating Equipment. National Fire Protection Association (NFPA), 8501 Prevention of Furnace Explosions in Fuel Oil and Natural Gas-Fired Single Burner Boiler Furnaces. Steel Structures Painting Council (SSPC), Surface Preparation SP-l. National Electric Code (NEC) National Electrical Manufacturers Association (NEMA). All equipment shall comply with the state, provincial or municipal laws and regulations governing the location where the equipment is to be installed. 1.2.4 Documentation Requirements Dimension drawing with dry and ooded weights, major component identication, and service connection location and size. Electrical drawings including elementary ladder logic and eld component interconnection diagram. Fuel train schematics. Two (2) copies of certied ASME Manufacturers Data Reports on the pressure vessel. Operating and maintenance manuals. Recommended spare parts list. 1.2.5 Design Requirements Design continuous capacity: _____ lb/hr. Design pressure: _____ psig. Operating pressure: _____ psig. Final steam temperature: _____ F. Steam quality (solids): _____ ppm. Feedwater temperature: _____ F. Elevation above sea level: _____ ft. Electrical characteristics: _____ Volts, _____ phase, ____ Hz. Primary fuel: _____, Supply pressure ______. Standby fuel _____, Supply pressure ______. Insurance requirements _____. 1.2.6 Manufacturer Subject to compliance with requirements, provide watertube boiler manufactured by Cleaver-Brooks, Division of Aqua-Chem, Inc. 1.2.7 Efciency Guarantee Fuel-to-steam efciency at above capacity is ____% when ring oil and ____% when ring gas. 1.2.8 Heating Surface The unit will have the following heating surface: Boiler heating surface: _____ sq-ft. Water wall projected surface: _____ sq-ft. Total heating surface: _____ sq-ft. Furnace volume: _____ cu-ft.
C-56
02-02

2.0 Product 2.1 Packaged Watertube Boiler(s) Boilers shall be factory-assembled, packaged, and mounted on heavy steel base frame, complete with integral forced draft burner, burner controls, boiler trim, and refractory. Boilers shall be assembled and wired so that only water, steam, fuel, blowdown, electrical, and vent connections are required. 2.2 Design Pressure The pressure vessel shall have a design pressure of 260 psig in accordance with ASME Power Boiler Construction Code, Section 1, and the laws of the state or province in which the equipment is to be installed. The boiler shall be registered with the National Board of Boiler and Pressure Vessel Inspectors (Provincial Boiler Inspection Agency in Canada), and with the specic state or provincial boiler inspection department. 2.3 Drums The boiler shall have one upper steam drum and one lower mud drum extending the full length of the boiler setting. Each drum head shall have a 12" x 16" manhole opening with cover, yoke, and gasket. Furnish one operating set of gaskets and two complete spare sets. Drums shall be X-rayed and stress relieved as required, and under the inspection of the Hartford Steam Boiler Inspection and Insurance Company. A. Steam Drum - The unit shall incorporate a steam drum of SA-515 grade 70 steel plate (70,000 psig tensile strength) welded construction in strict conformance with the ASME Power Boiler Code. The drum will be stress-relieved, seams radiographed, and hydrostatically tested at 1-1/2 times the design pressure. The steam drum shall be tted with an internal feed pipe, chemical feed pipe, and the blowdown pipe. Water level control bafing is to be installed to ensure that all steam released from the generating tubes is released behind the bafes and not through the water level. Drum internals shall consist of steam separators or dryers, which are installed to ensure that the steam leaving the drum contains not more than 1/2 of 1% moisture when boiler water concentrations are maintained in accordance with ABMA recommendations. B. Lower Drum - The lower drum shall be of fusion-welded construction and will be stress-relieved, seams radiographed, and hydrostatically tested at 1-1/2 times the design pressure. The lower drum shall be tted with an internal blowdown guide bafe to ensure effective blowdown of the lower drum disturbance to the water circulation in the unit. 2.3.1 Drum Connections Provide the following openings in the drums for piping connections, all anges shall be raised face and drilled 300 psig ANSI. Steam outlet: _____ One (1) anged. Safety valves: _____ as required by ASME. Sootblower: _____ One (1) 2" screwed. Water Column: _____ Two (2) 1" screwed. Feedwater Regulator: _____ Two (2) 1" screwed. Top Vent: _____ One (1) 1" screwed. Continuous Blowdown: _____ One (1) 1" screwed. Chemical Feed: _____ One (1) 1/2 screwed. Feedwater: _____ One (1) 2" screwed. Blowdown: _____ One (1) 1-1/4 screwed. All openings shall be properly protected from damage and weather during shipment.
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2.4.Boiler and Furnace 2.4.1. Furnace The furnace shall employ six-wall cooling with the following: Front wall tubes closely spaced around the burner. Membrane inner furnace wall. Tangent oor, roof, and outer furnace wall. Triple row of rear wall tubes. Double row of screen tubes at furnace exit. All tubes shall terminate in the upper and lower drums. No headers are to be used, and all heating surface in the furnace is based on actual projected tube surface and membrane surface. All tubes shall be cleanable by mechanical tube cleaners. All tubes to be expanded into upper and lower drums. 2.4.2 Boiler Section The boiler convection section shall consist of 2" OD tubes SA 178A Grade A arranged in line with longitudinal rows of tubes arranged on wide and narrow spacing to ensure proper and effective arrangement of sootblowing equipment. This arrangement shall also permit removal of any tube without the necessity of removing adjacent tubes. 2.4.3 Tube Material All tubes in the unit for boiler and furnace shall be 2" OD, of SA-178, Grade A, electric resistance welded construction in accordance with ASME Code. 2.4.4 Superheater (Optional) A bare tube, completely drainable superheater shall be furnished as an integral part of the boiler. All superheater elements and headers shall be of suitable carbon and alloy steel material of a thickness required for temperature and pressure prevailing under maximum load conditions. The superheater shall be equipped with a weld end superheater outlet connection and safety valve nozzle, drain, vent, thermometer, and thermocouple connections as required by the design. Safety valve, drain valve, vent valve, and thermometer shall be included. (A steam sampling connection shall be provided by the owner in the connecting steam line). Superheater outlet header is equipped with a connection for the customers automatic start-up and shut-down vent valve size. Piping contractor or others shall furnish and install an automatic controlled vent valve when superheater is subjected to low load conditions. All super heater tube material subject to radiant furnace heat shall be constructed of alloy steel suitable for the temperatures involved. 2.5 Boiler Enclosure 2.5.1 Casing The boiler shall be enclosed with Cleaver-Brooks standard double panel casing with the portion of the casing exposed to the products of combustion completely seal welded to form an air and gas tight enclosure. The outer casing panels shall also be welded. The casing is to be supported off the structural steel frame and shall not be welded or attached to tubing, thereby ensuring free expansion of pressure parts within the casing enclosure. 2.5.2 Arrangement of Casing Construction of the boiler casing enclosure shall be as follows 2.5.2.1 Front Wall - Furnace Area 3", 4-way interlocking tile. 4" high-temperature block insulation. 10-gauge inner seal welded casing. 2-1/2 low density block insulation. 1/4 burner front plate. C-58
02-02

2.5.2.2 Rear Wall - Furnace Area 3", 4-way interlocking tile. 4" high-temperature block insulation. 10-gauge inner seal welded casing. 2-1/2 low-density block insulation. 2.5.2.3 Convection Section - Furnace 10-gauge inner seal welded casing. 4-3/8 low-density mineral wool block. 2.5.3 Furnace Floor Furnace oor tubes shall be covered with 1-1/2 square edge tile. 2.5.4 Drum Enclosure The steam drum shall be shop-insulated with mineral wool block and enclosed in a welded 10-gauge casing. All drum heads will be shop-insulated and enclosed in a 10-gauge casing. No further insulation in the eld shall be required. 2.5.5 Access Access to the furnace shall be through the burner opening in the front wall, and through a separate refractory lined door on the rear wall. 2.5.6 Observation Two (2) air-cooled observation ports, with Pyrex eye shields, shall be provided in the rear wall. 2.5.7 Air Pressure Test The inner seal welded 10-gauge casing shall be subject to an air pressure test of 8" WC, and shall be considered satisfactorily tight if the air pressure drop does not exceed 2" WC in ve (5) minutes. 2.5.8 Bafing The convection section shall contain vertical bafes of 10-gauge steel to direct the ow of ue gases. The bafes shall not require removal for tube replacement. 2.5.9 Insulation The setting and insulation shall be so designed to ensure that a maximum average casing surface temperature of 130F is not exceeded under full load ring with an ambient air temperature of 80F and with a surface air velocity of two feet per second when burner is at maximum output. The manufacturer shall guarantee the design against overheating, warping, or burning of the casing. 2.5.10 Pressure Connection Provide a sensing location in furnace, free of turbulence from ame, for draft control sample connection. 2.5.11 Painting The surfaces shall be prepared per SSPC SP-l specications and nished with rust resistant primer and a high-quality, high-temperature nish coat of enamel paint. 2.6 Sootblower Provide, at a minimum, wall box(es) and bearings for boiler being red on natural gas and No. 2 oil. When heavy oil is specied, provide the following: Sootblowers shall be steam operated, valve-in-head type, and shall be furnished complete with wall sleeves, clamps, hangers, supports, operating chains, and other appurtenances required for a complete installation.
C-59
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Blower elements shall be so arranged that all parts of the heating surfaces shall be cleaned of any soot deposits when rotated by manual or automatic means. Elements shall be of such length, diameter, and total nozzle area that, for the operating pressure involved, there will be no signicant difference in the cleaning effect between the nozzle nearest the inlet and those farthest from the inlet of the element. Sootblower piping shall include a valve, chain-operated from the oor, in addition to an auxiliary steam-stop valve, and drain connection. Sootblowers shall be tted with scavenging air ports, and shall be connected by tubing to the draft fan in a manner to provide sufcient air, for continuous scavenging of the blowers. 2.7 Boiler and Trim Accessories Each unit shall be provided with the following trim (and quantity), which shall be designed for a minimum of 240 psig. Steam Pressure Gauge (1). Safety Valves, Consolidated/Kunkle (ASME Code). Feedwater Regulator, Fisher 2500 (1). Feedwater Regulator By-Pass, Velan S254B (1). Feedwater Regulator Shutoff, Velan S274B (2). Water Column, Cleaver-Brooks (1). Water Gauge, Reliance 404-RS (1). Feedwater Regulator Drain, Velan S274B (1). Gauge Cocks, Reliance No. GC-451 (3). Column Drain, Velan S274B (1). Gauge Drain, Velan S274B (1). Hi-Low Alarm, Warrick Probe (1). Low Water Cutoff, Warrick Probe (2). Feed Stop, Velan S254B (1). Feed Check, Lunkenheimer 624 (1). Drum Blowdown Valve, Edwards No. 848-849 (1 Set). Air Vent, Velan S274B (1). Continuous Blowdown, Velan/Vogt S2054B (1). Chemical Feed Stop, Edwards No. 848 (1). Chemical Feed Check, Edwards No. 838 (1). Auxiliary Low-Water Cutoff, Float Magnetrol #249 (1). Sootblower Shutoff, Velan S254B (1 when required). Sootblower Drain, Velan S274B (1 when required).
All above items, including required piping and supports, shall be assembled in the shop to assure proper t. Drain piping shall be extended for installation of valves at hand height. 2.8 Burner Provide the unit with a forced-draft, register-type burner, arranged to burn natural gas complete with gas electric ignition and observation port. The burner shall be of a type that can be readily converted to oil in the future. The windbox shall be ruggedly con-
C-60
02-02

structed and of a proven design which will assure an even supply of air to all quadrants of the burner register. The burner shall be a standard product of the boiler manufacturer specically designed for the boiler. 2.8.1 Forced Draft Fan The assembly shall be attached to the windbox in such a way that will allow easy access for maintenance. An inlet screen shall be provided, and the air volume shall be regulated by inlet vanes. The fan shall develop sufcient static pressure to ensure proper distribution of air over the entire turndown range of the burner. 2.8.2 Operating and Safety Controls The unit shall be provided with a full complement of operating and safety controls, consisting of not less than the following items and features, which shall be shop assembled: Automatic gas-electric ignition system for gas operation. Underwriters Laboratories listed and Factory Mutual approved microprocessor burner programming and safety controller to automatically provide proper cycling for pre-combustion purge, ignition, start, stop, post-combustion purge and safety shutdown, for use on gas ring and oil ring. This controller shall be a standard product of the boiler manufacturer. Electronic type ame failure protection as part of the program controller to provide safety shutdown on failure of either the main ame or the pilot ame, with manual reset, ame failure and high temperature alarm, all on either oil or gas-ring. Separate high-pressure safety cutoff for steam and low-re hold pressure control. Separate auxiliary low-water safety cutoff for water level with momentary bypass pushbutton for blowdown function. Blower damper to automatically proportion combustion air to ring rate. Air ow safety switch. The following gas valve trains shall be mounted on the burner windbox. All electrical devices shall be prewired to terminals within a burner mounted box. The gas train will be made from Schedule 40 pipe. Sizes 4" and above shall be with butt-weld ttings. The pilot gas train shall conform to NFPA-8501 and be of the interruptible type consisting of two (2) pilot gas solenoid valves, one (1) pilot vent valve, one (1) manual shutoff valve, and a gas pressure regulator. The main gas train shall conform to NFPA-8501 and consist of two (2) main gas valves with one valve having an overtravel protection interlock, a ow control valve, a gas pressure regulator, one (1) vent valve, one (1) manual gas shutoff valve, high and low gas pressure limit protection, and main gas valve leak-test provisions. 2.8.3 The oil burner shall be of the steam-atomizing type for fully-automatic operation. Low pressure air-atomazation is available as an option. Air-atomizing burners shall be supplied with a self-lubricating air compressor. The entire module, a motor driven air compressor and lubricating system, is to be mounted either on the front of the boiler or in a console that can be set adjacent to the boiler. The burner design shall assure proper fuel-air mixture for smoke-free operation at all loads. When ring heavy oil, a positive automatic burner oil gun purge system shall be provided to purge the oil gun on each shutdown of the burner. 2.8.4 The fuel train shall be constructed with Schedule 40 piping, and shall conform to NFPA-8501 requirements consisting of the appropriate pressure and temperature limits (if heavy oil is used), and one (1) fuel valve with valve seal overtravel interlock. If No. 2 oil is used, a second valve is required. All electrical devices shall be prewired to terminate within a burner mounted box. 2.8.5 All controls for the boiler shall be enclosed in a suitable cabinet, with hinged door and lock, containing all necessary relays, magnetic starters, contactors, terminal blocks, fuse blocks, fuses, transformers, switches, rheostats, and colored indicating lights. All instruments on the panel front shall be identied by nameplate. An alarm horn shall be provided on the panel to indicate ame failure and low water level. All wire terminations shall be numbered in accordance with the applicable wiring diagram. All wiring shall conform with the National Electric Code. Electronic continuity tests shall be provided on all circuits to ensure minimal start-up time. 3.0 Economizer (Optional)
NOTICE
Refer to Economizer, Section G, for specification.
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02-02

4.0 Controls 4.1 Feedwater Control Valve Provide a single element pneumatic system consisting of a steam drum water level sensing device that controls a diaphragm-operated control valve. The control valve shall be a tight shut-off with air-to-open type. Provide means to control set point and proportional band. 4.2 Feedwater - Two-Element Control (Optional) The feedwater system shall be of the two-element control type. Drum level shall be maintained by integrating both steam ow and water level signals to control nal drum level. A master controller, steam ow element (orice plate), pressure transducers and drum level transducers shall be included. 4.3 Feedwater - Three-Element Control (Optional) The feedwater system shall be of the three-element control type. Drum level shall be maintained by integrating steam ow, water level and feedwater ow signals to control nal drum level. A master controller, steam ow and water ow elements (orice plates), pressure transducers and drum level transducer shall be included. 4.4 Combustion Control - Single-Point Provide a full modulating single-point electronic combustion control package consisting of the following: Master controller shall maintain steam pressure at boiler outlet within 3% of set point. The control shall be capable of handling load swings from a steady state condition to an increase or decrease in load equal to 20% of the maximum rated capacity of the boiler. Provide a single jackshaft to regulate the ow of air and fuel(s) to the burner. The jackshaft shall be driven from an electric drive in response to the master steam pressure controller. Provide characterizable fuel and air cams for the optimizing of combustion fuel-to-air ratio throughout the ring range. 4.5 Combustion Control - Parallel Positioning (Optional) Provide a combustion control system that uses the concept of controlling the fuel and air ows through separate actuators. Provide a controller for boiler master, air ow controller, and fuel ow controller. If a multiple-boiler application, include a plant master controller. The combustion control system shall be congured to interface to a stand-alone burner management system. This interface shall include interlocks for purge and low re release. 4.6 Combustion control - Full Metering (Optional) Provide a single-fuel-red combustion control system that uses the concept of parallel metering of fuel(s) and air with cross-limiting. For multiple boiler applications, include a plant master single-loop controller in addition to a boiler-master, fuel ow controller(s), and an air ow controller. The combustion control system shall be congured to interface to a stand-alone burner management system. This interface shall include interlocks for purge and low-re release. Steam header pressure shall be controlled to within one percent of set point without excessive hunting or overshooting. 4.7 Monitoring and Recording (Optional) 4.7.1. The following items shall be recorded. Measuring devices such as orice plate and transmitters shall also be included: Steam ow. Water ow. Steam pressure. Stack temperature.
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Economizer outlet stack temperature. Feedwater temperature at economizer inlet. Fuel water temperature at economizer outlet. Fuel Flow. Drum Level. Percent Oxygen. 4.7.2 Multi-point indicator shall be provided for: Furnace pressure. Windbox pressure. Boiler outlet. 4.7.3 A multi-point annunciator shall be provided for the following as applicable: Flame failure. High-low gas pressure. High-low oil pressure. High-low oil temperature. Low atomizing media. Combustion air. Main and pilot failure. Drum level, High-low. High steam pressure. 4.7.4. The annunciator shall include alarm horn, silence and test switch. 4.8 Forced Flue Gas Recirculation - (Optional) 4.9 Induced Flue Gas Recirculation (Optional)
NOTICE
Refer to FGR specifications. 5.0 Execution 5.1 Testing A shop hydrostatic test shall be performed at 1-1/2 times the design pressure under the inspection of the Hartford Steam Boiler Inspection and Insurance Company. The boiler casing shall be subjected to a shop internal air test at a minimum pressure of 8" WC, and held for ve minutes without dropping 2" WC to ensure that no leaks are present. Any detected leaks shall be corrected. Provide electronic continuity tests on all circuits to ensure minimal start-up time. 5.2 Examination Examine and verify size, location, and condition of concrete pads upon which boilers are to be installed. Do not proceed with installation until unsatisfactory conditions have been corrected. 5.3 Installation
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5.3.1 General Install boilers in accordance with manufacturers installation instructions, requirements of state, provincial and local code, and requirements of the local utility company. Maintain manufacturers recommended clearances around and over boilers. 5.3.2 Support Install boilers on 15" high concrete pads. Pads to be located under each boiler drum saddle. 5.3.3 Erection Assemble boiler trim shipped loose or unassembled for shipment purposes. Follow manufacturers installation instructions. 5.3.4 Gas Piping Connect gas piping to boiler, full size of boiler gas train inlet, and provide union with sufcient clearance for burner removal and service. 5.3.5 Oil Piping Connect oil piping to boiler, full size of inlet to burner, and provide shutoff valve and union with sufcient clearance for burner removal and service. 5.3.6 Steam and Condensate Piping Connect supply, return, and blowdown boiler tappings as indicated, with shutoff valve and union, or ange, at each connection. 5.3.7 Breeching Connect breeching to boiler outlet, full size of outlet. 5.4 Cleaning Flush and clean boilers, upon completion of installation, in accordance with manufacturers instructions. 5.5 Field Quality Control 5.5.1 Hydrostatically test assembled boiler and piping in accordance with applicable sections of ASME Boiler and Pressure Vessel Code. 5.5.2 A representative of the National Board of Boiler and Pressure Vessel Inspectors (or Provincial Boiler Inspection Agency in Canada) shall inspect boiler installation, piping connections, and observe hydrostatic testing and for certication of completed boiler units. 5.6 Demonstrations 5.6.1 Services After testing and inspection is complete, provide the services of an authorized factory service representative to perform start-up and operation demonstration services. 5.6.2 Start-Up Perform services in accordance with manufacturers written start-up instructions. Test controls and demonstrate compliance with requirements. Replace or repair damaged or malfunctioning controls and equipment. 5.6.3 Maintenance and Operation Training As part of the maintenance and operating instructions, review data in operating and maintenance manual, including preventative maintenance schedule and procedures, and procedures for obtaining repair parts and technical assistance. Demonstrate all phases of operation including start-up and shut-down. Schedule training with Owner, and provide at least 7-day notice to Architect/Engineer. 5.6.4 Factory-trained authorized service and parts representative shall be located within 4 hours of boiler plant.
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Hot Water Generator
1.0 General 1.1 Shop-Assembled Watertube Hot Water Generator This specication shall govern the construction features, materials, fabrication, inspection, and preparation for shipment of packaged-type, shop-assembled, watertube hot water generating equipment with burner assembly, all necessary appurtenances, controls, and auxiliary equipment mounted to the maximum practical extent, as an integral unit on a steel base so as to make a complete self-contained assembly. 1.2 General Requirements 1.2.1 Proposal Complete description, drawings, and material specications and performance shall accompany each proposal. 1.2.2 Guarantee The generator manufacturer shall guarantee the Btu/hr generating capacity at the specied temperatures and pressures, and (fuelto-water) efciency as stated herein, while the unit is being red with the primary fuel at the specied operating conditions. Performance and efciency tests shall be conducted immediately after completion of start-up. The manufacturer must have a representative in attendance at the time the test is conducted. All equipment is to be guaranteed against defective design, workmanship, or material for one year from the date of initial operation, not to exceed eighteen (18) months from shipment. 1.2.3 Standards and Codes The following regulatory codes and standards, publication issue in effect at date of invitation for bids form a part of this specication. All applicable components shall be designed and constructed in accordance with these codes with additions or modications as required by this specication. American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section I, Power Boilers. American Boiler Manufacturers Association (ABMA) Manual of Industry Standards. Underwriters Laboratories, Inc. (UL), UL 795, Commercial-Industrial Gas-Fired Heating Equipment. National Fire Protection Association (NFPA), 85A, Prevention of Furnace Explosions in Fuel Oil and Natural Gas-Fired Single Burner Boiler Furnaces. Steel Structures Painting Council (SSPC), Surface Preparation SP-1. National Electric Code (NEC). National Electrical Manufacturers Association (NEMA). All equipment shall comply with the state, provincial or municipal laws and regulations governing the location where the equipment is to be installed. 1.2.4 Documentation Requirements Dimension drawing with dry and ooded weights, major component identication, and service connection location and size. Electrical drawings including elementary ladder logic and eld component interconnection diagram. Fuel train schematics. Two (2) copies of certied ASME Manufacturers Data Reports on the pressure vessel. Operating and maintenance manuals. Recommended spare parts list.
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1.2.5 Design Requirements Design continuous capacity: _____ Btu/hr. Design supply temperature: _____ F. Design return temperature: _____ F. Operating pressure: _____ psig. Flow rate:_____ gph. Elevation above sea level: _____ ft. Electrical characteristics: _____ Volts, _____ phase, _____ Hz. Primary fuel: _____, Supply pressure _____. Standby fuel: _____, Supply pressure _____. Insurance Requirements _____. 1.2.6 Manufacturer Subject to compliance with requirements, provide watertube generator manufactured by Cleaver-Brooks; Division of Aqua-Chem, Inc. 1.2.7 Efciency Guarantee Fuel-to-water efciency at above capacity is ____% when ring oil and ____% when ring gas. 1.2.8 Heating Surface The unit will have the following heating surface: Boiler heating surface: _____ sq-ft. Water wall projected surface: _____ sq-ft. Total heating surface: _____ sq-ft. Furnace volume: _____ cu-ft. 2.0 Product 2.1 Packaged Watertube Generator(s) Generator shall be factory-assembled, packaged, mounted on heavy steel base frame, complete with integral forced draft burner, burner controls, generator trim, and refractory. Factory-assemble and wire generators so that only water, steam, fuel, blowdown, electrical, and vent connections are required. 2.2 Design Pressure The pressure vessel shall have a design pressure of 260 psig in accordance with ASME Power Boiler Construction Code Section 1, and the laws of the state or province in which the equipment is to be installed. The generator shall be registered with the National Board of Boiler and Pressure Vessel Inspectors (or Provincial Boiler Inspection Agency in Canada), and with the specic state or provincial boiler inspection department. 2.3 Drums The generator shall have one upper drum and one lower mud drum extending the full length of the generator setting. The upper drum shall be of all welded construction, and shall be complete with all necessary openings. The lower drum shall be of all welded construction, and shall be complete with all necessary openings and internal water distribution pipe. The lower drum shall have a anged thermal sleeve type water inlet connection. The lower drum internals shall be of the jet inducing circulation and mixing type. The upper drum head shall have a 12" x 16" manhole opening with plate, yoke, and gasket. Furnish one operating set of gaskets and two complete spare sets. Drums shall be X-rayed and stress-relieved, as required, and under the inspection of the Hartford Steam Boiler Inspection and Insurance Company.
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2.3.1 Drum Connections Provide the following openings in the drums for all accessories and piping connections. All anges shall be raised faced and drilled 300 psig ANSI. Supply: one (1) anged. Return: one (1) anged. Safety relief valves: (as required by ASME) anged. Water column: two (2) 1" screwed. Top vent: one (1) 1" screwed. Chemical feed: one (1) 1/2 screwed. Blowdown: one (1) 1-1/4 screwed. All openings shall be properly protected from damage and weather during shipment. 2.4 Boiler and Furnace 2.4.1 Furnace The furnace shall employ six-wall cooling with the following: Front wall tubes closely spaced around the burner. Membrane inner furnace wall. Tangent oor, roof, and outer furnace wall. Triple row of rear wall tubes. Double row of screen tubes at furnace exit. All tubes shall terminate in the upper and lower drums. No headers are to be used, and all heating surfaces in the furnace are based on actual projected tube surface and membrane surface. All tubes shall be cleanable by mechanical tube cleaners. All tubes to be expanded into upper and lower drums. 2.4.2 Boiler Section The boiler convection section shall consist of 2" OD tubes arranged in line with longitudinal rows of tubes arranged on wide and narrow spacing to ensure proper and effective arrangement of sootblowing equipment. This arrangement shall also permit removal of any tube without the necessity of removing adjacent tubes. 2.4.3 Tube Material All tubes in the unit for boiler and furnace shall be 2" OD, SA-178, Grade A, electric resistance-welded construction in accordance with ASME Code. 2.5 Boiler Enclosure 2.5.1 Casing The boiler shall be enclosed with Cleaver-Brooks standard double-panel casing with the portion of the casing exposed to the products of combustion completely seal-welded to form an air and gas-tight enclosure. The outer casing panels shall also be welded. The casing is to be supported off the structural steel frame and shall not be welded or attached to tubing, thereby ensuring free expansion of pressure parts within the casing enclosure. 2.5.2 Arrangement of Casing Construction of the boiler enclosure shall be as follows: 2.5.2.1 Front Wall - Furnace Area 3", 4-way interlocking tile.
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4" high-temperature block insulation. 10-gauge inner seal welded casing. 2-1/2 low density block insulation. 1/4 burner front plate. 2.5.2.2 Rear Wall - Furnace Area 3", 4-way interlocking tile. 4" high-temperature block insulation. 10-gauge inner seal welded casing. 2-1/2 low-density block insulation. 2.5.2.3 Convection Section - Furnace 10-gauge inner seal welded casing. 4-3/8 low-density mineral wool block. 2.5.3 Furnace Floor Furnace oor tubes shall be covered with 1-1/2 square edge tile. 2.5.4 Drum Enclosure The steam drum shall be shop-insulated with mineral wool block and enclosed in a welded 10-gauge casing. All drum heads will be shop-insulated and enclosed in a 10-gauge casing. No further insulation in the eld shall be required. 2.5.5 Access Access to the furnace shall be through the burner opening in the front wall, and through a separate (optional) refractory lined door on the rear wall. 2.5.6 Observation Two (2) air-cooled observation ports, with Pyrex eye shields, shall be provided in the rear wall. 2.5.7 Air Pressure Test The inner seal welded 10-gauge casing shall be subject to an air pressure test of 8" WC, and shall be considered satisfactorily tight if the air pressure drop does not exceed 2" WC in ve (5) minutes. 2.5.8 Bafing The convection section shall contain vertical bafes of 10-gauge steel to direct the ow of ue gases. The bafes shall not require removal for tube replacement. 2.5.9 Insulation The setting and insulation shall be so designed to ensure that a maximum casing surface temperature of 130F is not exceeded under full load ring with an ambient air temperature of 80F and with a surface air velocity of two feet per second when burner is at maximum output. The manufacturer shall guarantee the design against overheating, warping, or burning of the casing. 2.5.10 Pressure Connection Provide a sensing location in furnace, free of turbulence from ame, for draft control sample connection. 2.5.11 Painting The surfaces shall be prepared per SSPC SP-l specications and nished with rust resistant primer and a high-quality, high-temperature nish coat of enamel paint.
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2.6 Sootblower Provide, at a minimum, wallbox and bearings for natural gas and No. 2 oil red units. If a heavy oil is specied, then provide a pneumatic sootblowing system including lances and controller for automatic operation upon operator initiation. If owner does not have plant air available, the contractor is to supply an appropriately sized air compressor/receiver. 2.7 Generator and Trim Accessories Each unit shall be provided with the following trim, designed for a minimum of 240 psig: Drum pressure gauge (1). Safety valves, Consolidated/Kunkle (ASME Code). Water column, Cleaver-Brooks (1). Water gauge, Reliance 404-RS (1). Gauge cocks, Reliance no. GC-451 (3). Column drain, Velan S274B (1). Gauge drain, Velan S274B (1). Low water cutoff, Warrick probe (2). Drum blow-off valve, Edwards No. 848-849 (1 Set). Air vent, Velan S274B (1). Continuous blow-off, Velan/Vogt (1). All above items, including required piping and supports, shall be assembled in the shop to assure proper t. Drain piping shall be extended for installation of valves at hand height. 2.8 Burner Provide a forced-draft, register-type burner arranged to burn the specied fuels complete with gas electric ignition, observation port. The windbox shall be ruggedly constructed, and of a proven design that will assure an even supply of air to all quadrants of the burner register. The burner shall be a standard product of the generator manufacturer, specically designed for the generator. 2.8.1 Forced Draft Fan Assembly shall be attached to the windbox in such a way that will allow easy access for maintenance. An inlet screen shall be provided, and air volume regulated by inlet vanes. The fan shall develop sufcient static pressure to insure proper distribution of air over the entire turndown range of the burner. 2.8.2 Operating and Safety Controls The unit shall be provided with a full complement of operating and safety controls consisting of not less than the following items and features which shall be shop assembled: Automatic gas-electric ignition system for gas operation. Underwriters Laboratories listed, and Factory Mutual approved microprocessor burner programming and safety controller to automatically provide proper cycling for pre-combustion purge, ignition, start, stop, post-combustion purge, and safety shutdown for the fuels as specied. This controller shall be a standard product of the generator manufacturer. Electronic-type ame failure protection as part of the program controller to provide safety shutdown on failure of either the main ame or the pilot ame, with manual reset, ame failure and high temperature alarm, all on either oil or gas-ring. Separate high-pressure safety cutoff and low re hold pressure control. A mounted 8-1/2 diameter pressure gauge for drum pressure. Blower damper to automatically proportion combustion air to ring rate. Air ow safety switch.
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2.8.3 If natural gas is specied, then the following is to be provided: Main manual gas shutoff valve with square head and wrench handle. Gas pressure regulators for both pilot and main gas. Gas control valve to regulate gas ow. Gas safety shutoff valves to conform to Underwriters Laboratories and the specied site insurance carrier requirements, consisting of main shutoff valve(s). As a minimum, one valve shall be with a proof-of-closure switch. Two (2) pilot gas solenoid valves, pilot vent valve, and manual stop cock. 2.8.4 If oil is specied, provide the following: Main shutoff valve (two required for light oil). Integral fuel oil metering controller with pressure gauges and temperature gauges if heavy oil. Components to be Factory Mutual and Underwriters Laboratories approved. The conguration, along with safety interlocks, shall be in accordance with the specied site insurance requirements. If heavy oil, a reverse oil-purge pump shall be supplied to evacuate the oil gun on burner shutdown. 2.8.5 All controls for the generator shall be enclosed in a suitable cabinet, with hinged door and lock, and containing all necessary relays, magnetic starters (if provided), conductors, terminal blocks, fuse blocks, fuses, transformers, switches, rheostats and colored indicating lights. All instruments on the panel front shall be identied by nameplate. Provide, on the panel, an alarm horn to indicate ame failure and low-water level. All wire terminations shall be numbered in accordance with the applicable wiring diagram. All wiring shall be done in conformity with the National Electric Code. 2.8.6 Two (2) 6" diameter pressure gauges and two (2) 5" diameter thermometers to be eld-installed into the supply and return lines. 2.8.7 Provide an interlock to the burner operation for low water circulation. This shall include an orice plate and differential pressure transmitter to be eld-installed. The contractor shall supply appropriate anges. The generator manufacturer to supply a threevalve manifold assembly for the transmitter. 3.0 Tests A shop hydrostatic test shall be performed at 1-1/2 times the design pressure under the inspection of the Hartford Steam Boiler Inspection and Insurance Company. The generator casing shall be subjected to a shop internal air test at a minimum pressure of 8" WC and held for ve minutes without dropping 2" WC to insure that no leaks are present. Any detected leaks shall be corrected. Provide electronic continuity tests on all circuits to ensure minimal start-up time. 4.0 Instrumentation and Control 4.1 System Instrumentation (Optional) Provide a freestanding panel piped, pre-wired with a nish coat of paint complete with the following: Four (4) pen recorder for water ow, water supply temperature, water return temperature, and stack temperature. Draft gauges, illuminated vertical scales for windbox pressure, furnace pressure and boiler outlet pressure. Temperature indicators, digital readouts for return water temperature, supply water temperature and stack temperature. Annunciator, rst-out indication, silence and reset buttons, per Instrument Society of America (ISA) standard F3M-3-14. Canopy light. 4.2 Combustion Control - Single Point Provide a full modulating single point electronic positioning combustion control consisting of the following:
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Master regulator to maintain temperature at generator outlet within 3% of control setpoint. Control shall be capable of swings from a steady state condition to an increase or decrease in load equal to thirty (30)% of the maximum rated capacity of the generator. Single jackshaft to regulate the ow of air and fuel to the burner. The jackshaft shall be driven from an electric drive in response to the master regulator. Provide characterizable fuel and air cams for the optimizing of combustion fuel-to-air ratio throughout the ring range. 5.0 Execution 5.1 Examination Examine and verify size, location, and condition of concrete pads upon which the generators are to be installed. Do not proceed with installation until unsatisfactory conditions have been corrected. 5.2 Installation 5.2.1 General Install generators in accordance with manufacturers installation instructions, requirements of state, provincial and local code, and requirements of local utility company. Maintain manufacturers recommended clearances around and over generators. 5.2.2 Support Install generators on 15" high concrete pads. 5.2.3 Erection Assemble generators trim shipped loose or unassembled for shipment purposes. Follow the manufacturers installation instructions. 5.2.4 Gas Piping Connect gas piping to the generators, full size of generator gas train inlet, provide union with sufcient clearance for burner removal and service. 5.2.5 Oil Piping Connect oil piping to the generators, full size of inlet to burner, provide shutoff valve and union with sufcient clearance for burner removal and service. 5.2.6 Connect supply and return piping. 5.2.7 Breeching Connect breeching to generator outlet, full size of outlet. 5.3 Cleaning Flush and clean generators upon completion of installation, in accordance with manufacturers instructions. 5.4 Field Quality Control Hydrostatically test-assembled generator and piping in accordance with applicable sections of ASME Boiler and Pressure Vessel Code. Arrange with National Board of Boiler and Pressure Vessel Inspectors (or Provincial Boiler Inspection Agency in Canada) for inspection of generator installation, piping connections, observation of hydrostatic testing, and for certication of completed generator units. 5.5 Demonstrations 5.5.1 Services After testing and inspection is complete, provide the services of an authorized factory service representative to perform start-up and operation demonstration services.
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5.5.2 Start-Up Perform services in accordance with manufacturers written start-up instructions. Test controls and demonstrate compliance with requirements. Replace or repair damaged or malfunctioning controls and equipment. 5.5.3 Maintenance and Operation Training As a part of the maintenance and operating instructions, review data in operating and maintenance manual, including preventative maintenance schedule and procedures, and procedures for obtaining repair parts and technical assistance. Demonstrate all phases of operation including start-up and shut-down. Schedule training with the owner, and provide at least 7-day notice to the Architect/Engineer.
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02-02

Flue Gas Recirculation (A, BR, and CN Burners)
1.0 Each boiler shall be furnished with a Cleaver-Brooks Flue Gas Recirculation (FGR) system capable of reducing the boiler NOx emissions to 40 ppm, corrected to 3% oxygen in the boiler ue gases when ring natural gas and 125 ppm corrected to 3% oxygen when ring #2 oil and/or #6 oil with a maximum fuel bound nitrogen content of.01 percent. 2.0 In forced FGR systems, the Flue Gas Recirculation fan motor, and belt drive shall be mounted on a steel base. The motor shall be a __________ hp, open drip proof (TEFC optional). The bearings shall be high temperature type capable of handling temperatures up to 550 F. The fan shall be shipped loose. The motor starter and overloads shall be provided. (Optional placement of motor starter.) 3.0 Flue Gas Recirculation control valve, __________ inch diameter, shall be of the buttery type to provide proportional control of fuel/air/FGR throughout the ring range of the boiler. The control valve is actuated through direct mechanical linkage by an assembly attached to the jackshaft. (Pre-t, shipped loose or mounted.) 4.0 Manual shutoff valve, *____________ inch diameter, shall be of the buttery type to provide for isolation of the FGR system during maintenance periods while allowing the boiler to operate. The valve shall include an open and closed limit switch to bypass the interlocks and prevent the fan from energizing. (Pre-t, shipped loose.) 5.0 Option (select A or B) A. Single fuel boilers: The control valve mechanical linkage assembly shall consist of a variable cam to provide a proper ue gas rate control throughout the ring range of the boiler. The mechanical linkage assembly on the fan housing, shall also include a linkage to the jackshaft and a linkage arm that connects to the control valve. B. Dual fuel boilers: The control valve mechanical linkage assembly shall consist of two variable cams, each providing independent control of the recirculated ue gas. These cams provide for proper ue gas control, respective to the fuel being used, throughout the ring range. A limit switch shall be used to distinguish the proper cam-to-fuel selection. The linkage assembly shall also include a linkage to the jackshaft and have a linkage arm that connects to the control valve. 6.0 Dual canister burner housing, for Model A burner, shall be designed to allow for the mixing of the burner combustion air and the recirculated ue gases. The dual canister housing shall consist of two separate housing chambers to provide for independent introduction of gaseous fuel and recirculated ue gas to the combustion process. (Mounted.) 7.0 Extended burner drawer, for Model BR and Model CN Burners, shall be designed to allow for mixing of the combustion air, recirculated ue gas and burner gases. Here the ue gas is introduced as a premix to cool the combustion temperature. (Mounted.) 8.0 Differential pressure interlock switch shall be installed across the Flue Gas Recirculation fan to ensure proper direction of ue gas ow. The switch shall operate such that it will prevent the Flue Gas Recirculation system and boiler from operating upon opening of the switch. (Shipped loose.) 9.0 Minimum ue gas temperature switch, located in boiler stack, shall prevent the boiler from modulating until the boiler has reached operational temperature. (Shipped loose.) 10.0 Miscellaneous timers and relays shall be provided to allow automatic operation of the boiler and FGR system, including a timer to keep the recirculation fan operational for a period of up to ten minutes after the boiler has been shutdown to allow for proper cooling of recirculation fan. (Mounted.) 11.0 All of the above equipment shall be designed and furnished by the boiler/burner manufacturer. Shipped loose items are to be eld-erected by others under the supervision of the boiler/burner manufacturer. 12.0 The installing contractor shall furnish and install all required duct work, insulation, and supports as required by safety codes or the customer unless specied otherwise. 13.0 After normal boiler start-up has been completed, the FGR system shall be placed into operation and calibrated for required performance. Any testing of emissions shall follow, and the cost of these tests shall be borne by the owner.
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Notes
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02-02
Controls
Section D
CONTROLS
CONTENTS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4 CB-HAWK ICS BOILER MANAGEMENT CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5 KEY FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-6 ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-7 SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-7 CB-HAWK ICS COMBUSTION AIR FAN VARIABLE SPEED DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10 FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10 ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10 SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-11 CB-HAWK ICS OXYGEN MONITORING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-12 FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-12 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-12 ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-13 SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-13 APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-13 CB-HAWK ICS ETHERNET COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-14 FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-14 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-14 ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-14 SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-14 CB-HAWK ICS PAGING and REMOTE DIAL-UP ACCESS with MODEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-15 FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-15 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-15 ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-15 SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-15 CB-HAWK ICS INTERNET WEB SITE MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-16 FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-16 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-16 SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-16 CB-HAWK ICS LEAD/LAG FOR TWO BOILER SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-17 FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-17 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-17 SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-17 APPLICATION AND SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-17 CB-HAWK ICS LEAD/LAG for up to EIGHT BOILERS SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-18 FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-18 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-18 SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-18 APPLICATION AND SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-19 CB780 CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-20 FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-20 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-21 ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-21 SAMPLE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-21
D-1
12-02
Controls
CB100E CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAMPLE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CB110 CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAMPLE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEAD/LAG SYSTEMS (TWO BOILER LEAD/LAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEAD/LAG SYSTEMS (TWO THROUGH FOUR BOILER LEAD/LAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOW FIRE HOLD CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MINIMUM TEMPERATURE LOW FIRE HOLD CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSURED LOW FIRE CUTOFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOTE MODULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAMPLE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUTOMATIC FUEL CHANGEOVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAMPLE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OXYGEN TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-22 D-22 D-22 D-22 D-22 D-23 D-23 D-23 D-23 D-23 D-24 D-24 D-24 D-24 D-25 D-26 D-26 D-26 D-26 D-26 D-27 D-28 D-28 D-28 D-28 D-28 D-29 D-29 D-29 D-29 D-29 D-30 D-30 D-30 D-30 D-30 D-31 D-31 D-31 D-31 D-31 D-32 D-32 D-32 D-32 D-32 D-33 D-33 D-33 D-34 D-34 D-35
D-2
12-02
Controls
CB-HAWK BOILER MANAGEMENT CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES & BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CB-LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CB-HAWK ENHANCER BASE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CB-HAWK ENHANCER EFFICIENCY MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CB-HAWK ENHANCER LEAD/LAG CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CB-HAWK TWO BOILER LEAD/LAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TABLES Table D-1. Flame Safeguard Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4 D-36 D-36 D-37 D-37 D-37 D-40 D-40 D-40 D-41 D-41 D-42 D-42 D-42 D-42 D-42 D-43 D-43 D-43 D-43 D-44 D-44 D-44 D-44 D-45 D-45 D-45 D-45
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Controls
GENERAL
Table D-1. Flame Safeguard Comparison
CB 110 DATA DISPLAY Display Type Character Type No. of Characters Alarm/Status LEDs No. of Keys/Buttons Fault Indication No. of Faults Fault History Flame Signal Burner Hours/Cycles Door/Remote Mountable Languages Available DIAGNOSTIC ANNUNCIATOR Availability LEDs Additional Points Additional Messages FEATURES Purge Time Fuel Pressure & Temperature Sensing Water Temp./Steam Press. Sensing Firing Rate Control Thermal Shock Protection Fixed Switches Switches Separate Optional DIP Switches Switches Switches Separate Optional Interchangeable Card Adjustable Switches Switches Separate Optional Interchangeable Card DIP Switches Switches Transmitter Integral (PID) Built-in (based on measured Water Temperature) Built-in Built-in Standard Standard Standard Standard EtherNet I/P or RAP Modem Windows 2000/XP RSLinx OPC Server Optional Standard EtherNet I/P RAP Modem Solid State Sensor(s) Switches Solid State Sensor Integral Built-in (indirectly based on Water Temperature) Optional Built-in Standard Optional Optional Optional CB-LINK Comm Module Windows GPI Interface NA NA NA CB-LINK Comm Module NA NA Yes Transmitter Integral (PID) Built-in (based on measured Water Temperature) Built-in Built-in Standard Standard Standard Standard EtherNet I/P or RAP Modem Windows 2000/XP RSLinx OPC Server Optional Standard EtherNet I/P RAP Modem NA NA NA NA CB300 none 17 31 CB783 26 18 36 Not Required NA NA NA Optional NA 16 16 Optional NA 16 16 Icons NA NA 7 1 Binary Codes 23 none no no no International Icons Backlit LCD Alpha-Numeric 2 x 16 none 3 Message 23 last 6 yes yes Optional English & Spanish VFD Alpha-Numeric 2 x 20 5 5 Code & Message 127 last 6 yes yes Optional English & Spanish LCD Alpha-Numeric 2 line x 40 5 12 Code & Message 73 last 6 yes yes Standard (Door) English Backlit LCD or Color Active Matrix TFT Graphical NA NA Touchscreen Code & Message up to 275 last 100 yes yes Standard (Door) English Backlit LCD or Color Active Matrix TFT Graphical NA NA Touchscreen Code & Message up to 75 last 100 yes yes Standard (Door) English CB 100E CB 780 CB Hawk CB Hawk ICS w/ CB780 CB Hawk ICS w/ CB100E
Hot Stand-By Operation Assured Low Fire Cutoff Setback Capability Lead/Lag Capability, Remote Modulation, Remote Setpoint High Stack Temp. Alarm & Shutdown Efciency Monitoring COMMUNICATION Local/Remote PC Software Type Building/EMS Interface Email & Paging of Alarms Printing Alarm History Remote Access Internet Remote Access Telephone OPTIONAL FEATURES Parallel-Positioning Control Variable Speed Fan Drive O2 Trim
Optional Optional Optional Optional Optional NA E500 Comm Module E500 Comm Module NA NA NA NA
Optional Optional Optional Optional Optional NA
Optional Optional Optional Optional Optional NA
E500 Comm Module CB-LINK Comm Module Windows E500 Comm Module GPI Interface or Mod Bus NA NA NA NA NA NA NA CB-LINK Comm Module Optional NA Optional
Terminal Emulation Terminal Emulation
Optional NA Optional
Optional NA Optional
CB Fuel-Air Ratio Control Yes Yes
CB Fuel-Air Ratio Control Yes Yes
D-4
12-02
Controls
CB-HAWK ICS BOILER MANAGEMENT CONTROL SYSTEM

The CB-HAWK ICS is a state-of-the-art boiler control system that integrates the functions of a Programmable Controller and Burner Management Controller, as well as other boiler operating and ancillary controls. The CB-HAWK ICS system incorporates a graphical Human Machine Interface (HMI), which displays boiler parameters, fault annunciation and alarm history, as well as providing access to boiler conguration and control functions. The CB-HAWK ICS system includes complete boiler ring rate controls for steam or hot water boilers. The CB-HAWK ICSs advanced technology features utilize the latest communication methods, such as DeviceNet, Ethernet, and the Internet. The CB-HAWK ICS also has the capability of interfacing with various Building/Plant Automation Systems. Additional features include lead/lag capability; e-mailing and paging of alarms, remote monitoring, and HMI alarm history printing. The CB-HAWK ICS Integrated Control System may be used on most types of steam or hot water boilers, including retube, industrial watertube, and commercial watertube. It is designed to operate with a gas, oil, or combination burner using a singlepoint modulating control or a parallel-positioning fuel-air ratio control system. In addition to installation on new boilers, the CB-HAWK ICS can be added as a retrot to existing boilers. Contact your local authorized Cleaver-Brooks representative for details. Assured low re cut-off Assured Start Permissive Safety Interlocking High Stack Temperature Alarm and Shutdown Boiler Efciency Calculations Optional Features: Color Graphical HMI E-Mail and Pager Alarm/Fault Forwarding Fuel-Air Ratio Control Building/Plant Automation System Interface Remote Internet Monitoring and Diagnostics O2 Monitoring and Trim Internet Parts and Service Lookup Built-in two boiler lead/lag control Lead/Lag Capability for Multiple Boiler Systems Variable Speed Drive on Combustion Air Fan Diagnostic Annunciator Safety Provisions and Diagnostics: A. Integrated Burner Management Utilizes the CB780 or CB100E Flame Safety Control Communicates with the Programmable Controller via DeviceNet Burner Control Status, Faults, and Diagnostics displayed on HMI B. Integrated Boiler Controls Operating and Modulating Controls Primary Low Water Cut-Off Variable Speed Drive fault shutdown communicates via DeviceNet (optional) Password protection of Programmable Controller Logic Password protection of Parallel Positioning Control (optional)
KEY FEATURES AND BENEFITS

Advanced Technology Standard Features: Integrates control function of burner sequencing and safety with ring rate, fuel-air ratio, and operating limit controls Incorporates a Programmable Controller Touch Screen Graphical Human Machine Interface (HMI) Monitors and Displays Connected Boiler Parameters Optimizes Boiler Firing Rate Control Alarm/Fault Indication and History On-Screen Fault Diagnostics Night/Day Setback Control Thermal Shock Protection Remote Modulation Remote Setpoint
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Controls
Powerful Display/Diagnostic Capabilities: Touch Screen Graphical Human Machine Interface (HMI). Color (optional). HMI allows easy screen navigation to monitor various boiler parameters & diagnostics and to congure boiler controls. Displays alarms/faults, burner status, and ame signal from the Flame Safety Control. Diagnostics in plain English and prioritized fault annunciation simplify troubleshooting. Displays Boiler Steam Pressure, Water Temperature, Firing Rate, Stack Temperature, Boiler Efciency, Combustion Air Temperature (optional), Flue Gas O2 Concentration (optional), Combustion Air Fan Motor Speed and kW (VSD option), Combustion Air Pressure (with VSD option), Water Level (CB-Level Master option), Shell Water Temperature (Steam Boilers), and other control points. Displays Boiler Operating Status (e.g. Warm Up, Auto/ Manual, Boiler On, fuel selection, etc.). Displays Boiler Firing Rate control parameters and settings. Provides Remote Monitoring and Diagnostic capabilities via the Internet or Modem (optional). Provides E-mail Forwarding and Paging of Alarm/Fault Codes (optional). Touch Screen controls simplify screen navigation and boiler conguration Reliable and accurate controls using microprocessor-based programming Simplified Servicing: Diagnostics and fault history, up to 100 faults, through touch screen display simplies troubleshooting procedures E-Mail Forwarding and Paging of System Fault Codes when applicable (optional) Connection to user Building Automation System when applicable (optional)
PRODUCT OFFERING
Included in each CB-HAWK ICS system is the following: Programmable Controller Touch Screen HMI DeviceNet Communication Network Various Controller Input/Output Modules Flame Safety Controller Various Temperature and Pressure Sensors Optional Features and Equipment: (see individual specifications for these options) Ethernet/IP Module to provide communication between the Programmable Controller and other Ethernet compatible devices OPC Server software for interface with Building/Plant Automation System Lead/Lag Control of Multiple Boilers Fuel-Air Ratio Control System and Actuators Variable Speed Drive for Combustion Air Fan Motor O2 Analyzer and/or External O2 Trim System Combustion Air Temperature Sensor Economizer Stack Flue Gas Temperature, Feed Water Temperature, Oil Temperature, and Gas & Oil Pressure Sensors Steam, Water, and Fuel Flow Monitoring CB-Level Master primary safety water level control Internet Web Site Monitoring Package Paging and Remote Dial-Up Access with Modem communication E-mailing with Ethernet/IP option
D-6
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Controls
ENGINEERING DATA
Supply Voltage: 120 VAC (+10%/-15%) 50 or 60 Hz. Maximum total connected load: 2000 VA Operating temperature limits: 32 to 130F 85% RH continuous, non-condensing, humidity 0.5G continuous vibration
Thermal Shock Protection based on water temperature and setpoint Various High and Low limit alarms and shutdowns Touch Screen graphical operator interface and monitoring Manual control of the boiler-ring rate utilizing control screens on the HMI to increment and decrement the ring rate On screen indication of burner management controller status and diagnostics On screen real-time display of all connected process parameters On screen display of system alarms and faults On screen history of alarms and faults On screen recommendation for troubleshooting fault conditions On screen water level indication (optional) and alarm(s) Printing Alarm/Fault history E-Mail or Paging of boiler alarms (with either Ethernet/IP or Modem Option) Building/Plant Automation System interface (with Ethernet/ IP Option) Ethernet and Internet communications (with Ethernet/IP Option) Tamper resistant control logic and password protection. Night/Day Setback control Stack Flue Gas, Combustion Air (optional), and Shell (water) temperatures Boiler Efciency calculation Outdoor Reset for Hot Water Boilers Remote Modulation or Firing Rate Setpoint control Assured Low Fire Cut-Off (ALFCO) Assured Start Permissive Safety Interlocking
1.0 Each unit shall be factory equipped with a Boiler Control System providing technology and functions equal to the CB-HAWK ICS Boiler Control system. 2.0 Each Boiler Control System shall be factory equipped with a pre-congured Programmable Controller and Human Machine Interface (HMI). 3.0 Major system components shall include: Programmable Controller Touch Screen HMI DeviceNet Communication Network Various Controller Input/Output Modules One Burner Management Controller and Wiring Sub-Base One Flame Scanner: Infrared, Ultra-Violet, or UV Self-Check One Flame Amplier, to correspond with the selected Flame Scanner Various Temperature and Pressure Sensors 4.0 Major functions that the Boiler Control System shall provide: Automatic sequencing of the boiler through standby, pre-purge, pilot ame establishing period, main ame establishing period, run and post purge Flame proving and lockout on ame failure during pilot ame proving, main ame proving, or run Low re damper/valve position for ame ignition trials Full modulating control of fuel and combustion air Utilize solid state controls and sensors to provide various control functions, such as: On/Off, and Modulating Control Modulating Control algorithm shall be ProportionalIntegral-Derivative (PID) type
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12-02
Controls
5.0 The Boiler Control System shall provide the following safety provisions for: A. Integrated Burner Management Examine all load terminals to assure it is capable of recognizing the true status of the external controls, limits and interlocks. If any input fails this test, the burner management system should lockout on safety shutdown. Closed-loop logic test veries integrity of safety critical loads (ignition, pilot, and main fuel valves) and must be able to lockout on safety. Pre-ignition interlocks (fuel valve proof of closure, etc.) and ame signal checked during Standby and Pre-Purge. Dynamic checking of the ame signal amplier. The control ame signal amplier must be able to recognize a no ame signal during this dynamic amplier check. Safe start check and expand check to include monitoring ame signal during standby. High and Low re switches checked for proper sequencing. Tamper-proof Purge Timing and safety logic. B. Integrated Boiler Controls Operating and Modulating Control Primary Low Water Cut-Off Variable Speed Drive (if used) fault shutdown Password protection of Programmable Controller Logic Password protection of Parallel Positioning Control (if used) 6.0 The Boiler Control System shall provide annunciation and diagnostics: Active alarm annunciation Provide historical alarm information for on screen display Detects and isolates an alarm, and reports internal circuit faults Printer output capable for logging alarms Capability of printing alarm history of date, time, cycle of occurrence and date and time of acknowledgement up to the most recent 100 faults English text description of the system fault and troubleshooting procedures Water Level indication and low water Shutdown Alarm Dynamic Self Checking 7.0 The Boiler Control System shall be able to operate in these environmental conditions. Supply Voltage: 120 VAC (+10%/-15%) 50 or 60 Hz Maximum total connected load: 2000 VA Operating temperature limits: 32 to 130F 85% RH continuous, non-condensing, humidity 0.5G continuous vibration 8.0 All Boiler Control System wiring shall be in accordance with the National Electrical Codes and local electrical codes. 9.0 Boiler Control System component functions shall be as follows: Burner Management Controller: Provides boiler sequencing logic to meet FM/IRI/UL/cUL approval body requirements. Touch Screen Graphical Interface: Provides user interface to the control system, boiler overview screen with connected boiler parameter readouts, Burner Management Control status screen, alarm banners, diagnostic screens for fault troubleshooting, alarm history screen, system ring rate screen and system conguration screens. DeviceNet Communication Network: Provides communication between the Programmable Controller and other peripheral devices. Various Programmable Controller Input/Output modules: Provides interface for discrete powered and/or isolated relay signals, as well as for analog signals, from and/or to other input/output devices. Stack Temperature Sensor: Measures and transmits a signal to the Programmable Controller in relation to boiler exit ue gas temperature. It is used for indication and in the calculation of boiler efciency; it can also be used for high stack temperature alarm and shutdown. Steam Pressure Transmitter (Steam Boiler): Provides an analog signal to the Programmable Controller for indication of boiler steam pressure; utilized for on/off and modulating control of the burner.
D-8
12-02
Controls
Water Temperature Transmitter (Hot Water Boilers): Provides an analog signal to the Programmable Controller for indication of boiler water temperature; utilized for thermal shock protection, on/off, and modulating control of the burner. Water (shell) Temperature Sensor: Measures and transmits a signal to the Programmable Controller in relation to boiler water temperature; used for indication and thermal shock protection. 10.0 Optional Equipment (see individual data sheets for these options) Ethernet/IP Module: Provides communication between the Programmable Controller and other Ethernet Compatible devices (e.g. Boiler Room Master Control, Building/Plant Automation system, and the Internet) and E-mail functionality Lead/Lag Control for Multiple Boiler Systems Fuel-Air Ratio Control System and Actuators Variable Speed Drive for Combustion Air Fan Motor O2 Analyzer and/or External O2 Trim System Combustion Air Temperature Sensor: Measures and transmits a signal to the Programmable Controller in relation to the combustion inlet temperature for indication and for use in the calculation of boiler efciency; also can be used for high combustion air temperature alarm and shutdown, based on setpoint Economizer Flue Gas Inlet and Outlet Temperatures, Feed Water Temperature, Oil Temperature, and Gas & Oil Pressure Sensors Steam, Water & Fuel Flow Monitoring CB-Level Master primary safety water level control Internet Web Site Monitoring Package Paging and Remote Dial-Up Access with Modem
D-9
12-02
Controls
CB-HAWK ICS COMBUSTION AIR FAN VARIABLE SPEED DRIVE

Provides variable speed output to the burners Combustion Air Fan blower motor for the purpose of improving boiler efciency and reducing electrical energy consumption.

Improved Boiler Efficiency: Maintains consistent Wind Box Pressure throughout the Modulating Firing Range of the Boiler Energy Savings: Reduces electrical energy consumption Soft starting reduces electrical and mechanical stress on the motor, extending the life of the motor Provides Substantial Savings from Mid to Low Fire modulation points Average Payback in approximately 6 8 Months PI Control Logic: Precise control. Monitors rate of change to anticipate needs of system, increasing and decreasing the output speed (frequency) to the blower motor as needed Maintains Wind Box Pressure at the Setpoint Communication: Communicates with the Boiler Controller through DeviceNet Provides Drive process information on the Boiler Control Panel Display Provides Drive faults and troubleshooting suggestions, in Plain English, on Boiler Control Panel Display
ENGINEERING DATA
Drive: Ambient Operating Temperatures: 32 122F Altitude: 3300 Ft (1000 m) Max without derating Shock: 15G peak for 11ms duration (1.0 ms) Vibration: 0.152 mm (0.0006 in.) displacement, 1G peak Voltage Tolerance: -10% of minimum, +10% of Maximum Frequency Tolerance: 47 63 Hz Input Phases: Three-phase input provides full rating of all drives, Single-phase operation provides 50% of rated current Displacement Power Factor: PF70 C & D Frames 0.92 lagging (entire speed range), PF70 A&B Frames 0.64 lagging, PF700 TBD Output Voltage: 0 to rated motor voltage Output Frequency Range: 0 400 Hz Frequency Accuracy: Digital Input Within 0.01% of set output frequency, Analog Input Within 0.4% of maximum output frequency Intermittent Overload: 110% Overload capability for up to 1 minute, 150% Overload capability for up to 3 seconds
PRODUCT OFFERING
Cleaver-Brooks shall supply the following equipment: Adjustable Frequency Variable Speed Drive. Wind Box Pressure Transmitter. VSD Compatible Combustion Air Fan Motor.
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Current Limit Capability: Proactive Current Limit programmable from 20 to 160% of rated output current; Independently programmable proportional and integral gain Line Transients: Up to 6000 volts peak per IEEE C62.41-1991 Ground Fault Trip: Phase-to-ground on drive output Short Circuit Trip: Phase-to-phase on drive output Drive Overcurrent Trip: Software 20 to 160% of rated current, Hardware 200% of rated current (typical), Instantaneous 220 to 300% of rated current (dependent on drive rating) Electronic Motor Overload Protection: Class 10 protection with speed sensitive response. Investigated by U.L. to comply with N.E.C. Article 430, UL File E59272 Volume 12 See Drive Manual for other, Model and Voltage Specic, specications. Pressure Transmitter: Pressure Range: 0 2 psig Output: 4 20mA DC Connection: 1/4" NPT Enclosure: NEMA 4 Accuracy: 0.25% FS Compensated Range: -4 to +176F Motor: Motor suitable for variable speed drive service Variable Torque, 3 phase Other specications based on Specic Horsepower, Voltage, and Frequency requirements. Contact your local Authorized Cleaver-Brooks Representative for further details.
The Boiler Manufacturer shall provide a Variable Speed Drive controller for use on the burners Combustion Air Fan blower motor for the purpose of providing Improved Boiler Efciency and Reduced Electrical Energy consumption. The Drives voltage, frequency, and current ratings shall be rated in accordance with the electrical requirements as dictated by job site specics, and for the properly rated motor horsepower. The Variable Speed Drive must be capable of communicating over the DeviceNet protocol. A pressure transmitter shall be supplied to measure the Wind Box Pressure of the Burner and shall be capable of supplying a 4 20mA process variable input signal to the VSD. A Motor suitable for variable speed drive service must be supplied for use in conjunction with the Variable Speed Drive, and sized to match the motor requirements of the Combustion Air Fan Blower. Variable Speed Drive shall be interlocked with boiler control to ensure safe operation.
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Controls
CB-HAWK ICS OXYGEN MONITORING SYSTEM

The CB-HAWK ICS Oxygen Monitoring System provides indication and monitoring of the boilers exit ue gas O2 concentration. In conjunction with Stack Flue Gas and Combustion Air Temperature measurements, the system also provides means for a more accurate boiler efciency calculation. If O2 Trim is desired see page D-33, Oxygen Trim, of the CB Boiler Book.

Integrated Type In-Situ Zirconia Oxygen Analyzer: Reduces wiring, piping and installation costs Allows replacement of the zirconia cell on site Built-in heater assembly of the probe can be replaced on site Can be congured on site without opening the cover using an infrared sensor O2 measurement circuitry built into probe head electronics O2 Level percentages displayed on the Boiler Control Panel Human Machine Interface (HMI) Provides accurate Boiler Efciency Calculations with the CB-HAWK ICS Programmable Controller Separate analyzer/converter display panel not required Combustion Air Temperature: Provides temperature measurement of boilers combustion air Indication on HMI display Used in overall boiler efciency calculations Stack Flue Gas Temperature (included in standard offering): Provides temperature measurement of boilers stack ue gas Indication on HMI display Used in overall boiler efciency calculations User Configurable Alarm Points Low O2 Alarm Analyzer Probe is Direct Insertion, In-situ Zirconia Type Which Provides: High accuracy Fast Response Proven Reliability
PRODUCT OFFERING
In-Situ Zirconia Probe and Analyzer Process Variable % O2 Readout on Control Panel HMI Combustion Air Temperature measurement and indication Accurate Efciency Calculations Options: Separate O2 Converter/Display Panel Replacement Zirconia Cell Auto Calibration Pneumatics Replacement Heater Assembly Remote Indicator/Alarm Probe Stack Mounting Adapter Calibration Gas Kit
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Controls
ENGINEERING DATA
Ambient Temperature: -4 to 131F (-20 to +55C) Sample Gas Temperature: 32 to 1292F (0 700C) Sample Gas Pressure: -1.5 to 73.8 in Hg (-5 to +250 kPa) Output Signal: 4 20mA DC, One Point, Maximum Load Resistance 550 Ohms Digital Output (HART): 250 500 Ohms Contact Output Signal: Two Points, 30 VDC 3A, 250 VAC 3A (one is fail safe normally open) Contact Input Signal: Two Points Reference Air: Natural Convection, Instrument Air, pressure compensated Instrument Air: 200 kPa plus the pressure in the furnace Power Supply: 100 240 VAC, 50/60Hz Power Consumption: Max 300 W, approx. 100 W for ordinary use Combustion Air Thermocouple: Type J
2.0 Combustion Air Temperature Probe Type J thermocouple 3.0 Analyzer Shall be of the Integrated Type (in probe head) Provide 4 20mA DC Signal output in relation to process variable for remote display 4.0 Monitoring System Indicate O2 Percentages Provide Low O2 Alarm Indication Perform Efciency Calculations and display results using O2 percentages 5.0 Combustion Air Thermocouple to be Type J 6.0 The system shall continuously monitor oxygen concentration in the boilers exit ue gas and provide indication of O2 percentages and alarm points on a Human Machine Interface (HMI) type display.
APPLICATION
This system is applicable to modulating burners using the CB-HAWK ICS Integrated Control System. This system shall monitor and display O2 concentration in the boilers exit ue gas and provide overall boiler efciency calculations.
This specication covers the hardware and monitoring functions of the CB-HAWK ICS Oxygen monitoring system. The system monitors and displays Oxygen concentration and is used, in conjunction with combustion air and stack ue gas temperature sensors, to calculate the overall efciency of the boiler. The system shall be completely congured from the factory requiring only job specic data to be entered (or modied) in the eld. O2 Sensor Requires calibration in the eld! Hardware: Hardware shall consist of the following: 1.0 Oxygen Sensor Integrated type Zirconia Oxygen Analyzer Direct Insertion Type Built-in Heater Assembly 4-20mA DC Process Variable Output Heater to be of eld replaceable construction Cell to be of eld replaceable construction
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Controls
CB-HAWK ICS ETHERNET COMMUNICATION

The CB-HAWK ICS Ethernet communication package provides Ethernet communications between the CB-HAWK ICS programmable controller and other Ethernet compatible devices such as the Boiler Room Master Lead/Lag Control Panel, Building/Plant automation system, and the Internet.
ENGINEERING DATA
Modular connection to CB-HAWK ICS Programmable Controller unit Ethernet Industrial Protocol (Allen-Bradley EPIC) Follows Ethernet Rules and Practices High Noise Rejection Cabling: Category 5E rated twisted pair cable (solid core, PVC jacket with RJ45 connections). Meets Open Industrial Network Standards IEEE 802.3 Physical and Data Link Standard Ethernet TCP/IP protocol suite industry standard Control and Information Protocol (CIP) Compliant OPC (OLE Process Control) communication compatibility with RSLinx OPC Server software

Provides communication between the CB-HAWK ICS programmable controller unit and other Ethernet Compatible Devices Provides interface capability with many Building/Plant automation systems when utilizing OPC server or protocol bridge Provides interface with plants LAN/WAN Provides interface to the Internet (requires static IP address) E-mailing of boiler alarms/faults Provides means of connection between various boiler room control systems, such as the CB-HAWK ICS Master Panel for lead/lag control Provides means of connection to a remote Personal Computer Ethernet Industrial Protocol IEEE 802.3 Physical and Data Link Standard Ethernet TCP/IP protocol suite industry standard Control and Information Protocol (CIP) Compliant
The Boiler Manufacturer shall furnish and install a control module capable of Ethernet communications between the boilers programmable logic control system and other Ethernet compatible devices, as needed, and provide the following minimum requirements: Interface with the Compact Logix Programmable Controller Protocol Ethernet Industrial Protocol (Allen-Bradley EPIC) Follows Ethernet Rules and Practices High Noise Rejection Open Industrial Network Standards IEEE 802.3 Physical and Data Link Standard Ethernet TCP/IP protocol suite industry standard Control and Information Protocol (CIP) Compliant
PRODUCT OFFERING
Ethernet/IP Module Optional Ethernet Communication Hub (necessary for standalone boiler (no Master Panel) connection to LAN/WAN and/or Paging Modem option) E-mail functionality requires customer provided e-mail service and address
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12-02
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CB-HAWK ICS PAGING and REMOTE DIAL-UP ACCESS with MODEM

Provides Paging of Alarms Faults, via Modem, from the CB-HAWK ICS Control System to the customer provided pager or a compatible cell phone.

Paging of boiler system alarms. (Paging Service and Pagers furnished by customer) Allows Remote Dial-Up Access for monitoring and troubleshooting.
PRODUCT OFFERING
Remote Access Paging Modem Easy to use conguration software Requires customer provided, dedicated phone line Requires customer provided Paging Service and pagers (or paging compatible cell phones) Requires Pager Numbers and PINs supplied by customer Congure up to 10 unique pagers
The boiler manufacturer shall provide a Paging and Remote Dial-Up Access Modem, using customer provided paging systems for the purpose of paging boiler system alarms and providing remote access to the control system. Pager number(s) and PINs to be supplied by customer. Dedicated telephone connection to be supplied by customer.
ENGINEERING DATA
Voltage: 24 VDC Baud Rate: 56K Type: External, Serial Paging functionality utilizes TAP Protocol
D-15
12-02
Controls
CB-HAWK ICS INTERNET WEB SITE MONITORING

Provides customer with a secure connection for monitoring site specic, Cleaver-Brooks Boiler(s) operating parameters and alarm conditions via the Internet. Website will also include links to boiler-serial-number based parts lookup and ordering. (Requires CB-HAWK ICS Ethernet Communication Option)

Provides monitoring of boiler on remote PC via the Internet Provides parts lookup and ordering via the Internet Provides remote troubleshooting capabilities by the customer and by Authorized Cleaver-Brooks Representatives and/or service personnel (with customer allowed password protected access) via the Internet E-Mail and Paging of boiler alarms. (A Modem may be required for some E-Mail and Paging system). E-Mail addresses and Pagers furnished by customer.
The boiler manufacturer shall provide an Internet Monitoring package for the purpose of monitoring the boiler system operating parameters and alarm conditions via the Internet. The offering shall supply at a minimum: 1. 2. 3. Provide monitoring of boiler on remote PC via the Internet. Provide parts lookup and ordering via the Internet. Provide remote troubleshooting capabilities by the customer and by Authorized Boiler Manufacturer Representatives and/or service personnel (with customer allowed password protected access) via the Internet. E-Mail and Paging of boiler alarms, understanding that a Modem and a dedicated phone line may be required for some e-mail and paging systems.
PRODUCT OFFERING
Internet Communication Access Requires CB-HAWK ICS Ethernet Communication Option Monthly/Quarterly/Annual monitoring subscription Requires customer provided, dedicated boiler room connection, which requires a global static IP address
4.
D-16
12-02
Controls
CB-HAWK ICS LEAD/LAG FOR TWO BOILER SYSTEMS

Provides Lead/Lag control for a two-boiler system when used in conjunction with the CB-HAWK ICS integrated boiler control system.
Two Boiler Lead/Lag Control

Controls Header Pressure and Temperature: Maintains steam pressure or hot water supply temperature based on system load demand. Compensates for varying losses between boiler and header. Sequences of Operation for Two Boilers: Provides maximum system efciency. Reduces cycling and boiler wear; thereby reducing maintenance and downtime costs. Optimizes fuel savings. Lead/Lag Start with Lead/Lag Modulation: Lead boiler operates at full capacity prior to starting lag boiler. Lag boiler starts modulation when lead boiler reaches maximum ring rate position. Ideal for steam boilers. Lead/Lag Start with Unison Modulation: Lead boiler operates at full capacity prior to starting lag boiler. Lag boiler operates at the same ring rate as a lead boiler. Ideal for hot water boilers. Unison Modulation Firing rates for both boilers are equal. Hot Standby System shall have a provision for keeping lag boiler in hot standby. Standby routine shall be based on a water temperature signal. Boilers Start and Stop Steam pressure, or hot water temperature, is compared with the setpoint and controllers processor executes PID algorithm. Lead boiler is commanded to come on line rst. Lag boiler is commanded to come on line when a ring rate signal for the lead boiler reaches lag boiler start point. Lag boiler is commanded to stop when a ring rate signal for the lag boiler reaches lag boiler stop point. Lead/Lag Modulation Lag boiler starts modulation after lead boiler reaches maximum ring rate.
Master Slave
Running Available Lag ###.# %
Idle Unavailable Lag ###.# %
PRODUCT OFFERING
Cleaver-Brooks shall supply the following equipment: Boiler control for each boiler shall be CB-HAWK ICS. Pressure (steam) or temperature (hot water) transmitter shipped loose for mounting in the common header.
APPLICATION AND SYSTEM REQUIREMENTS

This option is applicable to full modulation burners utilizing the CB-HAWK ICS advanced boiler control system and modulating controls. All logic for Lead/Lag Control shall reside in the boiler controller. No additional control panels shall be required.
Lead/Lag Start with either Lead/Lag or Unison Modulation.
D-17
12-02
Controls
CB-HAWK ICS LEAD/LAG for up to EIGHT BOILERS SYSTEM

Provides Lead/Lag control for up to eight boilers when used in conjunction with the CB-HAWK ICS integrated boiler control system.
Remote Return ###.# C Outdoor ###.# C Supply ###.# C Set Point ###.# C

Controls Header Pressure and Temperature: Maintains steam pressure or hot water supply temperature based on system load demand. Compensates for varying losses between boiler and header. Benefits: Maximizes system efciency. Reduces cycling and boiler wear, thereby reducing maintenance and downtime costs. System shall be provided with a sequence to automatically rotate sequence in which the boilers are red. Rotation shall be based on the elapsed time. Optimizes fuel savings. Boilers Start and Stop Lead/Lag Start with Lead/Lag Modulation: Lead boiler operates at full capacity prior to starting lag boiler #1. Lag boiler #1 starts when the lead boilers ring rate is close to the maximum. Operator can select this parameter via HMI. Lag boiler #1 starts modulation when the lead boiler reaches the maximum ring rate position. Subsequent lag boilers operate in the same fashion. Ideal for steam boilers. Lead/Lag Start with Unison Modulation: Lead boiler operates at full capacity prior to starting the lag boiler. All boilers operate at the same ring rate as the lead boiler. Ideal for Hot Water boiler systems. Steam pressure, or hot water temperature on hot water systems, is compared with the setpoint and controllers processor executes PID algorithm. Lead boiler is commanded to come on-line rst. Lag boiler #1 is commanded to come on-line when a ring rate signal for the lead boiler reaches lag boiler start point. Lag boiler #1 is commanded to stop when a ring rate signal for the lead boiler reaches lag boiler stop point. Lag boiler #2 is commanded to come on-line when a ring rate signal for the lag boiler #1 reaches lag boiler #2 start point. Lag boiler #2 is commanded to stop when a ring rate signal for the lag boiler #1 reaches lag boiler #2 stop point. Subsequent boilers operate in a similar fashion. Lead/Lag Modulation Lag boiler #1 starts modulation after lead boiler reaches maximum ring rate (or ring rate selected by the operator). Lag boiler #2 starts modulation after lag boiler #1 reaches maximum ring rate (or ring rate selected by the operator). Subsequent boilers operate in a similar fashion. Unison Modulation Firing rates for all boilers are equal. Master Control Panel shipped loose for eld mounting. Requires Ethernet/IP Communication Option
Working Entered Control ########## A ########## B ########## C ########## D Running Available # # ###.#
Running Running Running Available Available Available # # # # # # ###.# ###.# ###.# Auto Sequence Rotation in 0#h 0#m 0#s
Lead/Lag Start with either Lead/Lag or Unison Modulation.
PRODUCT OFFERING
Cleaver-Brooks shall supply the following equipment: Boiler control for each boiler shall be the CB-HAWK ICS. Pressure (Steam) or temperature (Hot Water) transmitter shipped loose for mounting in the common header.
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12-02
Controls
Hot Standby System shall have a provision for keeping lag boilers in hot standby. Standby routine shall be based on a water temperature signal. Firing Sequence Selection Sequence in which boilers come on-line shall be selected via HMI. Adequate check shall be provided that does not allow improper sequence selection. Automatic Rotation of the Boilers System shall be provided with a sequence to automatically rotate sequence in which the boilers are red. Rotation shall be based on the elapsed time. HMI (HUMAN MACHINE INTERFACE) Master panel shall include HMI for display and selection of the following parameters: Display Available boilers Number of boilers required Selected sequence of ring Control output to each boiler Header steam pressure or water temperature on hot water systems Setpoint Elapsed time from last rotation Selection Number of boilers Sequence of ring Automatic or manual rotation Individual boiler start and stop points with timers Setpoint Proportional, integral and derivative gains for control algorithm
APPLICATION AND SYSTEM REQUIREMENTS

This option is applicable to full modulation burners utilizing the CB-HAWK ICS advanced boiler control system and modulating controls. Logic for Lead/Lag control shall reside in the Master Control Panel. Communication between the Master Panel and the individual Boiler Control Panels shall be via Ethernet communication or hard wiring.
D-19
12-02
Controls
CB780 CONTROL
The CB 780 is a microprocessor-based, ame safeguard control used to monitor the presence of a ame inside a boiler, and include various interlocks to ensure safe operation. The ame safeguard also sequences the burner through several stages of operation to provide proper air purge, ignition, normal operation and shut down for safe operation.

Dynamic self-check logic and diagnostics: Dynamic self-check safety circuit checks microprocessor and safety relay to ensure safe and proper operation. Dynamic input check veries controls ability to recognize the true status of external controls, limits and interlocks. Closed-loop logic test veries integrity of safety critical loads (ignition, pilot, and main fuel valves) for proper operation. Pre-ignition interlocks (fuel valve proof-of-closure) and ame signal checked during Standby and Pre-Purge. High and Low re switches checked for proper sequencing. Tamper-proof Purge Timer Card. Powerful Display/Diagnostic Capabilities: 2 line x 20 character Vacuum Fluorescent Display is easy to read under all lighting conditions. Status and diagnostic messages displayed in English Language with no scrolling necessary (Spanish also available). Displays ame signal in Volts dc, eliminating need for separate meter. Displays burner hours and numbers of cycles. Diagnostic displays include on/off status of inputs and outputs, RUN/TEST switch status, selected purge time, amplier type and conguration data. Fault history (retained in non-volatile memory) displays the cycle, hours, code, description, and condition for the last six fault occurrences. Capability to mount display on front of Control Panel for improved access, or remotely, in separate control room. (Optional) 5 LEDs on base provide at-a-glance status of Power On, Pilot, Flame, Main Valves, and Alarm conditions (Power LED blinks periodically to indicate proper control operation). Diagnostic display capabilities are further enhanced by the optional CB783 Expanded Annunciator which provides 36 additional specic HOLD and Fault messages, as well as 26 LEDs to indicate current status or rst-out alarm indication (user-selectable). Communication capabilities to a local or remote Personal Computer, with optional CB-LINKcommunications module and Combustion System Manager software (runs under Microsoft Windows). Application Flexibility: Purge Timing Cards available in 30, 60, 90 seconds or 2-1/2 minutes cover a wide range of applications, while eliminating need for a separate purge timer. Separate output for ignition transformer simplies applications requiring early spark termination. Selectable conguration jumpers allow application-specic conguration. Simplified Servicing: Diagnostic and fault history information available through display simplies troubleshooting procedures. Removable access covers for checking voltage at terminals. 5-function RUN/TEST switch eases start-up procedure. Flame signal display facilitates pilot/light-off test procedures.
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Controls
PRODUCT OFFERING
Included in each CB 780 system is the following: One CB780 chassis, including display module. One Purge Timer Card. One wiring sub-base. One ame scanner, either Infrared, Ultra-Violet, or UV SelfCheck. One ame amplier, to correspond with the selected ame scanner. Included with the optional CB783 Expanded Annunciator is: One CB783 Annunciator. One wiring sub-base. All limits and interlocks are wired into wiring sub-base to provide individual hold/fault indication on LEDs of Expanded Annunciator, as well as on display module of CB 780 control.
ENGINEERING DATA
Supply voltage: 120 Vac (+10%/-15%) 50 or 60 Hz. Maximum total load: 2000 VA. Load rating-fuel valve output: 65 VA pilot duty plus 1150 VA inrush, 460 VA opening, 250 VA holding. Operating temperature limits: -40 to 140 F. Maximum ambient humidity: 85% non-condensing.
Flame safeguard shall be a Cleaver-Brooks Model CB 780 microprocessor-based control to monitor all critical boiler and burner interlocks, control and supervise burner light off sequence, and initiate an orderly safety procedure in the event of interlock or ame failure. The system shall provide status, fault history, and diagnostic information by means of a twoline alpha-numeric display and alarm/status LEDs. The system shall be approved by UL, FM, and CSA, and shall be acceptable by IRI.
D-21
12-02
Controls
CB100E CONTROL
The CB100E is a microprocessor-based, ame safeguard control used to monitor the presence of a ame inside a boiler, and include various interlocks to ensure safe operation. The ame safeguard also sequences the burner through several stages of operation to provide proper air purge, ignition, normal operation and shut down for safe operation.
PURGE 00:35

Display and Diagnostic Capabilities: 2 x 16 Backlit LCD display with a 3-key tactile dome keypad indicates 38 different messages regarding status and fault indication. Messages are spelled out in English. (Optional Spanish version is also available.) Provides indication of ame signal during operation. Provides indication of burner cycles and run time. Non-volatile memory retains last 6 fault/lockout conditions on power failure. Display module can be mounted in cabinet door for external indication. (Optional) Optional E300 expansion module provides additional 31 messages pertaining to fault or hold status indication. Communication with local or remote PC by means of an optional E500 communication module. Modular Design: Interchangeable program modules in English or Spanish. Purge time is selected via dip switches. Interchangeable ampliers for infrared, ultra-violet, or UV self-check ame scanners. Reduces part replacement costs.
HIGH FIRE PURGE SCRL RESET MODE
One ame scanner, either infrared, ultra-violet, or UV selfcheck. One ame amplier to correspond with the selected ame scanner. Included with optional E300 Expansion Module is: One E300 expansion module. One wiring subbase. One interconnection cable to E100E. All interlocks are wired into wiring sub base to provide individual hold/fault indication on display of CB100E control.
ENGINEERING DATA
Supply voltage: 120 Vac (+10%/-15%) 50/60 Hz. Maximum total load: 2000 VA. Fuel valve output load rating: 1250 VA opening, 500 VA holding. Operating temperature limits:32 F to 125 F. Maximum ambient humidity: 85% non-condensing.
PRODUCT OFFERING
Included in each CB100E System is the following: One chassis, including a dust cover. One 2-line display module. One Programmer Module. One wiring sub-base.
Flame safeguard shall be a Cleaver-Brooks Model CB100E microprocessor-based control to monitor all critical boiler and burner interlocks, control and supervise burner light-off sequence, and initiate an orderly safety procedure in the event of interlock or ame failure. The system shall provide status, fault history, and diagnostic information by means of a 2 x 16 backlit LCD display. The system shall be approved by UL, FM, and CSA, and shall be acceptable by IRI.
D-22
12-02
Controls
CB110 CONTROL
The CB 110 is a micro-processor-based, ame safeguard control used to monitor the presence of a ame inside a boiler, and include various interlocks to ensure safe operation. The ame safeguard also sequences the burner through several stages of operation to provide proper air purge, ignition, normal operation and shut down for safe operation.

Self Diagnostics: Seven LED display provided to indicate: Fan, High Fire, Low Fire, Ignition, Flame detected, Auto and Alarm. 23 Fault indications. Modular Design: Interchangeable ampliers for infrared, ultra violet, or UV self-check ame scanners. Reduces part replacement costs. Easily upgradeable to a CB 100E by replacing programmer and display modules.
ENGINEERING DATA
Supply voltage: 120Vac (+10%/-15%) 50/60 Hz. Maximum total load: 2000 VA. Fuel valve output load rating: 1250 VA opening, 500 VA holding. Operating temperature limits: -40 F to 125 F Maximum ambient humidity: 85% non-condensing.
PRODUCT OFFERING
Included in each CB 110 System is the following: One CB 110 chassis, including dust cover. One Programmer/Display Module. One wiring subbase. One ame scanner, either infrared, ultra-violet, or UV selfcheck. One ame amplier to correspond with the selected ame scanner.
Flame safeguard shall be a Cleaver-Brooks Model CB 110 microprocessor-based control to monitor all critical boiler and burner interlocks, control and supervise burner light-off sequence, and initiate an orderly safety procedure in the event of interlock or ame failure. The system shall provide status, fault history, and diagnostic information by means of an LED display. The system shall be approved by UL, FM, and CSA, and shall be acceptable by IRI.
D-23
12-02
Controls
LEAD/LAG SYSTEMS (TWO BOILER LEAD/LAG)

This section contains information on Multiple Boiler Lead/Lag systems. For Lead/Lag systems used with boilers equipped with the CB-HAWK Boiler Management System, refer to the CB-HAWK Enhancer Lead/Lag Control and the CB-HAWK Two Boiler Lead/Lag System.
PRODUCT OFFERING
Cleaver-Brooks shall supply the following equipment: Lead/Lag selector switch mounted on one boiler. On-off and ring rate controls shipped loose for mounting in common header piping. Minimum temperature low-re-hold control steam boilers. Low-re-hold control hot water boilers. Components shall be Underwriters Laboratories approved for intended service.

Controls Actual Header Pressure and Temperature: Maintains steam or hot water supply to system load. Compensates for varying losses between boiler and header. Sequences Operation of Two Boilers: Maximum system efciency. Reduces cycling and boiler wear reducing maintenance and downtime costs. Optimizes fuel savings. Lead/Lag Start with either Lead/Lag Modulation or Lead/Lag High-Low Fire: Lead boiler operates at full capacity prior to starting lag boiler. Ideal where load swings are infrequent and small such as heating applications. Lead/Lag Start with either Unison Modulation or Unison High-Low Fire: Boilers operate in unison when both are on line. Ideal where load swings are frequent and large, such as process applications.
Lead/Lag Start with either Lead/Lag Modulation or Lead/Lag High-Low Fire. The boiler manufacturer shall supply a control system to lead and lag two boilers. The system shall start, stop, and control the ring rate of both boilers. Upon system demand, the lead boiler shall start and operate to full capacity prior to starting the lag boiler. When both boilers are on line, the lead shall always operate to full capacity and the lag shall operate between minimum and maximum output to satisfy demand requirements. When system demand decreases, the lag boiler shall return to the minimum ring rate position and shut off. A further decrease shall cause the lead boiler to reduce its ring rate to minimum and shut off. A switch shall be provided to rotate the lead position between both boilers. For steam boilers, a means shall be provided to maintain minimum boiler water temperature at low-re when the boilers are off line.
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Controls
For hot water boilers, a means shall be provided to keep the boilers at low-re rate until a predetermined minimum temperature is reached. This releases the boiler to automatic operation from the ring rate control. All components shall be Underwriters Laboratories approved for intended service. Lead/Lag Start with either Unison Modulation or Unison HighLow-Fire. The boiler manufacturer shall supply a control system to lead and lag start of two boilers. The system shall start, stop, and control the ring rate of both boilers. Upon system demand, the lead boiler shall start and operate to full capacity prior to starting the lag boiler. When both boilers are on line, they shall operate in unison between minimum and maximum output to satisfy demand requirements. When system demand decreases, both boilers shall reduce their ring rate, in unison, to minimum. The lag boiler shall shut off and the lead boiler shall operate between minimum and maximum until demand is satised, and then shut off. A switch shall be provided to rotate the lead position between both boilers. For steam boilers, means shall be provided to maintain minimum boiler water temperature at low-re when boilers are off line. For hot water boilers, means shall be provided to keep boilers in a low-re-hold mode until a predetermined minimum temperature is reached. This shall then release the boiler to automatic operation from ring rate control. All components shall be Underwriters Laboratories approved for intended service. The lead/lag system is a specialized digital control that sequences the starting, stopping, and controls modulation ring rate for two boilers. It can be used for either steam or hot water applications.
APPLICATION
This option is applicable to full modulation burners utilizing standard Cleaver-Brooks modulating controls.
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12-02
Controls
LEAD/LAG SYSTEMS (TWO THROUGH FOUR BOILER LEAD/LAG)

The lead-lag system is a specialized digital control that sequences the starting, stopping, and controls modulation ring rate for two through four boilers. It can be used for either steam or hot water applications.
ENGINEERING DATA
Voltage input: 115 V, 60 Hz Power consumption: 30 VA maximum Output rating: Relays: 1 amp inductive, 10 amp resistive at 115 V, 60 Hz. (up to 4 relays used, plug in type). Firing rate signal: 0 to 135 ohm resistive. Sensor ranges: Temperature: -30 F to 250 F accuracy plus or minimum 1F. Pressure: 0-30 psig, 0-100 psig, 0-200 psig accuracy 1% full scale. Standby battery: Operates for 100 days minimum with overall average life of 5 years. Maximum ambient temperature: 120 F.

PID Control Logic: Precise control. Monitors rate of change to anticipate needs of system, turning boilers on or off as needed. Lead/Lag Start and Modulation: Provides optimal control action for different applications. Lead boiler rotates automatically every 24 hours or manually selected for xed lead position. Boilers Controlled From Header Pressure or Temperature: Maintain constant steam or hot water supply to system load. Compensate for varying losses between boiler and header. Sequences Optimal Number of Boilers on Line: Maximum system efciency. Reduces cycling and boiler wear reducing maintenance and downtime costs. Optimizes fuel savings.
1.0 The boiler manufacturer shall furnish a microprocessor based control system. The control shall be engineered and programmed exclusively for the operation of multiple steam or hot water full modulation boilers. It shall incorporate the following integrated functions: Manual or automatic lead stage rotation; boiler sequencing and burner ring rate (modulation control). The control shall be of modular construction to facilitate eld modication, upgrading or repair. It shall include the following features. 2.0 The control shall have the capability of operating in a temperature or pressure mode. Temperature sensors shall be of the thermistor type, suitable for insertion into a 3/8 ID well. Standard operating range shall be -30 F to +250 F. Pressure sensors shall be of the 4-20 ma type. Standard operating range shall be 0-30, 0-100, 0-150 or 0-200 psig. 3.0 The control shall provide an integral sensor set point adjustment. The set point shall be adjustable in 1 F or 1 psig increments (1/10 psig increments for 0-30 psig units) via a multi-turn knob. The setting value shall be stored in EEPROM indenitely.
PRODUCT OFFERING
Cleaver-Brooks shall supply the following equipment: Lead/lag sequencing control system for full modulating boilers (four boilers maximum). Relays on control system panel for start-stop control of boilers. Pressure or temperature sensor and immersion well. Assured low-re cutoff upon boiler shut off (steam and hot water boilers). Minimum temperature low-re-hold control (steam boilers). Low-re-hold control (hot water boilers).
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12-02
Controls
4.0 The control shall provide a LED bar graph display of each boilers approximate percent modulation. The control shall also provide a digital LED display of actual temperature or pressure, set point temperature or pressure, gain adjustment and each boilers exact percent modulation. In addition, the digital display shall be used to indicate the following four control settings as they are being adjusted: Modulation start point shall be adjustable from 50 to 100%. This setting determines the percent modulation a stage must achieve before the next stage is activated. There shall be independent adjustment of this setting for each burner. Purge timer shall be adjustable from 0-9.9 minutes. This setting determines the delay time between a burner being started and the beginning of modulation. Set back (additional set point) shall be adjustable from 0-75 F/psig (0-7.5 psig on 0-30 psig units). This setting determines the F/psig drop from the primary set point whenever the setback mode is activated. An off setting shall also be included for complete burner shutdown. The set back mode shall be activated by an external switch closure. Standby timer shall be adjustable from 1-60 minutes. This setting determines the delay period which must elapse before any designated standby boilers are activated. The timing sequence shall begin when all active boilers reach 100% ring rate. 5.0 LEDs shall be provided to indicate the lead stage and all activated stages. 6.0 A lithium coin type battery shall be included to maintain the correct lead stage and lead stage rotation timer in the event of power failure. Storage capacity shall be 100 days. 7.0 A four position selector switch shall be provided to set the operating mode of each stage. Positions include on, auto, off and standby. 8.0 The control shall have the capability of operating up to four full modulation boilers. Each stage shall have the following outputs: A normally open contact to start/stop the burner. A 0-135 ohm output to independently control each burners ring rate. 9.0 The control shall be UL listed, tested per Standard 873. Temperature Indicating and Regulating Equipment. It shall be CSA listed, tested per Standard C22.2 Number 24-1987 Temperature Indicating and Regulating Equipment. It shall also be approved for use in NYC by the City of New York; Department of Buildings, Bureau of Electrical Control and Department of Environmental Protection, Bureau of Air Resources. 10.0 A surface mounted, locking steel, NEMA 1 type, minimum 18 gauge enclosure shall be provided.
APPLICATION
D-27
12-02
Controls
LOW FIRE HOLD CONTROL

Prevents Automatic Control of Burner Firing Rate Until PreDetermined Boiler Water Temperature is Reached: Equalizes water temperature in boiler. Reduces possibility of thermal shock to pressure vessel and refractory.
PRODUCT OFFERING
Cleaver-Brooks shall provide a boiler water temperature control with sensor and immersion well. The control is Underwriters Laboratories approved for intended service and shall be mounted and wired on the boiler.
The boiler manufacturer shall furnish and install a control to sense boiler water temperature. The control shall maintain burner in a low-re hold mode until a pre-set temperature is satised. This shall then release boiler to automatic control of system demand. Control shall be Underwriters Laboratories approved for intended service.
APPLICATION
This option is applicable to full modulation and high-low re burners.
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Controls
MINIMUM TEMPERATURE LOW FIRE HOLD CONTROL

Maintains Minimum Boiler Water Temperature in Steam Boilers at Low-Fire Mode of Operation During Off Periods: Reduces lag-time to steaming rate. Reduces possibility of thermal shock to pressure vessel and refractory. Operational mode-manual or automatic.
PRODUCT OFFERING
Cleaver-Brooks shall supply: Boiler water temperature control and immersion well. Interface relay. Operation mode. Manual selector switch. Automatic activated by remote on-off boiler control device. Components Underwriters Laboratories approved for intended service.
The boiler manufacturer shall furnish and install a control to sense boiler water temperature. The control shall have an adjustable set point to maintain a minimum temperature at a pre-set level when the boiler is off line. This shall be accomplished at the burners minimum ring rate. The function can be activated either manually or automatically. Components shall be Underwriters Laboratories approved for intended service.
APPLICATION
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Controls
ASSURED LOW FIRE CUTOFF

Assures that the burner shuts off at minimum firing rate when signaled from remote disable source: Prevents shutoff at ring rates above low re. Reduces possibility of thermal shock to pressure vessel and refractory.
PRODUCT OFFERING
Cleaver-Brooks shall provide terminal connection points for remote disable/enable signals, and internally wire additional electrical components necessary to perform this function.
The boiler manufacturer shall make provisions to accept remote enable/disable signal contact. Any disable signal shall cause the burner to return to minimum low re position prior to shutting off the main fuel.
APPLICATION
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12-02
Controls
REMOTE MODULATION
Provides burner modulation from a customer supplied 4-20 ma control signal. Ties boiler ring rate control with customer control system (for example, building management, boiler room master, lead-lag control).
PRODUCT OFFERING
Standard Equipment Resistor kit to allow standard ring rate motor to operate from a 4-20 ma control signal. Relay with gold ashed contacts to switch between automatic and manual operation. Manual ring rate potentiometer to allow local manual operation. Optional Equipment Local remote ring rate control selector switch. Allows control of ring rate from standard local ring rate controller or remote 4-20 ma signal.
Furnish and install components to allow burner to modulate from a remote 4-20 ma control signal. Provisions shall be made for local manual ring rate control.
APPLICATION
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Controls
AUTOMATIC FUEL CHANGEOVER

Provides sequence to allow burner to automatically change fuel. Interfaces boiler-burner control with customer control system and avoids premium charges for fuel.
PRODUCT OFFERING
A selector switch. With selector switch in the AUTO position, burner shall re primary fuel when auxiliary contact governing fuel selection (for an example, gas pressure switch or outdoor thermostat) is closed. Upon opening of the above contact: a burner shall modulate to the minimum ring rate position, shutdown and restart ring stand by fuel. Fuel auto changeover switch (a low gas pressure switch or outdoor thermostat). This switch may be furnished by the boiler supplier, customer, or utility.
The boiler manufacturer shall furnish sequence to allow an automatic changeover from primary to stand by fuel and back. An automatic fuel changeover shall be initiated by gas pressure, outdoor temperature or other dry contact.
APPLICATION
This option is applicable to dual-fuel (i.e., gas-oil red) boilers with exception of Model LE Boilers.
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Controls
OXYGEN TRIM
The C-B Model O2 Trim System is a complete package used to maintain optimum fuel-to-air ratios and maximum fuel efciency.

Microprocessor-Based Control System Ensures Dependable Operation and Precise Oxygen Control: Selectable single point, automatic calibration (based on an internal, real-time clock) or dual point manual calibration mode. Dual calibration ensures accurate oxygen readings. Ten segment set point curves ensure accurate tracking of oxygen set points on both gas or oil fuels. The oxygen sensing cell in the analyzer probe is easily removed for service and replacement. Recorder output of oxygen values is operator selectable for either 4-20 ma or 1-5 Vdc. Firing rate output is 1-5 Vdc. The Model C-B O2 Trim System Incorporates Dual Analyzer Displays: A large LED display for oxygen levels. 40 character, back-lit, LCD for display of conguration and other data. Display is used for friendly prompts during programming calibration, service, and monitoring. The Controller Display is a Back-lit LCD Which Will Display the Following in Both Digital and Bar Graph Format: Process variable (% O2). Set point. Control Output. Graphic trending of O2 or ring rate on controller display for up to 24 hours. Graph timing is selectable. Two Alarm Contacts Which Are User-Configurable for Any of the Following Functions: Low O2 alarm. Low O2 shutdown. High stack temperature alarm and/or boiler cutoff (when used with optional stack temperature transmitter). Analyzer malfunction. Time delay may be incorporated into these contacts. Analyzer Probe is Direct Insertion, In-Situ Type Which Provides: High accuracy. Fast response. Reliability.
PRODUCT OFFERING
Oxygen trim system can be supplied for either fuel trim or air trim. NEMA 12 Control Panel with the following: Oxygen analyzer. Oxygen probe (15.75"). Oxygen controller. Fuel selection indicator lights. Pneumatic control components and actuator. In-situ probe with zirconia cell. Firing rate transducer. 50 ft cable for probe and ring rate transducer.
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Optional Equipment Pneumatic actuator for switch over. Stack temperature transmitter for display on analyzer. Control panel stand. Probe lter (stainless steel). Probe stack mounting adaptor. 27" probe.
This specication covers the hardware and control of the C-B O2 Trim System. The system adjusts the fuel-to-air ratio in order to maintain maximum efciency and features reliable monitoring and control of oxygen concentrations. 1.0 The system shall be completely congured from factory, requiring only job-specic data to be entered (or modied) in the eld. Controller/analyzer shall be shipped with default values and have a limit on the range of adjustments where applicable. Hardware: Hardware shall consist of the following: 2.0 Oxygen Sensor: The oxygen sensor shall be: Zirconia cell with temperature held constant by a heater. Probe is in-situ type to provide fast response to changes in O2 levels. 3.0 Analyzer: The analyzer shall be: 4-20 ma O2 output signal with linearly proportional to a 0-20% Capable of single-point automatic calibration or dual point manual calibration. Single point calibration is programmable based on an internal time clock. Able to provide a contact closure during calibration, which will be wired into controller to override trim function during calibration. Response 90% within ve (5) seconds after gas is introduced. Capable of providing the following control and monitoring ability in the analyzer: Display interactive operation. Analog bar display format on screen. Indicate average O2 computation. Maximum and minimum O2 levels. Large LED display of O2 level. 40 character dot matrix back-lit LCD display of conguration and other data. Self testing for cell life. Analog output range of 0-20% O2 computation.
ENGINEERING DATA
Probe: Sample Gas Temperature: 0 to 1100 F. Insertion length: 15.75", 27". Ambient Temperature: 14 to 176 F. Material in contact with gas: Stainless Steel, Zirconia. Installation: Flange mounting (equivalent to 2" 150 lbs FF. ANSI ange). Enclosure: NEMA 4. Weight: Insertion length 15.75" approximately 9 lbs. Insertion length 27" approximately 12 lbs. Control Panel: Power Supply: 110/120 Vac, 3 amps, 50/60 Hz. Dimensions: 20" H x 20" W x 13" D. Weight: Approximately 70 lbs. Ambient Temperature: 32 to 122 F. Air Supply: 25-126 psig instrument air dry, oil free. Outputs: Control: 3-15 psig. Recorder: O2 value 1-5 Vdc or 4-20 ma. Firing Rate 1-5 Vdc. Contact: 250 Vac, 2 amps. Low O2 alarm. Low O2 shutdown.
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Efciency calculations (with temperature transmitter option). 4.0 Controller: Controller shall: Be microprocessor based. Have means for indicating the process variable (% oxygen) setpoint, and output: each of these in both digital and bar graph format with range 0-20%. Allow for switching between automatic and manual control, and for changing the setpoint and output. Accept 4-20 ma signal from the O2 analyzer, a calibration contact from the analyzer, and a ring rate signal from a boiler-mounted potentiometer. Accept dry contact indication of fuel being red. The front panel display of the control shall be a bit mapped LCD type with a switch that allows operation and system adjustments to be performed from a menu. The display panel shall also include trend and alarm features for real-time, history, and allow viewing of related data while making adjustments. 5.0 The control panel of the controller shall also have the following features: Dedicated page key to be used for screen selection. Programmed function key to dene fuel type. Mode key to determine auto or manual mode. Failure light. Alarm light. 8 character display description. Oxygen level recorder output 4-20 ma or 1-5 Vdc. Firing rate output 1-5 Vdc. 6.0 The system shall continuously monitor oxygen concentration in boiler ue gas and adjust fuel or air ow to maintain oxygen level at set point. Set point shall be dependent on boiler ring rate and fuel selection inputs to controller. Controller shall determine set point internally based on these inputs, through separate curves (function generators) for each fuel. The rate-of-change of the ring rate input shall be limited to allow for the response time of the gases traveling through the boiler. Control to be direct acting. Proportional- plus-Integral (PI) with integral-only response to set point changes. Gain shall be varied based on ring rate, with faster response at high ring rates and slower response at low ring rates. Control to incorporate anti-reset windup capabilities when output reaches its limit. Since trim output must be able to add or subtract from fuel or air ow, the normal or no trim output shall be 50%.
APPLICATION
This system is applicable to modulating burners that utilize a Cleaver-Brooks fuel oil controller (on oil ring) and/or specic gas pressure regulators (on gas ring). Contact your local Cleaver-Brooks authorized representative for specic details.
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CB-HAWK BOILER MANAGEMENT CONTROL SYSTEM

The CB-HAWK is a complete boiler management control system which combines the functions of a ame safeguard programmer with those of operating and ring rate controls. It uses a solid state steam pressure or hot water temperature sensor. The CB-HAWK also monitors the fuel pressure and temperature (if required) with solid state sensors and provides a built-in safety limit control of those functions. The CB-HAWK may be used on most types of steam or hot water boilers, including retube, industrial watertube, and commercial watertube. It is designed to operate a gas, oil or combination burner using a single modulation motor and provides best results when used with a fully modulating burner. In addition to installation on new boilers, the CB-HAWK can be added as a retrot to existing boilers. Contact your local Cleaver-Brooks representative for details on retrotting CBHAWK to any boiler.
FEATURES & BENEFITS

Complete Boiler Control System: Combines control function of burner sequencing and safety with ring rate and operating limit control. Single boiler control with expansion capabilities for multiple boilers using Communication Interface, Enhancer, and General Purpose Interface (GPI). Keyboard/Display: Provides single point for boiler monitoring and adjustments. Digital set points and values for accurate information. English messages, labels, and prompts for easy use. Eliminates many screwdriver adjustments. Precise Control of Steam Pressure or Hot Water Temperature: Accurate measurement using solid state sensors. Advanced microprocessor control of ring rate is characterized to specic boiler. Special 400 position damper motor. Reduced Boiler Wear: Built in warm-up and shut down sequence to reduce thermal shock. Reduced modulation and cycling due to more accurate burner positioning. Greater Reliability and Safety with Solid State Design: Tamper resistant sensors prevent unsafe operation. Access code protection prevents unauthorized changes. Complete dynamic self check of all circuits and sensors. Complete Diagnostics Reduces Downtime: 73 fault messages. Fault History details: Cycles, hours of operation, boiler status, ring rate, fault codes and messages for last six safety shutdowns. Diagnostics provide status and voltage of all inputs, without the need for a test meter. Five function run test switch for improving set-up. Improved Energy Efficiency: Customized pre-purge sequence limits purge losses. Accurate ring rate control reduces excessive modulation.
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PRODUCT OFFERING
Standard Equipment: The CB-HAWK consists of the following components: Keyboard/display. Chassis module. Program module. Flame scanner and amplier (IR or UV type). Steam or hot water sensor. 400 Position damper motor. Fuel safety sensors. Optional Equipment: Details for the following optional equipment are found later in this section. CB-LINK Communications Module. CB-HAWK Enhancer Base Unit. CB-HAWK Enhancer Efciency Monitor. CB-HAWK Enhancer Auxiliary Input Monitor. CB-HAWK Time of Day Scheduling Control (Day/Night Setback). CB-HAWK Outdoor Reset Temperature Control. CB-HAWK General Purpose Interface (GPI). CB-HAWK Enhancer Lead-Lag Control. CB-HAWK Two Boiler Lead-Lag System.
Maximum Total Connected Load Chassis and Program Module. 2000 VA. Boiler Controller (Total System) Fuse: 15A maximum, type FRN or equivalent. Chassis Fuse: 10A, eld replaceable.
1.0 Each unit shall be factory equipped with a boiler management control system providing technology and functions equal to the Cleaver-Brooks model CB-HAWK. 2.0 Major functions of the boiler management system shall provide: Automatic sequencing of the boiler system through standby, pre-purge, pilot ame establishing period, main ame establishing period, run and post-purge. Flame proving and lockout on ame failure during pilot ame proving, main ame proving, or run. Low re damper motor position for ame ignition trails. Full modulating control of fuel and combustion air as well as ring rate control. Utilize solid state control and limit sensors providing the following control functions: Steam (or hot water) on/off and proportioning control. Gas pressure high and low pressure limit. (if required). Oil temperature high and low temperature limit (if required). Oil pressure high and low pressure limit (if required).
ENGINEERING DATA
Voltage and Frequency Chassis and Program Module. 120 Vac (+10%/-15%) 50/60 Hz 10%. Keyboard and Display Module. 24 Vac (+20%/-15%) 50/60 Hz. Power Dissipation Chassis and Program Module. 10 Watts maximum. Keyboard and Display Module. 2 Watts maximum.
Damper motor high and low re damper motor position. Manual control of the damper motor utilizing slewing keys to increment and decrement the damper motor position. Status light emitting diodes (LEDs) indicating: 1) Green LED demand present, 2) Yellow LED main valve energized, 3) Red LED (2) alarm, 4) Pulsing Green LED proper programmer operation. Field replaceable 10 amp fuse in the valve and ignition control circuit for short circuit protection. NEMA 1 rated enclosure.
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Line voltage terminal inputs for lockout, pre-ignition, and recycle limits and interlocks. 73 separate annunciation faults including damper motor operation, gas pressure limit operation (if required), oil pressure limit operation (if required), Oil temperature limit (if required), and hot water (or steam) sensor control operation. Self test for proper operation. Monitor system circuits status. Tamper resistant safety logic and timing. First out annunciation and diagnostics via a liquid crystal display (LCD). Thermal stress delayed release to modulation. Non-volatile lockout and history les with last (6) lockouts readable through integral LCD display. Dynamic Ampli-Check as standard ame amplication protection. Characterization to the applied boiler for ring rate control, cycling control, and system prepurge. A congurable rate linearization parameter which denes the relationship between damper motor position and ring rate and including drive to purge rate. Capability for remote or local communications to a personal computer including the capability to change non-safety related parameters remotely. Ability to be able to be installed in a continuous 0.5G environment. 3.0 Major system components shall include: 1. 2. 3. 4. 5. 6. 7. 8. Chassis. Program module. Keyboard and display module. Flame amplier, dynamic ampli-check infrared. Damper motor: 90 degree stroke, 400 position. Flame sensor: infrared. Control sensors: hot water temperature: 0 to 500 F range. Steam pressure specify psi range. Limit sensors: A. Gas pressure limit specify psig range. B. Oil pressure limit specify psig range. C. Oil temperature limit specify temperature range. 4.0 All boiler management control wiring shall be in accordance with the National Electrical Codes and local electrical codes. 5.0 The Boiler Management Control shall provide the following safety provisions: Dynamic self-check safety circuit. The boiler management controls microcomputer should continuously test itself and related hardware for proper circuit operation. Examine all load terminals to assure it is capable of recognizing the true status of external controls, limits and interlocks. If any input fails this test, the Boiler Management Control should lockout on safety shutdown. Closed-loop logic test of all safety critical loads (oil main valve, gas main valve, ignition transformer and pilot valve) and must be able to lockout on safety shutdown if any safety critical load is identied as operating improperly. Dynamic safety relay and contact. The control shall check the proper operation of the safety circuit, ability to open and close relay contact. This will assure the boiler management control is capable of de-energizing all safety critical terminals (oil main valve, gas main valve, ignition transformer and pilot valve). Dynamic amplier check of the ame signal amplier. The control ame signal amplier must be able to recognize a no ame signal during this dynamic amplier check. Safe start check and expand check to include monitoring ame signal during standby. Dynamic gas pressure sensor check. To assure the gas pressure limit sensor can signal zero gas pressure when gas pressure is not present at the gas pressure limit sensing element. Continuous monitoring of all applicable sensors, including steam pressure, gas pressure, and oil pressure to ensure signals are within operating range. Monitoring the damper motor via a feedback circuit to assure the damper motor is at the required position within 60 seconds, the damper motor is slewing properly, the damper motor is within 0 to 90 degrees, and ensures proper amount of prepurge air. Automatically returns the burner to the low re position before shutting off when power is interrupted. Tamper resistant timing and safety logic. Require mandatory reprogramming when being installed on another boiler.
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6.0 The Boiler Management Control System shall provide these annunciation and diagnostics: First out annunciation plus time and cycle in sequences of fault occurrence. Indication of sequence failures at start-up or during normal sequence operation. Test itself for failure, detect and isolate an alarm, and report internal circuit faults. The ability of reading limit sensor voltages and resistance at connector interface. English text description of the system fault, while maintaining the last six (6) faults in historical memory, which are readable through the LCD display. 7.0 The Boiler Management control shall be able to operate in these environmental conditions: 32 to 130 F temperature range; 85% RH continuous, noncondensing, humidity; 0.5G continuous vibration; 120 Vac (+10/- 15%) 50/60 Hz voltage/frequency; maximum connected load of 2000 VA. 8.0 Boiler Management Control System Component functions shall be as follows: Chassis module: Provides mounting means and line voltage I/O for the boiler room control. Program module: Provides boiler sequence logic to meet FM/IRI approval body requirements. The Program module is the location of the system micro-computer which generates fault messages and descriptions and processes boiler room I/O. Keyboard and display: Provides user interface to the system for sequence status fault history, and system conguration interface, all via a 2 row by 40 character LCD. Infrared ame amplier or UV amplier: Provides ame signal amplication. A dynamic ampli-check of the ame signal ampliers circuitry is conducted to assure the amplier responds to loss of ame. Gas pressure sensor: Provides a 1 to 6 Vdc signal to the Boiler Management Control. Gas pressure sensors provides high and low gas pressure limits with gas pressure ranges of 0.1 to 15 psig. Steam pressure sensor: Provides a 1 to 6 Vdc signal to the Boiler Management Control indicating steam pressure in the boiler. Signal provides on/off and modulating control of the burner, with ranges from .75 to 750 psig. Oil pressure sensor: Provides a 1 to 6 Vdc signal to the Boiler Management Control indicating oil pressure supplied to fuel oil controller. Signal provides high and low oil pressure limit functions within range of 7.5 to 150 psig. Oil temperature sensor: Provides a resistance signal to Boiler Management Control indicating oil temperature at the sensor well assembly. Signal provides high and low oil temperature limit functions within range of 0 to 300 F Water temperature: Provides a resistance signal to the Boiler Management Control indicating water temperature at the sensor well assembly. Provides on/off and release to modulation control of the burner. The sensors have ranges of 0 to 300 F and 0 to 500 F. Damper motor: Drives ring rate valve and combustion air damper based on input from the Boiler Management Control to purge the combustion chamber, provide fuel and air in proper proportion, and vary burner ring rate to meet the load demand on the boiler.
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CB-LINK
Connects up to six boilers: Allows single point monitoring and control of CB-HAWK. Allows single point monitoring of CB780. Allows multiple boiler control functions from Enhancer. Allows multiple boiler communications from General Purpose Interface (GPI). Remote Annunciation of Boiler Faults: Reduces response time of maintenance personnel. Reduces response time of service company. Allows unmanned facility to notify central ofce. Remote Monitoring of Boiler Operation: Monitor pressure, temperature, status, diagnostics. Reduce cost of maintenance and service calls. Data Logging Using Personal Computer: Reduces costs for recording information. Improved data accuracy. Improved planned maintenance by spotting trends. Help troubleshoot problems with historical data. Fault History Log Using Personal Computer: Time and Date stamp all faults. Provides a permanent record of fault conditions. Remote Setpoint Adjustments: Operator can take boilers on or off setback from remote location. Process engineers can adjust boiler settings affecting their process. Password Protection: Prevents unauthorized personnel from accessing The Boiler Management Control.
PRODUCT OFFERING
Base Unit includes the following: Communications module with local RS232 serial port, and six plug in module slots. One plug in module for each boiler. Combustion Systems Manager (CSM) software for operation on an IBM AT compatible computer. NEMA 1 enclosure (Metal enclosure with hinged door and removable sub-base is optional). Options: One additional plug in module required for each additional boiler. Maximum six boiler connected, ve if used with Enhancer, ve boilers if used with GPI card, and four boilers if used with GPI with Enhancer.
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ENGINEERING DATA
Power Required: Voltage and Frequency: 120 Vac (+10/-15%), 50/60 Hz ( 10%). Control Bus Communication: RS485. Hayes Smart Modem compatible for remote communication with a personal computer. Environmental Ratings: Ambient Temperature: Operating 32 to 130 F, Storage -30 to 150 F. Humidity: Operating, 85% RH Continuous, Noncondensing. Vibration: Continuous 0.5G. Enclosure: NEMA 1. Weight: 4 lbs 10 oz (unpacked without Control Bus Module).
3.0 The communications module shall be able to activate a remote pager as one of the three pre-programmed telephone numbers if desired. 4.1 Either the local or remote personal computer software shall be provided on 3-1/2 oppy diskette that will operate on Microsoft Windows 3.1 or later. Data logging of boiler operating pressures and/or temperatures at predetermined times shall be available. Access control password protection shall also be provided. The software shall be compatible with the following computer hardware. IBM AT Compatible Personal Computer with: 8 MHz or faster clock speed. 20 MB minimum hard disk drive. 5-1/4 or 3-1/2 oppy disk drive. VGA graphics capability. RS232 serial port (com 1 or 2). Optional 1200 BAUD external modem. 4.2 The HAWK LINK shall include communication protocol and device information to the building automation system integrator. Provide a General Purpose Interface module that occupies one of the six slots on the LINK chassis. This module shall support either ASCII or binary codes via RS-485 standards and connections. The system integrator can transfer select control and monitoring information from any CB HAWK, CB-780 or ENHANCER. Provide a disk to be used by the system integrator that contains protocol specications, device & point description les, instructions and ROM image le to convert any General Purpose Interface module into a Testcard device that implements all of the data types of all devices, a PC program to test and demonstrate the General Purpose Interface module and its protocols (a RS-232 to RS-485 adapter will be required)
1.0 A communications module shall be supplied providing technology and function equal to the Cleaver-Brooks model CB-LINK communications module that shall allow for remote programming control, monitoring and diagnostics up to 6 boilers equipped with CB-HAWK Boiler Management Control, with an IBM AT compatible personal computer or a building automation system. 2.0 The communications module shall provide for remote or local programming of non-safety functions such as boiler on, boiler off, operating setpoint, etc. It shall also provide for local and remote communication of individual boiler shutdowns and 73 fault codes that are date and time stamped. Local communications to an IBM AT compatible shall be via a RS232C port. Remote communications to an IBM AT compatible equipped with a modem shall be via a customer supplied external modem (Hayes Smart Modem or equal) to the CB-LINK communications module operating at 300 or 1200 BAUD. Building automation system tie-in shall be via a General Purpose Interface (GPI) device which provides a passive gateway. On a fault shutdown condition, the communications module shall report the shutdown to either a local computer or printer and/or call out up to 3 pre-programmed telephone numbers via an external modem.
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CB-HAWK ENHANCER BASE UNIT

Keyboard and Display: Single point monitor of multiple boilers. Membrane-type keypad for reliability in boiler room environments. Large 1" LED Status Display: Immediate annunciation of faults. Continuous display of boiler status can be seen across room. Base unit provides enclosure for Enhancer options. It must be used in conjunction with one or more Enhancer options.
PRODUCT OFFERING
The CB-HAWK Enhancer is used in conjunction with one to ve boilers that are equipped with CB-HAWK Boiler Management Control. The Enhancer and associated HAWK controls must all be connected to a CB-LINK communication module. Because of a conict between control actions, Outdoor Reset Control and Time of Day Schedule control can not be used together. One or more Enhancer options must be used in conjunction with the Enhancer base unit. Standard Equipment: The Enhancer comes in a single 24" x 24" x 8" NEMA 12 enclosure with keyboard/display, status display, 10-slot rack, power supply, and required modules.
The CB-HAWK Enhancer shall be provided complete in its own NEMA 12 enclosure, with the exception that the sensors are shipped loose for eld installation. The keyboard/display shall be mounted on the front door of the enclosure for access to setpoints and display parameters. An LED annunciator shall also be mounted on the front door for annunciation of alarm conditions and lead/lag boiler status.
ENGINEERING DATA
Power required: 120 Vac, 50/60 Hz, 3 amps.
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CB-HAWK ENHANCER EFFICIENCY MONITOR

Calculates Efficiency With or Without O2 Measurements: Uses separate O2 signal if available for increased accuracy. Estimates efciency without O2 for lower cost installation. Calculations based on boiler efciency and ring rate. Calculate Fuel Usage: Allows management to see where costs are. Easy to Understand Measurements: No need to convert stack temperature measurements. Instantaneous, 1 hour, 8 hours, 24 hours and 1 week averages. Indicates Conditions Requiring Attention: Assists the operator in maintaining optimal efciency. Preventative maintenance may be performed before expensive procedures are required. High stack temperature alarm indicates problems.
1.0 The Enhancer shall include the Boiler Efciency Monitor feature. It shall provide the user with basic information regarding boiler operation. Up to ve (5) boilers may be monitored simultaneously. The following operating parameters shall be displayed: Instantaneous boiler efciency. Average boiler efciency. Total Btu input. Total Btu output. Peak load. Quantity of fuel used (gallons of oil or therms of gas). Total fuel used. Average cost to generate output ($/M Btu). The above parameters shall be calculated from known operating characteristics and direct measurements based on the following formula: 2.0 Boiler Efciency = 100% (stack losses + radiation & convection losses). The Boiler Efciency Monitor shall not require mass ow meters for water, steam, or fuel.
PRODUCT OFFERING
The Enhancer Boiler Efciency Monitor is an optional feature of the CB-HAWK Enhancer and is used in conjunction with the Enhancer Base Unit and CB-LINK Communication Module. It may be used with up to ve CB-HAWK Boiler Management Control equipped boilers. The efciency calculation is not based on actual ow measurements, but on data calculated from quantitative test results and measurements of stack temperature, ambient temperature, oxygen (measured or estimated) and boiler information from the CB-HAWK Boiler Management Control. Equipment provided with the Enhancer Boiler Efciency Monitor: Stack temperature thermocouple for each boiler (shipped loose). Ambient air temperature thermocouple and bracket (shipped loose). Necessary input/output modules inside enclosure.
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CB-HAWK ENHANCER LEAD/LAG CONTROL

Unison or Lead/Lag Modulation for up to Five Boilers: Provides optimal control action for different applications. Controls Actual Header Pressure or Temperature: Maintains constant steam or hot water supply to load. Compensates for varying losses between boiler and header. Sequences Optimal Number of Boilers on Line: Maximum system efciency. Reduced cycling and boiler wear for lower maintenance and downtime costs. Boiler Sequencing Based on Boiler Firing Rate: Does not require a signicant change in pressure or temperature as in conventional systems. Starts new boiler as an immediate response to any boiler taken off line for uninterrupted operation. Minimum temperature control so lag boilers are always ready to respond to load changes. Alarm Annunciation: Load Exceeds Capacity alarm warns of potential problems before a signicant loss of pressure or temperature occurs.
The Enhancer Lead/Lag Control system provides lead/lag control of the steam pressure (or water temperature) in the main header, fed by up to ve (5) boilers. It shall provide the following functions: Control of header pressure (or water temperature) using solid state sensors for measurement. Control shall not require a noticeable change in pressure (or water temperature) to sequence a boiler on or off. Operator adjustable minimum-temperature control of lag boilers. Boiler status and ring rate information of each boiler shall be monitored and controlled by the lead/lag system via a direct bi-directional digital communication link. Large 1" LED display to annunciate lead and lag boiler run and alarm conditions. An alarm indicator annunciates conditions when the boiler system capacity is insufcient to maintain system pressure (or water temperature) or if a system fault occurs. Keyboard entry of following parameters: Lead Boiler. First through fourth lag boilers. System set point. System on point and off point. Lag-on trigger and delay set points.
PRODUCT OFFERING
The Enhancer Lead/Lag Control is an optional feature of the CB-HAWK Enhancer, and is used in conjunction with the Enhancer Base Unit and the CB-LINK communication module. It may be used with up to ve CB-HAWK Boiler Management Control equipped boilers. Equipment provided with the Enhancer Lead/lag Control includes: Header steam pressure or water temperature sensor (shipped loose). Minimum temperature controls for boilers (shipped loose). Necessary input/output modules inside enclosure.
Lag-off trigger and delay set points. Lead/lag system shall immediately start an additional lag boiler to compensate for lost capacity if an on-line boiler is turned off or if a fault causes a shut down. The lead and lag boilers may be changed at any time without upsetting the system pressure (or water temperature) regardless of the number of boilers currently on line.
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CB-HAWK TWO BOILER LEAD/LAG SYSTEM

Controls Actual Header Pressure or Temperature: Maintains steam or hot water supply to system load. Compensates for varying losses between boiler and header. Sequences Operation of Two Boilers: Maximum system efciency. Reduces cycling and boiler wear reducing maintenance and downtime costs. Optimized fuel savings. Lead/Lag Start with Lead/Lag Modulation: Lead boiler operates at full capacity prior to starting lag boiler. Ideal where load swings are small and infrequent, such as heating applications. When system demand decreases, the lag boiler shall return to the minimum ring rate position and shut off. A further decrease shall cause the lead boiler to reduce its ring rate to minimum and shut off. Provisions shall be made to transfer each boilers set point between normal and setback, as a means for determining lead and lag boiler. For steam boilers, a means shall be provided to maintain minimum boiler water temperature at low-re when the boilers are not required to support the load. The boilers shall also be held at low-re until this temperature is reached. For hot water boilers, a means shall be provided to keep the boilers at low re until predetermined minimum temperature is reached. This then releases the boiler to automatic operation from the ring rate control. All components shall be Underwriters Laboratories approved for intended use and bear the UL and CSA label.
PRODUCT OFFERING
Cleaver-Brooks shall supply the following equipment: Solid state sensors shipped loose for mounting in common header. Minimum temperature low re hold control (steam boilers). Low re hold control (hot water boilers). Provision for switching normal or setback set points for each boiler, as a means for selecting lead and lag boiler. Components shall be Underwriters Laboratories approved for intended service.
Lead/Lag Start with Lead/Lag Modulation: The boiler manufacturer shall supply a control system to lead and lag two boilers. The system shall start, stop, and control ring rate of both boilers. Upon system demand, the lead boiler shall start and operate to full capacity prior to starting the lag boiler. When both boilers are on line, the lead boiler shall always operate to full capacity and the lag boiler shall operate between minimum and maximum output to satisfy demand requirements.
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Section E
EMISSIONS
CONTENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3 POLLUTANTS AND CONTROL TECHNIQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3 NITROGEN COMPOUNDS (NOx). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3 NOx CONTROL TECHNOLOGIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4 POST COMBUSTION CONTROL METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4 Selective Non-catalytic Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4 Selective Catalytic Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4 COMBUSTION CONTROL TECHNIQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4 Low Excess Air (LEA) Firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4 Low Nitrogen Fuel Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5 Burner Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5 Water/Steam Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5 Flue Gas Recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5 CHOOSING THE BEST NOx TECHNOLOGY FOR THE JOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6 Turndown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6 Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6 Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6 Excess Air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7 Carbon Monoxide (CO) Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7 Total Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7 SULFUR COMPOUNDS (SOx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7 CARBON MONOXIDE (CO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8 PARTICULATE MATTER (PM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-8 VOLATILE ORGANIC COMPOUNDS (VOCs)/HYDROCARBONS (HC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-8 EMISSION LEVEL UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8 CORRECTING EMISSIONS TO 3% OXYGEN (15% EXCESS AIR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-9 CONVERTING EMISSIONS BETWEEN PPM AND LB/MMBTU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9 CALCULATION OF ANNUAL EMISSIONS FOR INDUSTRIAL BOILERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-11 NEW SOURCE PERFORMANCE STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-13 ILLUSTRATIONS Figure E-1. Effects of Fuel-Bound Nitrogen on NOx Emissions for Fuel Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3 Figure E-2. Selective Non-Catalytic Reduction (SNCR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4 Figure E-3. Selective Catalytic Reduction (SCR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5 Figure E-4. Effects of Fuel Sulfur Content on SOx Emissions for Fuel Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7 Figure E-5. CO Emissions Conversion Curves, 3% Oxygen, (15% Excess Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-9 Figure E-6. NOx Emissions Conversion Curves, 3% Oxygen, (15% Excess Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-10 Figure E-7. SOx Emissions Conversion Curves, 3% Oxygen, (15% Excess Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-10 Figure E-8. Volatile Organic Compound Conversion Curves, 3% Oxygen, (15% Excess Air) . . . . . . . . . . . . . . . . . . . . . .E-11 Figure E-9. Annual NOx Emissions for 250-800 Horsepower Boilers, NOx = 110 ppm (Corrected to 3% O2) . . . . . . . . .E-12 Figure E-10. Annual NOx Emissions for 250-800 Horsepower Boilers, NOx = 20 ppm . . . . . . . . . . . . . . . . . . . . . . . . . . .E-12 Figure E-11. Annual NOx Emissions for 250-800 Horsepower Boilers, NOx =25 ppm (Corrected to 3% O2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-12 E-1
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Figure E-12. Annual NOx Emissions for 250-800 Horsepower Boilers, NOx = 30 ppm (Corrected to 3% O2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-13 Figure E-13. Annual NOx Emissions for 250-800 Horsepower Boilers, NOx = 60 ppm (Corrected to 3% O2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-13 Figure E-14. Summary of Federal EPA Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-15
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INTRODUCTION
This section of the Boiler Book contains background information regarding boiler emissions. This section does not include emission performance for individual Cleaver-Brooks boiler models. Emission information for each product is included in the specic section of the Boiler Book for the product or you can contact your local Cleaver-Brooks authorized representative for the necessary information.
industrial sources, including industrial boilers. In industrial boilers, NOx is primarily formed in two ways; thermal NOx and fuel NOx: Thermal NOx is formed when nitrogen and oxygen in the combustion air combine with one another at the high temperatures in a ame. Thermal NOx makes up the majority of NOx formed during the combustion of gases and light oils. Fuel NOx is formed by the reaction of nitrogen in the fuel with oxygen in the combustion air. It is rarely a problem with gaseous fuels. But in oils containing signicant amounts of fuel-bound nitrogen, fuel NOx can account for up to 50% of the total NOx emissions. NOx emissions from boilers are inuenced by many factors. The most signicant factors are ame temperature and the amount of nitrogen in the fuel. Other factors affecting NOx formation are excess air level and combustion air temperature. While ame temperature primarily affects thermal NOx formation, the amount of nitrogen in the fuel determines the level of fuel NOx emissions. Fuel containing more nitrogen results in higher levels of NOx emissions (see Figure E-1). Most NOx control technologies for industrial boilers, with inputs less than 100 MMBtu/hr, reduce thermal NOx and have little affect on fuel NOx. Fuel NOx is most economically reduced in commercial and industrial boilers by switching to cleaner fuels (fuels containing less fuel-bound nitrogen), if available.
POLLUTANTS AND CONTROL TECHNIQUES

Combustion of standard fossil fuels (natural gas and ASTM Grade Oil) in commercial and industrial boilers results in the following nine emissions; carbon dioxide, nitrogen, oxygen, water, carbon monoxide, nitrogen oxide, sulfur oxides, volatile organic compounds, and particulate matter. The latter ve products of combustion are considered pollutants and are known to, either directly or indirectly, cause harmful affects on humans and the environment. The following section describes the formation and control of each of the pollutants in commercial and industrial boilers: Carbon Monoxide Nitrogen Oxides Sulfur Oxides Volatile Organic Compounds/Hydrocarbons Particulate Matter
Although there is evidence proving NOx, in itself, is harmful to humans, the main reason NOx is considered an environmental problem is because it initiates reactions that result in the production of ozone and acid rain. Ozone and acid rain can damage fabric, cause rubber to crack, reduce visibility, damage buildings, harm forests and lakes, and cause health problems. By controlling NOx levels, along with the other pollutants, the levels of acid rain and ozone can be reduced. The principal nitrogen pollutants generated by boilers are nitric oxide (NO) and nitrogen dioxide (NO2), collectively referred to as NOx. The contribution from different NOx sources to the total NOx levels varies among metropolitan areas. In general, the contribution of mobile sources to the total NOx level ranges from 60 to 80 percent: For stationary sources, it ranges between 20 and 40 percent. A signicant portion of the NOx from stationary sources can be attributed to residential, commercial, and
NOx Emissions(ppm at 3% O2) Increasing 0 0 Increasing Fuel-Bound Nitrogen (% weight)
NITROGEN COMPOUNDS (NOx)
Figure E-1. Effects of Fuel-Bound Nitrogen on NOx Emissions for Fuel Oils
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NOx CONTROL TECHNOLOGIES

NOx controls can be classied into two types: post combustion methods and combustion control techniques. Post combustion methods address NOx emissions after formation while combustion control techniques prevent the formation of NOx during the combustion process. Post combustion methods tend to be more expensive than combustion control techniques and generally are not used on boilers with inputs of less than 100 MMBtu/hr. Following is a list of different NOx control methods. Post combustion control methods include: Selective Non-Catalytic Reduction Selective Catalytic Reduction Combustion control techniques include: Low Excess Air Firing Low Nitrogen Fuel Oil Burner Modications Water/Steam Injection Flue Gas Recirculation Each method results in a different degree of NOx control. For example, when ring natural gas, low excess air ring typically reduces NOx by 10%, ue gas recirculation by 75%, and selective catalytic reduction by 90%.
However, the technology is extremely difcult to apply to industrial boilers that modulate or cycle frequently. This is because the ammonia (or urea) must be injected in the ue gases at a specic ue gas temperature. And, in industrial boilers that modulate or cycle frequently, the location of the exhaust gases at the specied temperature is constantly changing. Thus, it is not feasible to apply selective non-catalytic reduction to industrial boilers that have high turndown capabilities and modulate or cycle frequently.
Selective Catalytic Reduction

Selective catalytic reduction involves the injection of ammonia in the boiler exhaust gases in the presence of a catalyst (see Figure E-3). The catalyst allows the ammonia to reduce NOx levels at lower exhaust temperatures than selective non-catalytic reduction. Unlike selective non-catalytic reduction, where the exhaust gases must be approximately 1400-1600 F, selective catalytic reduction can be utilized where exhaust gasses are between 500 F and 1200 F, depending on the catalyst used. Selective catalytic reduction can result in NOx reductions up to 90%. However, it is costly to use and can rarely be cost justied on boilers with inputs less than 100 MMBtu/hr.
COMBUSTION CONTROL TECHNIQUES

Combustion control techniques reduce the amount of NOx emission by limiting the amount of NOx formation during the combustion process. This is typically accomplished by lowering ame temperatures. Combustion control techniques are more economical than post combustion methods and are frequently utilized on industrial boilers requiring NOx controls.
POST COMBUSTION CONTROL METHODS

Selective Non-catalytic Reduction
Selective non-catalytic reduction involves the injection of a NOx reducing agent, such as ammonia or urea, into the boiler exhaust gases at a temperature of approximately 1400-1600 F (see Figure E-2). The ammonia or urea breaks down the NOx in the exhaust gases into water and atmospheric nitrogen. Selective non-catalytic reduction reduces NOx up to 70%.
AMMONIA (NH3)
Low Excess Air (LEA) Firing

As a safety factor to assure complete combustion, boilers are red with excess air. One of the factors inuencing NOx formation in a boiler is the excess air levels. High excess air levels (>45%) may result in increased NOx formation because the excess nitrogen and oxygen in the combustion air entering the
FLUE GAS TEMPERATURE 1400 - 1600 F
NOx FLUE GAS NOx
* * * * *
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NH3 NOx NH3 NOx NH3
H2O N2 H2O N2 H2O CLEAN GAS
Figure E-2. Selective Non-Catalytic Reduction (SNCR) E-4
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AMMONIA (NH3) CATALYST
NOx FLUE GAS NOx
* * * * *
NH3 NOx NH3 NOx NH3
H2O N2 H2O N2 H2O CLEAN GAS
Figure E-3. Selective Catalytic Reduction (SCR) ame will combine to form thermal NOx. Low excess air ring involves limiting the amount of excess air that is entering the combustion process in order to limit the amount of extra nitrogen and oxygen that enters the ame. Limiting the amount of excess air entering a ame is accomplished through burner design and can be optimized through the use of oxygen trim controls. Low excess air ring can be used on most boilers and generally results in overall NOx reductions of 5-10% when ring natural gas. boiler performance when selecting NOx control technologies.
Water/Steam Injection
Water or steam injection can be utilized to reduce NOx levels. By injecting water or steam into the ame, ame temperatures are reduced, thereby lowering thermal NOx formation and overall NOx levels. Water or steam injection can reduce NOx up to 80% (when ring natural gas) and can result in lower reductions when ring oils. There is a practical limit to the amount of water or steam that can be injected into the ame before condensation problems are experienced. Additionally, under normal operating conditions, water/steam injection can result in a 3-10% boiler efciency loss. Many times water or steam injection is used in conjunction with other NOx control methods such as burner modications or ue gas recirculation.
Low Nitrogen Fuel Oil

When ring fuel oils, NOx formed by fuel-bound nitrogen can account for 20-50% of the total NOx level. One method to reduce NOx levels from boilers ring distillate oils is through the use of low nitrogen fuel oil. Low nitrogen oils can contain up to 15-20 times less fuel-bound nitrogen than standard No. 2 oil (less than 0.001% fuel-bound nitrogen). When low NOx oil is red in retube boilers utilizing ue gas recirculation, NOx reductions of 60%-70% over NOx emissions from standard No. 2 oils have been achieved. Low nitrogen oil is used most frequently in southern California.
Flue Gas Recirculation

Flue gas recirculation, or FGR, is the most effective method of reducing NOx emission from industrial boilers with inputs below 100 MMBtu/hr. FGR entails recirculating a portion of relatively cool exhaust gases back into the combustion process in order to lower the ame temperature and reduce NOx formation. It is currently the most effective and popular low NOx technology for retube and watertube boilers. And, in many applications, it does not require any additional reduction equipment to comply with regulations. Flue gas recirculation technology can be classied into two types; external or induced. External ue gas recirculation utilizes an external fan to recirculate the ue gases back into the ame. External piping routes the exhaust gases from the stack to the burner. A valve controls the recirculation rate, based on boiler input. Induced ue gas recirculation utilizes the combustion air fan to recirculate the ue gases back into the ame. A portion of the ue gases are routed by duct work or inter-
Burner Modifications
Burner modications for NOx control involve changing the design of a standard burner in order to create a larger ame. Enlarging the ame results in lower ame temperatures and lower thermal NOx formation which, in turn, results in lower overall NOx emissions. The technology can be applied to most boiler types and sizes. It is most effective when ring natural gas and distillate fuel oil and has little affect on boilers ring heavy oil. To comply with the more stringent regulations, burner modications must be used in conjunction with other NOx reduction methods, such as ue gas recirculation. If burner modications are utilized exclusively to achieve low NOx levels (30 ppm), adverse affects on boiler operating parameters such as turndown, capacity, CO levels, and efciency may result. It is important to address all aspects of
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nally to the combustion air fan, where they are premixed with the combustion air and introduced into the ame through the burner. New designs of induced FGR that utilize an integral FGR design are becoming popular among boiler owners and operators because of their uncomplicated design and reliability. Theoretically, there is no limit to the amount of NOx reduction with FGR; practically, there is a physical, feasible limit. The limit of NOx reduction varies for different fuels 80% for natural gas and 20-25% for standard fuel oils. The current trends with low NOx technologies are to design the boiler and low NOx equipment as a package. Designing as a true package allows the NOx control technology to be specically tailored to match the boiler's furnace design features, such as shape, volume, and heat release. By designing the low NOx technology as a package with the boiler, the adverse effects of the low NOx technology on boiler operating parameters (turndown, capacity, efciency, and CO levels) can be addressed and minimized. Every time the boiler cycles off, before it comes back on, it must go through a specic start-up sequence for safety assurance. It takes between one to two minutes to get the boiler back on line. If there is a sudden load demand, the response cannot be accelerated. Keeping the boiler on line assures a quick response to load changes. Frequent cycling also deteriorates the boiler components. The need for maintenance increases, the chance of component failure increases, and boiler downtime increases. So, when selecting NOx control, always consider the burners turndown capability.
Capacity
When selecting the best NOx control, capacity and turndown should be considered together because some NOx control technologies require boiler derating in order to achieve guaranteed NOx reductions. For example, ame shaping (primarily enlarging the ame to produce a lower ame temperature thus lower NOx levels) can require boiler derating, because the shaped ame could impinge on the furnace walls at higher ring rates. However, the boiler's capacity requirement is typically determined by the maximum load in the steam/hot water system. Therefore, the boiler may be oversized for the typical load conditions that may occur. If the boiler is oversized, its ability to handle minimum loads without cycling is limited. Therefore, when selecting the most appropriate NOx control, capacity and turndown should be considered together for proper boiler selection and to meet overall system load requirements.
CHOOSING THE BEST NOx TECHNOLOGY FOR THE JOB

What effect does NOx control technology ultimately have on a boiler's performance? Certain NOx controls can worsen boiler performance while other controls can appreciably improve performance. Aspects of the boiler performance that could be affected include turndown, capacity, efciency, excess air, and CO emissions. Failure to take into account all of the boiler operating parameters can lead to increased operating and maintenance costs, loss of efciency, elevated CO levels, and shortening of the boiler's life. The following section discusses each of the operating parameters of a boiler and how they are related to NOx control technologies.
Efficiency
Some low NOx controls reduce emissions by lowering ame temperature, particularly in boilers with inputs less than 100 MMBtu/hr. Reducing the ame temperature decreases the radiant heat transfer from the ame and could lower boiler efciency. The efciency loss due to the lower ame temperatures can be partially offset by utilizing external components, such as an economizer. Or, the offset technique can be inherent in the NOx design. One technology that offsets the efciency loss due to lower ame temperatures in a retube boiler is ue gas recirculation. Although the loss of radiant heat transfer could result in an efciency loss, the recirculated ue gases increase the mass ow through the boiler thus the convective heat transfer in the tube passes increases. The increase in convective heat transfer compensates for losses in radiant heat transfer, with no net efciency loss. When considering NOx control technology, remember, it is not necessary to sacrice efciency for NOx reductions.
Turndown
Choosing a low NOx technology that sacrices turndown can have many adverse effects on the boiler. When selecting NOx controls, the boiler should have a turndown capability of at least 4:1 or more, in order to reduce operating costs and the number of on/off cycles. A boiler utilizing a standard burner with a 4:1 turndown can cycle as frequently as 12 times per hour or 288 times a day because the boiler must begin to cycle at inputs below 25% capacity. With each cycle, pre- and post-purge air ow removes heat from the boiler and sends it out the stack. The energy loss can be reduced by using a high turndown burner (10:1), which keeps the boiler on even at low ring rates.
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Excess Air
A boiler's excess air supply provides for safe operation above stoichiometric conditions. A typical burner is usually set up with 10-20% excess air (2-4% O2). NOx controls that require higher excess air levels can result in fuel being used to heat the air rather than transferring it to usable energy. Thus, increased stack losses and reduced boiler efciency occur. NOx controls that require reduced excess air levels can result in an oxygen decient ame and increased levels of carbon monoxide or unburned hydrocarbons. It is best to select a NOx control technology that has little effect on excess air. coals) results in pollutants occurring in the forms of SO2 (sulfur dioxide) and SO3 (sulfur trioxide), together referred to as SOx (sulfur oxides). The level of SOx emitted depends directly on the sulfur content of the fuel (see Figure E-4). The level of SOx emissions is not dependent on boiler size or burner design. Typically, about 95% of the sulfur in the fuel will be emitted as SO2, 1-5% as SO3, and 1-3% as sulfate particulate. Sulfate particulate is not considered part of the total SOx emissions. Historically, SOx pollution has been controlled by either dispersion or reduction. Dispersion involves the utilization of a tall stack, which enables the release of pollutants high above the ground and over any surrounding buildings, mountains, or hills, in order to limit ground level SOx emissions. Today, dispersion alone is not enough to meet more stringent SOx emission requirements; reduction methods must also be employed. Methods of SOx reduction include switching to low sulfur fuel, desulfurizing the fuel, and utilizing a ue gas desulfurization (FGD) system. Fuel desulfurization, which primarily applies to coal, involves removing sulfur from the fuel prior to burning. Flue gas desulfurization involves the utilization of scrubbers to remove SOx emissions from the ue gases. Flue gas desulfurization systems are classied as either nonregenerable or regenerable. Non-regenerable FGD systems, the most common type, result in a waste product that requires proper disposal. Regenerable FGD converts the waste by-product into a marketable product, such as sulfur or sulfuric acid. SOx emission reductions of 90-95% can be achieved through FGD. Fuel desulfurization and FGD are primarily used for reducing SOx emissions for large utility boilers. Generally the technology cannot be cost justied on industrial boilers. For users of industrial boilers, utilizing low sulfur fuels is the
Carbon Monoxide (CO) Emissions

High ame temperatures and intimate air/fuel mixing are essential for low CO emissions. Some NOx control technologies used on industrial and commercial boilers reduce NOx levels by lowering ame temperatures by modifying air/fuel mixing patterns. The lower ame temperature and decreased mixing intensity can result in higher CO levels. An induced ue gas recirculation package can lower NOx levels by reducing ame temperature without increasing CO levels. CO levels remain constant or are lowered because the ue gas is introduced into the ame in early stages of combustion and the air fuel mixing is intensied. Intensied mixing offsets the decrease in ame temperature and results in CO levels that are lower than achieved without FGR. But, the level of CO depends on the burner design. Not all ue gas recirculation applications result in lower CO levels.
Total Performance
Selecting the best low NOx control package should be made with total boiler performance in mind. Consider the application. Investigate all of the characteristics of the control technology and the effects of the technology on the boiler's performance. A NOx control technology that results in the greatest NOx reduction is not necessarily the best for the application or the best for high turndown, adequate capacity, high efciency, sufcient excess air, or lower CO. The newer low NOx technologies provide NOx reductions without affecting total boiler performance.
1200 1000 SOx Emission Level* (ppm at 3% O2) 800 600 400 200 0 0 .2 .4 .6 .8 1.0 1.2 1.4 1.6 1.8 2.0 Sulfur in Fuel (% weight) *Based on EPA AP-42 Estimates
SULFUR COMPOUNDS (SOx)

The primary reason sulfur compounds, or SOx, are classied as a pollutant is because they react with water vapor (in the ue gas and atmosphere) to form sulfuric acid mist. Airborne sulfuric acid has been found in fog, smog, acid rain, and snow. Sulfuric acid has also been found in lakes, rivers, and soil. The acid is extremely corrosive and harmful to the environment. The combustion of fuels containing sulfur (primarily oils and
Figure E-4. Effects of Fuel Sulfur Content on SOx Emissions for Fuel Oils
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most cost effective method of SOx reduction. Because SOx emissions primarily depend on the sulfur content of the fuel, burning fuels containing a minimal amount of sulfur (distillate oil) can achieve SOx reductions, without the need to install and maintain expensive equipment.
four fuel constituents: sulfur, ash, carbon residue, and asphalenes. These constituents exist in fuel oils, particularly residual oils, and have a major effect on particulate emissions. By knowing the fuel constituent levels, the particulate emissions for the oil can be estimated. Methods of particulate control vary for different types and sizes of boilers. For utility boilers, electrostatic precipitators, scrubbers, and baghouses are commonly utilized. For industrial and commercial boilers, the most effective method is to utilize clean fuels. The emission levels of particulate matter can be lowered by switching from a residual to a distillate oil or by switching from a distillate oil to a natural gas. Additionally, through proper burner set-up, adjustment and maintenance, particulate emissions can be minimized, but not to the extent accomplished by switching fuels.
CARBON MONOXIDE (CO)

Carbon monoxide is a pollutant that is readily absorbed in the body and can impair the oxygen-carrying capacity of the hemoglobin. Impairment of the body's hemoglobin results in less oxygen to the brain, heart, and tissues. Even short-term over exposure to carbon monoxide can be critical, or fatal, to people with heart and lung diseases. It may also cause headaches and dizziness in healthy people. During combustion, carbon in the fuel oxidizes through a series of reactions to form carbon dioxide (CO2). However, 100 percent conversion of carbon to CO2 is rarely achieved in practice and some carbon only oxidizes to the intermediate step, carbon monoxide. Older boilers generally have higher levels of CO than new equipment because CO has only recently become a concern and older burners were not designed to achieve low CO levels. In today's equipment, high levels of carbon monoxide emissions primarily result from incomplete combustion due to poor burner design or ring conditions (for example, an improper air-to-fuel ratio) or possibly a leaky furnace. Through proper burner maintenance, inspections, operation, or by upgrading equipment or utilizing an oxygen control package, the formation of carbon monoxide can be controlled at an acceptable level.
VOLATILE ORGANIC COMPOUNDS (VOCs)/HYDROCARBONS (HC)

Volatile organic compounds, or VOCs, are compounds containing combinations of carbon, hydrogen, and sometimes oxygen. VOCs vaporize easily once emitted into the air and are of concern because of their role in ground level ozone formation. In reference to boiler performance, they are often referred to as hydrocarbons and generally are divided into two categories methane and non-methane. Formation of VOCs in commercial and industrial boilers primarily result from poor or incomplete combustion due to improper burner set-up and adjustment. To control VOC emissions from commercial and industrial boilers, no auxiliary equipment is needed; properly maintaining the burner/boiler package will keep VOC emissions at a minimum. Proper maintenance includes keeping the air/fuel ratio at the manufacturer's specied setting, having the proper air and fuel pressures at the burner, and maintaining the atomizing air pressure on oil burners at the correct levels. An improperly maintained boiler/ burner package can result in VOC levels over 100 times the normal levels.
PARTICULATE MATTER (PM)

Emissions of particulate matter (PM) from combustion sources consist of many different types of compounds, including nitrates, sulfates, carbons, oxides, and any uncombusted elements in the fuel. Particulate pollutants can be corrosive, toxic to plants and animals, and harmful to humans. Particulate matter emissions generally are classied into two categories, PM and PM10. PM10 is a particulate matter with a diameter less than 10 microns. All particulate matter can pose a health problem. However, the greatest concern is with PM10, because of its ability to bypass the body's natural ltering system. PM emissions are primarily dependent on the grade of fuel red in the boiler. Generally, PM levels from natural gas are signicantly lower than those of oils. Distillate oils result in much lower particulate emissions than residual oils. When burning heavy oils, particulate levels mainly depend on
EMISSION LEVEL UNITS

This section describes the different units for emission levels. Emission levels can be provided in many different units depending on whether the measurement is volume or mass based.
CORRECTING EMISSIONS TO 3% OXYGEN (15% EXCESS AIR)

The following equation shows how to correct emission readings to 3% oxygen (15% excess air). Because boilers don't
E-8
02-02
Emissions
Although emission levels can be given in many different units, the most common are ppm (corrected to 3% oxygen) and lb/ MMBtu. Conversion between these two types of units is very simple, however, it does depend on the fuel type and excess air level. The following graphs and equations show the relationships and conversions between ppm (corrected to 3% oxygen) and lb/ MMBtu. If the conversion involves a ppm level referenced to an oxygen level other than 3%, the ppm level must be corrected to 3% oxygen (see previous section) before using the following graphs and equations (Figure E-5 through E-8).
ppm
Parts per Million Indicates emission levels on a volume basis. Sometimes may be shown as ppmv. Part per million must be referenced to some oxygen level (excess air level) which, for industrial boilers, is typically 3% oxygen (15% excess air). Actual measurements recorded during boiler testing are usually in ppm. Pounds per Million Btu Indicates emission levels on a mass basis. Emission levels are shown in pounds of pollutant per million Btu input to the boiler. This level is useful when hourly or annual emission levels must be determined. Pounds per Hour Indicates emission levels on a mass basis. This unit represents the amount of pollutant emitted on an hourly basis. Tons per Year Indicates emission levels on a mass basis. This unit corresponds to the annual pollutant levels. Pounds per Million Cubic Feet Indicates emission levels on a mass basis. This unit is used for gaseous fuels and indicates the emission level in pounds per million cubic feet of fuel (gaseous fuel) input to the boiler. This is useful when the actual gas usage of the boiler is known. Pounds per Thousand Gallons Indicates emission levels on a mass basis. This unit is used for liquid (oil) fuels and indicates the emission level in pounds per thousand gallons of oil fired. This is useful when the actual oil usage of the boiler is known
lb/MMBtu
lb/hr
tpy
CALCULATION OF ANNUAL EMISSIONS FOR INDUSTRIAL

0.18 Dry Analysis
lb/106 cu-ft
0.16
No. 6 Oil No. 2 Oil Propane Natural Gas
lb/103 gal
0.14
CO Emissions (lb/MMBtu)
0.12
0.10
always operate at 3% oxygen, it is necessary to convert ppm values measured at various excess air levels to 3% oxygen for comparison and regulation compliance purposes. To correct emission levels to 3% oxygen that are referenced to excess air levels other than 3%, use the following equation.
0.08
0.04
CONVERTING EMISSIONS BETWEEN PPM AND LB/MMBTU

21 3 21 O2 (actual)
0.02
0.00 0 20 40 60 80 100 120 140 160 180 200
ppm (@3%) =
x ppm (actual)
CO Emissions (ppm) Conversion Equations No. 2 Oil: Natural Gas: ppm = (lb/MMBtu)*1290 ppm = (lb/MMBtu)*1370 lb/MMBtu = (ppm)/1290 lb/MMBtu = (ppm)/1370 No. 6 Oil: ppm = (lb/MMBtu)*1260 lb/MMBtu = (ppm)/1260 Propane: ppm = (lb/MMBtu)*1340 lb/MMBtu = (ppm)/1340
Example: What is the NOx level corrected to 3% oxygen for a measured level of 27 ppm at 7.1% oxygen? ppm (@3%) = 21 3 21 7.1 x 27 = 35 ppm NOx
Figure E-5. CO Emissions Conversion Curves, 3% Oxygen, (15% Excess Air)
E-9
02-02
Emissions
Dry Analysis 0.28 0.26 Propane 0.24 0.22 0.20 NOx Emissions (lb/MMBtu) 0.18 0.16 0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 Conversion Equations No. 2 and No. 6 Oil: ppm = (lb/MMBtu)*750 lb/MMBtu = (ppm)/750 Natural Gas: ppm = (lb/MMBtu)*850 lb/MMBtu = (ppm)/850 Propane: ppm = (lb/MMBtu)*810 lb/MMBtu = (ppm)/810 Natural Gas No. 2 and No. 6 Oil
20
40
60
80
100 120 140 160 180 200
NOx Emissions (ppm)
Figure E-6. NOx Emissions Conversion Curves, 3% Oxygen, (15% Excess Air)
Dry Analysis 2.4 2.2 2.0 SOx Emissions (lb/MMBtu) 1.8 1.6 1.4 1.2 1.0 0.8 0.6 0.4 0.2 0.0 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 SOx Emissions (ppm) Conversion Equations No. 2 and No. 6 Oil: ppm = (lb/MMBtu)*540 lb/MMBtu = (ppm)/540 No. 2 and No. 6 Oil
Figure E-7. SOx Emissions Conversion Curves, 3% Oxygen, (15% Excess Air)
E-10
02-02
Emissions
Dry Analysis 0.060 0.055 0.050 VOC Emissions (lb/MMBtu) 0.045 0.040 0.035 0.030 0.025 0.020 0.015 0.010 0.005 0.000 0 10 20 30 40 50 60 70 80 90 100 Conversion Equations No. 2 and No. 6 Oil: ppm = (lb/MMBtu)*2000 lb/MMBtu = (ppm)/2000 Natural Gas and Propane ppm = (Ib/MMBtu)*2500 lb/MMBtu = (ppm)/2500 Natural Gas and Propane No. 2 and No. 6 Oil
VOC Emissions (ppm)
Figure E-8. Volatile Organic Compound Conversion Curves, 3% Oxygen, (15% Excess Air)
BOILERS
Many provisions of the 1990 Clean Air Act Amendments assess the impact of pollution sources based on the potential annual emissions (usually expressed as tons per year, or tpy). When addressing industrial boilers, the potential annual emissions of NOx are of concern and frequently must be calculated. Following is an example of how to calculate the potential annual NOx emissions for industrial boilers. To determine the annual NOx emissions for an industrial boiler, three items must be known: 1. The NOx emission factor for the boiler. 2. The maximum rated input for the boiler. 3. The maximum allowable hours of operation for the boiler. Once the information above is obtained, the following equation can be used to determine annual emissions. Emission Factor x Boiler Input x Annual Hours of Operation = Total Annual Emissions For example, the calculation of the total annual NOx emissions for an 800 hp boiler operating 24 hours/day, 365 days/
year and having a NOx level of 110 ppm would be as follows. Emission Factor = 0.13 lb/MMBtu (110 ppm = 0.13 lb/ MMBtu) Boiler Input = 33.5 MMBtu/hr (Based on 80% Efciency) Annual Hours of Operation = 8760 hours/year (24 hours/ day x 365 days/year) Substituting this data into the previous equation yields the annual NOx emissions for this specic boiler, which is 19.1 tpy. The following graphs (Figure E- 9 through E-13) indicate the
0.13 lb NOx x 33.5 MMBtu x 8760 hrs MMBtu hr year x 1 ton = 19.1 tpy NOx 2000 lb
annual NOx emissions for boiler sizes 250-800 horsepower ring natural gas at maximum input operating 24 hours/day, 365 days/year. They are for NOx emission levels of 110, 60, 30, 25, and 20 ppm.
E-11
02-02
Emissions
20 800 HP 700 HP Annual NOx Emissions (tpy) 15 600 HP 500 HP 10 400 HP 350 HP 300 HP 250 HP 5 Efficiency = 80% 0 1000
2000
3000
4000
5000
6000
7000
8000
9000
Annual Hours of Operation
Figure E-9. Annual NOx Emissions for 250-800 Horsepower Boilers, NOx = 110 ppm (Corrected to 3% O2)
4 Annual NOx Emissions (tpy) 800 HP 3 700 HP 600 HP 2 500 HP 400 HP 350 HP 300 HP 250 HP Efficiency = 80% 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 Annual Hours of Operation
Figure E-10. Annual NOx Emissions for 250-800 Horsepower Boilers, NOx = 20 ppm (Corrected to 3% O2 )
5 Annual NOx Emissions (tpy) 800 HP 4 3 2 1 Efficiency = 80% 0 1000 700 HP 600 HP 500 HP 400 HP 350 HP 300 HP 250 HP
2000
3000
4000
5000
6000
7000
8000
9000
Figure E-11. Annual NOx Emissions for 250-800 Horsepower Boilers, NOx = 25 ppm (Corrected to 3% O2) E-12
02-02
Emissions
5 Annual NOx Emissions (tpy) 800 HP 4 3 2 1 700 HP 600 HP 500 HP 400 HP 350 HP 300 HP 250 HP Efficiency = 80% 0 1000
2000
3000
4000
5000
6000
7000
8000
9000
12 800 HP Annual NOx Emissions (tpy) 10 8 6 4 2 Efficiency = 80% 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 700 HP 600 HP 500 HP 400 HP 350 HP 300 HP 250 HP
NEW SOURCE PERFORMANCE STANDARDS

The Federal EPA has established nationally uniform sourcespecic regulations through the New Source Performance Standards, or NSPS, for which all applicable sources must comply. The standards, which set minimal requirements for individual sources, address approximately 65 categories of new or modied stationary sources, including industrial boilers. The NSPS for industrial boilers regulate levels for NOx, SOx, and particulate matter. The regulated pollutants and requirements vary for different fuels and boiler sizes. There are currently three categories for the NSPS: Boilers with inputs greater than 250 MMBtu/hr Boilers with inputs between 100-250 MMBtu/hr Boilers with inputs between 10-100 MMBtu/hr
The Small Boiler NSPS apply to all new, modied, or reconstructed boilers with inputs between 10-100 MMBtu/hr where construction, modication, or reconstruction commenced after June 9, 1989. The Small Boiler NSPS set emission standards for SOx and particulate matter for boilers ring coal, distillate and residual oil, and wood. The Small Boiler NSPS also dictate record keeping requirements regarding fuel usage for all fuels, including natural gas. Record keeping requirements and compliance standards for the different emissions depends on the type of fuel red and on the boiler size. For a summary of the Small Boiler NSPS, see Figure E-14. Be sure your boiler complies with the New Source Performance Standards as non-compliance may result in nes and/or forced boiler shutdown. Contact your local Cleaver-Brooks authorized representative if you have questions regarding the New Source Performance Standards.
E-13
02-02
Emissions
New Source Performance Standards for Boilers 10100 MMBtu/hr Built or Modied After 6/9/1989
RULES FOR SULFUR DIOXIDE (SO2) EMISSIONS 1. Coal Firing 1.2 lb SO2/MMBtu Limit all 10-100 MMBtu. 90% SO2 reduction required if > 75 MMBtu and > 55% annual coal capacity. Initial performance testing required within 180 days of start-up. 30 day rolling average used in calculations. Continuous Emission Monitoring System (CEMS) required except: Fuel analysis may be used (before cleanup equipment). Units < 30 MMBtu may use supplier certicate for compliance. 2. Residual Oil Firing Limit of 0.5 lb SO2/MMBtu or 0.5% sulfur in fuel. CEMS required to meet SO2 limit except fuel analysis can be used as red condition before cleanup equipment. Fuel sulfur limit compliance can be: Daily as red fuel analysis. As delivered (before used) fuel analysis. Fuel supplier certicate for units < 30 MMBtu. Initial performance testing and 30 day rolling average required except for supplier certicate. 3. Distillate Oil Firing (ASTM grades 1 and 2) Limit 0.5% sulfur in fuel (required in ASTM standard). Compliance by fuel supplier certicate. No monitoring or initial testing required. RULES FOR PARTICULATE MATTER (PM) EMISSIONS 1. General Limits established only for units between 30-100 MMBtu. All coal, wood and residual oil red units > 30 MMBtu must meet opacity limit of 20%, except one 6 minute/hour opacity of 27%. CEMS required to monitor opacity. 2. Coal Firing 0.05 lb/MMBtu limit if > 30 MMBtu and > 90% annual coal capacity. 0.10 lb/MMBtu limit if > 30 MMBtu and < 90% annual coal capacity. 20% opacity (CEMS) and initial performance tests on both PM limit and opacity. 3. Wood Firing 0.10 lb/MMBtu limit if > 30 MMBtu and > 30% annual wood capacity. 0.30 lb/MMBtu limit if > 30 MMBtu and < 30% annual wood capacity. Opacity limits and initial testing per above. 4. Oil Firing All units > 30 MMBtu subject to opacity limit, only residual oil ring must use CEMS. Initial performance testing required. REPORTING REQUIREMENTS Owners or operators of all affected units must submit information to the administrator, even if they are not subject to any emission limits or testing. Required reports include: Information on unit size, fuels, start-up dates and other equipment information. Initial performance test results, CEMS performance evaluation. Quarterly reports on SO2 and/or PM emission results, including variations from limits and corrective action taken. For fuel supplies certicate, information on supplies and details of sampling and testing for coal and residual oil. Records must be maintained for two years.
Figure E-14. Summary of Federal EPA Rules E-14

02-02
Section F
STACKS
CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3 Selection Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3 Special Stack Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5 ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5 Safety Specifications and Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5 Use of Noncombustible Enclosure or Chase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5 Clearance to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5 Connecting to the Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5 Expansion and Installation Concerns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7 Clearances For Noncombustible Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-11 Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-11 Stack Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-12 Typical Stack Arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-12 SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-15 ILLUSTRATIONS Figure F-1. System Extension Above Boiler Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7 Figure F-2. Thermal Expansion Between Two Fixed Points in Stack System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7 Figure F-3. Graphs for Calculating Thermal Expansion Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8 Figure F-4. Maximum Unsupported Distance Between Elbows, Tees, or Wyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8 Figure F-5. Maximum Support and Guide Assembly Spacing for Vertical, Horizontal, and Sloping Stack Runs . . . . . . . . F-10
F-1
02-02
Stacks
Figure F-6. Cable Guying Specifications for Roof Level Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-10 Figure F-7. Roof Framing and Curb Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-12 Figure F-8. Cable Guying Installation Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-12 Figure F-9. Model CBS-II Double Wall Stack Construction and Joint Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13 Figure F-10. Model CBS-III Triple Wall Stack Construction and Joint Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-13 Figure F-11. Model ICBS Fiber-Insulated Stack Construction and Joint Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-14 TABLES Table F-1. Stack Product Offering and Application Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4 Table F-2. System Component Names and Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-6 Table F-3. Maximum Stack Height Supported Per Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-9 Table F-4. Roof Opening Size for Penetration of Roof Support Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-11 Table F-5. Stack System Clearances to Combustible Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13 Table F-6. Weight of Straight Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-14 This section contains information on the complete line of stacks. This line includes stack components in single, double, and triple wall construction for discharging combustion gases and fumes from boilers, heaters, ovens and other sources generating exhaust vapors at temperatures up to 1400 F.
F-2
02-02
Stacks

Custom Built to Customer Specifications Using CAD Technology: Assures proper system sizing and design. Provides complete system drawing. Provides bill of material based on prefabricated CB-Stack components. System Designed to Use Standard Components: Reduces on-site construction costs. Additions and modications can be made easily and economically. All components are completely compatible. 15 Year Factory Warranty: Guaranteed to last. Longest warranty in the business. Backed by Cleaver-Brooks. Quick-Ship 10 Day Factory Delivery: Provides the customer "What they want - when they want it". Reduces downtime. Efcient job construction scheduling. Lowest Clearance to Combustibles: Reduces needed clearances to combustibles and noncombustibles. Increases usable oor space. Saves on construction costs. Shipped on Pallets and Shrink-Wrapped: Simplied on-site handling. Protects materials until installation. Reduces freight damage. No Welding or On-Site Fabrication Required: Saves time and labor costs. Components are light and easily assembled by one or two people. No special equipment or supervision required.
Stack Sections and Fittings are Continuous Welded: Prevents leakage from vented gases. Meets stringent UL and ULC requirements. Patented Spacer Design: Assures consistent product alignment and support. Built to perform under the most demanding conditions. Built With Captive Nuts and Bolts: Allows easy installation without the risk of losing hardware. Saves on installation time and cost.
PRODUCT OFFERING
Cleaver-Brooks manufactures a complete line of fully compatible stack components as follows: Ameri-Vent type "B": gas vent. Model CBS-I: single wall stainless steel. Model CBS-II: double wall air insulated. Model CBS-III: triple wall air insulated. Model ICBS: double wall - 1", 2", and 4" material insulated. See Table F-1 for the product that best ts your specic application.
Selection Considerations
The information in this section applies to product selection which is governed by four major considerations: Type of heating equipment. Fuels to be burned and vapor or gases to be removed. Exhaust operating temperatures of the equipment. Building use and type of construction materials used. All CBS/ICBS chimney components will be custom fabricated for your installation. Cleaver-Brooks application engineers design and size stack systems based on data provided by the engineer or contractor. These data include information such as job-site elevation, equipment and fuel type, equipment input (Btu/hr), ue gas temperature, as well as site dimensions and the need for offset, drains, ttings, roof penetration, etc. These data are used to generate a detailed installation drawing and component parts list. Prior to fabricating the parts at our plant, the installation drawing and parts list are returned to the engineer or contractor for verication. It is the engineers or
F-3
02-02
F-4 Table F-1. Stack Product Offering and Application Information

AMERI-VENT Type "B" Gas Vent AGA Listed Gas Appliances Air/Product Containment Breeching Systems, Grease Duct LP; Natural Gas; #2, #4A, #5A or #6A Fuel Oil; Wood; CoalA; Grease Vapors; Caustic Fumes; Particles Positive, Neutral or Negative Air Product Containment or 2000F for Grease Duct 6" through 48" Inner: Standard 304SS .035" All Diameters (Optional .035" 316SS Available) Outer: N/A Inner: .035" 20-ga 304SS Standard (Optional .035" 20-ga 316SS Available) Inner: .035" 20-ga 304SS Standard (Optional .035" 20-ga 316SS Available) Inner: .035" 20-ga 304SS Standard (Optional .035" 20-ga 316SS Available) 100 F Continuous, 1400 F Intermittent 1400 Continuous. 1800 F Intermittent Grease Duct 500 F Continuous Boiler and Breeching Systems, Engine/Turbine Exhausts, Grease/Oven Exhausts, Air/Particle Containment Single Wall Stainless Steel Double Wall Air Insulated Triple Wall Air Insulated CBS-I CBS-II CBS-III ICBS Double wall either 1", 2" or 4" Material Insulated Natural or LP Gas Neutral or Negative 400F Plus Ambient 3" through 30" Inner: .012" Aluminum 3" to 6" .014" Aluminum 7" to 18" .018" Aluminum 20" to 30" Outer: 28-ga Galvanized Steel 3" to 30" Outer: .025" 24-ga Aluminum Coated Steel 6" to 24" .034" 20-ga Aluminum Coated Steel 26" to 48" Optional 304 or 316SS Available) Center: .025" 24-ga Aluminum Coated Steel 6" to 24" .034" 20-ga Aluminum Coated Steel 26" to 48" (Optional 304 or 316SS Available) Outer: .025" 24-ga Aluminum Coated Steel 6" to 24" .034" 20-ga Aluminum Coated Steel 26" to 48" (Optional 304 or 316SS Available) 1/4" Air 3" through 6" 1/2 Air 7" through 30" N/A 1" Air Innerwall to Center = 1" Air Center to Outerwall = 1/2" Air Insulation Material: Eleven Pound Fiber Insulation of 1", 2" or 4" thickness Outer: .025" 24-ga Aluminum CoatedSteel 6" to 24" .034" 20-ga Aluminum Coated Steel 26" to 48" (Optional 304 or 316SS Available) 1" Material 2" Material or 4" Material Complies with one or more of the following: AGA; HUD; NBC; UBC; UMC; NMC; SMC; SBCCI; ICBO; BOCA; UL-103, 710, 411; ULC-S604; NFPA-85, A, B, D, 31, 34, 37, 54, 96, 211.
Stacks
MODEL NO.
Description
Applications
Fuel Types
Exhaust Pressures
Exhaust Temp. Continuous/Intermittent
Diameters
Materials
02-02
Insulation
Application Ref. & Listings
A. Recommended 316 Stainless Steel.
Stacks
contractors sole responsibility to eld verify all dimensions, components, and layouts on the installation drawing. This verication must include an authorized signature and date before the order will be fabricated and shipped. These stack systems must be installed as complete systems that originate at the boiler and terminate outdoors. Installing or using CBS or ICBS stack systems, or parts of systems, in ways other than those specied can be hazardous. Always contact local building and/or re ofcials concerning application restrictions and installation inspection procedures. Obtain all required building permits.
Special Stack Applications

Cleaver-Brooks can help in the design, layout and manufacture of the following special stack applications: Grease duct venting systems. Engine/turbine venting systems. Solid fuel venting systems. Special stack applications may require unique design and product modications. Contact your local Cleaver-Brooks authorized representative for assistance. Standard Components, Table F-2, lists the names and part numbers for the various components of all Cleaver-Brooks model lines. Each model line has its own letter designation. N is used to identify CBS-I single wall components. Double wall CBS-II uses the letter S, while CBS-III triple wall components are designated with the letter V. Fiber-Insulated components use the letter A for 1" insulated, B for 2" insulated, and D for 4" insulated. Every part shipped for your order has a label listing the component part number. The rst two digits identify the stack inner diameter. For example, a part labeled 16SEJ11 is a 16" ID, double wall, expansion joint. The last two digits of the part number are for manufacturing control. A part labeled 24BT9011 is a 24" ID, 90 tee that is ber insulated with 2" of insulation between its inner and outer walls.
Safety Specifications and Clearances

All CBS/ICBS stack systems should be sized in accordance with the instructions provided by the manufacturer and pertinent job-site data. The stack system must never be jacketed, wrapped, or enclosed in combustible materials. Never place insulation in required clearance spaces or ventilation openings.
Use of Noncombustible Enclosure or Chase

The following information on noncombustible chase and clearance to combustibles pertains to all applications, except grease duct systems: When the stack extends through any story above the one in which the boiler is located, including drop ceilings and crawl spaces, it must be enclosed in a continuous enclosure made of noncombustible materials. This enclosure or chase should extend from the rst ceiling above the boiler to, or through, the roof of the building. Refer to Figure F-1. It must maintain the integrity of the re separations required for the construction and occupancy classication of the building. When the stack is installed in a noncombustible enclosure, this enclosure becomes an extension of the boiler room to the outside of the building. It must be designed and sized to allow boiler room air to mix with outside air. This means there must be sufcient clearance between the walls of the enclosure and the stack, its supports, and its guides.
ENGINEERING DATA
Information in this section outlines typical installation requirements when installing a stack or breeching to a CleaverBrooks boiler. Actual installation and arrangements will be dictated by design, state, provincial or local codes, job-site conditions and number of boilers installed. This information, in addition to information listed in Table F-1, will assist you in determining equipment required. For special applications or additional information contact your local Cleaver-Brooks authorized representative.
Clearance to Combustibles
Care must be taken when using combustible material around the stack. Refer to "Clearances for Non-Combustible Enclosures" in this section for recommended clearances.
Connecting to the Boiler

CBS/ICBS stack systems, in most applications, can be connected directly to, and supported by the boiler. Refer to Table F-6 for typical stack weights. For special applications contact your local Cleaver-Brooks authorized representative.
Application
Cleaver-Brooks CBS/ICBS stack systems comply with the requirements of the approval bodies listed in Table F-1. These stack systems are not for installation in one and two family dwellings.
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Stacks
Table F-2. System Component Names and Part Numbers
PART NAME DESCRIPTION MODEL NO. CBS-I N18 Straight pipe section
A
PART NUMBERS CBS-II S18 S30 S42 ST90 ST45 SY SDY SEB15 SEB30 SEB45 SEJ SBJ SFAL SNS SDS SHD SSBD SDP SIP SSJ SSIR SWPA SRSA SPA SSC STCF SSCR SSTC SOT SSEC CB1 CB2 HCB2 SBA SGA SSSA SSCF SHSAR SSAR SHB SFAG SWGA STB SWSA CBS-III V18 V30 V42 VT90 VT45 VY VDY VEB15 VEB30 VEB45 VEJ VBJ VFAL VNS VDS VHD VSBD VDP VIP VSJ VSIR VWPA VRSA VPA VSC VTCF VSCR VSTC VOT VSEC CB1 CB2 CB3 HCB2 HCB3 VBA VGA VSSA VSCF VHSAR VSAR VHB VFAG VWGA VTB VWSA ICBS-1" A18 A30 A42 AT90 AT45 AY ADY AEB15 AEB30 AEB45 AEJ ABJ AFAL ANS ADS AHD ASBD ADP AIP ASJ ASIR AWPA ARSA APA ASC ATCF ASCR ASTC AOT ASEC CB1 ACB2 AHCB2 ABA AGA ASSA ASCF AHSAR ASAR AHB AFAG AWGA ATB AWSA INS-3 ICBS-2" B18 B30 B42 BT90 BT45 BY BDY BEB15 BEB30 BEB45 BEJ BBJ BFAL BNS BDS BHD BSBD BDP BIP BSJ BSIR BWPA BRSA BPA BSC BTCF BSCR BSTC BOT BSEC CB1 BCB2 BHCB2 BBA BGA BSSA BSCF BHSAR BSAR BHB BFAG BWGA BTB BWSA INS-3 ICBS-4" D18 D30 D42 DT90 DT45 DY DDY DEB15 DEB30 DEB45 DEJ DBJ DFAL DNS DDS DHD DSBD DDP DIP DSJ DSIR DWPA DRSA DPA DSC DTCF DSCR DSTC DOT DSEC CB1 DCB2 DHCB2 DBA DGA DSSA DSCF DHSAR DSAR DHB DFAG DWGA DTB DWSA INS-3
N30 N42
90 tee 45 tee Wye Drain wye 15 elbow 30 elbow 45 elbow Expansion joint Bellows joint Fixed adjustable length Nozzle section Drain section Horizontal drain Stack base drain Drain plug Inspection plug Slip joint Stepped increaser Wall penetration assembly Roof support assembly Penetration assembly Storm collar Tall cone flashing Stack closure ring Stack termination cap Open termination Stack exit cone Containment band Closure bands Half closure bands Boiler adapters Generator adapters Stack support assembly Split clamp flange Half split angle ring Split angle ring Hanger bracket Floor alignment guide Wall guide assembly Transition band Wall support assembly Fiber insulation strips
NT90 NT45 NY NDY NEB15 NEB30 NEB45 NEJ NBJ NFAL NNS NDS NHD NSBD NDP NIP NSJ NSIR NWPA NSC NTCF NSCR NSTC NOT NSEC CB1 NBA NGA NSSA NSCF NHSAF NSAR NHB NFAG NWGA NWSA -
A. Straight pipe sections are custom fabricated to required lengths but are priced at 18, 30, and 42 in. lengths. For example, a 24 in. straight pipe section will be billed at the 30 in. section price.
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Stacks
Not load bearing. Therefore, these systems are usually between support or guide assemblies. Expansion Direction To determine expansion direction, it is necessary to understand how the expansion or bellows joint works. The expansion or bellows joint itself does not expand. In fact, the opposite happens. It compresses to absorb the movement of the parts expanding around it. This expansion movement occurs from xed points in the system toward the expansion or bellows joint. Refer to Figure F-2. Calculating Expansion The amount of thermal expansion that will occur is calculated by the following equation: Expansion = 1" per 100 of stack per 100 F above ambient temperature.
Figure F-1. System Extension Above Boiler Room
Expansion and Installation Concerns

When stack systems are exposed to the heating and cooling of normal operation, the components will expand and contract. The systems are designed to adjust to this movement, provided the amount and direction of expansion is accurately calculated, and the system is correctly installed. The amount of thermal expansion that will occur depends on the length of breeching, height of the stack, temperature of the ue gas, and arrangement of the system. Therefore, the following must be considered. Thermal Expansion The CBS/ICBS systems use two different parts to compensate for thermal expansion between two xed points in the system. They are: expansion joints and bellows joints. Each type of joint is: Designed to compensate for linear expansion only. Never used to correct for misalignment between components. Figure F-2. Thermal Expansion Between Two Fixed Points in Stack System
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Stacks
Expansion is calculated between xed points in the system. If more than 1/4" of expansion will occur between xed points, an expansion or bellows joint must be installed within that run of stack. Thermal expansion can also be determined using the graphs shown in Figure F-3. Support Assemblies CBS/ICBS support assemblies are load bearing items. They are designed to carry the weight of the system and withstand expansion forces. Support assemblies are connected to the inner wall ange of the stack. They must always be bolted or otherwise tied into rigid structural building supports. They must never be suspended from lightweight rods or tubing. Three different types of support assemblies are used: Stack support assembly (SSA). Wall support assembly (WSA). Roof support assembly (RSA). Refer to Table F-3 for the maximum stack height supported per assembly. Support assemblies must also be located within 6 of elbows, tees, or wyes. It may be necessary to reduce this spacing if anticipated expansion is greater than 1/4" between xed points. Refer to Figure F-4 for the maximum unsupported distance between elbows, tees, or wyes. Refer to Figure F-5 for the maximum support and guide assembly spacing for vertical, horizontal and sloping stack runs. Guide Assemblies Guide assemblies are designed to provide lateral support and guidance for the stack system. They must be rigidly mounted to the building and plumb with the stack. Guide assemblies are not tied into, or attached to, the stack in any way, but they do bear part of the overall load in horizontal and sloped runs. Three types of guide assemblies are used: Split angle rings. Wall guide assemblies. Floor alignment guides. The maximum spacing between any two guide assemblies, or between a support assembly and a guide assembly, is 15 for vertical runs and 12 for horizontal or sloping runs. Refer to Figure F-5.
Figure F-3. Graphs for Calculating Thermal Expansion Movement
Figure F-4. Maximum Unsupported Distance Between Elbows, Tees, or Wyes
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Stacks
Table F-3. Maximum Stack Height Supported Per Assembly

MODEL CBS-I CBS-II ID (INCHES) 6-48 6-16 18 20 22 24 26 28 30 32 34 36 42 48 CBS-III 6-16 18 20 22 24 26 28 30 32 34 36 42 48 ICBS-1 6-10 12 14 16 18 20 22 24 26 28 30 32-34 36 42 48 SSA (FT) 210 210 203 192 189 178 175 169 162 155 148 142 121 100 136 131 127 122 118 113 109 104 100 95 91 77 64 210 188 163 144 134 128 123 120 105 104 104 103 101 87 77 WSA RSA (FT) 78A 78 77 75 73 70 68 65 63 61 58 56 49 42 50 50 48 47 45 44 42 40 39 37 36 31 26 78 70 61 53 51 49 48 47 41 41 40 40 40 35 30 ICBS-4 ICBS-2 6 8 10 12 14 16 18 20 22 24 26-28 30-32 34 36 42 48 6 8 10 12 14 16 18 20 22 24 26-34 36 42 48 210 198 165 141 123 109 103 98 95 93 83 82 81 81 70 61 143 119 102 89 79 71 67 65 63 62 57 56 49 43 78 73 61 52 45 40 39 38 37 36 33 32 32 31 28 24 53 44 37 33 29 26 25 25 24 24 22 22 20 17
NOTE: 1. A. Single wall VSI-I piping prohibits the use of penetration assemblies. A transition to double wall VSI-II pipe will be required where the piping passes through a penetration assembly. 2. Numbers in table are in inches. 3. SSA = Stack Support Assembly. 4. WSA = Wall Support Assembly. 5. RSA = Roof SUpport Assembly.
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Stacks
Figure F-5. Maximum Support and Guide Assembly Spacing for Vertical, Horizontal, and Sloping Stack Runs The maximum height a vertical stack can extend above its uppermost guide or guy cable location is 9. Refer to Figure F6. Load Bearing When designing or installing a CBS/ICBS stack, remember the inner stack wall is the load bearing member. All stack supports must be connected to the inner wall anges. Outer or center walls (three wall stack) are not designed to bear loads. They act as jackets only. Never connect system supports or pierce these walls. Roof Penetrations Proper selection and use of various components at the location the system penetrates the roof, are based on a number of factors, including roof material (combustible/noncombustible), the use of noncombustible enclosures or chases, and the general layout of the system. When a stack system passes through a roof made of combustible materials, a penetration or roof assembly that consists of a ventilated storm collar must be used. These assemblies are specically designed to provide the proper clearances and ventilation openings. These assemblies must be installed without modications and all ventilation openings must remain open and unobstructed. When the stack system passes through oors or zones above the boiler room, it must be installed in a noncombustible enclosure or chase. The enclosure must extend to, or above, the roof deck and a penetration or roof assembly must be used regardless of the roof material. A third roof penetration uses tall cone ashing along with a F-10
02-02
storm collar. This method may only be used if: The roof deck and framing materials are noncombustible. The stack does not pass through oors, drop ceiling or other occupance zones on its way to the roof. The area above the boiler, to the roof level, is basically open, providing adequate air movement around the system. Roof Opening Size, Framing and Curbing Opening size varies according to stack OD. In most cases the opening will be square and cut so it is basically ush with the framing members. If the roof is made of noncombustible materials, the roof opening may be round. The opening must be level and provide attachment points for external brackets. The opening should be boxed in with struc-
Figure F-6. Cable Guying Specications for Roof Level Guide
Stacks
tural steel or wood framing on all four sides. The framing must be capable of supporting the load, or the penetration assembly, when the stack is exposed to wind loading and thermal expansion forces. On sloping roofs, a level curb must be constructed and tied into the openings framing so that the stack maintains its true vertical positions. Both framing and curbing can be constructed of combustible materials if proper clearances are maintained. Table F-4 list roof openings for all models in width of square, or diameter of circle. Figure F-7 shows roof framing and curbing details for at or sloping roofs. Cable Guying Above the Roof - Guy cables are an acceptable method of providing lateral support to stack sections that extend above the roof level. A stack should not use cable guying at locations higher than 15 above a roof, pier or superstructure may be used for this type of application. The stack may also extend 9 above guy cable connections. Refer to Figures F-7 and F-8. Above the Roof Guiding Stacks extending more than 24 above a roof, pier or wall should use a guide assembly rigidly mounted to a superstructure, tower, or wall. The structure must be capable of supporting lateral wind load and maintain plumb alignment between the guide assemblies and the stack.
Clearances For Noncombustible Enclosures

Although consistent clearances are not critical, a minimum open area equivalent to a 1-1/2" clearance between the enclosure, its supports and guides, must exist at any plane within the enclosure. Refer to Figure F-1.
Clearances to Combustibles
When installed within the same room or zone as the boiler, the stack must have a minimum air space clearance to combustible construction, including building insulation and electrical wiring as listed in Table F-5. These minimum clearances must never be altered in any way. Lower than listed ue gas temperatures do not alter the clearances listed. For example, if the maximum ue gas temperature in a model CBS-II system will be 500 F, the full clearance for that diameter listed for 1000 F stack system must be used. When smaller clearances are desired, specify model CBS-III or ICBS ber insulated stacks.
Table F-4. Roof Opening Size for Penetration of Roof Support Assemblies
STACK ID (INCHES) CBS-II 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 42 48 17-1/2 19-1/2 21-1/2 23-1/2 25-1/2 27-1/2 29-1/2 31-1/2 33-1/2 35-1/2 37-1/2 39-1/2 41-1/2 43-1/2 45-1/2 47-1/2 53-1/2 59-1/2 WIDTH OF SQUARE OR DIAMETER OF CIRCLE CBS-III 18-1/2 20-1/2 22-1/2 24-1/2 26-1/2 28-1/2 30-1/2 32-1/2 34-1/2 36-1/2 38-1/2 40-1/2 42-1/2 44-1/2 46-1/2 48-1/2 54-1/2 60-1/2 ICBS-1" 17-1/2 19-1/2 21-1/2 23-1/2 25-1/2 27-1/2 29-1/2 31-1/2 33-1/2 35-1/2 37-1/2 39-1/2 41-1/2 43-1/2 45-1/2 47-1/2 53-1/2 59-1/2 ICBS-2" 19-1/2 21-1/2 23-1/2 25-1/2 27-1/2 29-1/2 31-1/2 33-1/2 35-1/2 37-1/2 39-1/2 41-1/2 43-1/2 45-1/2 47-1/2 49-1/2 55-1/2 61-1/2 ICBS-4" 23-1/2 25-1/2 27-1/2 29-1/2 31-1/2 33-1/2 35-1/2 37-1/2 39-1/2 41-1/2 43-1/2 45-1/2 47-1/2 49-1/2 51-1/2 53-1/2 59-1/2 65-1/2
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Stacks
Figure F-7. Roof Framing and Curb Details To assist with selection, the following gures will provide basic construction details of the different types of stacks: Figure F-9 shows model CBS-II double wall stacks. Figure F-10 shows model CBS-III triple wall stacks. Figure F-11 shows model ICBS ber insulated stacks. Each model includes: Spacer bands that hold the sections together and maintain the proper air space between the walls. One air space is designed into model CBS-II and two spaces are designed into model CBS-III. Model ICBS are available with 1", 2", or 4" of ber insulation between the walls. For information on single wall or type "B" gas vent stacks, contact your local Cleaver-Brooks authorized representative. These weights include the stack sections and connecting hardware.
Typical Stack Arrangements

The purpose of a stack and breeching on a boiler is to conduct the products of combustion to a point of safe discharge (atmosphere). The forced draft design of Cleaver-Brooks burner and boiler combinations, eliminates the need for a stack designed to create a draft. A static pressure of 1/2" WC at the boiler ue gas outlet will have no appreciable effect on burner operation. Refer to the individual product sections for allowable pressure variations. If the stack height is over 150 or if an extremely large breeching and stack combination cause excessive draft, a simple barometric damper can be located in the breeching - close to the stack. Automatic or special draft controls are not required and are not recommended, except where dictated by state, provincial or local codes. A manual or automatic open-close outlet damper can be installed on a single boiler installation, and is recommended for safety concerns on a multiple common breeching or stack installation. The amount of condensation in the stack will vary with the type of fuel utilized, the type and operating pressure or temperature of the boiler, and the stack ue gas temperature. Stack condensation is most likely to occur on boiler installations where light loads or intermittent ring causes a cool stack condition, which results in condensation of the water vapor in the ue gas.
Stack Weight
Table F-6 lists weights of all models in pounds per linear foot.
Figure F-8. Cable Guying Installation Details F-12
The following items should be considered when planning to keep stack condensation to a minimum:
02-02
Stacks
Table F-5. Stack System Clearances to Combustible Materials
MODEL NO. CBS-I CBS-II ID 6-48 6-8 10-12 14-16 18 20 22 24 26 28 30 32 34 36 42 48 CBS-III 6-16 18-20 22-24 26-28 30-32 34-36 42 48 ICBS-1 6-16 18 20 22 24 26 28 30 32 34 36 42 48 ICBS-2 & ICBS-4 6-16 18 20 22 24 26 28 30 32 34 36 42 48 1000F CHIMNEY 6 6 6 7 7 8 8 8 9 9 10 10 10 18 18 4 4 4 4 4 4 18 18 2 3 3 3 4 4 5 5 5 6 6 14 14 0.5 1.0 1.5 2.0 2.0 3.0 3.0 4.0 4.0 5.0 5.0 12.0 12.0 1400 F CHIMNEY 6 6 6 8 9 10 12 13 14 16 17 19 20 20 20 6 9 12 14 17 20 20 20 2 4 5 7 8 9 11 12 14 15 16 16 16 0.5 2.0 4.0 5.0 6.0 8.0 9.0 11.0 12.0 13.0 15.0 15.0 15.0 500F GREASE DUCT 18 7 8 9 10 10 11 11 12 12 13 13 14 14 16 17 4 5 6 7 8 9 10 12 3 4 4 5 5 6 6 7 7 8 8 10 11 1.0 2.0 2.0 3.0 3.0 4.0 4.0 5.0 5.0 6.0 6.0 8.0 9.0
Figure F-9. Model CBS-II Double Wall Stack Construction and Joint Details
NOTE: Numbers in table above are in inches.
Figure F-10. Model CBS-III Triple Wall Stack Construction and Joint Details F-13
02-02
Stacks
The boiler should be sized as close as possible to the true operating load. Oversized boilers should be avoided. An off-set stack is recommended, with bottom clean-out and drain connection, to prevent any condensed water from draining back into the ue gas side of the boiler. State, provincial and local codes may govern the stack height above the roof. If down drafts are unavoidable, the stack outlet can be provided with a ventilator. A rain cap or hood should be used at the top of the stack to minimize the entrance of snow or rain.
Figure F-11. Model ICBS Fiber-Insulated Stack Construction and Joint Details Table F-6. Weight of Straight Stack
STACK ID (INCHES) CBS-I 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 42 48 2.43 3.25 4.05 4.86 5.67 6.48 7.29 8.09 8.89 9.71 10.51 11.32 12.13 12.94 13.75 14.56 16.97 19.40 CBS-II 4.83 6.17 7.50 8.84 10.17 11.66 12.84 14.18 15.51 16.85 21.88 23.43 24.99 26.55 28.10 29.66 34.83 40.20 WEIGHT IN POUNDS PER LINEAR FOOT CBS-III 7.50 9.38 11.26 13.14 15.02 17.16 18.78 20.66 22.54 24.42 33.48 35.78 38.09 40.39 42.70 45.00 54.98 66.40 ICBS-1" 7.01 9.01 11.01 13.00 15.00 16.99 18.99 20.97 22.97 24.98 30.33 32.45 34.67 36.90 39.13 41.35 48.01 54.69 ICBS-2" 9.85 12.36 14.83 17.32 19.81 22.30 24.78 27.26 29.74 32.23 38.31 40.91 43.64 46.35 49.08 51.79 59.92 68.08 ICBS-4" 17.01 20.49 23.96 27.43 30.90 34.37 37.83 41.29 44.76 48.23 55.65 59.33 63.05 66.74 70.44 74.13 85.21 96.31
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Stacks
The following sample specication is provided by Cleaver- Brooks to assist you in specifying your customers specic needs and application. 1.0 Standard Component Specications Boiler stack and breeching components, supports and terminations shall be factory prefabricated. All stack and breeching components shall be tested and listed by Underwriters Laboratories (UL and ULC), for use with building heating equipment burning gas, liquid, or solid fuels, as described in NFPA 211, Chapter 2. All stacks and breechings will have inner walls of 20-gauge Type 304 stainless steel for gas and No. 2 oil, or 20-gauge Type 316 stainless steel for coal, solid fuels, and No. 4 thru No. 6 oil. Outer walls shall be 24-gauge aluminum-coated steel for sizes up to 24" ID and 20-gauge for sizes of 26" to 48" ID. The stack and breeching shall be engineered, approved, and manufactured for the boiler equipment manufacturer. The stack and breeching manufacturer must supply complete CAD system design drawings which include a complete component bill of materials. Stack and breeching systems must be designed to adjust to thermal expansion caused by the heating and cooling of normal boiler operation. All stack and breeching components must be warranted for a minimum of 15 years when installed according to the manufacturers installation instructions. The stack and breeching shall comply with national safety standards and all building codes where applicable. The stack section joints shall be eld sealed by use of containment bands with captive fasteners and high temperature joint sealant. All stack and breeching components shall be shipped on pallets and shrink-wrapped to simplify on-site handling and protect materials until installation. The system is to maintain air-tight integrity at pressures up to 72" WC at room temperature. The system shall have a ______" minimum clearance to combustibles with ue gas temperatures greater than 1000 F and not exceeding 1400 F continuous, and a _____" minimum clearance to combustibles with ue gases not exceeding 1000 F continuous. 2.0 Specications Specic to Double Wall Air Insulated Components There shall be a minimum of 1" air space between the inner and outer wall. 3.0 Specication Specic to Triple Wall Air Insulated Components There shall be a minimum of 1" air space between the inner and center wall, and a minimum of 1/2" air space between the center and outer wall. 4.0 Specication Specic to Double Wall 1", 2", or 4" Material Insulated Components There shall be a minimum of (1", 2", or 4") bonded ber insulation between the inner and outer wall.
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Stacks
NOTES
F-16
02-02
Section G
ECONOMIZERS
CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3 Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3 DIMENSIONS AND WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4 PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5 ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6 SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-12
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Economizers
ILLUSTRATIONS Boilermate Cylindrical Economizer Mounting to Firetube Boiler (Model CB Boilers) . . . . . . . . . . . . . . . . . . G-7 Economizer Above Industrial Watertube Boiler (Example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8 Economizer on Side of Industrial Watertube Boiler (Example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8 Typical Economizer Feedwater Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-9 Typical Economizer Feedwater Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-9 Typical Economizer Feedwater Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-10 Typical Economizer Feedwater Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-10 Typical Economizer Feedwater Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-11 Typical Economizer Feedwater Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-11
Figure G-1. Figure G-2. Figure G-3. Figure G-4. Figure G-5. Figure G-6. Figure G-7. Figure G-8. Figure G-9.
TABLES Table G-1. Firetube Boiler Cylindrical Economizers Dimensions and Weights (Model CB Boilers) . . . . . . . . . . . . . . . . . G-4 Table G-2. Industrial Watertube Boiler Rectangular Economizers, Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . G-4 Table G-3. Firetube Boiler Cylindrical Economizer, Performance Data (Model CB Boilers) . . . . . . . . . . . . . . . . . . . . . . . G-5 Table G-4. Industrial Watertube Boilers Rectangular Economizer Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6 Table G-5. Firetube Boiler Cylindrical Economizers, Efficiencies (Model CB Boilers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6 Table G-6. Industrial Watertube Boiler Rectangular Economizers, Efficiencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6
This section contains information on Economizers. An economizer recovers heat from ue gases and uses it to increase boiler feedwater temperatures, prior to entering the boiler. Cleaver-Brooks offers a variety of types, sizes, and custom designs. Each assures proper match for your specic retube or watertube boiler.
G-2
04-02
Economizers

Reduces Fuel Use and Cost: Recovers heat from ue gases that would otherwise be wasted. Heat is used to raise boiler feedwater temperature prior to entering the boiler. Load Changes: Rapid changes in load demands can be met faster due to higher feedwater temperature. Emissions: Reduced fuel-ring rates for any given steam output means reduced NOx emissions. ASME Construction: Ensures high quality design and manufacturing standards. Provides safety and reliability. High Efficiency Heat Exchanger: Provides continuous, high-frequency resistance welding. Provides uniform n-to-tube contact for maximum heat transfer. Fin tubing offers up to 12 times the heat exchange surface of bare tubing of the same diameter. Self-Draining Design: Suitable for outdoor installation. Low Pressure Drop: Provides gas side pressure drops of 0.8" WC or less. Permits use of smaller forced draft fans. Permits use of existing fans in almost all installations. Gas Tight Combustion Stack: Provides inner casing of carbon steel. Provides outer casing of weather resistant, corrugated, galvanized carbon steel. Compact dimensions provide for easy installation. Feedwater Preheating System: Controls cold end corrosion through all ow rates.
Prevents the forming of corrosive acids in the economizer. Prevents stack corrosion. Guaranteed Efficiency on Model CB Firetube Boilers: $10,000 rebated for every full 1.0% efciency point less than guaranteed.
PRODUCT OFFERING
Cleaver-Brooks offers a line of custom-engineered economizers for boiler sizes up to and including 150 MMBtu/hr input. The model designation is Boilermate Fuel Economizers, and they are available in either cylindrical or rectangular designs.
Standard Equipment
Equipment described is for the standard Boilermate Fuel Economizer, as dened later in the specications, and in the current literature. Standards for both cylindrical and rectangular Boilermate Economizers include: Designed and fabricated in accordance with the ASME Boiler and Pressure Vessel Code, Section I, Power Boilers. Thermometer and safety valve connections at the feedwater headers. Incorporates self-draining design. Safety valve - standard with industrial watertube boilers only. Valve is set at 490 psig.
Optional Equipment
Vertical or horizontal ue gas ow patterns on rectangular design. Utilization of waste gas. Soot blowers for oil ring. Feedwater and sootblower piping from economizer to boiler. Feedwater preheating system. Safety valve optional with retube boilers. If supplied, valve is set at 450 psig.
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Economizers
DIMENSIONS AND WEIGHTS

Information in this section outlines typical dimensions and weights of an economizer, and typical ratings and efciencies when utilizing an economizer. Table G-1 lists dimensions and weights for a cylindrical Boilermate Economizer typically installed with a retube boiler. (Model CB Boilers). Table G-2 lists dimensions and weights for a rectangular Boilermate Economizer typically installed with an industrial watertube boiler. The selection of a cylindrical or rectangular economizer for a particular application will depend on type and capacity of the boiler and job site conditions.
Table G-1. Firetube Boiler Cylindrical Economizers Dimensions and Weights (Model CB Boilers)
DIMENSIONS (APPROX) BOILER HP ECONOMIZER MODEL NUMBER EC-40821 EC-41221 EC-41021 EC-40820 EC-41120 EC-40931 EC-40831 EC-40830 EC-40831 EC-30830 EC-30842 EC-30841 HEIGHT (IN.) 61 85 73 61 85 73 61 73 61 73 73 73 DIA (IN.) 34 34 34 34 34 43 43 43 43 43 52 52 DRY UNIT WEIGHT (LBS) 1110 1496 1285 1354 1757 2166 1979 2272 1979 2121 2626 2938
100 hp 125 hp 150 hp 200 hp 250 hp 300 hp 350 hp 400 hp 500 hp 600 hp 700 hp 800 hp
NOTES: 1. Dimensions in inches. 2. Boiler firing natural gas. 3. Boiler operating pressure is 125 psig (acceptable tolerance is 5 psig). 4. Do not use this table for model CB-LE boilers. Contact your local Cleaver-Brooks representative for sizing detail.
Table G-2. Industrial Watertube Boiler Rectangular Economizers, Dimensions and Weights
BOILER MODEL D-34 D-52 D-76 D-94 ECONOMIZER GAS FLOW DIRECTION (EXAMPLE) VERTICAL HORIZONTAL VERTICAL VERTICAL APPROXIMATE DIMENSIONS (INCHES) LENGTH 105 49 140 155 WIDTH 29 110 47 59 HEIGHT 76 47 76 80 4400 5800 8800 11600 DRY UNIT WEIGHT (LBS)
NOTES: 1. Dimensions in inches. 2. Data indicated is for select applications. Each Economizer is designed on a job to job basis. 3. Boiler is firing natural gas. 4. Boiler operating pressure is 150 psig (acceptable tolerance is 5 psig). 5. Economizer gas flow direction can be either horizontal or vertical.
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Economizers
PERFORMANCE DATA
Tables listed here contain performance data for: Gas red, 100 through 800 hp retube boilers operating at 125 psig, and utilizing a cylindrical fuel economizer. Gas red, industrial watertube boilers operating at 150 psig and utilizing a rectangular fuel economizer. For additional operating pressures, load capacity or fuel selections, contact your local Cleaver-Brooks authorized representative. Table G-3 lists typical water and gas side temperatures when utilizing a cylindrical Boilermate Economizer with a retube boiler (Model CB Boilers).
NOTICE
Do not use on boilers equipped with flue gas recirculation. Contact your local Cleaver-Brooks authorized representative. Table G-4 lists typical water and gas side temperatures when utilizing a rectangular Boilermate Economizer with an industrial watertube boiler. Table G-5 lists typical increases in efciency for a retube boiler (Model CB Boilers). Table G-6 lists typical increases in efciency for an industrial watertube boiler. Table G-3. Firetube Boiler Cylindrical Economizer, Performance Data (Model CB Boilers)
WATER SIDE BOILER HP LOAD % ECONOMIZER MODEL NO. FLOW PPH TEMPERATURE IN F OUTF PRESS. DROP PSIG FLOW PPH GAS SIDE TEMPERATURE IN F OUT F PRESS. DROP IN. WC HEAT RECOVD BTU/HR HEATING SURFACE SQ-FT
100 125 150 200 250 300 350 400 500 600 700 800
100 100 100 100 100 100 100 100 100 100 100 100
EC-40821 EC-41221 EC-41021 EC-40820 EC-41120 EC-40931 EC-40831 EC-40830 EC-40831 EC-30830 EC-30842 EC-30841
3450 4313 5175 6900 8625 10350 12075 13800 17250 20700 24150 27600
220 220 220 220 220 220 220 220 220 220 220 220
253 270 255 249 266 260 252 256 244 241 239 241
0.6 1.3 1.6 2.5 1.1 1.8 2.1 3.0 4.3 6.7 10.6 15.8
3968 4959 5951 7935 9919 11903 13886 15870 19838 23805 27773 31740
410 465 420 395 460 435 410 425 385 370 365 370
299 295 300 296 306 302 304 304 302 299 301 298
0.2 0.5 0.5 0.3 0.7 0.4 0.4 0.4 0.8 0.7 0.8 0.6
117213 223989 189303 209230 405328 420422 388523 508748 431393 447492 464527 589092
240 361 301 361 496 646 574 695 574 566 589 775
NOTES: 1. Feedwater temperature to economizer is at least 220 F (Deaerated). 2. Boiler operating pressure is 125 psig (acceptable tolerance 5 psig). 3. Gas side flow (pph) determined with 10% excess air (50 to 100% of capacity). 4. Continuous modulated feedwater flow must be provided. 5. Boiler firing natural gas 6. Do not use this table for model CB-LE boilers. Contact your local Cleaver-Brooks representative for sizing detail.
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Economizers
Table G-4. Industrial Watertube Boilers Rectangular Economizer Performance Data
ECONOMIZER WATER SIDE MODEL NO. LOAD % FLOW PPH IN F D-34 D-52 D-76 D-94 100 100 100 100 15000 31000 51500 63000 225 225 225 225 OUT F 292 292 280 269 TEMPERATURE PRESS. DROP PSIG 6.8 5.6 8.1 9.9 FLOW PPH IN F 15884 32582 53999 66018 532 532 498 459 OUT F 318 318 318 318 GAS SIDE TEMPERATURE HEAT PRESS- RECOVERED DROP BTU/HR IN. WC (MAX) 0.75 0.75 0.75 0.75 1237000 2530000 3424000 3260000 HEATING SURFACE SQ-FT
786 1616 2370 2462
NOTES: 1. Feedwater temperature to Economizer is at least 220 F (Deaerated). 2. Boiler operating pressure is 150 psig (acceptable tolerance 5 psig). 3. Gas side flow (pph) determined with 10% excess air. 4. Continuous modulated feedwater must be provided. 5. Data indicated is for select application. Each Economizer is designed on a job to job basis. 6. Boiler is firing natural gas.
Table G-5. Firetube Boiler Cylindrical Economizers, Efciencies (Model CB Boilers)

BOILER HP LOAD % ECONOMIZER MODEL NO. EFF W/0 ECON % FUEL SAVED EFF WITH ECON
Table G-6. Industrial Watertube Boiler Rectangular Economizers, Efciencies

BOILER MODEL LOAD % FLOW PPH EFF W/O ECON % FUEL SAVED EFF WITH ECON
100 hp 125 hp 150 hp 200 hp 250 hp 300 hp 350 hp 400 hp 500 hp 600 hp 700 hp 800 hp
100 100 100 100 100 100 100 100 100 100 100 100
EC-40821 EC-41221 EC-41021 EC-40820 EC-41120 EC-40931 EC-40831 EC-40830 EC-40831 EC-30830 EC-30842 EC-30841
82.2 81.0 82.1 82.7 81.3 81.9 82.5 82.2 83.1 83.5 83.6 83.5
3.3 5.1 3.6 3.0 4.6 4.0 3.2 3.6 2.4 2.1 1.9 2.1
84.9 85.1 85.0 85.1 85.1 85.2 85.1 85.2 85.1 85.2 85.2 85.2
D-34 D-52 D-76 D-94
100 100 100 100
15000 31000 51500 63000
77.47 78.07 79.17 80.15
6.3 6.3 5.2 4.1
82.72 83.34 83.54 83.59
NOTES: 1. Feedwater temperature to Economizer is at least 220 F (Deaerated). 2. Savings depend on total design of the system. 3. Data indicated is for select applications. Each Economizer is designed on a job to job basis. 4. Boiler is firing natural gas. 5. Boiler operating pressure is 150 psig (acceptable tolerance 5 psig).
Firetube Boilers (Model CB Boilers) Installation - economizer above boiler: All standard retube boilers (125 hp and above) can support up to 2,000 lbs without additional reinforcement. Firetube boilers up to 250 hp can be reinforced to support 2,500 lbs, however, this must be specied. Firetube boiler sizes 250 hp through 800 hp can be reinforced to support 3,000 lbs, however, this must be specied. All weights listed in Table G-1 are shipping weights. When installed, the water weight must be added to obtain total load to be supported. Use an average add-on of 200 lbs.
NOTES: 1. Feedwater temperature to Economizer is at least 220 F (Deaerated). 2. Selections are based on best Btu savings per dollar costs. 3. Boiler is firing natural gas. 4. Boiler operating pressure is 125 psig (acceptable tolerance 5 psig). 4. Do not use this table for model CB-LE boilers. Contact your local Cleaver-Brooks representative for sizing detail.
ENGINEERING DATA
Information in this section outlines typical installation. Actual installation and piping arrangements will be dictated by design, state, provincial or local codes, and job-site conditions.
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Economizers
Add the weight of any stack (if unsupported) from the economizer to the outside. Although the economizer can support additional weight, the total weight of economizer and stack will very likely exceed the allowable weight on the boiler. Be certain that either the economizer or the stack, or both, are supported external from the boiler. If an expansion joint is used, the economizer and stack must be supported to ensure all loading is removed from the expansion joint. Refer to Figure G-1 for suggested mounting to a retube boiler (Model CB Boilers). For information on Model CB-LE Boilers, contact your local Cleaver-Brooks authorized representative. Industrial Watertube Boilers Installation - economizer above boiler: Maximum vertical loading of top mounted economizer and stack at the boiler connection must not exceed 2,000 lbs. The stack must be top-guided to prevent any overturning moment at boiler connection. The economizer and stack must be supported to ensure all loading is removed from the expansion joint. All weights listed in Table G-2 are shipping weights. When installed, the water weight must be added to obtain total load to be supported. Water weights will vary and can only be obtained after economizer is selected. Refer to Figure G-2 for suggested mounting above an industrial watertube boiler. Installation - economizer on side of boiler: Breeching must be supported to ensure all loading is removed from expansion joints. Concrete must be suitably reinforced. Piers and footings must be designed to meet soil conditions and local ordinances at job site. The economizer support stand must be designed to support the economizer and water weight. All weights listed in Table G- 2 are shipping weights. When installed, the water must be added to obtain total load to be supported. Water weights will vary and can only be obtained after economizer is selected. Refer to Figure G-3 for suggested mounting on side of an industrial watertube boiler.
Boiler hp No. of Bolts Bolt Size Bolt Circle Vent Opening (OD) 13-7/8 12 BOLT SPECIFICATIONS 100 8 125-200 12 250-350 12 400-800 16
Feedwater Piping Piping arrangements are dictated by ASME Code, location of the economizer in relation to the boiler, and feedwater regulating system. Figure G-4 outlines typical feedwater piping per ASME Code jurisdiction. If the economizer can be shut off from the boiler by valve(s), the economizer must have a safety valve and the boiler must have feed and check valves. Refer to Figure G-5. Figure G-5 outlines feedwater piping with the economizer mounted above the boiler. Figure G-6 outlines feedwater piping with the economizer mounted and the economizer outlet at or below water level in boiler drums. Figures G-7, G-8, and G-9 outline different feedwater piping arrangements with the economizer mounted above the boiler and with gas and water isolation by-passes.
3/8 - 16 (threads per inch) 17-7/8 16 21-7/8 20 25-7/8 24
NOTES: 1. Dimensions in inches. 2. For allowable weights on vent stub refer to dimensions and weights in this section. 3. For information on stacks refer to Section F.
Figure G-1. Boilermate Cylindrical Economizer Mounting to Firetube Boiler (Model CB Boilers)
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Economizers
Figure G-2. Economizer Above Industrial Watertube Boiler (Example)
Figure G-3. Economizer on Side of Industrial Watertube Boiler (Example) G-8

04-02
Economizers
Figure G-4. Typical Economizer Feedwater Piping
REFER TO PRODUCT OFFERING, PAGE G-3.
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Economizers
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Economizers
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Economizers
The following sample specication is provided by Cleaver- Brooks to assist you in specifying your customers specic needs and application. 1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-12 2.0 Common Construction Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-12 3.0 Specifications Specific To Cylindrical Economizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-12 4.0 Specifications Specific To Rectangular Economizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-12 5.0 Quality Control and Code Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-13
1.0 General Specications for Boilermate cylindrical and rectangular economizers shall include the furnishing of (___________) complete packaged, extended surface boiler economizer(s), as furnished by Cleaver-Brooks. 2.0 Common Construction Specications Tube material is to be SA-178-A boiler tube. Extended surface is to be of solid, continuous, high- frequency, resistance welded carbon steel ns. Serrated ns are not acceptable. Tube arrangement is to be square pitch only. Triangular or staggered tube pitch will not be acceptable. Inner casing is to be a minimum of 10-gauge carbon steel. Insulation type is to be mineral wool. Outer casing is to be weather-proof with a minimum 27- gauge, corrugated, galvanized, carbon steel casing. All exposed surfaces not enclosed by the outer casing are to be painted with high-temperature paint. The economizer shall be completely drainable by gravity, after installation. Safety valve to be supplied. 3.0 Specications Specic To Cylindrical Economizers The economizer shall be of the cylindrical design. Fins are to be not less than .060" thick. The economizer shall be equipped with a built-in sootblower and shall utilize lane blowing to provide maximum cleaning capabilities. Longitudinal or mass blowing shall not be acceptable. For economizers used on boilers which have an on/off type feedwater control system, a modulating feedwater system shall be incorporated into the system to ensure proper economizer operation. 4.0 Specications Specic To Rectangular Economizers Tubes are to be commercially available 2" OD. Fins are to be not less than .075" thick. Tube sheets are to be of the open lattice design. Tube walls (pressure parts) shall not be in contact with tube sheets. The ns shall rest on the tube sheet. Sootblower wall boxes and distal bearings shall be included and are to be installed on the economizer by the vendor. Sootblowers shall be installed (when specied) transversely to provide maximum cleaning capabilities. Longitudinal or mass blowing shall not be acceptable. An insulated access door of carbon steel construction, 16" square inside-to-inside, shall be included in the economizer design.
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Economizers
5.0 Quality Control And Code Requirements Economizer is to be designed and fabricated in accordance with the ASME Boiler and Pressure Vessel Code, Section I, Power Boilers. Minimum design temperature is to be 700 F. Unit shall be hydrostatically tested at 1.5 times the design pressure in the presence of a Code Inspector. Unit is to be ASME Code Stamped, and is to include nameplate and applicable code papers.
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Economizers
NOTES
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Section H
FEEDWATER SYSTEMS
Spraymaster Deaerators (Single Tank) Spraymaster Deaerators (Duo Tank) Boilermate Deaerators Surge Tanks Boiler Feed Systems Chemical Feed Systems and Metering Pumps Filters Softeners Dealkalizers Blowdown Separators Blowdown Heat Recovery Systems Flash Tank Heat Exchangers Sample Coolers H1 H2 H3 H4 H5 H6 H7 H8 H9 H10 H11 H12 H13
H-a
02-02
Feedwater Systems
H-b
Section H1
SPRAYMASTER DEAERATORS (Single Tank)
CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-3 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-3 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-4 Deaerator Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-4 Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-4 DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-5 RETURN ON INVESTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-8 Flash Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-8 Exhaust Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-8 Surface Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-8 Chemical Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-8 Makeup Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-8 Sewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-8 Intangibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-8 SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-9 ILLUSTRATIONS Figure H1-1. Spraymaster Tank Supports and Saddles, Details and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-5 Figure H1-2. Spraymaster Deaerator Dimensions and Ratings (Single Tank) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . H1-6 TABLES Table H1-1. Spraymaster Deaerator Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-4
H1-1
02-02
Spraymaster Deaerators (Single Tank)
Feedwater Systems
The Cleaver-Brooks designed deaerator assures high purity efuent by removing oxygen and other dissolved gases in boiler feed. Thus, it is the answer to long-lasting boiler equipment for industrial and commercial boiler users. Built of corrosion-resistant alloys for lifetime service, the deaerator employs those basic principals of gas removal proven most effective and economical to every boiler owner. Contact your local CleaverBrooks authorized representative for component sizing information.
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Feedwater Systems

Low Profile Design: Low head allows installation in space restricted areas. Two-Stage Deaeration in a Common Vessel: Recycle pumps are not required. Packaged for easy maintenance. ASME Code Design (Section VIII): Assures deaerator vessel quality in materials and fabrication to meet safety requirements. Internal Stainless Steel Vent Condenser: Protects deaerator vessel against corrosive gases while providing a means for removal of corrosive gases from boiler feedwater. Self-Cleaning Water Spray Valve: Angles associated with the water spray valve assembly and actual water spray pattern, maintains deposit-free surfaces. Reduces maintenance requirements. Internal Automatic Check Valves Prevent Back Flooding: Both the water spray valve and steam atomizing valve are in the normally closed position under no ow conditions. Prevents steam back-ow through the water spray valve and water back ow through the steam atomizing valve. Removable Water Spray Inlet Assembly: Flanged assembly allows easy access for maintenance and/ or inspections. Stainless Steel Deaeration Assembly: Ensures a longer life of wetted materials in intimate contact with corrosive liquids and released corrosive gases. Pressurized Tank Reduces Flashing and Minimal Venting: Recovery of exhaust and turbine steam. Saves Btus that would normally be exhausted to atmosphere. Improves plant efciency. Auto Vent Valve Eliminates Dissolved Gases at Start-Up: Atmospheric contamination virtually eliminated for incoming water.
Exceeds ASME Recommendations for Oxygen Level: Guaranteed to remove oxygen concentrations to 0.005 cc/ liter while operating between 5% and 100% capacity. Carbon dioxide concentrations are practically reduced to zero. Capacity Not Affected by Mixed Inlet Temperature: Consistent performance under variable conditions. Integral Level Control Automatically Introduces Cold Water Make-Up to Supplement Condensate Only When Necessary to Meet Boiler Demand: Saves Btus by accepting condensate before cold make-up water. Maintains a minimal water level within the deaerator vessel to prevent damage to the boiler feedpumps, and to maintain system operation. Variety of Tank Sizes to Handle Volume-Swings in Condensate Return: Provides exibility for selecting a tank for specic applications, limiting the loss of hot condensate to drain. Packaged Units for Cost Effective Installation: Complete packages are pre-fabricated in the manufacturing facility to ensure piping alignment and control wiring function. The unit is partially disassembled, and match marked for efcient eld re-assembly. Available in Horizontal and Vertical Configuration: Provides adaptability for installation in space restricted areas. Internal Pump Suction Vortex Breakers: Eliminates the problems of loss in NPSHA and cavitation associated with the creation of vortices within pump suction piping. Vessel Corrosion Protection When Off-Line: Optional epoxy lining
PRODUCT OFFERING
Information in this section applies directly to Cleaver- Brooks packaged Spraymaster Deaerators ranging from 7,000 to 280,000 pounds/hour. For larger capacities contact your local Cleaver-Brooks authorized representative. The product offering for Spraymaster Deaerators is shown in Table H1-1.
H1-3
02-02

Table H1-1. Spraymaster Deaerator Product Offering
STORAGE MODEL NO. CAP. (MIN) SM- 7 7000 230 16 SM-15 15000 300 10 SM- 30 30000 600 10 SM- 45 45000 900 10 SM -70 70000 1400 10 SM-100 100000 2000 10 SM-140 140000 2800 10 SM-200 200000 4000 10 SM- 280 280000 5600 10 NOTE: Model number designation (example, SM-7) is: SM = Spraymaster Deaerator. 7 = 7,000 lbs/hr rating. Optional tank sizes available, contact your local Cleaver-Brooks authorized representative. RATING (LBS/H) TANK CAPACITY
Feedwater Systems
Piping Pump and motor sets are mounted on individual bases before mounting on stand base. Individual suction piping (including strainer, shutoff valve, exible connector) are provided for all feed pumps. Standard Equipment Spraymaster deaerator. Deaerator storage tank. Deaerator water inlet atomizing valve. Deaerator steam inlet atomizing valve. Deaerator manual and automatic vent. Gauge glass.
The Spraymaster Deaerator is a pressurized low-headroom system designed to remove dissolved oxygen in boiler feedwater to 0.005 cc per liter, or less, and eliminate carbon dioxide. A typical deaerator package includes the deaerator tank mounted on a stand of appropriate height along with all operating controls, feed pumps assembled and piped (typically knocked down for shipment and eld assembly). The tank conforms to section VIII of the ASME code. The main deaerating portion is located internally and consists of a water collector and steam atomizing valve. Built into a ange on top of the tank is a spring loaded water spray nozzle which includes an automatic and manual vent valve. Packaged Spraymaster systems offer substantial advantages through, lower cost installation and simplied operation and maintenance. Spraymaster Deaerators arrive on site ready for hookup to your water, steam, and electric power connections. The deaerator stand comes with feed pump/motor set mounted on a solid base. The base is specially reinforced to prevent vibration wear on vital system components. Rugged square structural tubing combines lasting strength with generous working space for inspection or routine servicing. Control Panel The control panel, complete with starters, fuse protection, switches, lights and pre-wired terminal blocks is mounted on the stand assembly. Wiring to feed pump motor and all controls is standard. Deaerator Tank ASME construction - certied to 50 psig. All tanks provided with manhole, individual pump suction tappings and other openings as required. Saddles or legs standard on all sizes. Select from sizes for 5 to 30 minutes of storage to overow.
Steam pressure gauge. Feedwater thermometer. Required tappings. Optional Equipment Steam pressure reducing valve. Three valve bypass and strainer (PRV). Water level controller with make-up valve. Three valve bypass and strainer (MUV). Steam relief valves. High water alarm. Low water alarm. Low water pump cut off. High temperature condensate diffuser tube (over 227 F). Boiler feed pump and motor sets. Recirculation orice or relief valve Suction shutoff valve. Suction strainer. Suction exible tting. Discharge check valve. Discharge shutoff valve. Discharge pressure gauge. Discharge manifold. Overow drainer.
H1-4
02-02
Feedwater Systems
Control panel. Chemical feed quill. Vacuum breaker. Insulation and lagging. Sentinel relief valve. Tank drain valve. Back pressure relief valve. Magnesium anode (not available with lined tanks). Epoxy lining. Stand.

Packaging Fully packaged, factory piped and wired. Half packaged, suitable for eld erection with interconnecting piping and wiring by others.

Dimensions and ratings for Spraymaster Deaerators are shown in Figures H1-1 and H1-2.
TANK SUPPORT LEGS FRONT HEAD "E" STANDARD ON 36" 48" & 54" TANKS FRONT HEAD "E"
SADDLES
"A"
"A"
(4) .875" E HOLES FOR .75" E BOLTS

"C" "D" "H"
(4) 1.125" E HOLES FOR .75" E BOLTS "D" "C"
"F" 6 "F" "G" "B" "G"/2 "B"
TANK CAPACITY (GALLONS) 230 300 450 LEGS A B C D E F G H 47 52.5 29.5 31.25 12 0.875 5.5 7 67.5 74 38 40 14.25 1 6.5 9.75 102 108.5 38 40 16 1 6.5 9.75 86 92.5 44.75 46.75 16 1 6.5 13.75 102 108.5 44.75 46.75 17 1 6.5 13.75 600 700 900 SADDLES 95 101 44.75 57 17 6.125 N/A N/A 102.5 108.5 44.75 57 19.75 6.125 N/A N/A 138 144 50 62 19 6 N/A N/A 156 162 52 67 21.5 7.5 N/A N/A 138 144 62 77.5 22.5 7.75 N/A N/A 128 134 72 88 24.5 8 N/A N/A 145 151 83 98.75 26 7.875 N/A N/A 1000 1400 2000 2800 4000 5600
Figure H1-1. Spraymaster Tank Supports and Saddles, Details and Dimensions
H1-5
02-02

"B"
(NOTE 14)
Feedwater Systems
4 3 5 1 1 1
(9" FOR SM15) .5" NPT. AUTO VENT VALVE "N" NPT. MANUAL VENT VALVE 4 2 DIA. HOLE IN LIFTING LUGS 6 12 "C" 0 "D" "E" "F" "G" "J" "H" "K" "L"
(NOTE 20)
12 2 "P" 13
20
"A" TANK DIA. "R" 8 9 10
21
14
5 "M"
(NOTE 1)
15 18
16 (NOTE 2)
11
17 (NOTE 3) 22
STAND HEIGHT VARIES PER PROJECT REQUIREMENTS
19 (NOTE 4)
"D4" "C3" FRONT VIEW (4) "E5" E HOLES FOR "F6" E BOLTS
"B2" "A1" SIDE VIEW
1. Mounted at dim. "H" (top of tank) on non-packaged units. 2. Tank mounted on non-packaged units. 3. Packaged units only. Mounted on front of stand. 4. Suction piping includes strainer, gate valve and flexible connector. 5. All couplings are 3000# F.S. 6. All flanges are 150# F.F. except as noted. 7. Two water and steam inlets used for SM200 and SM2800. 8. Customer to plug all fittings not being used. 9. Mount tank above pump at elevation necessary for static head including safe allowance for piping friction as approved by pump manufacturer. 10. Deaerator tank is built to ASME Code. 11. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension prints. 12. Add Suffix "P" to Model no. for packaged units (SMP-45). 13. Optional tanks available for 5 minutes storage (except SM7 & SM15), other combinations of capacities as required - contact your local Cleaver-Brooks authorized representative. 14. Dimension "B" will change depending on controls required - contact your local Cleaver-Brooks authorized representative. 15. No interconnecting piping or wiring furnished on non-packaged units unless specified, contact your local Cleaver-Brooks authorized representative for specific piping or wiring furnished on packaged assemblies. 16. Weights shown are without controls or packaging - contact your local Cleaver-Brooks authorized representative for additions. 17. Capacities other than shown as standard available by proper selection of controls - contact your local Cleaver-Brooks authorized representative. 18. Optional tank sizes and ratings available - contact your local Cleaver-Brooks authorized representatives. 19. Lifting lugs are for lifting empty tank only. 20. Manway is standard. Manufacturing may require a larger manway for fabrication. See dimensional diagram for actual size.
RATINGS Capacity (Gal. to Overow) Tank Weight (Dry) (lb) Tank Weight (Flooded) (lb) Tank Size (Dia x Length) 230 1100 3600
36 x 71
SM TANK 300 1750 7850

48 x 96
450 2200 10700
600 2250 11750
700 2500 13450

54 x 136
900 2650 15500

60 x 129
1000 2850 17000

60 x 142
1400 4150 25450

66 x 176
2000 4950 33650

72 x 199
2800 5800 41550
4000 7400 52500
5600 9500 73600
48 x 134 54 x 118
84 x 183 96 x 177 108 x 197
TANK DIMENSIONS A B C D Overall Height Overall Width Front Head Water Inlet - SM 7 Water Inlet - SM 15 Thru 100 Water Inlet - SM140 E F Steam Inlet Level Alarm 58 51 8 16.5 N/A N/A 5.5 32 70 63 10 N/A 20 N/A 40 50 70 63 10 76 69 11 76 69 11 N/A 22 N/A 42 54 82 75 12 82 75 12 88 81 13 94 87 14 108 99 16.5 N/A 22 18 42 56 120 111 18.5 132 123 20
Figure H1-2. Spraymaster Deaerator Dimensions and Ratings (Single Tank) - Sheet 1 of 2 H1-6
02-02
Feedwater Systems
RATINGS G H J K L M P R High Temperature Return Level Control Relief Valve Relief Valve Relief Valve Drain Overow Overow 27 44.5 38.5 50 N/A 10 5 10 55 60 66 N/A N/A 30 10 N/A N/A 3.75 98 84 62 79 70 86 N/A 98 10 3.75
SM TANK 63 90 100 111 122 93 103 135 153 135 14 6.75 6.75 6.5 8 14.5 26.5 27.5 127 114
STAND DIMENSIONS A1 Overall Length B2 C/L to C/L Bolt Holes C3 Overall Width D4 C/L to C/L Bolt Holes E5 Hole Size F6 Anchor Bolt Size 52.5 47.5 49 46 0.75 0.625 74 69 62 59 1 0.875 108.5 102.5 66 63 1 0.875 92.5 87.5 64 61 1 0.875 108.5 102.5 66 63 1 0.875 101 95 71 68 1.125 1 108.5 102.5 71 68 1.125 1 144 138 76 73 1.125 1 162 155 83 80 1.125 1 149 146 86.5 79.5 1.125 1 134 127 102 99 1.125 1 151 144 113 110 1.25 1.125
CONNECTIONS AND TRIM 1 2 3 4 5 6 7 8 9 Relief Valve Size Overow Size Steam Inlet Size Water Inlet Size High Temperature Return Size Drain Size Suction Size Thermometer (.75" NPT) Sample (.5" NPT) 1.5" NPT 1.5" NPT 3" NPT 1.5" NPT 2" NPT 3" NPT 2" NPT 2" NPT 3" NPT 1.5" NPT 3" NPT 3" NPT Contact Your Local Cleaver-Brooks Authorized Representative 3" NPT 3" NPT 3" NPT 3" NPT 4"-150 # FF 4"-150# FF 4"-150# 6"-150# 6"-150# FF FF FF
See Table Below See Table Below 3" NPT 2" NPT 4"-1503 FF
10 Chemical Feed (1" NPT) 11 Recirculation (1" NPT) 12 Gauge Glass Assembly 13 Level Controller 14 Make-Up Valve 15 Pressure Gauge 16 Thermometer 17 Control Panel (Optional) 18 Feed Pump/Motor (Optional) 19 Suction Piping (Optional) 20 Manway, 12 x 16 21 Level Alarms (Optional) 22 Overow Drainer (Optional) RATINGS for SPRAYMASTER MODEL SM-7 SM-15 SM-30 SM-45 SM-70 SM-100 SM-140 SM-200 (NOTE 7) SM-280 (NOTE 7) TANK SIZES 230 300 Thru 700 300 Thru 5600 300 Thru 5600 300 Thru 5600 300 Thru 5600 2000 Thru 5600 2000 Thru 5600 2000 Thru 5600 RATING (lb/hr) 7000 15000 30000 45000 70000 100000 140000 200000 280000 Conn 3 Steam Inlet 3"-150# FF Flg 6"-150# FF Flg 6"-150# FF Flg 6"-150# FF Flg 6"-150# FF Flg 6"-150# FF Flg 8"-150# FF Flg 6"-150# F.F.Flg (2) 8"-150# FF Flg (2) Conn 4 Water Inlet 1" NPT. 1.5"-150# RF Fl. 2"-150# RF Flg 2"-150# RF Flg 2.5"-150# RF Flg 3"-150# RF Flg 4"-150# RF Flg 3"-150# RF Flg (2) 4"-150# RF Flg (2)
Figure H1-2. Spraymaster Deaerator Dimensions and Ratings (Single Tank) - Sheet 2 of 2 H1-7
02-02
Feedwater Systems
Theoretically, it takes approximately 8 ppm of sodium sulte as Na2S03 to scavenge 1 ppm of dissolved O2
RETURN ON INVESTMENT
Payback for a pressurized deaerator verses an atmospheric boiler feed system is based on an additional capital expenditure required divided by the yearly operating cost savings. The differential in yearly operating costs are in the following areas: Flash steam Exhaust steam Blowdown Chemical treatment Makeup water Sewer Intangibles
Makeup Water
Increased make-up water is required because of lost ash steam, lost exhaust steam, and additional surface blowdown. This additional makeup water can be associated to a cost. Makeup water cost should be a combination of the utility charge plus pretreatment equipment consumable costs.
Sewer
Utilities often base a sewer charge on make-up water usage. If it is metered, the additional surface blowoff should only be considered.
Flash Steam
A percentage of the high-pressure condensate returns will ash to steam and be lost in an atmospheric vessel application. This ash steam loss can be converted to an energy loss and associated fuel cost.
Intangibles
It is difcult to calculate a cost savings for items such as reduced ue gas emission due to higher plant efciencies of steam recovery and the prevention of boiler thermal shock.
Exhaust Steam
Exhaust steam cannot be recovered in an atmospheric vessel application. This exhaust steam loss can be converted to energy loss and associated fuel cost. An example would be steam turbine exhaust.
Surface Blowdown
Increased makeup water is required because of lost ash and exhaust steam. This increase in makeup water requires an increase of surface blowdown. This is directly related to cycles of concentration in the boiler. The additional blowdown loss can be converted to an energy loss and associated fuel cost. The additional surface blowdown may also result in an increase in capital expenditure for a larger blowdown heat recovery system.
Chemical Treatment
Dissolved oxygen content in an atmospheric boiler feedwater system relates to water temperature. Lowering the dissolved oxygen content below what is naturally present, based on mixed water temperature at atmospheric pressure, requires the addition of a chemical treatment program. The most common oxygen scavenger used is sodium sulte. Sodium sulte reacts with dissolved oxygen as follows: 2Na2SO3 + O2 2Na2SO4
H1-8
02-02
Feedwater Systems
The following sample specications are provided by Cleaver-Brooks to assist you in specifying your customers specic needs and application. 1.0 Deaerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H1-9 2.0 Make Up Valve and Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H1-10 3.0 Steam Pressure Reducing Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H1-11 4.0 Boiler Feedwater Pump and Motor Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H1-11 5.0 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H1-12 1.0 Deaerator Provide one Cleaver-Brooks Model _________ spray type, pressurized, horizontal deaerator rated at _____ pounds per hour. The system shall be of the single tank design and shall guarantee oxygen removal to not more than 0.005 ccs/liter in the efuent throughout all load conditions between 5 and 100 percent. Two-compartment designs are not acceptable. The deaerator shall be designed for operation at 5 psig, but shall be suitable for use from 2 to 15 psig. Atmospheric operating designs are not acceptable. Feedwater and condensate shall be admitted to the deaerator through a single spring-loaded, self-cleaning, adjustable stainless steel spray valve, which shall provide proper internal vent condensing and water distribution at any load between 5 and 100 percent of rated capacity. The water temperature in the primary heating and vent concentrating section is to be raised within 2 or 3 F of steam temperature and most of the gases released. The water is then to be collected in a conical water collector. From there, it is to ow to an atomizing valve where high velocity steam strikes it, breaks it down into a ne mist, and heats it to a full steam saturation temperature. The mixture is to strike a deecting bafe, which separates water and steam. Hot, gas-free water is to then drop to the storage compartment to complete the cycle. The steam and non-condensables are to ow upward, through the primary heating spray, into the internal vent concentrating section, where they contact the cold inuent water. Here, the steam is to be condensed to continue the cycle. Released gasses are discharged to atmosphere through the vent outlet. All internal surfaces, which come in contact with un-deaerated water, shall be constructed of Type 316 stainless steel. Automatic vent valve shall be thermostatically controlled to provide a fast means of venting when a sudden buildup of gases occurs, such as seen at start up. The manual vent valve shall have an orice for continuous minimum venting. Venting rate shall not exceed 0.1 of 1% of the rated deaerator capacity at 5 psig. The deaerated water storage tank shall have _____ minutes of storage and have a capacity of _____ gallons measured to overow. The tank shall be _____ diameter x ____ long. An 11" x 15" elliptical manhole shall be provided for access. All nozzles 3" and under shall be 3000 lbs forged steel couplings and over 3" shall be 150 lbs at face anges. Heads to be ASME torispherical type constructed of ASTM A516 GR 70 carbon steel with a minimum thickness of 0.25 inches. Shell plate to be fabricated of ASTM A36 carbon steel with a minimum thickness of 0.25 inches. The tank shall be designed in accordance with ASME, Section VIII of the Pressure Vessel Code for 50 psig at 650 F and stamped accordingly. Certication shall be required. Joint efciencies to be 70% circumferential per Table UW-12, which does not require stress relieving or nondestructive examination. The deaerator loads shall be as specied in the table below. Low temperature returns are dened as condensate with a temperature below that of the deaerator operating temperature. High temperature returns are dened as condensate with a temperature above that of the deaerator operating temperature. 1.1 Optional The tank shall be factory-insulated and lagged with blanket insulation, pins, clips, and a durable steel jacket. Block-type insulation is not acceptable. The blanket insulation is to be berglass, 2" thick, 1 lb/cu-ft, and have a rating of R3.85. Pins are to be located on 18" centers and holding clips attached. The steel jacket or lagging shall have a shell thickness of 22 gauge (0.299") minimum and head thickness of 12 gauge (0.1046") minimum. Load Specications
LOAD Make up Pumped Low Temp Returns High Temp Returns Not To Exceed 30% PERCENTAGE LBS/HR GPM TEMP PRESSURE 25 psig Minimum 10 psig Minimum
H1-9
02-02

1.2 Optional
Feedwater Systems
The tank shall be factory-lined with a high quality baked epoxy lining. The lining is to be applied to a sandblasted (SSPC-SP-5) white metal surface. Spray-apply 4 to 6 coats with each dry coat being approximately 1.5 mils dry for a total thickness of 6 mils dry minimum. Baking schedule for intermediate coats to be 10 to 20 minutes at 250 to 300 F and nal baking to be 1-1/2 hours at 350 to 400 F. Lining to be Holliday spark tested using low voltage and a wet sponge to ensure uniform coating free of pin holes. Magnesium anodes shall not be acceptable in this application. The lining is to meet requirements of FDA and MID of the USDA. The lining is to be suitable for temperatures up to 250 F. 1.3 Optional The magnesium or sacricial anode shall provide cathodic protection against galvanic corrosion. This rod shall be 1-5/16" diameter with a 1/4" steel core to assure a good electrical contact and added strength. The design shall have a small weep hole to signal it has been consumed. Linings shall not be acceptable in this application. 1.4 Optional The high temperature diffuser or sparge tube shall be located beneath the normal tank water level. The tube shall be constructed of 2 inch pipe. This tube shall provide even distribution and blending of high-temperature condensate returns. 1.5 Optional The chemical feed quill shall be located beneath the normal tank water level. The quill material shall be constructed of stainless steel. The tube shall provide even distribution and blending of chemical. 1.6 Optional The basic deaerator shall be equipped with the following trim and accessories. Piping on packaged units shall comply with ASME Power Piping Code B31.1. 2.0 Make Up Valve and Controller 2.1 Option - Mechanical ____ " inlet water regulating lever valve with ______ body and _______ connections. The valve Cv shall not exceed ______ and be rated for _____ gpm at ______ psig inlet pressure. The pressure drop across the valve shall not exceed a delta-P of 10 psig. This valve shall be suitable for temperatures up to 300 F. The valve manufacture shall be _______, Model _____ . This valve shall be mechanically controlled by an external oat cage with cast iron body and 8" stainless steel oat. The oat cage manufacturer shall be __________, Model ______. 2.2 Option - Electronic ______" inlet water motorized regulating valve with steel body and threaded NPT connections. Motor shall be 110V bi-directional, with a permanently lubricated gear train, and be directly coupled to the valve stem. The valve Cv shall not exceed _____ and be rated for_____ gpm at ______ psi inlet pressure. Valve shall not exceed a delta-P of 10 psig. This valve shall have teon seats and be suitable for temperatures up to 300 F. The motorized valve manufacturer shall be __________. This valve shall be electronically controlled by a solid state control with internally mounted capacitance probes. The electronic solid state control shall be able to set desired level point and acceptable deviation. The electronic solid state control shall include a selection for automatic and manual operating mode. The internals shall include two additional probes for high and low water alarm. The controller manufacturer shall be Cleaver-Brooks Model TW82. A solenoid valve and oat switch are not acceptable. (Available only in the U.S.) 2.3 Option - Pneumatic _______" inlet water diaphragm actuated regulating valve with cast iron body and _____ connections. The valve shall be globe type with proportional control and a spring opposed diaphragm actuator arranged for 3 - 15 psig operating signal. The valve shall be normally open on loss of air. The valve Cv shall not exceed _____ and be rated for ______ gpm at ______ psig inlet pressure. Valve shall not exceed a delta-P of 10 psig. This valve shall have stainless steel trim with TFE packing and be suitable for temperature up to 410 F. The diaphragm actuated valve manufacturer shall be ___________, Model _____. This valve shall be pneumatically controlled by an external proportional type sensor. The sensor shall be a 14" displacer that produces a pneumatic output signal. The controller manufacturer shall be _________, Model ______. A lter regulator is to be provided to reduce 50 psig instrument air supply to 3 - 15 psig for proper operation.
H1-10
02-02
Feedwater Systems
2.4 Optional
The make up valve shall include a ANSI Class 125 lb three-valve bypass with inlet Y-type cast iron strainer. Strainer screen to be removable and of stainless steel construction. 3.0 Steam Pressure Reducing Station 3.1 Option - Mechanical _______" steam pressure reducing valve with cast iron body and _____ connections. The valve shall be a self-contained unit capable of reducing ____ psig saturated steam to the operating pressure of the deaerator at a ow rate of _____ lbs/hr. The valve shall be 250 lb class with stainless steel trim and an adjustable pilot. The valve manufacturer shall be _____, Model _____. 3.2 Option - Pneumatic _______" diaphragm actuated steam pressure reducing valve with cast iron body and _______ connections. The valve shall be globe type with proportional control and a spring opposed diaphragm actuator arranged for ____ psig operating signal. The valve shall be normally closed on loss of air. The valve shall be capable of reducing _____ psig saturated steam to the operating pressure of the deaerator at a ow rate of ____ lbs/hr. This valve shall be 250 lb class and have stainless steel trim. The diaphragm actuated valve manufacturer shall be ________, Model _______. This valve shall be pneumatically controlled by an external transmitter. The transmitter set pressure shall be adjustable. The transmitter manufacturer shall be _________________, Model _________. 3.3 Optional The steam pressure reducing valve shall include a three valve bypass with Y-type cast iron strainer. Strainer screen to be removable and of stainless steel construction. 3.4 Optional Quantity ______, _______ " relief valves sized to relieve full capacity of the pressure reducing valve in the event of its failure. Valves to meet Paragraph UG-125 of ASME Unred Pressure Vessel Code, Section VIII. Valve body to be of bronze construction. Relieving set pressure to be 50 psig. Relief valve manufacturer to be _______________________, Model____________. 3.5 Optional High level alarm switch. This shall be an externally mounted oat type switch. The switch shall make contact on rise and break on fall. The oat cage construction shall be cast iron. (Not required with electronic make up controller.) 3.6 Optional Low level alarm switch. This shall be an externally mounted oat type switch. The switch shall make contact on fall and break on rise. The oat cage construction shall be cast iron. (Not required with electronic make up controller.) 3.7 Optional ________ " overow drainer sized to relieve full capacity at the operating pressure of the deaerator. The overow drainer shall be a oat type trap. The construction is to be a steel housing with stainless steel oat ball. The overow drainer manufacturer shall be _______, Model _______. 3.8 Optional Suction piping for pumps shall consist of a gate valve, cast iron Y-type strainer with replaceable stainless steel screen and exible connector or hose. This piping assembly shall be 125 lb class construction. The vortex breaker shall be located in the tank nozzle. Manifold suction lines are not acceptable. 4.0 Boiler Feedwater Pump And Motor Set 4.1 Option - Intermittent Quantity________, turbine type boiler feedwater pump and motor set. Centrifugal type pumps are not acceptable in this application. Pump to be rated for _____ gpm at _____ feet TDH with ______ feet NPSH required. Pump to be ______ materials of construction and have ______ seals for a maximum water temperature of 250 F. Pump impeller to be hydraulically balanced. The pump shall be mounted on a steel baseplate and exibly coupled with an OSHA type coupling guard to a ____ hp, _____ phase,
H1-11
02-02
Feedwater Systems
______ Hz, ______ Volt, _______ rpm, ________enclosure motor. Motor to be non-overloading at the rated condition without using any portion of the service factor. Pump and motor set to be factory aligned prior to shipment. Pump manufacturer to be______________, Model ________, size ____ " x _______". 4.2 Option - Continuous Quantity ______, centrifugal type boiler feedwater pump and motor set. Turbine type pumps are not acceptable in this application. Pump to be rated for _____ gpm at ______ feet TDH with ____ feet NPSH required. Pump to be _______ materials of construction as dened by the Hydraulic Institute and have _______ seals for a maximum water temperature of 250 F. Pump impeller to be hydraulically balanced. The pump shall be mounted on a steel baseplate and exibly coupled with an OSHA type coupling guard to a _______ hp, ______ phase, _________ Hz, _________ Volt, _____ rpm, _______ enclosed motor. Motor to be non-overloading at the rated condition without using any portion of the service factor. Pump and motor set to be factory aligned prior to shipment. Pump manufacturer to be _________, Model _______, size _____ " x _______ ". A stainless steel recirculation orice is to be supplied with the pump and shipped loose for eld installation to provide minimum bypass ow. 4.3 Optional The stand shall elevate the deaerator tank to provide the net positive suction head required by the pump at the rated condition to prevent cavitation plus a 1-1/2 foot safety factor. The stand shall be constructed of heavy square steel tubing for the legs and 1/4" steel plate covering the oor. 5.0 Control Panel 5.1 Optional - Base Control panel shall be in a NEMA 1 enclosure and wired to the National Electric Code. The wire shall be black number coded. The assembly is to contain individual motor starters with 120 Volt holding coil and fuse protection. Individual green oil-tight pump run lights shall be provided. All switches and lights to have nameplate identication. The assembled panel shall be given a factory continuity test prior to shipment. 5.2 Optional - Electric Components Audible and visual high and low water alarm function shall be provided by a bell or horn with silence switch and individual red oiltight lights. Control circuit transformer to supply 110-120 Volts, single-phase power supply. The transformer shall be mounted, wired and fused. Auxiliary contacts shall be furnished for chemical feed pump initiation. Contacts shall be normally open. 5.3 Standard The deaerator shall have a gauge glass assembly that covers the entire tank diameter. The gauge glass shall be quartz, 0.625 inch diameter by 24 inch maximum length. Each length of glass shall be furnished with a bronze gauge cock set and protector rods. The deaerator shall be supplied with a pressure gauge that has a 4-1/2 inch dial with a 0-60 psig range and a thermometer with a 50 to 300 F range. Packaged units are required to have both gauges bracket-mounted at eye level. The deaerator is to be hand cleaned with a solvent to SSPC- SP-1 standards prior to painting. Prime coated to not less than 1 mil thick and nish coated with an enamel paint to not less than 1 mil thick prior to shipment. Unit is to be knocked down for shipment. Piping is to be matched marked. Three, bound, Operating and Maintenance manuals to be provided. Warranty period to be twelve months after start-up or eighteen months after shipment, whichever comes rst.
H1-12
02-02
Section H2
SPRAYMASTER DEAERATORS (Duo-Tank)
CONTENTS FEATURES AND BENEFITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-3 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-3 DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-4 SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-8 ILLUSTRATIONS Figure H2-1. Spraymaster Duo-Tank Supports and Saddles, Details and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-4 Figure H2-2. Spraymaster Deaerator (Duo-Tank) Dimensions and Ratings - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . .H2-5 TABLES Table H2-1. Spraymaster Deaerator Duo-Tank Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-3
H2-1
02-02
Spraymaster Deaerators (Duo Tank)
Feedwater Systems
The Duo Tank product combines a surge tank with a Spraymaster deaerator into a single combined vessel, providing a complete engineered and packaged system. The Cleaver-Brooks designed deaerator assures high purity efuent by removing oxygen and other dissolved gases in boiler feed. Thus, it is the answer to long-lasting boiler equipment for industrial and commercial boiler users. Built of corrosion- resistant alloys for lifetime service, the deaerator employs those basic principles of gas removal proven most effective and economical to every boiler owner. Contact your local Cleaver-Brooks authorized representative for component sizing information.
H2-2
02-02
Feedwater Systems

The Duo Tank product combines a surge tank with a Spraymaster deaerator in to a single combined vessel, providing the following features and benets in addition to the benets of the deaerator and surge tank independently. Surge Section Includes a Protective Lining: As a deterrent to corrosion of vessel steel due to dissolved gases, the vessel is lined with an epoxy coating. Double Inner Head Separates the Deaerator Pressure Vessel From Surge Tank: Ensures the deaerator and surge tank are two separate vessels while structurally attached for space considerations. This also limits heat transfer from the deaerator pressure vessel to the surge atmospheric vessel, preventing energy loss due to surge tank water boiling. Vented and Insulated Gap Between the Deaerator and Surge Tank: Insulation is placed between the double inner head to further limit heat transfer from the deaerator pressure vessel to the surge atmospheric vessel. A vent is placed between the double inner head to allow moisture evaporation eliminating corrosion potential.
Low Profile Design: Low head room allows for installation in space restricted areas. Two-Stage Deaeration in a Common Vessel: Recycle pumps are not required. Packaged for easy maintenance. Packaged Units for Cost Effective Installation: Complete packages are pre-fabricated in the Cleaver-Brooks manufacturing facility to ensure piping alignment and control wiring function. The unit is disassembled, match marked for efcient eld re-assembly.
PRODUCT OFFERING
Information in this section applies directly to Cleaver-Brooks packaged Spraymaster Deaerators in duo-tank arrangement ranging from 7000 to 280,000 lbs/hr. The product offering for Duo-Tank packaging is a combination of the product offering for the Spraymaster Deaerator and the Surge Tank. The combined package product offering for DuoTank products is shown Table H2-1.
Table H2-1. Spraymaster Deaerator Duo-Tank Offering

MODEL NO. SD-7 SD-15 SD-30 SD-45 SD-70 SD-100 SD-40 SD-200 SD-280 Rating (lbs/hr) 7000 15000 30000 45000 70000 100000 140000 200000 280000 Deaerator Gallons 230 300 600 900 1400 2000 2800 4000 5600 to Overow Deaerator Storage 16 10 10 10 10 10 10 10 10 Capacity (min) Surge Gallons to 160 300 600 900 1400 2000 2800 4000 5600 Flooded Surge Storage 11.5 10 10 10 10 10 10 10 10 Capacity (Min) NOTE: Model designation (example SD-7) is: S = Spraymaster Deaerator, D = Duo-tank, 7 = 7,000 lbs/h rating, combined deaerator and surge tank package.
H2-3
02-02
Feedwater Systems

Dimensions and ratings are shown in Figures H2-1 and H2-2.
TANK CAPACITY (GALLONS) 230 AA AB AC AD AE AF AG AH AJ AK AL AM AN AP AR AS AT 81-1/2 875-1/2 31-3/4 29-1/2 6-1/8 2 4 1-1/8 12-1/2 7/8 3/4 N/A N/A N/A N/A N/A N/A 300 108-1/2 114-1/2 40-1/4 38 7-3/8 3 6 1-1/4 16-1/2 7/8 3/4 N/A N/A N/A N/A N/A N/A 600 N/A N/A N/A N/A N/A N/A N/A M/A N/A N/A N/A 148 154 51-1/2 44-3/4 3-3/8 16-1/2 900 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 169-1/2 175-1/2 57 44-3/4 6-18 18-3/4 1400 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 231-1/2 237-1/2 62 50 6 20 2000 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 270 276 67 52 7-1/2 25 2800 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 257 263 77-1/2 62 7-3/4 22-1/2 4000 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 245-1/2 251-1/2 88 72 8 31-5/8 5600 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 281 287 98-3/4 83 7-7/8 34
Figure H2-1. Spraymaster Duo-Tank Supports and Saddles, Details and Dimensions
H2-4
02-02
Feedwater Systems
NOTES: 1. Mounted at dim. "H" (top of tank) on non-packaged units. 2. Tank mounted on non-packaged unit. 3. Packaged units only. Mounted on left end, right side of stand on 48" dia. 450 gal, 66" dia. 1400 gal & 72" dia. 2000 gal units as shown. 4. Suction piping includes strainer, gate valve and flexible connector. 5. Discharge piping includes gate valve, check valve, control valve, by-pass orifice, and pressure gauge. 6. All couplings are 3000# F.S. 7. All flanges are 150# F.F. except as noted. 8. Two water and steam inlets used, one shown. 9. Customer to plug all fittings not being used. 10. Mount tank above pump at elevation necessary for static head including safe allowance for piping friction as approved by pump manufacturer. 11. Deaerator section of tank is built to ASME Code. 12. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension prints. 13. Add suffix "P" to Model no. for packaged units (SDP-45). 14. Optional tanks available for 5 minutes storage (except SDP-7 & SDP-15), other combinations of capacities as required - contact your local Cleaver-Brooks authorized representative. 15. Using Warren #377 float cage (except SM7 which uses MCD-M #51), dimension "B" may change with other controls - contact your local Cleaver-Brooks authorized representative. 16. No interconnecting piping or wiring furnished on non-packaged units unless specified, contact your local Cleaver-Brooks authorized representative for specific piping or wiring furnished on packaged assemblies. 17. Weights shown are without controls or packaging - contact your local Cleaver-Brooks authorized representative for additions. 18. Capacities other than shown as standard available by proper selection of controls - contact your local Cleaver-Brooks authorized representative. 19. Optional tank sizes and ratings available - contact your local Cleaver-Brooks authorized representative. 20. Lifting lugs are for lifting empty tank only. 21. Raw water make-up should first pass through a water softener if hardness is present. 22. All dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimensional prints.
Figure H2-2. Spraymaster Deaerator (Duo-Tank) Dimensions and Ratings - Sheet 1 of 3
H2-5
02-02
Feedwater Systems
STORAGE TANK DETAIL AND DIMENSIONS SPRAYMASTER MODEL NO. Ratings (lb/h) Tank Weight (lbs) Tank Weight Flooded (lbs) Tank Cap-Deaerator (Gal to Overflow) Storage Cap (Min) Tank Cap-Rec Section (Gal to Flooded) Storage Cap (Min) Tank Size (Dia x Length) A B C D E F G H J K L M N P R S T W X Y z KK LL MM NN PP RR SS TT WW XX YY ZZ 12 10 16 12-1/2 19 16 69 85 2 1/2 3 10 68 74 72 82 75 95 115 2-1/2 3/4 6 C L 38 64 60 90 90 109 52 N/A N/A 56 31 47 90 50 65 Overall Height Overall Width SM-7D 7000 1530 5165 230 16 160 11.5 36 x 106-1/2 58 51 8-1/2 28-1/2 43 48-1/2 11 21 SM-15D 15000 2500 10835 300 10 300 10 48 x 141-1/2 66-1/2 62 10-1/2 72-1/2 54-1/2 34-1/2 16 26 SM-30D 30000 3650 17720 600 10 600 10 54 x 181 74-1/2 68 11-1/2 92-1/2 74 54 31 45 SM-45D 45000 4500 24440 900 10 900 10 60 x 207 80-1/2 75 12-1/2 101 83 63 42 54 SM-70D 70000 6770 38450 1400 10 1400 10 66 x 270-1/2 88 80 13-1/2 146 124 104 68 80 SM-100D 100000 8810 52310 2000 10 2000 10 72 x 302 96-1/2 87 14-1/2 164 142 122 68 104 SM-140D 140000 10760 68045 2800 10 2800 10 84 x 302-1/4 109 99 16-1/2 146 124 104 73 86 SM-200D 200000 12975 80290 4000 10 4000 10 96 x 308-3/4 120-1/2 111 18-5/8 4 136 24 116 44 60 82 96 8 SM-280D 280000 18735 106475 5600 10 5600 10 108 x 349 133 123 20-3/4 4 153 24 133 48 109 59 98 8
Contact Your Local Cleaver-Brooks Authorized Representative Contact Your Local Cleaver-Brooks Authorized Representative Contact Your Local Cleaver-Brooks Authorized Representative Contact Your Local Cleaver-Brooks Authorized Representative 102 32 74 144 35 115 164 36 132 147 28 126 130 35 106 144 28 123
Consult Your Local Cleaver-Brooks Authorized Representative 27 126 27 169 32 224 27 205 36 160 27 186
Consult Your Local Cleaver-Brooks Authorized Representative 120 155 2-1/2 3/4 6 4 112 120 126 144 132 145 171 2-1/2 3/4 10 7 127 133 138 160 153 198 230 2-1/2 1 6 6-1/2 180 200 188 218 208 192 266 2-1/2 1-1/2 6 8 197 227 214 243 267 177 258 2-1/2 2 8 14-1/2 173 205 183 232 249 196 258 2-3/4 2 @ 1-1/2 12 26-1/2 175 201-1/2 190 213 206 196 249 2-3/4 2@2 12 27-1/2 191 211 229 249 279
94 101 95 109 108
Consult Your Local Cleaver-Brooks Authorized Representative 22 19-1/2 24 22 27 25 31 30 36 34-1/2 40 40
H2-6
02-02
Feedwater Systems
STAND BASE DIMENSIONS TANK CAPACITY (GAL) A1 B2 C3 D4 E5 F6 Outside Length C to C Anchor Bolt Holes L L Outside Width C to C Anchor Bolt Holes L L 230 87 82 49 46 3/4 5/6 300 115 110 62 59 1 7/8 600 154 148 66 63 1 7/8 900 175-1/2 169-1/2 71 68 1 7/8 1400 237-1/2 230-1/2 76 73 1-1/8 1 2000 276 269 81 78 1-1/8 1 2800 268 265 86-1/2 79-1/2 1-1/8 1 4000 144 137 102 99 1-1/8 1 5600 297 294 112 101 1-1/8 1
TANK CONNECTION SIZES 1 2 3 4 5 6 7 8 9 10 11 12 13 Relief-Valve(s) Overflow (Dea) Pump Suction (Optional) Steam Inlet (Dea Flg) High Temp Return Water Inlet (150# RF Flg) Drain (Dea) Overflow (Rec) Pump Suction (Optional) Vent (Rec) Low Pressure Return (Rec) Cold Water Inlet (Rec) Drain (Rec) 3 NPT 2 NPT 2 NPT 1-1/4 NPT 3 NPT 2 NPT 2 NPT 2 NPT 3 1-1/4 NPT 1 NPT 1-1/4 NPT 2 NPT 6 1-1/2 NPT 1-1/2 2 NPT 2 NPT 6 2 NPT 2 2 NPT 2 NPT 1-1/4 NPT 3 NPT Contact Your Local Cleaver-brooks Authorized Represaentative 3 NPT 3 NPT 4 FLG 4 FLG 4 FLG 6 FLG 6 FLG
Contact Your Local Cleaver-Brooks Authorized Representative 6 2 NPT 2 2 NPT 3 NPT 6 3 NPT 2-1/2 2 NPT 3 NP 6 3 NPT 3 2 NPT 3 NPT 8 3 NPT 4 2 NPT 4 NPT 2@6 2 @ 3 NPT 2@3 2 NPT 4 NPT 2@8 2 @ 3 NPT 2@4 2 NPT 6 NPT
Contact Your Local Cleaver-Brooks Authorized Representative 3 NPT 3 NPT 2 NPT 2 NPT 3 NPT 3 NPT 2 NPT 2 NPT ITEM LIST 4 NPT 3 NPT 2 NPT 2 NPT 4 NPT 3 NPT 2 NPT 2 NPT 4 NPT 4NPT 2 NPT 2 NPT 4 NPT 4 NPT 2 NPT 2 NPT 6 NPT 6 NPT 3 NPT 2 NPT
14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Suction Pump, (optional) (For each pump) (Note 4) Pump/Motor, (optional) Control Panel, (optional) Manway 11 x 15 Overflow Drainer, (optional) Make-Up Valve, (optional) Gauge Glass Assembly Pressure Gauge Thermometer (3/4 NPT) Level Alarms (1 NPT), (optional) Level Control (1-1/2 NPT), (optional) Sample Connection (1/2 NPT) Recirculation Connection (1 NPT), (optional) (For each pump) High Temp Return Connection-Rec (3 NPT) Diffuser Tube (2-1/2 NPT, (optional) Breather Connection (1/2 NPT -Do Not Plug) Discharge Piping, (optional) (For each pump) (NOTE 5)
Sizes listed for items 22 thru 29 are for tank connections only.
H2-7
02-02
Feedwater Systems
The following sample specications are provided by Cleaver-Brooks to assist you in specifying your customers specic needs and application. 1.0 Deaerator and Surge Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-8 2.0 Make Up Valve And Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-10 3.0 Steam Pressure Reducing Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-10 4.0 Boiler Feedwater Pump And Motor Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-11 5.0 Make Up Valve and Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-11 6.0 Transfer Pump and Motor Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-12 7.0 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-13 1.0 Deaerator and Surge Tank Cleaver-Brooks Model _________ spray type, pressurized, horizontal deaerator is rated at _____ pounds per hour. The system shall be guarantee oxygen removal to not more than 0.005 CCS/liter in the efuent throughout all load conditions between 5 and 100 percent. The deaerator shall be designed for operation at 5 psig, but shall be suitable for use from 2 to 15 psig. The surge tank shall receive returning condensate and supplement make up water to maintain the desired operating level. Condensate and make up water mix into a blended temperature, as determined by the percentage of each. The surge tank shall be vented to atmosphere. The collected water is then transferred to the deaerator. The collected water shall be admitted to the deaerator through a single spring-loaded, self-cleaning, adjustable stainless steel spray valve, which shall provide proper internal vent condensing and water distribution at any load between 5 and 100 percent of rated capacity. The water temperature in the primary heating and vent concentrating section is to be raised within 2 or 3 F of steam temperature and most of the gases released. The water is then to be collected in a conical water collector. From there, it is to ow to an atomizing valve where high velocity steam strikes it, breaks it down into a ne mist, and heats it to a full steam saturation temperature. The mixture is to strike a deecting bafe, which separates water and steam. Hot, gas-free water is to then drop to the storage compartment to complete the cycle. The steam and non-condensables are to ow upward, through the primary heating spray, into the internal vent concentrating section, where they contact the cold inuent water. Here, the steam is to be condensed to continue the cycle. Released gasses are discharged to atmosphere through the vent outlet. All internal surfaces, which come in contact with un-deaerated water, shall be constructed of Type 316 stainless steel. Automatic vent valve shall be thermostatically controlled to provide a fast means of venting when a sudden buildup of gases occurs, such as seen at start up. The manual vent valve shall have an orice for continuous minimum venting. Venting rate shall not exceed 0.1 of 1% of the rated deaerator capacity at 5 psig. The duo tank shall be divided into two separate sections. The deaerator water storage and condensate surge section shall be divided by a double inner head. The dead air space between the two inner heads shall be packed with a berglass insulation and have a breather and drain connection. The duo tank shall be _____ " diameter and _____ " long. The deaerated water storage tank section shall have _____ minutes of storage and have a capacity of _______ gallons measured to overow. An 11" x 15" elliptical manhole shall be provided for access. All nozzles 3" and under shall be 3000 lbs forged steel couplings and over 3" shall be 150 lbs at face anges. Heads to be ASME torispherical type constructed of ASTM A516 GR 70 carbon steel with a minimum thickness of 0.25 inches. Shell plate to be fabricated of ASTM A36 carbon steel with a minimum thickness of 0.25 inches. The tank shall be designed in accordance with ASME, Section VIII of the Pressure Vessel Code for 50 psig at 650 delta-F and stamped accordingly. Certication shall be required. Joint efciencies to be 70% circumferential per Table UW-12, which does not require stress relieving or nondestructive examination. The surge tank section shall have __________ minutes of storage and have a capacity of _______ gallons ooded. An 11" x 15" elliptical manhole shall be provided for access. All nozzles shall be 3000 lbs forged steel couplings. Heads to be ASME torispherical type (at heads are not acceptable) constructed of ASTM A516 GR 70 carbon steel with a minimum thickness of 0.25 inches. Shell plate to be fabricated of ASTM A36 carbon steel with a minimum thickness of 0.25 inches. The loads shall be as specied in the table below. Low temperature returns are dened as condensate with a temperature below that of the deaerator operating temperature. High temperature returns are dened as condensate with a temperature above that of the deaerator operating temperature. H2-8
02-02
Feedwater Systems

Load Specications
LOAD Make up to Deaerator Make up to Surge Tank Pumped Low Temp Returns Gravity Feed Low Temp Returns High Temp Returns
PERCENTAGE
LBS/HR GPM GPM
TEMP
PRESSURE 25 psig Min.
1.1 Optional The surge tank section shall be designed in accordance with Section VIII of the ASME Pressure Vessel Code for ________ psig, and stamped accordingly. Certication shall be required. Joint efciencies to be 70% circumferential per Table UW-12, which does not require stress relieving or nondestructive examination. 1.2 Optional The duo tank shall be factory-insulated and lagged with blanket insulation, pins, clips, and a durable steel jacket. Block-type insulation is not acceptable. The blanket insulation is to be berglass, 2" thick, 1 lb/cu-ft, and have a rating of R3.85. Pins are to be located on 18" centers and holding clips attached. The steel jacket or lagging shall have a shell thickness of 22 gauge (0.299") minimum and head thickness of 12 gauge (0.1046") minimum. 1.3 Standard The surge tank section shall be factory-lined with a high quality baked epoxy lining. The lining is to be applied to a sandblasted (SSPC-SP-5) white metal surface. Spray-apply 4 to 6 coats, with each dry coat being approximately 1.5 mils dry, for a total thickness of 6 mils dry minimum. Lining to be Holliday spark tested using low voltage and a wet sponge to ensure uniform coating free of pin holes. Magnesium anodes shall not be acceptable in this application. The lining is to be suitable for temperatures up to 212 F. 1.4 Optional The deaerated water storage tank section shall be factory-lined with a high quality baked-on epoxy lining. The lining is to be applied to a sandblasted (SSPC-SP-5) white metal surface. Spray-apply 4 to 6 coats with each dry coat being approximately 1.5 mils dry for a total thickness of 6 mils dry minimum. Baking schedule for intermediate coats to be 10 to 20 minutes at 250 to 300 F and nal baking to be 1-1/2 hours at 350 to 400 F. Lining to be Holliday spark tested using low voltage and a wet sponge to ensure uniform coating free of pin holes. Magnesium anodes shall not be acceptable in this application. The lining is to meet requirements of FDA and MID of the USDA. The lining is to be suitable for temperatures up to 250 F. 1.5 Optional The magnesium or sacricial anode shall provide cathodic protection against galvanic corrosion. This rod shall be 1-5/16" diameter with a 1/4" steel core to assure a good electrical contact and added strength. The design shall have a small weep hole to signal it has been consumed. Linings shall not be acceptable in this application. 1.6 Optional The high temperature diffuser or sparge tube shall be located beneath the normal tank water level. The tube shall be constructed of 2 inch pipe. This tube shall provide even distribution and blending of high-temperature condensate returns. 1.7 Optional The chemical feed quill shall be located beneath the normal tank water level. The quill material shall be constructed of stainless steel. The tube shall provide even distribution and blending of chemical. 1.8 Optional The basic deaerator section shall be equipped with the following trim and accessories. Piping on packaged units shall comply with ASME Power Piping Code B31.1.
H2-9
02-02

2.0 Make Up Valve And Controller 2.1 Option - Mechanical
Feedwater Systems
____ " inlet water regulating lever valve with ______ body and _______ connections. The valve Cv shall not exceed ______ and be rated for _____ gpm at ______ psi inlet pressure. The pressure drop across the valve shall not exceed a delta-P of 10 psig. This valve shall be suitable for temperatures up to 300 F. The valve manufacture shall be ___________, Model _____ . This valve shall be mechanically controlled by an external oat cage with cast iron body and 8" stainless steel oat. The oat cage manufacturer shall be ___________________, Model ______. 2.2 Option - Electronic ______" inlet water motorized regulating valve with steel body and threaded NPT connections. Motor shall be 110V bi-directional type with a permanently lubricated gear train, and be directly coupled to the valve stem. The valve Cv shall not exceed _____ and be rated for_____ gpm at ______ psig inlet pressure. Valve shall not exceed a delta-P of 10 psig. This valve shall have teon seats and be suitable for temperatures up to 300 F. The motorized valve manufacturer shall be ____. This valve shall be electronically controlled by a solid state control with internally mounted capacitance probes. The electronic solid state control shall be able to set desired level point and acceptable deviation. The electronic solid state control shall include a selection for automatic and manual operating mode. The internals shall include two additional probes for high and low water alarm. The controller manufacturer shall be Cleaver-Brooks Model TW82. A solenoid valve and oat switch are not acceptable. (Available only in the U.S.) 2.3 Option - Pneumatic _______" inlet water diaphragm actuated regulating valve with cast iron body and _____ connections. The valve shall be globe type with proportional control and a spring opposed diaphragm actuator arranged for 3 - 15 psig operating signal. The valve shall be normally open on loss of air. The valve Cv shall not exceed _____ and be rated for ______ gpm at ______ psig inlet pressure. Valve shall not exceed a delta-P of 10 psig.This valve shall have stainless steel trim with TFE packing and be suitable for temperature up to 410 F. The diaphragm actuated valve manufacturer shall be ___________, Model _____. This valve shall be pneumatically controlled by an external proportional type sensor. The sensor shall be a 14" displacer that produces a pneumatic output signal. The controller manufacturer shall be _________, Model ______. A lter regulator is to be provided to reduce 50 psig instrument air supply to 3 - 15 psig for proper operation. 2.4 Optional The make up valve shall include an ANSI Class 125 lb three-valve bypass with inlet Y-type cast iron strainer. Strainer screen to be removable and of stainless steel construction. 3.0 Steam Pressure Reducing Station 3.1 Option - Mechanical _______" steam pressure reducing valve with cast iron body and _____ connections. The valve shall be a self-contained unit capable of reducing ____ psig saturated steam to the operating pressure of the deaerator at a ow rate of _____ lbs/hr. The valve shall be 250 lb class with stainless steel trim and an adjustable pilot. The valve manufacturer shall be ____________, Model _____. 3.2 Option - Pneumatic _______" diaphragm actuated steam pressure reducing valve with cast iron body and _______ connections. The valve shall be globe type with proportional control and a spring opposed diaphragm actuator arranged for ______ psig operating signal. The valve shall be normally closed on loss of air. The valve shall be capable of reducing _____ psig saturated steam to the operating pressure of the deaerator at a ow rate of ____ lbs/hr. This valve shall be 250 lb class and have stainless steel trim. The diaphragm actuated valve manufacturer shall be __________, Model ____. This valve shall be pneumatically controlled by an external transmitter. The transmitter set pressure shall be adjustable. The transmitter manufacturer shall be ______________, Model ____. 3.3 Optional The steam pressure reducing valve shall include a three valve bypass with Y-type cast iron strainer. Strainer screen to be removable and of stainless steel construction. 3.4 Optional Quantity ______, _______ " relief valves sized to relieve full capacity of the pressure reducing valve in the event of its failure.
H2-10
02-02
Feedwater Systems
Valves to meet Paragraph UG-125 of ASME Unred Pressure Vessel Code, Section VIII. Valve body to be of bronze construction. Relieving set pressure to be 50 psig. Relief valve manufacturer to be ________________, Model _______. 3.5 Optional High level alarm switch. This shall be an externally mounted oat type switch. The switch shall make contact on rise and break on fall. The oat cage construction shall be cast iron. (Not required with electronic make up controller.) 3.6 Optional Low level alarm switch. This shall be an externally mounted oat type switch. The switch shall make contact on fall and break on rise. The oat cage construction shall be cast iron. (Not required with electronic make up controller.) 3.7 Optional ________ " overow drainer sized to relieve full capacity at the operating pressure of the deaerator. The overow drainer shall be a oat type trap. The construction is to be a steel housing with stainless steel oat ball. The overow drainer manufacturer shall be _______, Model _______. 3.8 Optional Suction piping for pumps shall consist of a gate valve, cast iron Y-type strainer with replaceable stainless steel screen and exible connector or hose. This piping assembly shall be 125 lb class construction. The vortex breaker shall be located in the tank nozzle. Manifold suction lines are not acceptable. 4.0 Boiler Feedwater Pump and Motor Set 4.1 Option - Intermittent Quantity________, turbine type boiler feedwater pump and motor set. Centrifugal type pumps are not acceptable in this application. Pump to be rated for _____ gpm at _____ feet TDH with ______ feet NPSH required. Pump to be ______ materials of construction and have ______ seals for a maximum water temperature of 250 F. Pump impeller to be hydraulically balanced. The pump shall be mounted on a steel baseplate and exibly coupled with an OSHA type coupling guard to a ____ hp, _____ phase, ______ Hz, ______ Volt, _______ rpm, ________enclosure motor. Motor to be non-overloading at the rated condition without using any portion of the service factor. Pump and motor set to be factory aligned prior to shipment. Pump manufacturer to be_____________, Model ________, size ____ " x _______". 4.2 Option - Continuous Quantity ______, centrifugal type boiler feedwater pump and motor set. Turbine type pumps are not acceptable in this application. Pump to be rated for _____ gpm at ________ feet TDH with ____ feet NPSH required. Pump to be _______ materials of construction as dened by the Hydraulic Institute and have _______ seals for a maximum water temperature of 250 F. Pump impeller to be hydraulically balanced. The pump shall be mounted on a steel baseplate and exibly coupled with an OSHA type coupling guard to a ______ hp, ______ phase, _______ Hz, ______ Volt, _____ rpm, _______ enclosure motor. Motor to be non-overloading at the rated condition without using any portion of the service factor. Pump and motor set to be factory aligned prior to shipment. Pump manufacturer to be _________, Model _______, size _____ " x _______ ". A stainless steel recirculation orice is to be supplied with the pump and shipped loose for eld installation to provide minimum bypass ow. 4.3 Optional The basic surge tank shall be equipped with the following trim and accessories. Piping on packaged units shall comply with ASME Power Piping Code B31.1. 5.0 Make Up Valve and Controller 5.1 Option - Mechanical ____ " inlet water regulating lever valve with ______ body and _______ connections. The valve Cv shall not exceed ______, and shall be rated for _____ gpm at ______ psi inlet pressure. The pressure drop across the valve shall not exceed a delta-P of 10 psig. This valve shall be suitable for temperatures up to 300 F. The valve manufacture shall be ____________, Model _______ . This valve shall be mechanically controlled by an external oat cage with cast iron body and 8" stainless steel oat. The oat cage manufacturer shall be _______________, Model __________.
H2-11
02-02

5.2 Option - Electronic
Feedwater Systems
______" inlet water motorized regulating valve with steel body and threaded NPT connections. Motor shall be 110V bi-directional type, with a permanently lubricated gear train, and directly coupled to the valve stem. The valve Cv shall not exceed _____ and be rated for_______ gpm at ________ psi inlet pressure. Valve shall not exceed a delta-P of 10 psig. This valve shall have teon seats and be suitable for temperatures up to 300 F. The motorized valve manufacturer shall be _________. This valve shall be electronically controlled by a solid state control with internally mounted capacitance probes. The electronic solid state control shall be able to set desired level point and acceptable deviation. The electronic solid state control shall include a selection for automatic and manual operating mode. The internals shall include two additional probes for high and low water alarm. The controller manufacturer shall be Cleaver-Brooks, Model TW82. A solenoid valve and oat switch are not acceptable. (Available only in the U.S.) 5.3 Option - Pneumatic _______" inlet water diaphragm actuated regulating valve with cast iron body and _____ connections. The valve shall be globetype with proportional control and a spring-opposed diaphragm actuator arranged for 3 - 15 psig operating signal. The valve shall be normally open on loss of air. The valve Cv shall not exceed _____ and be rated for ________ gpm at ______ psi inlet pressure. Valve shall not exceed a delta-P of 10 psig. This valve shall have stainless steel trim with TFE packing and be suitable for temperature up to 410 F. The diaphragm actuated valve manufacturer shall be ___________, Model _______. This valve shall be pneumatically controlled by an external proportional type sensor. The sensor shall be a 14" displacer that produces a pneumatic output signal. The controller manufacturer shall be _____________, Model __________. A lter regulator is to be provided to reduce 50 psig instrument air supply to 3 - 15 psig for proper operation. 5.4 Optional The make up valve shall include a ANSI Class 125 lb three-valve bypass with inlet Y-type cast iron strainer. Strainer screen to be removable and of stainless steel construction. 5.5 Optional High-level alarm switch. This shall be an externally mounted oat-type switch. The switch shall make contact on rise and break on fall. The oat cage construction shall be cast iron. (Not required with electronic make up controller.) 5.6 Optional Low-level alarm switch. This shall be an externally mounted oat-type switch. The switch shall make contact on fall and break on rise. The oat cage construction shall be cast iron. (Not required with electronic make up controller.) 5.7 Optional Suction piping for pumps shall consist of a gate valve, cast iron Y-type strainer with replaceable stainless steel screen and exible connector or hose. This piping assembly shall be 125 lb class construction. The vortex breaker shall be located in the tank nozzle. Manifold suction lines are not acceptable. 6.0 Transfer Pump And Motor Set Quantity ______, centrifugal type transfer pump and motor set. Turbine type pumps are not acceptable in this application. Pump to be rated for _______ gpm at ________ feet TDH with ______ feet NPSH required. Pump to be _______ materials of construction as dened by the Hydraulic Institute, and have _______ seals for a maximum water temperature of 212 F. Pump impeller to be hydraulically balanced. The pump shall be mounted on a steel baseplate and exibly coupled with an OSHA type coupling guard to a ______ hp, ______ phase, _______ Hz, ______ Volt, _____ rpm, _______ enclosure motor. Motor to be non-overloading at the rated condition without using any portion of the service factor. Pump and motor set to be factory aligned prior to shipment. Pump manufacturer to be _________, Model _______, size _____ " x _______ ". A stainless steel recirculation orice is to be supplied with the pump and shipped loose for eld installation to provide minimum bypass ow. 6.1 Optional The duo stand shall elevate the deaerator and surge tank sections to provide the net positive suction head required by the pump at the rated condition to prevent cavitation. The stand shall be constructed of heavy square steel tubing for the legs and 1/4" steel plate covering the oor.
H2-12
02-02
Feedwater Systems
7.0 Control Panel 7.1 Optional - Base
Control panel shall be in a NEMA 1 enclosure and wired to the National Electric Code. The wire shall be black number coded. The assembly is to contain individual motor starters with 120 Volt holding coil and fuse protection. Individual green oil-tight pump run lights shall be provided. All switches and lights to have nameplate identication. The assembled panel shall be given a factory continuity test prior to shipment. 7.2 Optional - Electric Components Audible and visual high and low water alarm function shall be provided by a bell or horn with silence switch and individual red oiltight lights. Control circuit transformer to supply 110-120 Volts, single-phase power supply. The transformer shall be mounted, wired and fused. Auxiliary contacts shall be furnished for chemical feed pump initiation. Contacts shall be normally open. 7.3 Standard The deaerator and surge section shall have a gauge glass assembly that covers the entire tank diameter. The gauge glass shall be quartz 0.625 inch diameter by 24 inch maximum length. Each length of glass shall be furnished with a bronze gauge cock set and protector rods. The deaerator section shall be supplied with a pressure gauge that has a 4-1/2 inch dial with a 0-60 psig range and a thermometer with a 50 to 300 F range. Packaged units are required to have both gauges bracket-mounted at eye level. The surge tank section shall be supplied with a thermometer with a 50 to 300 F range. The duo tank is to be hand cleaned with a solvent to SSPC- SP-1 standards prior to painting. Prime coated to not less than 1 mil thick and nish coated with an enamel paint to not less than 1 mil thick prior to shipment. Unit is to be knocked down for shipment. Piping is to be matched marked. Three, bound, Operating and Maintenance manuals to be provided. Warranty period to be twelve months after start-up or eighteen months after shipment, whichever comes rst.
H2-13
02-02
Feedwater Systems
NOTES
H2-14
02-02
Section H3
BOILERMATE DEAERATORS
CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-3 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-4 DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-6 RETURN ON INVESTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-9 SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-10 ILLUSTRATIONS Figure H3-1. Boilermate Deaerator Dimensions and Ratings - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-6 Figure H3-2. Boilermate Tank Supports and Saddles, Details and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-8 TABLES Table H3-1. Cleaver-Brooks Boilermate Deaerator Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-5
H3-1
02-02
Boilermate Deaerators
Feedwater Systems
The Cleaver-Brooks designed deaerator assures high purity efuent by removing oxygen and other dissolved gases in boiler feed. Thus, it is the answer to long-lasting boiler equipment for industrial and commercial boiler users. Built of corrosion-resistant alloys for lifetime service, the deaerator employs those basic principals of gas removal proven most effective and economical to every boiler owner. Contact your local Cleaver-Brooks authorized representative for component and sizing information.
H3-2
02-02
Feedwater Systems

The following features and benets apply to the Boilermate Deaerator product line. The Boilermate design uses a packed column to deaerate the water. Less Mechanical Movement of Deaerator Components: The water spray valve is the only internal moving component within the deaerator vessel. Two-Stage Deaeration in a Common Vessel: Recycle pumps are not required. Packaged for easy maintenance. ASME Code Design (Section VIII): Assures deaerator vessel quality in materials and fabrication to meet safety requirements. Internal Stainless Steel Vent Condenser: Protects deaerator vessel against corrosive gases while providing a means for removal of corrosive gases from boiler feedwater. Self-Cleaning Water Spray Valve: Maintains deposit-free surface. Reduces maintenance requirements. Internal Automatic-Check Valve Prevents Steam Back-Flow: The water spray valve is normally closed at no ow. Prevents steam back ow through the water spray valve at no ow conditions. Removable Water Spray Inlet Assembly: Flanged assembly allows easy access for maintenance and/ or inspections. Stainless Steel Deaeration Assembly: Ensures a longer life of wetted materials in intimate contact with corrosive liquids and released corrosive gases. Pressurized Tank Reduces Flashing and Minimal Venting: Recovery of exhaust and turbine steam. Saves Btus that would normally be exhausted to atmosphere. Improves plant efciency.
Auto Vent Valve Eliminates Gases at Start-Up: Atmospheric contamination virtually eliminated for incoming water. Exceeds ASME Recommendations for Oxygen Level: Cleaver-Brooks deaerator is guaranteed to remove oxygen concentrations to 0.005 cc/liter while operating between 5 and 100%capacity. Carbon dioxide concentration is practically reduced to a zero. Integral Level Control Automatically Introduces Cold Water Make-Up to Supplement Condensate Only When Necessary to Meet Boiler Demand: Saves Btus by accepting condensate before cold make-up water. Maintains a minimal water level within the deaerator vessel to prevent damage to the boiler feedpumps, and to maintain system operation. Variety of Tank Sizes to Handle Volume-Swings in Condensate Return: Provides exibility for selecting a tank for specic applications to limit the loss of hot condensate to drain. Packaged Units for Cost Effective Installation: Complete packages are pre-fabricated in the Cleaver- Brooks manufacturing facility to ensure piping alignment and control wiring function. The unit is partially disassembled, match marked for efcient eld re-assembly. Internal Pump Suction Vortex Breakers: Eliminates the problems of loss in NPSHA and cavitation associated with the creation of vortices within pump suction piping. Vessel Corrosion Protection When Off-Line: Optional epoxy lining.
H3-3
02-02
Feedwater Systems
Steam pressure gauge. Feed water thermometer. Required tappings. Optional Equipment Steam pressure reducing valve. Three valve bypass and strainer (PRV). Water level controller with make-up valve. Three valve bypass and strainer (MUV). Steam relief valves. High water alarm. Low water alarm. Low water pump cut off. High-temperature condensate diffuser tube (over 227 F). Boiler feed pump and motor sets. Recirculation orice or relief valve. Suction shutoff valve. Suction strainer. Suction exible tting. Discharge check valve. Discharge shutoff valve. Discharge pressure gauge. Discharge manifold. Overow drainer. Control panel. Chemical feed quill. Vacuum breaker. Insulation and lagging. Sentinel relief valve. Tank drain valve. Back pressure relief valve. Magnesium anode (not available with lined tanks). Epoxy lining. Stand. Packaging Fully packaged, factory piped and wired. Half packaged, suitable for eld erection with interconnecting piping and wiring by others.
PRODUCT OFFERING
Information in this section applies directly to Cleaver-Brooks packaged boilermate deaerators ranging from 1,500 lbs/hr at 50 F makeup to 135,000 lbs/hr at 200 F make-up. Larger capacities can be obtained by using two columns. The Boilermate deaerator product offering is shown in Table H3-1. The Boilermate deaerator is a pressurized packed column, low maintenance system designed to remove dissolved oxygen in boiler feed water to 0.005 cc per liter or less and eliminate carbon dioxide. A typical deaerator package includes the packed column and storage tank mounted on a stand of appropriate height along with all operating controls, feed pumps assembled and piped (typically knocked down for shipment and eld assembly). The tank conforms to Section VIII of the ASME Code. The packed column design is best for handling high-temperature returns. The column is constructed of a carbon steel casing with a stainless steel liner. Built into a ange on top of the column is a spring loaded self-cleaning water spray nozzle and an automatic and manual vent valve. From experience, large industrial plants and utilities have learned that the most practical and economical way to remove oxygen from feedwater is through mechanical deaeration. The Boilermate deaerator economically effects oxygen removal through a design that is trouble free in performance. Raw water, untreated and not deaerated, contains as much as ten cubic centimeters of corrosion-causing oxygen per liter. Oxygen in water corrodes and shortens the life of boiler feed lines, boilers and condensate return lines. The Cleaver-Brooks designed deaerator assures high purity efuent by removing oxygen and other dissolved gases in boiler feed. Thus, it is the answer to long-lasting boiler equipment for industrial and commercial boiler users. Built of corrosion-resistant alloys for lifetime service, the deaerator employs those basic principals of gas removal proved to most effective and economical to every boiler owner. Contact your local Cleaver-Brooks authorized representative for component and sizing information. The design of the Boilermate deaerator offers simplicity in both operation and service. The exchange packing, the heart of the deaerator, requires no maintenance. There are no moving parts to adjust or maintain. Installation is simple and quick. Standard Equipment Boilermate column. Deaerator storage tank. Stainless steel exchange packing. Deaerator water inlet atomizing valve. Gauge glass. Deaerator manual and automatic vent valve. H3-4
02-02
Feedwater Systems
Table H3-1. Cleaver-Brooks Boilermate Deaerator Selection Guide

140
140
120
120 42
INLET CAPACITY - LBS/HR X 1000 WATER
100
100
80
80
36
60
60 30
40
40 24
20 20 20 16 12 8 50 70 90 110 130 150 170 190
FEEDWATER MIX TEMPERATURE - F

*DEARERATOR CAPACITY LBS/HR MODEL NO BM-8 50F 100F 150F 200F Weight (lbs) Including Packing 1,500 2,000 2,700 5,000 250 BM-12 3,500 4,500 6,000 11,000 350 BM-16 6,000 8,000 11,000 20,000 410 BM-20 10,000 12,500 17,000 30,000 560 BM-24 15,000 18,000 24,000 44,000 960 BM-30 23,000 28,000 38,000 69,000 1,275 BM-36 33,000 40,000 55,000 100,000 1,810 BM-42 45,000 54,000 75,000 135,000 2,390
NOTE: Model Designation (example BM-8) is: BM = Boilermate Deaerator. 8 = size of packed column. Ratings for each column size vary with makeup water temperature. * Capacities may be doubled by using two columns.
MODEL
H3-5
02-02
Feedwater Systems

Dimensions and ratings for Boilermate Deaerators are shown in Figures H3-1 and H3-2.
(9" FOR MODEL 8 & 16) .5" NPT AUTO. VENT VALVE "D" NPT. MANUAL VENT VALVE
B B
2" NPT. INSPECTION PORT (PLUGGED) (1.5" NPT. FOR MODELS 8 & 12)
"C"
3 "S" 2 DIA. HOLE IN LIFTING LUGS "A" (NOTE 18) 20 TANK DIA. 21 "P" 2 0 "T" "E"
"F" "G" "J" "H" "K" "L"
6 12 13
"R" (NOTE 12)
10 14
5 "M" (NOTE 1) 15 18 17 (NOTE 3) 16 STAND HEIGHT VARIES PER PROJECT REQUIREMENTS 11 (NOTE 2) 4 7 6
19 (NOTE 4)
"D4" "C3" FRONT VIEW
(4) "E5"E HOLES FOR "F6" E BOLTS
"B2" "A1" SIDE VIEW
1. Mounted at dim. "M" (top of tank) on non-packaged units. 2. Tank mounted on non-packaged unit. 3. Packaged units only. Mounted on left end, right side of stand on 48" dia. 1070 gal 54" dia. 1500 gal as shown. 4. Suction piping includes strainer, gate valve and flexible connector. 5. All couplings are 3000# F.S. 6. All flanges are 150# F.F. except as noted. 7. Customer to plug all fittings not being used. 8. Mount tank above pump at elevation necessary for static head including safe allowance for piping friction as approved by pump manufacturer. 9. Tank is built to ASME Code. 10. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension prints. 11. Add suffix "P" to Model no. for packaged units (BMP-24). 12. Dimension "R" will change depending on controls required- contact your local Cleaver-Brooks authorized representative. 13. No interconnecting piping or wiring furnished on non-packaged units unless specified, contact your local Cleaver-Brooks authorized representative for specific piping or wiring furnished on packaged assemblies. 14. Weights shown are without controls or packaging - contact your local Cleaver-Brooks authorized representative for additions. 15. Capacities other than shown as standard available by using two columns - contact your local Cleaver-Brooks authorized representative. 16. Optional tank sizes available - contact your local Cleaver-Brooks authorized representative. 17. Lifting lugs are for lifting empty tank only. 18. Manway is standard. Manufacturing may require a larger manway for fabrication. See dimensional diagram for actual size. COLUMN DETAILS AND DIMENSIONS BOILERMATE MODEL NO. A B C D Height Water Inlet (150# RF Flg) Column Outside Diameter Manual Vent Valve Size Column Weight (lb) Volume Packing (Cu ft) Packing Weight (lb) 8 46 1.25 8.63 .5" NPT 250 0.7 25 12 48.5 1.5 12.8 .5" NPT 350 1.6 50 16 58 1.5 16 .75" NPT 450 3.0 150 20 62 2 20 .75" NPT 600 5.0 200 24 64 2 24 .75" NPT 750 8.0 300 30 71.5 2.5 30 1" NPT 850 12.0 450 36 78.5 3 36 1.5" NPT 1050 18.0 650 42 80 4 42 2" NPT 1300 29.0 1050
Figure H3-1. Boilermate Deaerator Dimensions and Ratings - Sheet 1 of 2 H3-6

02-02
Feedwater Systems
RATINGS Cap (Gal to Overow) Tank Weight (Dry) (lb) Tank Weight (Flooded) (lb) Tank Size (Dia x Length) E F G H J K L M P R S T A1 B2 C3 D4 E5 F6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Steam Inlet Level Alarm High Temp Return Level Control Relief Valve Relief Valve Relief Valve Drain Overow Overall Width Front Head Column Overall Length C/L to C/L Bolt Holes Overall Width C/L to C/L Bolt Holes Hole Size Anchor Bolt Size Relief Valve Size Overow Size Steam Inlet Size Suction Size High Temp Return Size Drain Size Recirc (1" NPT) Thermometer (.75" NPT) Sample (.5" NPT) Chem Feed (1" NPT) Thermometer Gauge Glass Assy Level Controller Make-Up Valve Pressure Gauge Overow Drainer (Opt) Control Panel (Opt) Feed Pump/Motor (Opt) Suction Piping, (Opt) Manway, 12 x 16 Level Alarms (Opt) 1.25" NPT 2" NPT 3" NPT 1" NPT 2" NPT 110 750 1850 24 x 70 29 23 35 42 48 N/A N/A 36 Rear Hd 39 6 8.5 54 49 42 39 0.75 0.625 330 1200 4250 36 x 86 TANK DIMENSIONS 33 26 21 41 50 60 N/A 47 60 51 8 8.5 61 56 49 46 1 0.875 STANDARD DIMENSIONS 86 80 64 61 1 0.875 101 95 71 68 1.125 1 51 8 22 53 45 39 61 69 79 N/A 76 10 63 10 69 11 12 60 50 43 69 77 86 95 93 10 75 430 1400 5300 36 x 110 800 1900 9100 48 x 114 1070 2500 12700 54x 127 1500 2750 15600 60 x 129
CONNECTIONS & TRIM Contact your local Cleaver-Brooks authorized representative 2" NPT 3" NPT 3" NPT 1.5" NPT 2" NPT 3" NPT 4"-150# FF 6"-150# FF 3" NPT 2" NPT 2" NPT 3" NPT 6"-150# FF 4"-150# FF 3" NPT 2" NPT
Figure H3-1. Boilermate Deaerator Dimensions and Ratings - Sheet 2 of 2
H3-7
02-02
Feedwater Systems
TANK SUPPORT LEGS FRONT HEAD

"E"
STANDARD ON 110, 330, 430 & 800 GALLON TANKS

"A"
SADDLES FRONT HEAD

"E"
STANDARD ON 1070 & 1500 GALLON TANKS

"A"
(4) .875" E HOLES FOR .75" E BOLTS
(4) 1.125"E HOLES FOR .75" E BOLTS "C" "D" "D" "C"
"H"
"F"
6 "F"
"G"
"G"/2
"B"
"B"
TANK CAPACITY (GAL.) MODEL 110 LEGS A B C D E F G H 48.5 54 22.5 24.25 11 0.875 5.5 7 55.5 61 29.5 31.25 15 0.875 5.5 7 80 85.5 29.5 31.25 15 0.875 5.5 7 86.5 38 40 17 1 6.5 9.75 330 430 800 SADDLES 95 101 44.75 51.5 16 3.38 N/A N/A 57 17 6.13 1070 1500
Figure H3-2. Boilermate Tank Supports and Saddles, Details and Dimensions
H3-8
02-02
Feedwater Systems
Theoretically, it takes approximately 8 ppm of sodium sulte as Na2S03 to scavenge 1 ppm of dissolved O2
RETURN ON INVESTMENT
Payback for a pressurized deaerator verses an atmospheric boiler feed system is based on the additional capital expenditure required divided by the yearly operating cost savings. The differential in yearly operating costs are in the following areas: Flash steam Exhaust steam Blowdown Chemical treatment Make-up water Sewer Intangibles
Makeup Water
Increase makeup water is required because of lost ash steam, lost exhaust steam, and additional surface blowdown. This additional make-up water can be associated to a cost. Makeup cost should be a combination of the utility charge plus pretreatment equipment consumable costs.
Sewer
Utilities often base a sewer charge on make-up water usage. If it is metered, the additional surface blowoff should only be considered.
Flash Steam
A percentage of the high-pressure condensate returns will ash to steam and be lost in an atmospheric vessel application. This ash steam loss can be converted to an energy loss and associated fuel cost.
Intangibles
It is difcult to calculate a cost savings for items such as reduced ue gas emission due to higher plant efciencies of steam recovery and the prevention of boiler thermal shock.
Exhaust Steam
Exhaust steam cannot be recovered in an atmospheric vessel application. This exhaust steam loss can be converted to energy loss and associated fuel cost. An example would be steam turbine exhaust.
Surface Blowdown
Increased makeup water is required because of lost ash and exhaust steam. This increase in makeup water requires an increase of surface blowdown. This is directly related to cycles of concentration in the boiler. The additional blowdown loss can be converted to an energy loss and associated fuel cost. The additional surface blowdown may also result in an increase in capital expenditure for a larger blowdown heat recovery system.
Chemical Treatment
Dissolved oxygen content in an atmospheric boiler feedwater system relates to the water temperature. Lowering the dissolved oxygen content below what is naturally present, based on mix water temperature at atmospheric pressure, requires the addition of a chemical treatment program. The most common oxygen scavenger used is sodium sulte. Sodium sulte reacts with dissolved oxygen as follows: 2Na2SO3 + O2 2Na2SO4
H3-9
02-02
Feedwater Systems
The following sample specications are provided by Cleaver-Brooks to assist you in specifying your customers specic needs and application. 1.0 Deaerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 Make Up Valve and Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Steam Pressure Reducing Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 Boiler Feedwater Pump And Motor Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 Deaerator Cleaver-Brooks Model _________ packed column type, pressurized, horizontal deaerator is rated at _____ pounds per hour at ____ F mixed inlet water temperature. The system shall be of the single tank design and guarantee oxygen removal to not more than 0.005 CCS/liter in the efuent throughout all load conditions between 5 and 100 percent. Tray-type designs are not acceptable. The deaerator shall be designed for operation at 5 psig, but shall be suitable for use from 2 to 15 psig. Atmospheric operating designs are not acceptable. Feedwater and condensate shall be admitted to the deaerator through a single spring-loaded, self-cleaning, adjustable stainless steel spray valve, which shall provide proper internal vent condensing and water distribution at any load between 5 and 100 percent of rated capacity. The water temperature in the primary heating and vent concentrating section is to be raised within 2 or 3 F of steam temperature and most of the gases released. The water is then to drop down through the columns stainless steel exchange packing counterow to the steam, which enters at the top of the storage tank and rises up through the column. The column is to be ____" in length and ____ " in diameter. The column shall have a stainless liner and grid support. Hot, gas-free water is to then drop to the storage compartment to complete the cycle. The steam and non-condensables are to ow upward, through the primary heating spray, into the internal vent concentrating section, where they contact the cold inuent water. Here, the steam is to be condensed to continue the cycle. Released gases are discharged to atmosphere through the vent outlet. All internal surfaces, which come in contact with un-deaerated water, shall be constructed of Type 316 stainless steel. Automatic vent valve shall be thermostatically controlled to provide a fast means of venting when a sudden buildup of gases occurs, such as seen at start up. The manual vent valve shall have an orice for continuous minimum venting. Venting rate shall not exceed 0.1 of 1% of the rated deaerator capacity at 5 psig. The deaerated water storage tank shall have _____ minutes of storage and have a capacity of _____ gallons measured to overow. The tank shall be _____ diameter x _____ long. An 11" x 15" elliptical manhole shall be provided for access. All nozzles 3" and under shall be 3000 lbs forged steel couplings and over 3" shall be 150 lbs at face anges. Heads to be ASME torispherical type constructed of ASTM A516 GR 70 carbon steel with a minimum thickness of 0.25 inches. Shell plate to be fabricated of ASTM A36 carbon steel with a minimum thickness of 0.25 inches. The tank and column shall be designed in accordance with ASME, Section VIII of the Pressure Vessel Code for 50 psig at 650 F and stamped accordingly. Certication shall be required. Joint efciencies to be 70% circumferential per table UW-12, which does not require stress relieving or nondestructive examination. The deaerator loads shall be as specied in the table below. Low temperature returns are dened as condensate with a temperature below that of the deaerator operating temperature. High temperature returns are dened as condensate with a temperature above that of the deaerator operating temperature. 1.1 Optional The tank and column shall be factory-insulated and lagged with blanket insulation, pins, clips, and a durable steel jacket. Blocktype insulation is not acceptable. The blanket insulation is to be berglass, 2" thick, 1 lb/cubic foot, and have a rating of R3.85. Pins Load Specications
LOAD Make up Pumped Low Temp Returns High Temp Returns Not To Exceed 30% PERCENTAGE LBS/HR TEMP PRESSURE 25 psig Minimum 10 psig Minimum
H3-10 H3-11 H3-12 H3-12 H3-13
H3-10
02-02
Feedwater Systems
are to be located on 18" centers and holding clips attached. The steel jacket or lagging shall have a shell thickness of 22 gauge (0.299") minimum and head thickness of 12 gauge (0.1046") minimum. 1.2 Optional The tank shall be factory-lined with a high quality baked-on epoxy lining. The lining is to be applied to a sandblasted (SSPC-SP-563) white metal surface. Spray-apply 4 to 6 coats with each dry coat being approximately 1.5 mils dry for a total thickness of 6 mils dry minimum. Baking schedule for intermediate coats to be 10 to 20 minutes at 250 to 300 F and nal baking to be 1-1/2 hours at 350 to 400 F. Lining to be Holliday spark tested using low voltage and a wet sponge to ensure uniform coating free of pin holes. Magnesium anodes shall not be acceptable in this application. The lining is to meet requirements of FDA and MID of the USDA. The lining is to be suitable for temperatures up to 250 F. 1.3 Optional The magnesium or sacricial anode shall provide cathodic protection against galvanic corrosion. This rod shall be 1-5/16" diameter with a 1/4" steel core to assure a good electrical contact and added strength. The design shall have a small weep hole to signal it has been consumed. Linings shall not be acceptable in this application. 1.4 Optional The high temperature diffuser or sparge tube shall be located beneath the normal tank water level. The tube shall be constructed of 2 inch pipe. This tube shall provide even distribution and blending of high-temperature condensate returns. 1.5 Optional The chemical feed quill shall be located beneath the normal tank water level. The quill material shall be constructed of stainless steel. The tube shall provide even distribution and blending of chemical. 1.6 Optional The basic deaerator shall be equipped with the following trim and accessories. Piping on packaged units shall comply with ASME Power Piping Code B31.1. 2.0 Make Up Valve and Controller 2.1 Option - Mechanical ____ " inlet water regulating lever valve with ______ body and _______ connections. The valve Cv shall not exceed ______ and be rated for _____ gpm at ______ psig inlet pressure. The pressure drop across the valve shall not exceed a delta-P of 10 psig. This valve shall be suitable for temperatures up to 300 F. The valve manufacture shall be __________ Model _____ . This valve shall be mechanically controlled by an external oat cage with cast iron body and 8" stainless steel oat. The oat cage manufacturer shall be _______________, Model ______. 2.2 Option - Electronic ______" inlet water motorized regulating valve with steel body and threaded NPT connections. Motor shall be 110V bi-directional type with a permanently lubricated gear train, and be directly coupled to the valve stem. The valve Cv shall not exceed _____ and be rated for_____ gpm at ______ psig inlet pressure. Valve shall not exceed a delta-P of 10 psig. This valve shall have teon seats and be suitable for temperatures up to 300 F. The motorized valve manufacturer shall be ____. This valve shall be electronically controlled by a solid state control with internally mounted capacitance probes. The electronic solid state control shall be able to set desired level point and acceptable deviation. The electronic solid state control shall include a selection for automatic and manual operating mode. The internals shall include two additional probes for high and low water alarm. The controller manufacturer shall be Cleaver-Brooks Model TW82. A solenoid valve and oat switch are not acceptable. (Available only in the U.S.) 2.3 Option - Pneumatic _______" inlet water diaphragm actuated regulating valve with cast iron body and _____ connections. The valve shall be globe type with proportional control and a spring opposed diaphragm actuator arranged for 3 - 15 psig operating signal. The valve shall be normally open on loss of air. The valve Cv shall not exceed _____ and be rated for ______ gpm at ______ psig inlet pressure. Valve shall not exceed a delta-P of 10 psig. This valve shall have stainless steel trim with TFE packing and be suitable for temperature up to 410 F. The diaphragm actuated valve manufacturer shall be ________, Model _____. This valve shall be pneumatically controlled by an external proportional type sensor. The sensor shall be a 14" displacer that produces a pneumatic output signal. The
H3-11
02-02
Feedwater Systems
controller manufacturer shall be _________ , Model ______. A lter regulator is to be provided to reduce 50 psig instrument air supply to 3 - 15 psig for proper operation. 2.4. Optional The make up valve shall include a ANSI Class 125 lb three-valve bypass with inlet Y-type cast iron strainer. Strainer screen to be removable and of stainless steel construction. 3.0 Steam Pressure Reducing Station 3.1 Option - Mechanical _______" steam pressure reducing valve with cast iron body and _____ connections. The valve shall be a self-contained unit capable of reducing ____ psig saturated steam to the operating pressure of the deaerator at a ow rate of _____ lbs/hr. The valve shall be 250 lb class with stainless steel trim and an adjustable pilot. The valve manufacturer shall be _____ Model _____. 3.2. Option - Pneumatic _______" diaphragm actuated steam pressure reducing valve with cast iron body and _______ connections. The valve shall be globe type with proportional control and a spring opposed diaphragm actuator arranged for ____ psig operating signal. The valve shall be normally closed on loss of air. The valve shall be capable of reducing _____ psig saturated steam to the operating pressure of the deaerator at a ow rate of ____ lbs/hr. This valve shall be 250 lb class and have stainless steel trim. The diaphragm actuated valve manufacturer shall be _________ Model ____. This valve shall be pneumatically controlled by an external transmitter. The transmitter set pressure shall be adjustable. The transmitter manufacturer shall be __________________, Model _______. 3.3 Optional The steam pressure reducing valve shall include a three valve bypass with Y-type cast iron strainer. Strainer screen to be removable and of stainless steel construction. 3.4 Optional Quantity ______, _______ " relief valves sized to relieve full capacity of the pressure reducing valve in the event of its failure. Valves to meet Paragraph UG-125 of ASME Unred Pressure Vessel Code, Section VIII. Valve body to be of bronze construction. Relieving set pressure to be 50 psig. Relief valve manufacturer to be ___________________ , Model ______. 3.5 Optional High level alarm switch. This shall be an externally mounted oat type switch. The switch shall make contact on rise and break on fall. The oat cage construction shall be cast iron. (Not required with electronic make up controller.) 3.6. Optional Low level alarm switch. This shall be an externally mounted oat type switch. The switch shall make contact on fall and break on rise. The oat cage construction shall be cast iron. (Not required with electronic make up controller.) 3.7. Optional ________ " overow drainer sized to relieve full capacity at the operating pressure of the deaerator. The overow drainer shall be a oat type trap. The construction is to be a steel housing with stainless steel oat ball. The overow drainer manufacturer shall be ____________, Model _______. 3.8 Optional Suction piping for pumps shall consist of a gate valve, cast iron Y-type strainer with replaceable stainless steel screen and exible connector or hose. This piping assembly shall be 125 lb class construction. The vortex breaker shall be located in the tank nozzle. Manifold suction lines are not acceptable. 4.0 Boiler Feedwater Pump And Motor Set 4.1 Option - Intermittent Quantity________, turbine type boiler feedwater pump and motor set. Centrifugal type pumps are not acceptable in this application. Pump to be rated for _____ gpm at _____ feet TDH with ______ feet NPSH required. Pump to be ______ materials of con-
H3-12
02-02
Feedwater Systems
struction and have ______ seals for a maximum water temperature of 250 F. Pump impeller to be hydraulically balanced. The pump shall be mounted on a steel baseplate and exibly coupled with an OSHA type coupling guard to a ____ hp, _____ phase, ______ Hz, ______ Volt, _______ rpm, ________enclosure motor. Motor to be non-overloading at the rated condition without using any portion of the service factor. Pump and motor set to be factory aligned prior to shipment. Pump manufacturer to be_____________, Model ________, size ____ " x _______". 4.2 Option - Continuous Quantity ______, centrifugal type boiler feedwater pump and motor set. Turbine type pumps are not acceptable in this application. Pump to be rated for _____ gpm at ______ feet TDH with ____ feet NPSH required. Pump to be _______ materials of construction as dened by the Hydraulic Institute and have _______ seals for a maximum water temperature of 250 F. Pump impeller to be hydraulically balanced. The pump shall be mounted on a steel baseplate and exibly coupled with an OSHA type coupling guard to a _____ hp, ______ phase, _______ Hz, ______ Volt, _____ rpm, _______ enclosure motor. Motor to be non-overloading at the rated condition without using any portion of the service factor. Pump and motor set to be factory aligned prior to shipment. Pump manufacturer to be _________, Model _______, size _____ " x _______ ". A stainless steel recirculation orice is to be supplied with the pump and shipped loose for eld installation to provide minimum bypass ow. 4.3 Optional The stand shall elevate the deaerator tank to provide the net positive suction head required by the pump at the rated condition to prevent cavitation plus a 1-1/2 foot safety factor. The stand shall be constructed of heavy square steel tubing for the legs and 1/4" steel plate covering the oor. 5.0 Control Panel 5.1 Optional - Base Control panel shall be in a NEMA 1 enclosure and wired to the National Electric Code. The wire shall be black number coded. The assembly is to contain individual motor starters with 120 Volt holding coil and fuse protection. Individual green oil-tight pump run lights shall be provided. All switches and lights to have nameplate identication. The assembled panel shall be given a factory continuity test prior to shipment. 5.2. Optional - Electric Components Audible and visual high and low water alarm function shall be provided by a bell or horn with silence switch and individual red oiltight lights. Control circuit transformer to supply 110-120 volts, single-phase power supply. The transformer shall be mounted, wired and fused. Auxiliary contacts shall be furnished for chemical feed pump initiation. Contacts shall be normally open. 5.3 Standard The deaerator shall have a gauge glass assembly that covers the entire tank diameter. The gauge glass shall be quartz 0.625 inch diameter by 24 inch maximum length. Each length of glass shall be furnished with a bronze gauge cock set and protector rods. The deaerator shall be supplied with a pressure gauge that has a 4-1/2 inch dial with a 0-60 psig range and a thermometer with a 50 to 300 F range. Packaged units are required to have both gauges bracket-mounted at eye level. The deaerator is to be hand cleaned with a solvent to SSPC- SP-1 standards prior to painting. Prime coated to not less than 1 mil thick and nish coated with an enamel paint to not less than 1 mil thick prior to shipment. Unit is to be knocked down for shipment. Piping is to be matched marked. Three bound Operating and Maintenance manuals to be provided. Warranty period to be twelve months after start-up or eighteen months after shipment, whichever comes rst.
H3-13
02-02
Feedwater Systems
NOTES
H3-14
02-02
Section H4
SURGE TANKS
CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ILLUSTRATIONS H4-3 H4-3 H4-4 H4-7
Figure H4-1. Surge Tank Dimensions and Ratings - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-4 Figure H4-2. Surge Tank Supports and Saddles, Details and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-6 TABLES Table H4-1. Surge Tank Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-3
H4-1
02-02
Surge Tanks
Feedwater Systems
This section contains information on the complete line of surge tanks ranging in sizes from 300 to 3000 gallon capacities. The Cleaver-Brooks Surge Tank products provide additional storage time and handle volume-swings in condensate returns. Because condensate return volume is largely unpredictable, a surge tank provides a means to collect intermittent condensate returns and supply water at a relative constant volume, while limiting discharge to drain. Contact your local Cleaver-Brooks authorized representative for component sizing information.
H4-2
02-02
Feedwater Systems
Surge Tanks
Table H4-1. Surge Tank Product Offering
MODEL NO. FLOODED CAPACITY (GAL.) SRG-300 300 SRG-450 450 SRG-600 600 SRG-900 900 SRG-1200 1200 SRG-1400 1400 SRG-1600 1600 SRG-2000 2000 SRG-2500 2500 SRG-3000 3000 NOTE: Model number (example, SRG-300) is: SRG = surge tank. 300 = 300 gal. capacity.

The following features and benets apply to Cleaver-Brooks Surge Tank Products. ASME Heads: Assures vessel quality in materials and fabrication. 1/4" Thick (Minimum) Shell: Quality construction. Longer material life. Boosts Condensate Return Pressure: Acts as a collecting point for low pressure and gravity returns. Allows pumping of returns to a pressurized vessel. Accepts Gravity Returns: Vessels are vented to atmosphere, therefore providing no pressure resistance that would inhibit gravity return.
water makeup to supplement condensate only when necessary to meet boiler demand. This translates into reduced fuel costs for heating boiler feedwater. Standard Equipment Surge tank. Thermometer. Gauge glass.
PRODUCT OFFERING
Information in this section applies directly to Cleaver- Brooks package surge tanks ranging from 300 to 3,000 gallon capacity. Contact your local Cleaver-Brooks authorized representative for larger capacities. The product offering for surge tanks is shown in Table H4-1. Surge tanks can reduce dependance on cold, untreated raw water to replace boiler system losses, by collecting condensate for re-use in the boiler. Dedicated surge tanks are required when intermittent peak loads of condensate can exceed the surge capacity of the deaerator. The surge tank receives returning condensate and is supplemented by raw make-up water to maintain the desired operating level. Condensate and make-up water mix into a blend temperature as determined by the percentage of each. The surge tank is vented to atmosphere. Surge tanks are designed to work with the deaerator. They can be packaged with transfer pumps, stand and controls of the same sturdy construction as the deaerator. Custom arrangements are also available. Contact local Cleaver-Brooks authorized representative for component and sizing information. Surge tanks provide additional storage time and handle volume swings in condensate return. Surge tanks are used when gravity or pumped condensate returns do not have enough pressure to enter the deaerator on their own. Water and treatment costs are reduced by recycling condensate that has already been treated. Integral control automatically introduces cold
Required tappings, and manway. Optional Equipment ASME code tank. Water level controller with make-up valve. Three valve bypass and strainer. Suction shutoff valve. Suction strainer. Suction exible tting. Discharge check valve. Discharge shutoff valve. Discharge pressure gauge. Discharge manifold. High water alarm. Low water alarm. Low water pump cut off. Condensate diffuser tube. Control panel. Transfer pump and motor. Recirculation orice or relief valve. Insulation and lagging.
H4-3
02-02
Surge Tanks
Epoxy lining. Magnesium anode (not available with lined tanks). Chemical feed quill. Drain valve. Stand. Packaging Fully packaged, factory piped and wired.
Feedwater Systems
Half packaged, suitable for eld erection with interconnecting piping and wiring by others.

Dimensions and ratings for surge tanks are shown in Figure H4-1 and H4-2.
NOTES: 1. Mounted on packaged units only. 2. Suction piping includes strainer, gate valve and flexible connector. 3. All couplings are 3000# F.S. 4. All flanges are 150# F.F. except as noted. 5. Customer to plug all fittings not being used. 6. Mount tank above pump at elevation necessary for static head including safe allowance for piping friction as approved by pump manufacturer. 7. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension prints. 8. Add suffix P to Model no. for packaged units (SRG45-P). 9. Using Warren #377 float cage - dimension N may change with other controls - contact your local Cleaver-Brooks authorized representative. 10. No interconnecting piping or wiring furnished on non-packaged units unless specified, contact your local Cleaver-Brooks authorized representative for specific piping or wiring furnished on packaged assemblies. 11. Weights shown are without controls or packaging - contact your local Cleaver-Brooks authorized representative for additions. 12. Optional tank sizes available - contact your local Cleaver-Brooks authorized representative. 13. Lifting lugs are for lifting empty tank only. 14. Raw water make-up should first pass through a water softener if hardness is present. STAND BASE DIMENSIONS Tank Capacity (gal) A1 B2 C3 D4 E5 FZ Outside Length CL to CL Anchor Bolt Holes Outside Width CL to CL Anchor Bolt Holes 300 61 56 49 46 1 7/8 450 60-1/2 55-1/2 58 55 1 7/8 600 84-1/2 79-1/2 58 55 1 7/8 900 100 95 62 59 1 7/8 1200 121-3/4 115-3/4 60-1/2 57-1/2 1 7/8 1400 94 88 71 68 1 7/8 1600 108-1/2 102-1/2 71 68 1 7/8 2000 95-1/2 89-1/2 81 78 1 7/8 2500 119-1/2 112-1/2 83 80 1-1/8 1 3000 105-1/2 102-1/2 86-1/2 79-1/2 1-1/8 1
Figure H4-1. Surge Tank Dimensions and Ratings - Sheet 1 of 2 H4-4

02-02
Feedwater Systems
Surge Tanks
STORAGE TANK DETAIL AND DIMENSIONS Tank Capacity (gal) Tank Weight (b) Flooded Weight (lb) Tank Size (Dia X Length) A B C D E F G H J K L M N 54 11 10 51 54 14 10 57 300 935 3605 36x80 6 23-1/2 32 40 57-1/2 8-1/2 9-1/2 450 1095 4905 42x84 6 23 32-1/2 42 59 9-1/2 11 600 1330 6360 42x109 8 30 45 60 82 9-1/2 14 900 1690 9195 48x124 12 34 52 69-1/2 91-1/2 10-1/2 14 1200 2420 12480 48x164 20 52 68 91-1/2 123-1/2 10-1/2 28 1400 2625 14595 60x125 12 34 50 66 88 12-1/2 14 1600 2765 16235 60x143 14 43 55 75 104 12-1/2 21 2000 3255 20610 72x131 15 37 51 64-1/2 86-1/2 14-1/2 17 2500 3680 24505 72x155 15 41 59 84-1/2 110-1/2 14-1/2 19 3000 4370 29240 84x138 15 36 52-1/2 70-1/2 91-1/2 16-1/2 16
Contact Your Local Cleaver-Brooks Authorized Representative Contact Your Local Cleaver-Brooks Authorized Representative 76 14 10 57 89-1/2 16 12-1/2 63 115-1/2 15 12-1/2 63 86 20-1/2 19-1/2 75 97 20-1/2 19-1/2 75 84-1/2 25-1/2 25 87 106-1/2 29-1/2 25 87 90-1/2 31 30 99
TANK CONNECTION SIZES Tank Capacity (gal) 1 2 3 4 5 Low Pressure Return (2) Vent Cold Water Inlet Overflow Connection Pump Suction (For Each Pump) 300 3 NPT 3 NPT 1-1/4 NPT 3 NPT 450 3 NPT 3 NPT 1-1/4 NPT 3 NPT 600 3 NPT 3 NPT 1-1/4 NPT 3 NPT 900 3 NPT 3 NPT 1-1/4 NPT 3 NPT 1200 4 NPT 4 NPT 1-1/4 NPT 4 NPT 1400 4 NPT 4 NPT 1-1/4 NPT 4 NPT 1600 4 NPT 4 NPT 1-1/4 NPT 4 NPT 2000 4 NPT 4 NPT 1-1/4 NPT 4 NPT 2500 4 NPT 4 NPT 1-1/4 NPT 4 NPT 3000 4 NPT 4 NPT 1-1/2 NPT 4 NPT
Contact Your Local Cleaver-Brooks Authorized Representative ITEM LIST
6 7 8 9 10 11 12 13 14 15 16 17 18
High Temperature Return (3 NPT) Suction Piping (Optional) (For Each Pump) (Note 2) Pump/motor (Optional) Manway (11 X 15) Diffuser Tube (2-1/2 NPT) (Optional) Makeup Valve (Optional) Gauge Glass Assembly Control Panel (Optional) Drain (2 NPT) Thermometer (3/4 NPT) Level Alarms (1 NPT (Optional) Level Control (1-1/2 NPT) (Optional) Recirculating Connection (1 NPT) (For Each Pump) Sizes Listed for items15 thru 18 are for Tank Connections Only.
Fighure H4-1. Surge Tank Dimensions and Ratings - Sheet 2 of 2
H4-5
02-02
Surge Tanks
Feedwater Systems
TANK CAPACITY (GALLONS) 300 AA AB AC AD AE AF AG AH AJ AK AL AM AN AP AR AS 55-1/2 59-1/2 31-3/4 29-1/2 5 2 4 5/8 12-1/2 3/4 N/A N/A N/A N/A N/A N/A 450 55 59 36-3/4 34-1/2 6-1/8 2 4 3/4 14-1/2 7/8 N/A N/A N/A N/A N/A N/A 600 79 83 36-3/4 34-1/2 6-1/8 2 4 3/4 15 7/8 N/A N/A N/A N/A N/A N/A 900 93-1/2 99-1/2 40-1/2 38 7-1/4 3 6 3/4 15-1/2 7/8 N/A N/A N/A N/A N/A N/A 1200 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 4-1/4 115-3/4 121-3/4 46-1/2 38 24-1/2 1400 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 6-1/8 88 94 57 44-3/4 18-1/2 1600 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 6-1/8 102-1/2 108-1/2 57 44-3/4 20-1/4 2000 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 7-1/2 89-1/2 95-1/2 67 52 20-1/2 2500 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 7-1/2 113-1/2 119-1/2 67 52 20-1/2 3000 N/A
VENT CAPACITY CHART SIZE (NPT) 1 N/A N/A N/A N/A N/A N/A N/A N/A N/A 7-3/4 94-1/2 100-1/2 77-1/2 62 21-7/8 1-1/4 1-1/2 2 2-1/2 3 4 5 6 8 CAPACITY (lbs/hr) 175 350 525 1000 1600 2800 4800 10500 17000 35000
Values given based on: 1) 50 ft. equivalent pipe length. 2) Schedule 40 pipe 3) 2 psi back pressure 4) Vent capacities should be compared with anticipated venting needs. Oversized vents are available.
Figure H4-2. Surge Tank Supports and Saddles, Details and Dimensions
H4-6
02-02
Feedwater Systems
Surge Tanks
The following sample specications are provided by Cleaver-Brooks to assist you in specifying your customers specic needs and application 1.0 Surge Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 Make Up Valve and Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Transfer Pump and Motor Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 Surge Tank Cleaver-Brooks Model _________________ shall be an atmospheric, horizontal Surge Tank. The surge tank shall receive returning condensate and supplement make up water to maintain the desired operating level. Condensate and make up water mix into a blended temperature, as determined by the percentage of each. The surge tank shall be vented to atmosphere. The collected water is then transferred to the deaerator. The surge tank shall have _______ minutes of storage and have a capacity of _______ gallons ooded. The tank shall be ____" diameter x ______" long. An 11" x 15" elliptical manhole shall be provided for access. All nozzles shall be 3000 lbs forged steel couplings. Heads shall be ASME torispherical type (at heads are not acceptable) constructed of ASTM A516 GR 70 carbon steel with a minimum thickness of 0.25". Shell plate to be fabricated of ASTM A36 carbon steel with a minimum thickness of 0.25". The surge tank loads shall be as specied in the following table. Load Specications
LOAD Make up Low Temp Returns High Temp Returns PERCENTAGE LBS/HR TEMP PRESSURE 20 psig Minimum
H4-7 H4-8 H4-9 H4-9
1.1 Optional The tank shall be designed in accordance with Section VIII of the ASME Pressure Vessel Code for ______ psig, and stamped accordingly. Certication shall be required. Joint efciencies to be 70% circumferential per table UW-12, which does not require stress relieving or nondestructive examination. 1.2 Optional The tank shall be factory-insulated and lagged with blanket insulation, pins, clips, and a durable steel jacket. Block-type insulation is not acceptable. The blanket insulation is to be berglass, 2" thick, 1 lb/cu-ft, and have a rating of R3.85. Pins are to be located on 18" centers and holding clips attached. The steel jacket or lagging shall have a shell thickness of 22 gauge (0.299") minimum and head thickness of 12 gauge (0.1046") minimum. 1.3 Optional The tank shall be factory-lined with a high quality ___________ epoxy lining. The lining is to be applied to a sandblasted (SSPCSP-5) white metal surface. Spray-apply 4 to 6 coats, with each dry coat being approximately 1.5 mils dry, for a total thickness of 6 mils dry, minimum. Lining to be Holliday spark tested using low voltage and a wet sponge to ensure uniform coating free of pin holes. Magnesium anodes shall not be acceptable in this application. The lining is to be suitable for temperatures up to ______ F. 1.4 Optional The magnesium or sacricial anode shall provide cathodic protection against galvanic corrosion. This rod shall be 1-5/16" diameter with a 1/4" steel core to assure a good electrical contact and added strength. The design shall have a small weep hole to signal it has been consumed. Linings shall not be acceptable in this application.
H4-7
02-02
Surge Tanks
1.5 Optional
Feedwater Systems
The high-temperature diffuser or sparge tube shall be located beneath the normal tank water level. The tube shall be constructed of 2" pipe. This tube shall provide even distribution and blending of high-temperature condensate returns. 1.6 Optional The chemical feed quill shall be located beneath the normal tank water level. The quill material shall be constructed of stainless steel. The tube shall provide even distribution and blending of chemical. 1.7 Optional The basic surge tank shall be equipped with the following trim and accessories. Piping on packaged units shall comply with ASME Power Piping Code B31.1. 2.0 Make Up Valve and Controller 2.1 Option - Mechanical ____ " inlet water regulating lever valve with ______ body and _______ connections. The valve Cv shall not exceed ______, and shall be rated for _____ gpm at ______ psig inlet pressure. The pressure drop across the valve shall not exceed a delta-P of 10 psig. This valve shall be suitable for temperatures up to 300 F. The valve manufacture shall be _________, Model _______ . This valve shall be mechanically controlled by an external oat cage with cast iron body and 8" stainless steel oat. The oat cage manufacturer shall be ____________, Model __________. 2.2 Option - Electronic ______" inlet water motorized regulating valve with steel body and threaded NPT connections. Motor shall be 110V bi-directional type, with a permanently lubricated gear train, and directly coupled to the valve stem. The valve Cv shall not exceed _____ and be rated for_______ gpm at ________ psig inlet pressure. Valve shall not exceed a delta-P of 10 psig. This valve shall have teon seats and be suitable for temperatures up to 300 F. The motorized valve manufacturer shall be _________. This valve shall be electronically controlled by a solid state control with internally mounted capacitance probes. The electronic solid state control shall be able to set desired level point and acceptable deviation. The electronic solid state control shall include a selection for automatic and manual operating mode. The internals shall include two additional probes for high and low water alarm. The controller manufacturer shall be Cleaver-Brooks, Model TW82. A solenoid valve and oat switch is not acceptable. (Available only in the U.S.) 2.3 Option - Pneumatic _______" inlet water diaphragm actuated regulating valve with cast iron body and _____ connections. The valve shall be globetype with proportional control and a spring-opposed diaphragm actuator arranged for 3 - 15 psig operating signal. The valve shall be normally open on loss of air. The valve Cv shall not exceed _____ and be rated for ________ gpm at ______ psig inlet pressure. Valve shall not exceed a delta-P of 10 psig. This valve shall have stainless steel trim with TFE packing and be suitable for temperature up to 410 F. The diaphragm actuated valve manufacturer shall be ___________, Model _______. This valve shall be pneumatically controlled by an external proportional type sensor. The sensor shall be a 14" displacer that produces a pneumatic output signal. The controller manufacturer shall be _____________, Model __________. A lter regulator is to be provided to reduce 50 psig instrument air supply to 3 - 15 psig for proper operation. 2.4 Optional The make up valve shall include a ANSI Class 125 lb three-valve bypass with inlet Y-type cast iron strainer. Strainer screen to be removable and of stainless steel construction. 2.5 Optional High level alarm switch. This shall be an externally mounted oat-type switch. The switch shall make contact on rise and break on fall. Float cage construction shall be cast iron. (Not required with electronic make up controller.) 2.6. Optional Low level alarm switch. This shall be an externally mounted oat-type switch. The switch shall make contact on fall and break on rise. Float cage construction shall be cast iron. (Not required with electronic make up controller.)
H4-8
02-02
Feedwater Systems
2.7 Optional
Surge Tanks
Suction piping for pumps shall consist of a gate valve, cast iron Y-type strainer with replaceable stainless steel screen and exible connector or hose. This piping assembly shall be 125 lb class construction. The vortex breaker shall be located in the tank nozzle. Manifold suction lines are not acceptable. 3.0 Transfer Pump and Motor Set (Optional) Quantity ______, centrifugal type transfer pump and motor set. Turbine type pumps are not acceptable in this application. Pump to be rated for _______ gpm at ________ feet TDH with ______ feet NPSH required. Pump to be _______ materials of construction as dened by the Hydraulic Institute, and have _______ seals for a maximum water temperature of 212 F. Pump impeller to be hydraulically balanced. The pump shall be mounted on a steel baseplate and exibly coupled with an OSHA type coupling guard to a ________ hp, ________ phase, _______ Hz, ________ Volt, _____ rpm, _______ enclosure motor. Motor to be non-overloading at the rated condition without using any portion of the service factor. Pump and motor set to be factory aligned prior to shipment. Pump manufacturer to be _________, Model _______, size _____ " x _______ ". A stainless steel recirculation orice is to be supplied with the pump and shipped loose for eld installation to provide minimum bypass ow. 3.1 Optional The stand shall elevate the surge tank to provide the net positive suction head required by the pump at the rated condition to prevent cavitation. The stand shall be constructed of heavy square steel tubing for the legs and 1/4" steel plate covering the oor. 4.0 Control Panel 4.1 Optional - Base Control panel shall be in a NEMA 1 enclosure and wired to the National Electric Code. The wire shall be black number coded. The assembly is to contain individual motor starters with 120 Volt holding coil and fuse protection. Individual green oil-tight pump run lights shall be provided. All switches and lights to have nameplate identication. The assembled panel shall be given a factory continuity test prior to shipment. 4.2 Optional - Electric Components Audible and visual high and low water alarm function shall be provided by a bell or horn with silence switch and individual red oiltight lights. Control circuit transformer to supply 110-120 Volts, single-phase power supply. The transformer shall be mounted, wired and fused. Auxiliary contacts shall be furnished for chemical feed pump initiation. Contacts shall be normally open. 4.3 Standard The surge tank shall have a gauge glass assembly that covers the entire tank diameter. The gauge glass shall be quartz 0.625 inch diameter by 24-inch maximum length. Each length of glass shall be furnished with a bronze gauge cock set and protector rods. The surge tank shall be supplied with a thermometer with a 50 to 300 F range. The surge tank is to be hand cleaned with a solvent to SSPC- SP-1 standards prior to painting. Prime coated to not less than 1 mil thick and nish coated with an enamel paint to not less than 1 mil thick prior to shipment. Unit is to be knocked down for shipment. Piping is to be matched marked. Warranty period to be twelve months after start-up or eighteen months after shipment, whichever comes rst.
H4-9
02-02
Surge Tanks
Feedwater Systems
NOTES
H4-10
02-02
Section H5
BOILER FEED SYSTEMS
CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-3 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-3 Simplex Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-3 Duplex Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-3 Dual Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-4 Triplex Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-4 Boiler Feedwater Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-4 DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-4 SELECTION GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-4 Optional Steam Preheating Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-4 PACKAGE CONCEPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-10 Intermittent (On-Off) Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-10 Pump Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-10 Pump Total Dynamic Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-10 Pump Material of Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-10 Receiver Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-11 Receiver Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-11 Optional Steam Preheater Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-11 Preheater Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-11 Make-up Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-11 SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-12
H5-1
02-02
Boiler Feed Systems
Feedwater Systems
ILLUSTRATIONS Figure H5-1. Dimensions and Ratings for Boiler Feed Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-5 TABLES Table H5-1. Boiler Feedwater System Tank Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-3 Table H5-2. Simplex and Duplex System Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-6 Table H5-3. Dual System Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-7 Table H5-4. Triplex System Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-8 Table H5-5. Internal Steam Heater Assemblies for High Pressure System (30-250 psig Steam), Thermostatic Regulating Valve with Pressure Reducing Attachment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-9 Table H5-6. Internal Steam Heater Assemblies for Low Pressure System (10-15 psig Steam), Thermostatic Regulating Valve without Pressure Reducing Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-10 This section contains information on Cleaver-Brooks Boiler Feed Systems. Cleaver-Brooks boiler feed systems help maintain peak efciency and prolong the life of boilers where investment in a deaerator cannot be justied. Consisting of one or more feed pumps and a corrosion resistant receiver tank, the system automatically supplements condensate with makeup water to replace system losses. Cold water is heated by mixing with hot condensate and pumped to the boiler on demand. Information in this section addresses tank size and typical offering of Boiler Feed Systems.
H5-2
02-02
Feedwater Systems
Boiler Feed Systems

based on boiler size, pump requirements (ow, pressure, hp), and water storage requirements (tank size). Contact your local Cleaver-Brooks authorized representative for detailed component sizing information. Table H5-1 shows available tank sizes for boiler feedwater systems. When equipped with an automatic steam preheater, feedwater temperature can be maintained at 210 F. At this higher temperature, oxygen and carbon dioxide are released, reducing corrosion problems in the boiler. Pre-heating is recommended if return condensate constitutes 50% or less of the feedwater required. Cleaver-Brooks Packaged Feedwater Systems include pumps, control panel with magnetic starters, and necessary switches. Systems are available in simplex, duplex, dual and triplex arrangements. Custom arrangements are also available. Accessories include high temperature diffuser tube, automatic preheater, make-up valves, electrolytic corrosion inhibitor, and ASME tanks. Contact your local Cleaver-Brooks authorized representative for information on alternate Cleaver-Brooks/Aurora Pump Feed Systems. Simplex Units Simplex units include one pump set complete with open driproof motor on steel channel base with exible coupling between pump and motor, one large receiver mounted on structural steel stand, complete with make-up valve, gauge glass with shutoff valves, thermometer, and suction piping from receiver to pump with Y-type strainer, exible hose and gate valve. Duplex Units Duplex units are similar to simplex units, but with two pumps and one receiver. Magnetic starters (where required) are mounted in a NEMA I enclosure, with manual transfer switch for standby pump. Table H5-1. Boiler Feedwater System Tank Capacities
CAPACITY (GAL.) 45 75 100 200 270 340 500 750 1000

The following features and benets apply to Cleaver-Brooks Boiler Feed system products. All Pumps Deliver the Required Capacity at 210 F: Guaranteed pump performance. All Pumps Have Mechanical Seals (Standard): Reduces maintenance when compared to packing type seals. Tank Includes a Protective Lining: The vessel is lined with an epoxy coating, deterring corrosion of vessel steel due to dissolved gases. Specifically Designed for Compatibility With Cleaver-Brooks Boilers: Quick, accurate equipment selection. Single source responsibility. Proven performance. Provides Additional Storage Time and Handles VolumeSwings in Condensate Return: Feedwater tank collects intermittent condensate returns and supplies water at a relative constant volume. Minimizes problem from unpredictable condensate ow rates. Boosts Condensate Return Pressure: Acts as a collecting point for low pressure and gravity returns. Allows the introduction of returns to a high pressure vessel. Accepts Gravity Returns: Vessels are vented to atmosphere, providing no pressure resistance that would inhibit gravity return. Internal Pump Suction Vortex Breakers: Eliminates the problems of loss in NPSHA and cavitation associated with the creation of vortices within pump suction piping.
PRODUCT OFFERING
Information in this section applies directly to Cleaver- Brooks Feed Systems for low and high pressure (15 - 300 psig) boilers (15 - 800 horsepower). Selection of Boiler Feed Systems is
H5-3
02-02
Boiler Feed Systems

Dual Unit Dual units are similar to duplex units, except that receiver tank is sized for two boiler operation. Transfer switch is not required. Triplex Units Triplex units are similar to Dual units but with three pumps and one receiver. Boiler Feedwater Systems Standard equipment includes the following: Lined tank. Stand. Boiler feed pump and motor. Magnetic starter. Suction shutoff valve. Suction strainer. Suction exible ttings. Gauge glass. Internal oat make-up valve. Thermometer. Required tappings. Optional Equipment Preheating systems. High temperature diffuser tube. Manhole. External oat make-up valve. Electric alternator. Special electrical requirements. ASME Code tank. Discharge pressure gauge. Magnesium anode.
Feedwater Systems
SELECTION GUIDE
Refer to Table H5-2, 3, and 4 for basic feed system selection. Optional Steam Preheating Equipment All standard tanks are supplied with extra openings for preheating equipment. Preheating systems are provided with thermostatically controlled steam pressure regulators connected to the perforated tube installed in the tank by means of a special bushing. Feed systems with optional steam preheat also include a sentinel valve installed on the tank. On standard high pressure units (30 through 250 psi) the following equipment is furnished (refer to Table H5-5): 1. Perforated heater tube with special bushing. 2. Pressure/temperature regulating valve. 3. Strainer for regulating valve. 4. Pressure gauge. 5. Sentinel valve on tank. On standard low pressure units (10 through 15 psi) the following equipment is furnished (refer to Table H5-2): 1. Perforated heater tube with special bushing. 2. Temperature regulating valve. 3. Strainer for temperature regulating valve. 4. Pressure gauge. 5. Sentinel valve on tank.

Dimensions and ratings for boiler feed systems are shown in Figure H5-1.
H5-4
02-02
Feedwater Systems
1" NPT SENTINAL VALVE CONNETION
Boiler Feed Systems
NOTE: 1. Control panel not furnished with single phase motor. 2. Dim. H may not reflect overall unit width. Overall width may be greater due to pump/motor bases extending past stand posts and varying control panel depths, contact your local Cleaver-Brooks authorized representative. 3. All above dimensions while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension prints. TANK CAPACITY (GALLONS) 45 A B C D E F G H J K* L M N P R S T W X Y Z 18 69 64 55 35-1/2 26-1/2 43 34 2 4 1-1/4 3/4 6-1/4 6-1/4 11-3/4 33-1/4 33-1/4 5-1/2 3/4 5/8 2 75 24 75 70 58 33 26-1/2 40 34 2 4 1-1/4 3/4 9 9 11-1/2 30 30 7 3/4 5/8 2 100 24 75 70 58 47-1/2 26-1/2 55 34 2 4 1-1/4 3/4 9 9 16-1/4 42-3/4 42-3/4 7 3/4 5/8 2 200 30 89 84 69 58-1/2 39-1/2 67 43-1/2 3 4 2 1 11-1/2 11-1/2 14-1/2 55 55 10-1/2 3/4 5/8 3 270 36 95 90 72 54-1/2 39-1/2 63 43-1/2 3 4 2 1 14 14 13-1/2 51-1/2 51-1/2 13 3/4 5/8 3 340 36 95 90 72 69-1/2 39-1/2 78 43-1/2 3 4 2 1 14 14 17-1/4 64-3/4 64-3/4 13 1 7/8 3 500 42 109 104 83 73 44 84 49 3 4 2 1-1/2 17 17 19-1/2 68-3/4 68-3/4 16 1 7/8 3 750 48 115 110 86 85 44 96 49 3 4 2 1-1/2 19 19 22-1/2 79-1/4 79-1/4 19 1 7/8 3 1000 48 115 110 86 117 44 128 49 3 4 2 1-1/2 19 19 30-1/2 107-1/4 107-1/4 19 1 7/8 3 4 5 6 8 VENT CAPACITY CHART SIZE (NPT) CAPACITY (#/hr) 4800 10,500 17,000 35,000
Values given based on: 1) 50 ft. equivalent pipe length 2) Schedule 40 pipe 3) 2 psi back pressure 4) Vent capacities should be compared with anticipated venting needs. Oversized vents are available.
* See Vent Capacity Chart
Figure H5-1. Dimensions and Ratings for Boiler Feed Systems H5-5
02-02
Boiler Feed Systems
Feedwater Systems
Table H5-2. Simplex and Duplex System Selection

ACTUAL PUMP DISCHARGE PRESSURE (PSI) BOILER HR EVAP RATE TANK CAP. TANK SIZE DIA. X LENGTH 30 105 130 155 205 255 305 MAKE-UP VALVE (IN.) 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 1 1 1 1 1 1 1-1/2 1-1/2 1-1/2
BOILER OPERATING PRESSURE (PSI) 15 100 P-2D-1 2.4 P-2E-1 4.1 P-2E-1 4.1 P-2E-1 4.1 P-2F-2 6.9 P-2F-2 6.9 R-2G-2 8.3 R-2I-3 11 R-2I-3 11 S-2IA-3 15 S-3I-3 18 S-3IA-5 25 T-K-7-1/2 28 T-L-7-1/2 37 V-L-7-1/2 37 V-2EE-10 45 W-2FF-10 50 W-2GG-15 65 X-2JJ-15 81 X-2JJ-15 81 X-2JJ-15 81 125 P-2E-1-1/2 2.3 P-2F-2 5.0 P-2F-2 5.0 P-2F-2 5.0 P-2G-3 5.6 P-3F-3 7.9 R-3G-3 10 R-3G-3 10 R-3I-3 15 S-3I-3 15 S-3IA-5 18 S-K-7-1/2 21 T-L-10 28 T-2K-15 36 V-2EE-15 41 V-2L-15 50 V-2L-15 50 W-2GG-15 61 X-2JJ-15 72 X-2KK-20 83 Y-2KK-20 83 150 P-2F-2 3.0 P-2F-2 3.0 P-3E-3 4.1 P-3E-3 4.1 P-3F-3 6.9 P-3F-3 6.9 R-3G-3 8.3 R-3I-5 11 R-3I-5 11 S-3IA-5 14 S-L-10 21 S-L-10 21 T-2II-15 26 T-2K-15 34 V-2EE-15 38 V-2L-15 45 W-2GG-15 52 W-2JJ-15 66 X-2KK-20 81 X-2KK-20 81 Y-2KK-20 81 200 P-3E-3 2.0 P-3F-2 4.5 P-3F-3 4.5 P-3F-3 4.5 P-4F-3 6.7 P-4G-5 8.5 R-4G-5 8.5 R-4I-5 11.3 R-4I-5 11.3 S-4IA-7-1/2 14 S-2II-15 22 S-2II-15 22 T-2K-15 27 T-2EE-15 32 V-2L-15 38 V-3L-25 47 W-3GG-25 56 W-4GG-30 66 X-3KK-30 83 X-3KK-30 83 Y-3KK-30 83 250 2-3F-3 2.1 P-4E-3 2.8 P-4F-5 4.8 P-4F-5 4.8 P-4G-5 5.8 P-4I-7-1/2 6.9 R-4IA-7-1/2 8.3 R-5I-7-1/2 12 R-2II-15 17 S-2II-15 17 S-2II-15 17 S-2K-15 20 T-2L-20 28 T-3K-20 32 V-3L-25 42 V-3GG-25 48 W-4GG-30 58 W-3KK-30 70 300 P-4F-5 3.2 P-4F-5 3.2 P-4G-7-1/2 4.0 P-4G-7-1/2 4.0 P-5I-7-1/2 7.0 P-5I-7-1/2 7.0 R-5IA-10 10 R-5IA-10 10 R-2II-15 14 S-2II-15 14 S-2EE-20 17 S-2L-20 20 T-3K-20 27 T-3EE-25 32 V-3L-25 38 V-4L-25 45 W-4GG-30 52
15 20 25 30 40 50 60 70 80 100 125 150 200 250 300 350 400 500 600 700 800
1.0 1.4 1.7 2.1 2.8 3.5 4.1 4.8 5.5 6.9 8.6 10 14 17 21 24 28 35 41 48 55
45 45 45 45 45 45 75 75 75 100 100 100 200 200 270 270 340 340 500 500 750
18 x 43 18 x 43 18 x 43 18 x 43 18 x 43 18 x 43 24 x 40 24 x 40 24 x 40 24 x 55 24 x 55 24 x 55 30 x 67 30 x 67 36 x 63 36 x 63 36 x 78 36 x 78 42 x 84 42 x 84 48 x 96
P-D-1/2 5.0 P-D-1/2 5.0 P-D-1/2 5.0 P-D-1/2 5.0 P-E-1/2 7.0 P-E-1/2 7.0 R-F-1/2 10 R-F-1/2 10 R-G-1/2 12 S-H-3/4 17 S-H-3/4 17 S-I-3/4 20 T-IA-1 28 T-P-1-1/2 45 V-P-1-1/2 45 V-R-2 50 W-R-2 50 W-GG-3 68 X-HH-5 75 X-HH-5 75 Y-KK-7-1/2 83
NOTE: 1. Selection for intermittent operation through boiler level switches for 60 Hz applications only. 2. Prefix Model number with S Simplex or D for Duplex. 3. Example V-R-2: V-size tank is 260 gal, R-Model Pump, 2 hp motor. 50: 50 gpm capacity at rated discharge capacity on 210F water. 4. Contact your local Cleaver-Brooks authorized representative for information on 50 Hz applications.
H5-6
02-02
Feedwater Systems
Table H5-3. Dual System Selection
Boiler Feed Systems
ACTUAL PUMP DISCHARGE PRESSURE (PSI) BOILER HR EVAP RATE TANK CAP. TANK SIZE DIA. X LENGTH 30 105 130 155 205 255 305 MAKE-UP VALVE (IN.) 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 1 1 1 1 1 1 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2
BOILER OPERATING PRESSURE (PSI) 15 100 P-2D-1 2.4 P-2E-1 4.1 P-2E-1 4.1 P-2E-1 4.1 R-2F-2 6.9 R-2F-2 6.9 S-2G-2 8.3 S-2I-3 11 T-2I-3 11 T-2IA-3 15 V-3I-3 18 V-3IA-5 25 W-K-7-1/2 28 125 P-2E-1-1/2 2.3 P-2F-2 5.0 P-2F-2 5.0 P-2F-2 5.0 R-2G-3 5.6 R-3F-3 7.9 S-3G-3 10 S-3G-3 10 T-3I-3 15 T-3I-3 15 V-3IA-5 18 V-K-7-1/2 21 W-L-10 28 W-2K-15 36 X-2EE-15 41 X-2L-15 50 Y-2L-15 50 Y-2GG-15 61 Z-2JJ-15 72 Z-2KK-20 83 150 P-2F-2 3.0 P-2F-2 3.0 P-3E-3 4.1 P-3E-3 4.1 R-3F-3 6.9 R-3F-3 6.9 S-3G-3 8.3 S-3I-5 11 T-3I-5 11 T-3IA-5 14 V-L-10 21 V-L-10 21 W-2II-15 26 W-2K-15 34 X-2EE-15 38 X-2L-15 45 Y-2GG-15 52 Y-2JJ-15 66 Z-2KK-20 81 Z-2KK-20 81 200 P-3E-3 2.0 P-3F-2 4.5 P-3F-3 4.5 P-3F-3 4.5 R-4F-3 6.7 R-4G-5 8.5 S-4G-5 8.5 S-4I-5 11.3 T-4I-5 11.3 T-4IA-7-1/2 14 V-2II-15 22 V-2II-15 22 W-2K-15 27 W-2EE-15 32 X-2L-15 38 X-3L-25 47 Y-3GG-25 56 Y-4GG-30 66 Z-3KK-30 83 Z-3KK-30 83 250 2-3F-3 2.1 P-4E-3 2.8 P-4F-5 4.8 P-4F-5 4.8 R-4G-5 5.8 R-4I-7-1/2 6.9 S-4IA-7-1/2 8.3 S-5I-7-1/2 12 T-2II-15 17 T-2II-15 17 V-2II-15 17 V-2K-15 20 W-2L-20 28 W-3K-20 32 X-3L-25 42 X-3GG-25 48 Y-4GG-30 58 Y-3KK-30 70 300 P-4F-5 3.2 P-4F-5 3.2 P-4G-7-1/2 4.0 P-4G-7-1/2 4.0 R-5I-7-1/2 7.0 R-5I-7-1/2 7.0 S-5IA-10 10 S-5IA-10 10 T-2II-15 14 T-2II-15 14 V-2EE-20 17 V-2L-20 20 W-3K-20 27 W-3EE-25 32 X-3L-25 38 X-4L-25 45 Y-4GG-30 52
15 20 25 30 40 50 60 70 80 100 125 150 200 250 300 350 400 500 600 700
1.0 1.4 1.7 2.1 2.8 3.5 4.1 4.8 5.5 6.9 8.6 10 14 17 21 24 28 35 41 48
45 45 45 45 75 75 100 100 200 200 270 270 340 340 500 500 750 750 1000 1000
18 x 43 18 x 43 18 x 43 18 x 43 24 x 40 24x 40 24 x 55 24 - 55 30 x 67 30 x 67 36 x 63 36 x 63 36 x 78 36 x 78 42 x 84 42 x 84 48 x 96 48 x 96 48 x 128 48 x 128
P-D-1/2 5.0 P-D-1/2 5.0 P-D-1/2 5.0 P-D-1/2 5.0 R-E-1/2 7.0 R-E-1/2 7.0 S-F-1/2 10 S-F-1/2 10 T-G-1/2 12 T-H-3/4 17 V-H-3/4 17 V-I-3/4 20 W-IA-1 28
W-P-1-1/2 W--L-7-1/2 45 37 X-P-1-1/2 45 X-R-2 50 Y-R-2 50 Y-GG-3 68 Z-HH-5 75 Z-HH-5 75 X-L-7-1/2 37 X-2EE-10 45 Y-2FF-10 50 Y-2GG-15 65 Z-2JJ-15 81 Z-2JJ-15 81
NOTE: 1. Selection for intermittent operation through boiler level switches for 60 Hz applications only. 2. Prefix Model number with U for Dual. 3. Example X-R-2: X-size tank is 500 gal, R-Model Pump, 2 hp motor. 50: 50 gpm capacity at rated discharge capacity on 210F water. 4. Contact your local Cleaver-Brooks authorized representative for information on 50 Hz applications.
H5-7
02-02
Boiler Feed Systems
Feedwater Systems
Table H5-4. Triplex System Selection

ACTUAL PUMP DISCHARGE PRESSURE (PSI) TANK SIZE DIA. X LENGTH 30 105 130 155 205 255 305 MAKE-UP VALVE (IN.)
BOILER HR
EVAP RATE
TANK CAP.
BOILER OPERATING PRESSURE (PSI) 15 100 T-2F-2 6.9 T-2G-2 8.3 T-2I-3 11 T-2I-3 11 T-2IA-3 15 V-3I-3 18 V-3IA-5 25 W-K-7-1/2 28 W-L-7-1/2 37 X-L-7-1/2 37 X-2EE-10 45 Y-2FF-10 50 Y-2GG-15 65 Z-2JJ-15 81 Z-2JJ-15 81 125 T-3F-3 7.9 T-3G-3 10 T-3G-3 10 T-3I-3 15 T-3I-3 15 V-3IA-5 18 V-K-7-1/2 21 W-L-10 28 W-2K-15 36 X-2EE-15 41 X-2L-15 50 Y-2L-15 50 Y-2GG-15 61 Z-2JJ-15 72 Z-2KK-20 83 150 T-3F-3 6.9 T-3G-3 8.3 T-3I-5 11 T-3I-5 11 T-3IA-5 14 V-L-10 21 V-L-10 21 W-2II-15 26 W-2K-15 34 X-2EE-15 38 X-2L-15 45 Y-2GG-15 52 Y-2JJ-15 66 Z-2KK-20 81 Z-2KK-20 81 200 T-4G-5 8.5 T-4G-5 8.5 T-4I-5 11.3 T-4I-5 11.3 T-4IA-7-1/2 14 V-2II-15 22 V-2II-15 22 W-2K-15 27 W-2EE-15 32 X-2L-15 38 X-3L-25 47 Y-3GG-25 56 Y-4GG-30 66 Z-3KK-30 83 Z-3KK-30 83 250 T-4I-7-1/2 6.9 T-4IA-7-1/2 8.3 T-5I-7-1/2 12 T-2II-15 17 T-2II-15 17 V-2II-15 17 V-2K-15 20 W-2L-20 28 W-3K-20 32 X-3L-25 42 X-3GG-25 48 Y-4GG-30 58 Y-3KK-30 70 300
50 60 70 80 100 125 150 200 250 300 350 400 500 600 700
3.5 4.1 4.8 5.5 6.9 8.6 10 14 17 21 24 28 35 41 48
200 200 200 200 200 270 270 340 340 500 500 750 750 1000 1000
30 x 67 30 x 67 30 x 67 30 x 67 30 x 67 36 x 63 36 x 63 36 x 78 36 x 78 42 x 84 42 x 84 48 x 96 48 x 96 48 x 128 48 x 128
T-E-1/2 7.0 T-F-1/2 10 T-F-1/2 10 T-G-1/2 12 T-H-3/4 17 V-H-3/4 17 V-I-3/4 20 W-IA-1 28 W-P-1-1/2 45 X-P-1-1/2 45 X-R-2 50 Y-R-2 50 Y-GG-3 68 Z-HH-5 75 Z-HH-5 75
T-5I-7-1/2 7.0 T-5IA-10 10 T-5IA-10 10 T-2II-15 14 T-2II-15 14 V-2EE-20 17 V-2L-20 20 W-3K-20 27 W-3EE-25 32 X-3L-25 38 X-4L-25 45 Y-4GG-30 52
1 1 1 1 1 1 1 1 1 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2
NOTE: 1. Selection for intermittent operation through boiler level switches for 60 Hz applications only. 2. Prefix Model number with T for Triplex 3. Example Y-R-2: Y-size tank is 750 gal, R-Model Pump, 2 hp motor. 50: 50 gpm capacity at rated discharge capacity on 210F water. 4. Contact your local Cleaver-Brooks authorized representative for information on 50 Hz applications.
H5-8
02-02
Feedwater Systems
Boiler Feed Systems
Table H5-5. Internal Steam Heater Assemblies for High Pressure System (30-250 psig Steam), Thermostatic Regulating Valve with Pressure Reducing Attachment
HEATING RATE (GPM) MODEL NUMBER 50F TEMP RISE 100F TEMP RISE 150F TEMP RISE SIZE OF STEAM CONTROL VALVE & STRAINER (INCHES) MINIMUM STEAM SUPPLY LINE (INCHES) MINIMUM STEAM SUPPLY PRESSURE MAXIMUM STEAM SUPPLY PRESSURE
25PT-5-.75 17 9 6 3/4 1 30 50 25PT-5-.75 3/4 1 50 100 25PT-5-.5 1/2 3/4 100 125 25PT-5-.5 1/2 3/4 125 150 25PT-5-.5 1/2 3/4 150 200 25PT-5-.5S 1/2 3/4 200 250 25PT-5-.1 28 13 9 1 1-1/4 30 50 25PT-5-.75 3/4 1 50 100 25PT-5-.75 3/4 1 100 125 25PT-5-.5 1/2 3/4 125 150 25PT-5-.5 1/2 3/4 150 200 25PT-5-.5 1/2 3/4 200 250 25PT-5-1.25 37 18 12 1-1/4 1-1/2 30 50 25PT-5-.1 1 1-1/4 50 100 25PT-5-.75 3/4 1 100 125 25PT-5-.75 3/4 1 125 150 25PT-5-.5 3/4 1 150 200 25PT-5-.5 3/4 1 200 250 25PT-5-1.5 53 26 18 1-1/2 2 30 50 25PT-5-1.25 1-1/4 1-1/2 50 100 25PT-5-1 1 1-1/4 100 125 25PT-5-.75 3/4 1 125 150 25PT-5-.75 3/4 1 150 200 25PT-5-.75 3/4 1 200 250 25PT-5-2 92 42 28 2 2-1/2 30 50 25PT-5-2 2 2-1/2 50 100 25PT-5-1.25 1-1/4 1-1/2 100 125 25PR-5-1 1 1-1/4 125 150 25PR-5-1 1 1-1/4 150 200 25PT-5-.75 3/4 1 200 250 25PT-5-2.5 140 68 45 2-1/2 3 30 50 25PT-5-2 2 2-1/2 50 100 25PT-5-1.5 1-1/2 2 100 125 25PT-5-1.5 1-1/2 2 125 150 25PT-5-1.25 1-1/4 1-1/2 150 200 25PT-5-1 1 1-1/4 200 250 25PT-5-3 190 90 60 3 4 30 50 25PT-5-2.5 2-1/2 3 50 100 25PT-5-2 2 2-1/2 100 125 25PT-5-2 2 2-1/2 125 150 25PT-5-1.5 1-1/2 2 150 200 25PT-5-1.25 1-1/4 1-1/2 200 250 NOTE: Not applicable for steam pressure over 250 psi, if available steam pressure is over 250 psi, contact your local CleaverBrooks authorized representative.
H5-9
02-02
Boiler Feed Systems
Feedwater Systems
Table H5-6. Internal Steam Heater Assemblies for Low Pressure System (10-15 psig Steam), Thermostatic Regulating Valve without Pressure Reducing Attachment
HEATING RATE (GPM) MODEL NUMBER 50F TEMP RISE 13 18 25 44 70 92 100F TEMP RISE 6.5 8.7 12.6 22 35 46 150F TEMP RISE 4.2 5.9 8.4 14.6 23 31 SIZE OF STEAM CONTROL VALVE & STRAINER (INCHES) 1 1-1/4 1-1/2 2 2-1/2 FLG 3 FLG MINIMUM STEAM SUPPLY LINE (INCHES) 1-1/4 1-1/2 2 2-1/2 3 4
25T-5-1 25T-1.25 25T-5-1.5 25T-5-2 25T-5-2.5 25T-5-3
NOTE: 1. For operation on steam supply pressure less than 10 psig, consult your local Cleaver-Brooks authorized representative. 2. Specify available steam pressure when ordering.
PACKAGE CONCEPT
Cleaver-Brooks line of packaged catalog feed systems is based on the following parameters.
Pump Flow
One Boiler Horsepower is equal to an evaporation rate of 34.5 pounds of water per hour at 212 F. To convert the value to gallons per minute, divide by the weight of one gallon water, or 8.33 lbs, to obtain gallons per hour. Divide this value by 60 to determine the number of gallons per minute. The result of this calculation is 0.069 gallons per minute, which is the theoretical evaporation rate for each boiler horsepower. When selecting the boiler feed pump ow, it is necessary to provide for excess capacity to take care of the boiler load without running the pump continuously. For this reason, selections for intermittent boiler feed pumps are based on a value of 1-1/2 to 2 times the theoretical evaporation rate.
Intermittent (On-Off) Pump Operation

As the water level in the boiler falls to a certain level, contacts close in the oat switch on the boiler and the pump starts. As the water level in the boiler rises to a certain level, the contacts open in the oat switch on the boiler and the pump stops. The operation repeats as the water levels drop again. The intermittent operation, normally used on Cleaver-Brooks retube boilers, is well suited to the regenerative turbine pump, for the following reasons: The pump covers a broad range of pressures, which covers a wide boiler pressure range. Comparatively low capacities are ideal for the small and medium range boilers. The pump is allowed to operate at a nearly constant headcapacity point and not over the entire pump curve as with continuous operation using a modulating feedwater valve, normally used on large industrial watertube boilers. The pump can obtain rated ow and head at a relatively low speed. The pumps are run at 1750 rpm, which gives a longer desired life. The pump is exibly coupled to the motor, which reduces the possibility of heat transfer from the liquid being pumped to the driver.
Pump Total Dynamic Head

The pump head to be developed by a boiler feed pump that is returning water directly to the boiler must be equal to the boiler pressure, plus static head differences, plus friction losses in the piping, valves and any other equipment between the pump and the boiler. EXAMPLE: Boiler operating at 100 psig. CALCULATION: 100 psig (oper) + 5 psig (loss) x 2.31 (constant) 0.96 (specic gravity) = 225 TDH.
Pump Material of Construction

Material of construction for a boiler feed pump should be carefully selected for compatibility of the liquid being pumped. In general, the Cleaver-Brooks bronze-tted pump is best suited for most applications. Factors that will affect this decision are
H5-10
02-02
Feedwater Systems
water quality and treatment. An example: In situations when alkalinity is higher than a pH of 8.5, do not use a bronze-tted pump. There is no substitute for experience in selecting materials for pump construction. Previous experience in handling a particular application should be the main criteria. 1. 2.
Boiler Feed Systems

The risk of damage to the boiler caused by thermal shock is reduced. The dissolved oxygen content can be reduced, slowing corrosion and showing a savings in the chemical treatment program of the boiler. Oxygen in 212 F feedwater is roughly 1.8 cc/liter as opposed to 50 F feedwater, which is 5.9 cc/liter. The American Society of Engineers, in a paper called Consensus On Operating Practices For The Control of Feedwater and Boiler Water Quality in Modern Industrial Boilers, suggests dissolved oxygen limits that should be considered. A preheater by no means deaerates water to an acceptable level by itself.
Receiver Size
The receiver should be sized for a capacity sufcient to allow feed water for a minimum of 10 to 15 minutes of boiler operation at rated horsepower. The run time is essential because of unpredictable surges of condensate returns. Since 0.069 gpm is the theoretical rate of evaporation per boiler horsepower, the maximum tank size should be approximately 0.069 boiler hp x 10 minutes. If it is known that the receiver will see 100% make-up with no returns, a ve minute capacity tank can be substituted. The reduced storage capacity is acceptable, since the receiver will have a steady predictable load.
Preheater Components
Preheater Components include the following: 1. Perforated heater tube, also referred to as a diffuser or sparge tube. The tube is located under the water level in the tank, and its purpose is steam distribution. Regulating valve to control the incoming steam supply. When the steam supply pressure is between 10-15 psi, a one-element regulating valve (temperature sensor) is used. On higher pressure packages, when the steam supply is between 30-250 psi, a two-element regulating valve, sensing pressure and temperature, is used. The twoelement regulating valve is furnished and packaged with higher steam supply pressures, instead of one element regulating valve for added safety, even through the receiver is vented and pressurization should not occur. Strainer for arresting any dirt or scale carried over with the supply steam. For its protection, the strainer is located upstream of the regulating valve. Pressure gauge for monitoring down stream steam pressure from the regulating valve. Sentinel valve to warn if the receiver is pressurized, if the regulating valve fails, or a vent becomes plugged. The valve is not required by a code, but is added for safe operation.
Receiver Construction
Standardly, tanks are protected by three coats of a two-part, air cured, epoxy lining or by an optional hot-dipped galvanization process. The receivers are manufactured as a non-code tank for venting to atmosphere. As an option, Cleaver-Brooks offers receivers constructed for ASME Section VIII, Division 1 of the ASME Pressure Vessel Code. When an ASME Code receiver is required, contact your local Cleaver-Brooks authorized representative for additional factors to be considered in this application. Coded tanks supplied will normally be furnished unlined because of possible increased operating temperature limitations.
2.
3.
4. 5.
Optional Steam Preheater Size

Three basic factors are considered when sizing a preheater: 1. The heating rate in gallons per minute. It is generally assumed the same as the total evaporation rate of the boilers being supplied with water, unless otherwise specied. The temperature rise required to raise the temperature in the tank based on condensate returns and make-up water mixed inlet temperature to 212 F. The available steam supply pressure at the regulating valve is generally assumed the same as the operating pressure of the boiler from which the steam is being tapped, unless otherwise specied.
Make-up Valve Size

The valves are sized for the maximum theoretical evaporation rate of the boiler, with no condensate return as a supplement. The sizing criteria makes the water level in the receiver selfadjusting for any loss of condensate return. These parameters are based on more than 60 years experience at Cleaver-Brooks in the packaged boiler room equipment market, and should not be ignored.
2.
3.
Two basic benets are gained by supplying a preheat package.
H5-11
02-02
Boiler Feed Systems
Feedwater Systems
Boiler Feed System shall be Cleaver-Brooks Model _______________________ (Specify simplex, duplex, dual, or triplex) packaged boiler system suitable for ______gpm, at a discharge pressure of ___________ psig. (Refer to Tables H5-4, 5, and 6.) The unit shall consist of the following components: One (substitute two for duplex or dual; three for triplex) bronze-ringed, pump(s) certied by Cleaver-Brooks for a minimum of ________________ gpm or 212 F water at __________ psig. The pump(s) shall be guaranteed for one year against defects in workmanship and material. The pump(s) shall be equipped with mechanical seals for temperatures up to 225 F. One non-code welded receiver made of structural grade steel with epoxy resin lining applied to a clean surface to resist corrosion while in service. The tank shall be furnished with integral supports and connections for inlet, outlet drain, makeup valve, thermometer and gauge glass. Tank size shall be __________ inches diameter with _______ gallon capacity. One fresh water makeup valve consisting of a ____________ inch oat type mechanical valve suitable for tight shutoff against 100 psig inlet pressure. Piping between the receiver and the pump shall consist of one (substitute two for duplex or dual; three for triplex) section(s) containing a gate valve(s), one exible hose(s) and Y-type strainer(s) to ensure minimum pressure drop between receiver and pump. One (substitute two for duplex or dual,; three for triplex) 1750 rpm, 60 Hz, drip-proof motor(s) for __________ phase, _______ Volt operation. Motor(s) shall not be loaded in excess of NEMA service factor for integral drip-proof motors. Provide gauge glass (with shutoff valves) of proper size and tank thermometer.
H5-12
02-02
Section H6
CHEMICAL FEED SYSTEMS AND METERING PUMPS
CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H6-3 H6-3 H6-3 H6-3 H6-6
ILLUSTRATIONS Figure H6-1. Manual System Dimensions (By-Pass Feeders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-4 Figure H6-2. Manual System Dimensions (Shot Feeders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-4 Figure H6-3. Automatic System Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-5 TABLES Table H6-1. Automatic Chemical Feed System Pump Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-3
H6-1
02-02
Chemical Feed Systems and Metering Pumps
Feedwater Systems
This section contains information on a complete line of manual and automatic chemical feed systems and associated metering pumps. These products are used to treat boiler feed water and condition blowdown sludge to protect the boiler against corrosion and scaling.
H6-2
02-02
Feedwater Systems

Complete Standard Packaging Provides: Lower installation costs. Easy installation. Alternative Materials of Construction: Product selection to match system requirements. Custom Pump Selection: Piston or diaphragm. Direct Drive, Clamp Mounted Agitator: Ability to mix and dilute powdered materials. Ease of maintenance. Adjustable Pump Parameters: Ability to adjust pump output based upon system requirements. Controls chemical cost. Standard 6" Funnel on Manual Chemical Feed Systems: Less product loss due to spillage.

Dimension and rating information is shown in Figures H6-1 through H6-3, and Table H6-1.
ENGINEERING DATA
The V-5 Simplex Piston Pump and V-5 Duplex Piston Pump are used in this system. These pumps are of the high pressure, low volume, reciprocating plunger, positive placement type, ideal for use in feeding chemicals to hot water and steam boilers. These pumps are designed for trouble-free operation where a controlled volume of chemical treatment is required. Units have over 20 years of proven eld installations. All are equipped with relief valves for positive protection at all times. Max pump discharge pressure is 1000 psig. The stroke can be simply and quickly adjusted by loosening the nut and turning the head screw to the desired length stroke; then, re-tighten nut against the slide. The stroke adjustment (0 to maximum capacity) may be performed while the pump is running or when the pump is shut down. Table H6-1. Automatic Chemical Feed System Pump Ratings
MODEL TYPE STROKING RATE SIMPLEX V-5 - 1560 V-5 - 1530 V-5 - 1460 V-5 - 1430 V-5 - 1360 V-5 - 1330 V-5 - 1260 V-5 - 1230 (Std)A 60 30 60 30 60 30 60 30 DUPLEX V-5 - 2560 (Std) V-5 - 2530 V-5 - 2460 V-5 - 2430 V-5 - 2360 V-5 - 2330 V-5 - 2260 V-5 - 2230
A
PISTON DIA (IN.)
GPH MAX
PRODUCT OFFERING
Cleaver-Brooks chemical feed systems treat feedwater and condition blowdown sludge where an extra measure of protection against corrosion and scaling is required. Automatic systems are available for single- or multiple-boiler installations. They are fully packaged and can be equipped with either piston or diaphragm pump(s) capable of accurately injecting chemical from 0 to 6.2 gph at up to 1000 psig. Automatic Systems Tank materials: polyethylene, stainless steel, carbon steel or overpack (steel tank with polyethylene liner and cover). Tank sizes: 30 to 200 gal. Pressures: up to 1000 psig. Agitator included. Manual Shot Feeders Manual shot feeders are used for batch feeding of chemicals into closed loop or low makeup water systems. They are completely assembled and ready for installation for: Pressures: 125 to 300 psig. Capacities: 3/4 to 30 gal.
5/8 5/8 1/2 1/2 3/8 3/8 1/4 1/4
6.20 3.10 3.30 1.65 1.62 0.81 1.00 0.50
60 30 60 30 60 30 60 30
5/8 5/8 1/2 1/2 3/8 3/8 1/4 1/4
12.40B 6.20B 6.60B 3.30B 3.24B 1.72B 2.00B 1.00B
A. Unless otherwise specified, Model V-5 - Type 1560 pumps will be shipped for Simplex systems and Model V-5 - Type 2560 for Duplex systems. B. For both pumping heads. Specifications subject to change without notice.
H6-3
02-02
Feedwater Systems
TANK CAPACITY
A WIDTH (INCH)
B BODY (INCH)
C OVERALL HEIGHT (INCH)
CONNECTIONS IN OUT SAMPLE
3/4 Gal 1 Gal 1-1/2 Gal 2 Gal 2-1/2 Gal 5 Gal 10 Gal 18 Gal 25 Gal
4-1/2 6 6 8 8 10 10 14 18
12 10 12 10 12 15 29 32 28
31-3/4 28 30 28 30 33 47 50 46
1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2
3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8
1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2
By Pass Feeders Include:
Tank 1/2" screwed inlet 3/8" screwed outlet 3/8" flow control valve Sight glass with gauge valves and guards 1/2" sample valves 6" diameter funnel Tanks 5 gallon capacity and larger have three 12-inch support legs.
Figure H6-1. Manual System Dimensions (By-Pass Feeders)
TANK CAPACITY
A WIDTH (INCH)
B BODY (INCH)
C OVERALL HEIGHT (INCH)
CONNECTIONS IN OUT SAMPLE
3/4 Gal 1 Gal 1-1/2 Gal 2 Gal 2-1/2 Gal 5 Gal 10 Gal 18 Gal 25 Gal
4-1/2" 6" 6" 8" 8" 10" 10" 14" 18
12" 10" 12" 10" 12" 15" 29" 32" 28
26" 23" 25" 23" 25" 27" 42" 45" 41
1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2
1/2" 1" 1" 1" 1" 1" 1" 1" 1
1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2
Shot Feeders Include: Tank 1/2" screwed inlet 1/2" or 1" screwed outlet 1/2" sample valve 6" diameter funnel Tanks 5 gallon capacity and larger have three support legs.
Figure H6-2. Manual System Dimensions (Shot Feeders)
H6-4
02-02
Feedwater Systems
STAINLESS & CARBON STEEL TANKS CAPACITY (GAL.) B A C 50 100 150 200 D DIMENSIONS (INCHES) A 23 36 36 36 B 58 61 66 78 C 31 31 36 48 D 17 20 20 20 E 22 31 31 31 F 18 27 27 27
POLYETHYLENE TANKS CAPACITY (GAL.) B D A 30 55 100 150 C DIMENSIONS (INCHES) A 18 22 28 31 B 30 34 42 47 C 13 17 18 18 D 51 63 73 78
OVER PACK CHEMICAL SYSTEMS 50OP-1V5 90 The Over Pack chemical feed system is recommended for almost all industrial applications. A polyethylene liner and cover are inserted into a steel tank with welded steel frame and pump support.
17
22
Figure H6-3. Automatic System Dimensions
(Rev 7/97)
02-02
H6-5
Feedwater Systems
The following specications are provided by Cleaver-Brooks to assist you in specifying your customers requirements. 1.0 General Provide completely preassembled, packaged chemical feed system(s)/chemical metering pump(s), as manufactured by _______________. Package shall be hydraulically and electrically tested at the factory and shall be assembled to the fullest extent possible. Package shall be furnished with all required lubricants, special tools, and installation instructions. 2.0 Pump Pump capacity shall be adjustable through 100% of the range by manual micrometer dial while the pump is running or stopped. Pump stroking speed shall not exceed 60 spm. The pump shall be sized to deliver the required capacity at 85% of maximum stroke length. Stroke adjustment shall be a variable micrometer type mechanism, with the plunger powered through its entire travel. Lost motion designs are not acceptable. The pump shall include an automatic vent and rell mechanism on the hydraulic side, which operates once each stroke. The pump shall have an external hydraulic relief valve which is adjustable. Double ball check valves shall be provided on the discharge to ensure accurate repeatable metering. The pump valves shall be removable for cleaning or replacement without the need to disturb suction or discharge piping. The pump shall be eld convertible to automatic stroke adjustment without the use of special tools, and without the need to replace any major frame parts. The pump shall be furnished with a factory-mounted driver suitably sized for continuous operation at the maximum relief setting. The motor shall be (integrally mounted direct coupled ange mounted with exible coupling). No belts or pulleys should be used in the drive train or for capacity adjustment. 3.0 Feed System Complete chemical feed system(s) shall be furnished suitable for handling ___________________. Each system will consist of ______ pump(s), tank, piping, and accessories as dened below. Manufacturer will select all materials in contact with the chemical and guarantee their suitability for the particular service. Pump(s) shall be mounted below the tank. 4.0 Tank The tank(s) shall be constructed of (polyethylene/304SS/316SS/other) and furnished with a hinged or removable cover. Tank shall include connections for pump suction, drain, level gauge, chemical ll, dilution water, and relief valve return piping. Drain connection shall be separate from pump suction connection. Drain shall be located in the bottom of the tank for complete emptying of contents. Tank shall be furnished with (drain valve) (level switch) (level gauge). 5.0 Mixer An angle plate mount mixer with 304SS shaft and propeller shall be furnished. The mixer propeller shall operate at 1750 rpm. The purpose of the mixer shall be to (mix liquids/dissolve powder in liquid/create and maintain a suspension).
H6-6
02-02
Section H7
FILTERS
CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-3 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-3 Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-3 Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-3 DIMENSIONS, RATINGS, AND SIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-3 Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-5 Chlorine, Organics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-5 Particles Down to 10-Micron Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-5 Sand, Heavy Sediment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-5 Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-5 ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-6 SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-11 ILLUSTRATIONS Figure H7-1. Dimensional Data, Filter System Without Regeneration Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H7- 4 TABLES Table H7-1. Model CF Activated Carbon Media Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-6 Table H7-2. Model MF Multi-Layered Media Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-7 Table H7-3. Model SF Sand Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-8 Table H7-4. Model IF Iron Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-8 Table H7-5. Engineering Data (Filters) (Page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-9
H7-1
02-02
Filters
Feedwater Systems
This section contains information on water filters used for the removal of impurities from raw water. Filters discussed here remove: Chlorine and organics. Particles down to 10-micron size. Sand and heavy sediment. Iron.
H7-2
02-02
Feedwater Systems
Filters
Locking bayonet cover. Fine slotted tubular PVC distributor.

Complete Range of Sizes and Filter Media Available: Precisely match customer needs (system specic). Pre-Engineered Packaged Units Shipped From Stock: Short lead times. Minimum down time. Industrial Grade Multiport Control Valve: Long lasting. High reliability. Easy maintenance. Backwash Control Actuated On a Time Clock, Pressure Differential Switch, or Water Meter Basis: Versatility. Inlet and Outlet Pressure Gauges and Sample Cocks: Easy monitoring of system performance. Fully Assembled Manifold Piping: Ease of installation, lower installation costs. Heavy Duty Steel Tanks With Galvanized or Prime Coat Exterior Finish (Specialty Linings Optional): Corrosion resistance and longer life. Premium Grades of Filter Media: Optimum performance.
Automatic time clock operation. Automatic Units 20" - 42" Diameter: Structural steel legs. Double hot-dipped galvanized interior and exterior. ML and AC lters are epoxy lined with prime coat exterior. 20" - 30" have access handhole in top head and lower sideshell. 36" - 42" have 11" x 15" elliptical manhole in top head. PVC radial distribution. Automatic time clock operation. Automatic Units 48" Diameter and Larger: Adjustable jack support legs. Prime coat exterior. 12" x 16" elliptical manhole in top head. Header and lateral distribution system. Inlet and outlet pressure gauges. Air relief valve. Flanged tank openings. Automatic time clock operation.
Optional Equipment
ASME code tanks. Specialty tank linings. Skid mounted, fully pre-piped and wired. Automatic operation by pressure differential or water meter. Manual backwash controls. Backwash with water from auxiliary source.
PRODUCT OFFERING
The need for special lter equipment for removal of impurities can be readily determined by raw water analysis. Where lters are recommended, cost is quickly recovered by eliminating need for frequent equipment cleaning and servicing, inefcient performance, damage to system components, and premature equipment failure.
DIMENSIONS, RATINGS, AND SIZING

Dimensions for lter systems without regenerant tanks are shown in Figure H7-1.
Standard Equipment
Automatic Units 12" - 16" Diameter: Skirt type tanks. Epoxy lined interior. Painted exterior.
H7-3
02-02
Filters
Feedwater Systems
FILTER TANK SIZE (IN) AxB 20x54 24x54 30x54 36x60 42x60 48x60 54x60 60x60 72x60 84x60 96x60
SYSTEM DIMENSIONS SINGLE L1 20 24 30 36 42 48 54 60 72 84 96 TWIN L2 58 66 78 90 102 114 126 138 162 186 210 TRIPLE L3 96 108 126 144 162 180 198 216 252 288 324 QUAD W L4 134 150 174 198 222 246 270 294 342 390 438 28-1/2 33 40 46 53-1/2 64 70 76 88 100 114 72 75 78 89 91 86 87 89 93 97 101 38 42 48 54 60 66 72 78 90 102 114 H C
OTHER APPLICABLE DIMENS IONS D 15-1/2 18 21-1/8 24-1/8 27-1/8 35 38 41 47 53 41-1/4 E 43 43 43 43 43 36-1/2 37-1/4 38 41-1/4 43 45 F 3-1/4 3-1/4 4-5/8 4-5/8 6-5/8 6-5/8 6-5/8 6-5/8 6-5/8 6-5/8 6-5/8 G 5-3/8 5-7/8 11 11-1/4 14-1/4 14-1/2 14-1/2 14-1/2 14-1/2 53-1/4 53-1/4 I 3-9/16 3-9/16 4-1/2 4-1/2 6-7/16 6-7/16 6-7/16 6-7/16 6-7/16 6-7/16 6-7/16 J 4/12 4-1/2 9 9-1/2 10-7/8 11-1/4 12-7/8 12-7/8 12-7/8 17-3/4 17-3/4
NOTES: 1. All values are in inches. 2. System dimensions based on 18" space between pressure tanks.
Figure H7-1. Dimensional Data, Filter System Without Regeneration Tanks
H7-4
02-02
Feedwater Systems
Sizing
In addition to service ow, the selection of a lter system must take into account the available backwash ow rate. This is the most important function in the proper operation of a lter. A periodic backwash and rinse is required to cleanse and reclassify the lter media. Backwash ow rates are always higher than service ow rates and therefore limit the lter size that can be installed. As a general rule, select the largest lter that can be back washed with the ow rate available at the point of lter installation. Then note the service ow rate for the lter selected. If it is not adequate for the ow to be treated, a twin lter installed in parallel is required. A parallel installation will increase the service ow and permit each lter to be back washed separately with the existing water supply. Generally, lower ows produce higher quality water and a larger volume of treated water between backwashing. Cleaver-Brooks rates the performance of each lter as follows: Superior Recommended for most applications under all operating conditions. Best quality water. Maximum on line time between backwashing. Lowest pressure loss. Recommended for inuent suspended solids loads up to or greater than 300 ppm. High Well suited for many applications. Very good quality water. Moderate on line time between backwashing. Increased pressure loss. Recommended for inuent suspended solids loads less than 300 ppm. Utility Flow rates listed are at peak design: operation at higher ows not recommended. Satisfactory water quality. Shorter on line time. Higher pressure loss. Recommended for inuent suspended solids loads less than 150 ppm.
Filters
Chlorine, Organics
CB activated carbon lters (Table H7-1) remove free chlorine, some dissolved organics and sediment, down to 40-micron particle size, from boiler makeup water. By removing sediment, activated carbon lters also help control sludge buildup in boilers. They protect pretreatment equipment by: 1) removal of free chlorine, which is corrosive and attacks the ion exchange resin cross-linking agent in water softeners and dealkalizers, and the membranes in reverse osmosis equipment, and 2) removing organics which promote fouling in ion exchange beds, that can contaminate water supplies and cause foaming in boilers and heat exchange equipment. Periodic backwashing is required to remove collected matter from the lter bed. Flow rates: 3 to 226 gpm. Tank sizes: 12" to 72" dia. Operating temperatures: 40 F to 120 F.
Particles Down to 10-Micron Size

Multilayered lters (Table H7-2) are used for ner levels of ltration and for handling heavy ow rates. They remove sediment, suspended solids and colloidal matter, down to 10micron particle size, from boiler makeup water. They are highly effective in controlling sludge buildup. Periodic backwashing is required to remove collected matter from the lter bed. Flow rates: 8 to 393 gpm. Tank sizes: 12" to 60" dia. Operating temperatures: 40 F to 120 F.
Sand, Heavy Sediment

Sand lters (Table H7-3) can handle heavy loads in controlling sludge buildup. They remove heavy, large-particle sediment and suspended solids, down to 40-micron size, from makeup water. Periodic backwashing is required to remove collected matter from the lter bed. Flow rates: 3 to 170 gpm. Tank sizes: 12" to 72" dia. Operating temperatures: 40 F to 130 F.
Iron
Cleaver-Brooks iron lters (Table H7-4) remove both soluble and insoluble iron, suspended solids and colloidal matter down to 40-micron particle size from boiler makeup water. They are used to control sludge buildup caused by iron precipitation.
H7-5
02-02
Filters
Water pH must be at least 6.2. Occasional regeneration with potassium permanganate may be required. Flow rates: 3 to 226 gpm. Tank sizes: 12" to 72" dia. Operating temperatures: 40 F to 120 F.
Feedwater Systems
ENGINEERING DATA
Select a lter from the tables to produce the desired ow rate and pressure drop. Check to assure the required backwash ow rate is available. Twin lters may be required to produce maximum ow rate and still enable backwash with the existing piping system.
Table H7-1. Model CF Activated Carbon Media Filter

MODEL NUMBER WATER QUALITY PIPE SIZE SUPERIOR HIGH UTILITY BACKWASH RATE TANK SIZE DIA x SIDE SHELL IN. 12x54 14x60 16x60 20x54 24x54 30x54 36x60 42x60 42x60 48x60 54x60 60x60 72x60 72x60 FILTER MEDIA LOAD FLOOR SPACE REQ'D
HEIGHT
OPER WT
CFBIN. 2-1 3-1 4-1 5-1/2-1 7-1-1/4 12-1/2-1-1/2 18-2 25-2 25-2-1/2 34-3 44-3 54-3 78-3 78-4 1 1 1 1 1-1/4 1-1/2 2 2 2-1/2 3 3 3 3 4
FLOW PRESS. FLOW PRESS. FLOW PRESS. RATE LOSS RATE LOSS RATE LOSS GPM 3 4 6 9 13 20 28 38 38 50 64 79 113 113 PSIG 1 1 1 1 2 3 2 3 2 1 2 2 3 2 GPM 4.5 6 8 13 19 29 42 58 58 75 95 118 170 170 PSIG 2 3 3 2 3 4 4 6 3 2 3 4 7 3 GPM 6 9 11 17 25 39 57 77 77 100 127 157 226 226 PSIG 3 4 4 3 6 7 7 9 5 3 5 7 11 5
GPM 8.3 10 13.5 20 30 46 70 95 95 115 150 180 270 270
CU FT 2 3 4 5.5 7 12.5 18 25 25 34 44 54 78 78
IN. 13x21 15x23 17x25 21x29 25x33 31x40 37x48 43x56 43x57 49x64 55x70 61x76 73x88 73x90
IN. 60 66 66 72 74 79 90 92 92 86 87 89 93 93
LBS 450 550 700 100 1650 2700 4200 5800 5900 7100 9100 11400 15700 15800
NOTES: Filter Media Consists of Granular Activated Carbon. For chlorine removal only use the flow rates from the utility water quality column. For sediment and organic removal use the flow rates from the superior water quality column.
H7-6
02-02
Feedwater Systems
Filters
Table H7-2. Model MF Multi-Layered Media Filter

MODEL NUMBER WATER QUALITY PIPE SIZE SUPERIOR HIGH UTILITY BACKWASH RATE TANK SIZE DIA x SIDE SHELL IN. 12x54 14x60 16x60 20x54 20x54 24x54 24x54 30x54 30x54 36x60 36x60 42x60 42x60 48x60 48x60 54x60 54x60 60x60 60x60 FILTER MEDIA LOAD FLOOR SPACE HEIGHT REQ'D
OPER WT
MFBIN. 2-1 2-1/2-1 4-1-1/4 5-1-1/4 5-1-1/2 7-1-1/4 7-1-1/2 10-1-1/2 10-2 15-2 15-2-1/2 21-2-1/2 21-3 27-3 27-4 34-3 34-4 43-3 43-4 1 1 1-1/4 1-1/4 1-1/2 1-1/4 1-1/2 1-1/2 2 2 2-1/2 2-1/2 3 3 4 3 4 3 4
FLOW PRESS. FLOW PRESS. FLOW PRESS. RATE LOSS RATE LOSS RATE LOSS GPM 8 11 14 22 22 31 31 49 49 71 71 96 96 126 126 159 159 197 197 PSIG 5 6 7 6 3 9 5 10 6 9 5 7 6 6 3 8 4 10 5 GPM 12 16 21 33 33 47 47 74 74 106 106 144 144 188 188 239 239 295 295 PSIG 8 11 12 12 6 18 9 19 13 17 10 13 11 11 5 15 6 20 9 GPM 16 21 28 44 44 63 63 98 98 141 141 192 192 251 251 318 318 393 393 PSIG 12 17 18 19 10 29 16 26 20 27 15 20 16 17 8 22 10 31 13
GPM 11.5 15 20 30 30 45 45 75 75 105 105 150 150 180 180 240 240 300 300
CU-FT 2 2.5 4 5 5 7 7 10 10 15 15 21 21 27 27 34 34 43 43
IN. 13x21 15x23 17x25 21x29 21x30 25x33 25x34 31x40 31x41 37x46 37x48 43x53 43x54 49x64 49x66 55x70 55x72 61x76 61x78
IN. 60 66 66 72 72 74 74 79 79 90 90 92 92 86 86 87 87 89 89
LBS 500 690 850 1800 1850 2350 2400 3675 3700 5550 5650 8295 8350 10400 10500 12800 12900 15800 15900
NOTES: 1. Filter media consists of various size, distinctly layered sand. 2. All pressure drop data based on new filter media and 60 F water temperature 3. Backwash when pressure drop increases by 12-15 psig over pressure drop of a clean filter. 4. Consult Cleaver-Brooks for larger diameter tanks. 5. Allow a minimum of 24" above filter for access into top of tank.
H7-7
02-02
Filters
Table H7-3. Model SF Sand Filter
MODEL NUMBER WATER QUALITY PIPE SIZE SUPERIOR FLOW RATE IN. 2-1 3-1 4-1 6-1 9-1-1/4 14-1-1/2 20-2 28-2 28-2-1/2 34-3 44-3 54-3 78-4 1 1 1 1 1-1/4 1-1/2 2 2 2-1/2 3 3 3 4 BWA GPM 3 3 4 7 9 15 21 29 29 38 48 59 85 PRESS. LOSS PSIG 2 2 2 2 2 3 2 3 2 2 2 3 3 FLOW RATE GPM 4 5 6 10 14 22 32 43 43 57 72 88 127 HIGH PRESS. LOSS PSIG 3 4 4 3 4 5 5 6 4 4 4 5 6 UTILITY FLOW RATE GPM 5 6 8 13 19 29 42 58 58 75 95 118 170 PRESS. LOSS PSIG 5 5 6 5 6 7 7 9 6 5 6 7 9 BACKWASH RATE TANK SIZE DIA x SIDE SHELL IN. 12x54 14x60 16x60 20x54 24x54 30x54 36x60 42x60 42x60 48x60 54x60 60x60 72x60
Feedwater Systems
FILTER MEDIA LOAD
FLOOR SPACE REQ'D
HEIGHT
OPER WT
SFB-
GPM 10 13.5 15 25 35 60 85 115 115 150 190 230 330
CU-FT 2 3 4 6 9 14 20 28 28 34 44 54 78
IN. 13x21 15x23 17x25 21x29 25x33 31x40 37x46 43x53 43x54 49x64 55x70 61x76 73x88
IN. 60 66 66 72 74 79 90 92 92 86 87 89 93
LBS 490 650 850 1700 2250 3500 5300 7900 8000 9900 12200 15100 21700
NOTES: 1. Filter media consists of silica sand. 2. 4BWA - minimum 4" water supply required. FIlter manifold connections are 3" inlet/outlet and 3" backwash assist. 3. All pressure drop data based on new filter media and 60 F water temperature. 4. Backwash when pressure drop increases by 12-15 psig over pressure drop of a clean filer. 5. Consult Cleaver-Brooks for larger diameter tanks. 6. Allow a minimum of 24" above filter for access into top of tank.
Table H7-4. Model IF Iron Filter

MODEL NUMBER WATER QUALITY PIPE SIZE SUPERIOR FLOW RATE IN. 2-1 3-1 4-1 6-1 9-1-1/4 13-1-1/2 18-2 28-2 28-2-1/2 34-3 44-3 54-3 78-3 78-4 1 1 1 1 1-1/4 1-1/2 2 2 2-1/2 3 3 3 3 4 GPM 3 4 6 9 13 20 28 38 38 50 64 79 113 113 PRESS. LOSS PSIG 3 3 3 3 5 3 2 5 3 3 4 4 5 3 FLOW RATE GPM 5 6 8 13 19 29 42 58 58 75 95 118 170 170 HIGH PRESS. LOSS PSIG 5 5 6 6 7 6 4 9 5 5 6 7 9 6 UTILITY FLOW RATE GPM 6 9 11 17 25 39 57 77 77 100 127 157 226 226 PRESS. LOSS PSIG 7 8 8 8 10 9 6 13 8 7 9 10 15 9 BACKWASH RATE TANK SIZE DIA x SIDE SHELL IN. 12x54 14x60 16x60 20x54 24x54 30x54 36x60 42x60 42x60 48x60 54x60 60x60 72x60 72x60 FILTER MEDIA LOAD FLOOR SPACE REQ'D OPER WT
HEIGHT
IFB-
GPM 8.3 10 13.5 20 30 46 69 90 90 115 150 190 270 270
CU-FT 2 3 4 6 9 13 18 28 28 34 44 54 78 78
IN. 13x21 15x23 17x25 21x29 25x33 31x40 37x46 43x53 43x54 49x64 55x70 61x76 73x88 73x90
IN. 60 66 66 72 74 79 90 92 92 86 87 89 93 93
LBS 490 660 850 1550 2200 3600 5200 7500 7600 9800 10800 13900 20400 20500
Note: Filter media consists of manganese greensand. It must periodically be regenerated with potassium permanganate (KMnO ). 4
H7-8
02-02
Feedwater Systems
Filters
Table H7-5. Engineering Data (Filters) (Page 1 of 2)

MODEL NUMBER TANK SIZE (DIA x HT) PIPE SIZE (IN.) FREE MEDIA (CU-FT) BOARD (IN.) SUPPT BED (LBS) NO. OF DIST SERV FLOW (GPM) PRESS. LOSS (PSIG) PEAK FLOW GPM) PRESS. LOSS (PSIG) BACK WASH GPM DRAIN PIPE SIZE (IN.) SHIP WT (LBS) OP WT (LBS)
ACC-MFB 2-1 2-1/2-1 4-1-1/4 5-1-1/4 5-1-1/2 7-1-1/4 7-1-1/2 10-1-1/2 10-2 15-2 15-2-1/2 21-2-1/2 21-3 27-3 27-4 34-3 34-4 43-3 43-4 ACC-SFB 2-1 3-1 4-1 6-1 9-1-1/4 14-1-1/2 20-2 28-2 28-2-1/2 34-3 44-3 54-3 78-4 12x54 14x60 16x60 20x54 24x54 30x54 36x60 42x60 42x60 48x60 54x60 60x60 72x60 1 1 1 1 1-1/4 1-1/2 2 2 2-1/2 3 3 3 4 2 3 4 6 9 14 20 28 28 34 44 54 78 16 18 17-1/2 13 15 15 22-1/2 22 22 24 24 24 24 40 60 85 200 200 400 500 700 700 1000 1300 1800 2600 1 1 1 4 4 6 8 12 16 10 16 16 26 12x54 14x60 16x60 20x54 20x54 24x54 24x54 30x54 30x54 36x60 36x60 42x60 42x60 48x60 48x60 54x60 54x60 60x60 60x60 1 1 1-1/4 1-1/4 1-1/2 1-1/4 1-1/2 1-1/2 2 2 2-1/2 2-1/2 3 3 4 3 4 3 4 2 2.5 4 5 5 7 7 10 10 15 15 21 21 27 27 34 34 43 43 19 24-1/2 25 19 19 23-1/2 23-1/2 23 23 30-1/2 30-1/2 31 31 31 31 31 31 31 31 40 60 85 200 200 200 200 400 400 500 500 700 700 1000 1000 1300 1300 1800 1800 1 1 1 4 6 4 6 6 8 8 12 12 16 26 26 36 36 36 36
MULTI-LAYERED 8 11 14 22 22 31 31 49 49 71 71 96 96 126 126 159 159 197 197 SAND 3 3 4 7 9 15 21 29 29 38 48 59 85 2 2 2 2 2 3 2 3 2 2 2 3 3 5 6 8 13 19 29 42 58 58 75 95 118 170 5 5 6 5 6 7 7 9 6 5 6 7 9 10 13.5 15 25 35 60 85 115 115 150 190 230 330 3/4 3/4 1 1-1/4 1-1/4 2 2 2-1/2 2-1/2 3 3 4 6 386 534 701 1073 1545 2532 3630 4781 5385 6045 7566 9623 14727 490 650 850 1700 2250 3500 5300 7900 8000 9900 12200 15100 21700 5 6 7 6 3 9 5 10 6 9 5 7 6 6 3 8 4 10 5 16 21 28 44 44 63 63 98 98 141 141 192 192 251 251 318 318 393 393 12 17 18 19 10 29 16 26 20 27 15 20 16 17 8 22 10 31 13 11.5 15 20 30 30 45 45 75 75 105 105 150 150 180 240 240 240 300 300 3/4 3/4 1 1-1/4 1-1/4 1/1/4 1-1/4 2 2 2 2 2-1/2 2-1/2 3 3 3 3 4 4 377 483 621 955 982 1283 1314 2046 2066 3180 3391 3741 3761 5370 5888 6566 7087 8999 9213 500 690 850 1800 1850 2350 2400 3675 3700 5550 5650 8295 8350 10400 10500 12800 12900 15800 15900
H7-9
02-02
Filters
Feedwater Systems
Table H7-5. Engineering Data (Filters) (Page 2 of 2)

MODEL NUMBER TANK SIZE (DIA x HT) PIPE SIZE (IN.) FREE MEDIA (CU-FT) BOARD (IN.) SUPPT BED (LBS) NO. OF DIST SERV FLOW (GPM) PRESS LOSS PSIG) PEAK FLOW (GPM) PRESS LOSS (PSIG) BACK WASH GPM DRAIN PIPE SIZE (IN.) SHIP WT (LBS) OP WT (LBS)
ACC-CFB 2-1 3-1 4-1 5-1/2-1 7-1-1/4 12-1/2-1-1/2 18-2 25-2 25-2-1/2 34-3 44-3 54-3 78-3 78-4 ACC-IFB 2-1 3-1 4-1 6-1 9-1-1/4 13-1-1/2 18-2 28-2 28-2-1/2 34-3 44-3 54-3 78-3 78-4 12x54 14x60 16x60 20x54 24x54 30x54 36x60 42x60 42x60 48x60 54x60 60x60 72x60 72x60 1 1 1 1 1-1/4 1-1/2 2 2 2-1/2 3 3 3 3 4 2 3 4 6 9 13 18 28 28 34 44 54 78 78 16 18 17-1/2 13 15-1/2 17-1/2 26 22 22 24 24 24 24 24 40 60 85 200 200 400 500 700 700 1000 1300 1800 2600 2600 12x54 14x60 16x60 20x54 24x54 30x54 36x60 42x60 42x60 48x60 54x60 60x60 72x60 72x60 1 1 1 1 1-1/4 1-1/2 2 2 2-1/2 3 3 3 3 4 2 3 4 5-1/2 7 12-1/2 18 25 25 34 44 54 78 78 16 18 17-1/2 16 22-1/2 18-1/2 26 25-1/2 25-1/2 24 24 24 24 24 40 60 85 200 200 400 500 700 700 1000 1300 1800 2600 2600
ACTIVATED CARBON 1 1 1 4 4 6 8 8 12 16 16 26 26 26 3 4 6 9 13 20 28 38 38 50 64 79 113 113 IRON 1 1 1 4 4 6 8 8 12 16 16 26 26 26 3 4 6 9 13 20 28 38 38 50 64 79 113 113 3 3 3 3 5 3 2 5 3 3 4 4 5 3 6 9 11 17 25 39 57 77 77 100 127 157 226 226 7 8 8 8 10 9 6 13 8 7 9 10 15 9 8.3 10 13.5 20 30 46 69 90 90 115 150 190 270 270 3/4 3/4 1 1-1/4 1-1/4 2 2 2-1/2 2-1/2 3 3 4 6 6 356 489 633 983 1380 2232 3160 4361 4965 5522 6882 8813 12952 13403 490 660 850 1550 2200 3600 5200 7500 7600 9800 10800 13900 20400 20500 1 1 1 1 2 3 2 3 2 1 2 2 3 2 6 9 11 17 25 39 57 77 77 100 127 157 226 226 3 4 4 3 6 7 7 9 5 3 5 7 11 5 8.3 10 13.5 20 30 46 70 95 95 115 150 190 270 270 3/4 3/4 1 1-1/4 1-1/4 2 2 2-1/2 2-1/2 3 3 4 6 6 206 324 421 633 855 1407 2170 2731 3335 3652 4462 5856 8662 9113 450 550 700 1200 1650 2700 4200 5800 5900 7100 9100 11400 15700 15800
H7-10
02-02
Feedwater Systems
Filters
The following sample specications are provided by Cleaver-Brooks to assist you in meeting your customers requirements. 1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H7-11 2.0 Mineral Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-11 3.0 Upper Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-11 4.0 Lower Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-11 5.0 Main Operating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-11 6.0 Filter Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-12 7.0 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-12 8.0 Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-12 9.0 Guarantees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H7-12 1.0 General Furnish, install, and place in service an assembled vertical, pressure type, water ltration system of an approved design fabricated by a manufacturer regularly engaged in the production of water conditioning equipment. It shall be a Cleaver-Brooks Model ___ having ____ cubic feet of lter media in each lter tank. Service ow rate through each lter tank shall be ____ gpm at pressure loss not to exceed ____ psig. 2.0 Mineral Tank The mineral tank(s) shall be of welded construction of tank quality carbon steel. It shall be _____ " diameter with a _____ " straight shell with reinforced openings for pipe connections and an 11" x 15" manhole in the top head (for tank 30" diameter and smaller; two (2) 4" spin off handholes are provided in the top head and lower sideshell). The mineral tank shall be rated for 100 psig working pressure and hydrotested to 150 psig. Support legs shall be strap type - permanently welded to the lower tank head. Mineral tank(s) shall have both the exterior and interior protected with a hot dipped galvanized application prior to fabrication and shipment. Options: ASME Code 100 psig working pressure, 150 psig test pressure stamped and certied. Cold set epoxy polyamide internal lining 8-10 mils DFT, with external rust resistance prime coat, 2-3 mils DFT. (For activated carbon and multilayer lters, cold set epoxy lining must be used due to highly corrosive effects of activated carbon.) A minimum freeboard of 50% shall be provided for backwash expansion above the normal lter media bed level. 3.0 Upper Distributor The upper distributor system shall be of the single point bafe type. Constructed of Schedule-40 galvanized steel and ttings. 4.0 Lower Distributor The lower radial distribution system shall be the hub and radial type of Schedule-80 PVC construction with a sub-ll of 1/8" x 1/16" gravel covering the distributor system laterals with slotted full ow non-clogging replaceable polypropylene strainers. 5.0 Main Operating Valve The main operating valve on the lter shall be of the automatic multiport type, consisting of ve (5) individual diaphragm valves housed in a compact casting. These valves are to be pressure actuated by an external pilot valve, automatically or manually. The valve shall be manufactured by the same manufacturer as the entire ltering system. The valve guides, seats, and diaphragm shall be constructed of Noryl plastic. Pressure gauges and sample cocks to be provided on the inlet and outlet of the lter system. An automatic backwash control shall be provided to maintain a proper backwash and ush ows over wide variations of operating pressure. Controller shall contain no moving parts and require no eld adjustment. The regeneration sequence shall be the accepted standard, which is backwash, fast ush, and return to service.
H7-11
02-02
Filters
Feedwater Systems
An external PVC constructed eductor is to be provided to draw regenerant solution and rinse water to regenerate the lter media mineral. (On iron removal lters only.) The pipings shall be galvanized Schedule-40 galvanized steel with galvanized ttings. All face piping shall be preassembled to the tank in a professional manner. 6.0 Filter Media The lter media shall be S (No. 26 sand) for removal of sand and heavy sediment from water. The lter media shall be ML (Multi-Media) consisting of reverse grading of ne gravel, coarse gravel, red int sand, and activated carbon. The lter media shall be M (Manganese Greensand) that will be periodically regenerated with potassium permanganate (KMnO4). The lter media shall be AC (Granular Activated Carbon). 7.0 Controls Regeneration shall be controlled by a fully automatic time clock control (TCC) which is fully adjustable or a remote manual controller. For fully automatic operation, the regeneration shall be initiated by a calendar clock. A pointer shall indicate the cycle of operation at all times. When two (2) lters, or more, are required, a lockout shall be provided to allow only one (1) unit to regenerate at any one time. In the event of a power failure, a complete regeneration can be performed by manual operation of the external pilot valve. Control Options: Regeneration to be initiated by head loss across the lter(s). A delay timer is to be provided to prevent false backwashing due to pressure surges in the system. 8.0 Instructions A complete set of installation and operating instructions shall be included. 9.0 Guarantees Attrition loss of mineral is guaranteed not to exceed 3% per year for a period of three (3) years. All mechanical equipment is guaranteed for one (1) year against any defects in workmanship or materials. Any part proving defective will be replaced or repaired within this period. The manufacturer guarantees that under actual operating conditions, the mineral shall not be washed out of the system during the service run or backwashing period; that the turbidity and color of the efuent, by reason of passing through the lter system, shall not be less than the incoming water; and that the under-drain system, gravel, and mineral shall not become fouled, either with turbidity or by dirt, while operating as noted on manufacturers instructions.
H7-12
02-02
Section H8
SOFTENERS
Models SSE & FSE
Models SMR
CONTENTS MODELS SSE & FSE FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-3 MODELS SMR FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-4 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-5 Standard Equipment - SSE & FSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-5 Standard Equipment - SMR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-5 Optional Equipment - SSE & FSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-5 Optional Equipment - SMR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-5 Operating Specifications - SMR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-5 DIMENSIONS, RATINGS AND SIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-6 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-6 Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-6 Sizing Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-6 SAMPLE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-18
H8-1
02-02
Softeners
ILLUSTRATIONS
Feedwater Systems
Figure H8-1. SSE Model (Size 30 - 1200) Softener Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-7, 8 Figure H8-2. FSE Model (Size 30 - 600) Softener Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-9, 10 Figure H8-3. Crossover Twin (Size 30-300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-11 Figure H8-4. SMR Dimensions (Size 150-1050 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-12 Figure H8-5. Water Softener Sizing Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-17
TABLES Table H8-1. SSE Water Softener Ratings Polybond Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-13 Table H8-2. FSE Water Softener Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-14 Table H8-3. FSE Water Softener Ratings with Crossover Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-15 Table H8-4. SMR Water Softener Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-16 This section contains information on Cleaver-Brooks cation, ion exchange, and water softeners available in package designs for virtually any commercial or industrial application. Softeners should be used whenever raw water hardness exceeds 5 ppm. Cleaver-Brooks water softeners remove hardness, preventing scale buildup on heat transfer surfaces, while maintaining peak boiler efciency. Removing hardness also reduces the need for chemical treatment used to control scale.
H8-2
02-02
Feedwater Systems
Softeners
control after a power loss. A capacitor operates the microprocessor in case of short term power loss. An easy-to-read LCD display continuously displays system status and allows instant access to current operating conditions, including ow rate, total treated ow, remaining capacity, valve position and many more important features. The display is illuminated for easy reading, even in low-light conditions. Self-diagnostic electronics provide 24-hour per day review of the system, and stores historical data to allow system optimization and simplify troubleshooting. A built-in speaker can transmit this System Performance Analysis (SPA) data via regular telephone lines to a remote service center for computerized troubleshooting, or, data can be recorded for later transmission. Controls have a look-ahead feature. The main memory monitors operation, tracks data, then adjusts regenerations automatically for high- and low-water use periods. All controls are designed for use with Fleck regeneration valves as well as traditional valve nest operated systems. Prewired components with indexed cables make installation quick and simple, and eliminate the need for complicated wiring diagrams and wiring connection instructions. Low voltage 24-volt operation simplies installation and minimizes electrical hazards. Two models are available to meet varying needs: EDS/EDT, and VF. EDS/EDT controls are capable of operating one or two softener tanks in single, parallel, or alternating modes. VF controls can operate two, three, or four softener tanks in parallel, alternating, or variable ow mode. Each tank has its own owmeter, so that the control knows how much softening capacity remains in each tank. If water demand increases, the system can be expanded by adding more softener tanks, and the control can be reprogrammed to handle the larger system. If one softener tank is taken of-line, the VF control adjusts the remaining tanks to maintain the same system ow rate. It also staggers tank regeneration to prevent all tanks from being exhausted simultaneously, thus maintaining sufcient softened water ow to the boiler or process need. In variable mode, the VF control monitors ow rate and switches tanks into service to meet changes in system demand, thus making sure that sufcient softened water is available, and that each tank is efciently used. H8-3
02-02
MODELS SSE & FSE FEATURES AND BENEFITS

Quality Constructed Tanks: Two types of softener resin tanks are available to meet environmental requirements. Both rugged lined steel or berglass lined plastic (FRP) vessels are available. Exclusive Polybond tanks are made of industrial grade steel. The tank interior is lined with a heat-fused virgin polyethylene lining, creating a 40-60 mil thick, resilient, and non-corrosive tank within a tank. The lining material is Food and Drug Administration (FDA) listed. All surfaces that contact water during system operation, including valve anges and openings, are covered with the lining material, so that water never touches bare steel, providing maximum protection against rust and corrosion. In addition, gasketed tank openings provide dry thread closures, eliminating coated threads which can be weak spots in tank linings. All tanks are 100% spark tested to ensure the integrity of the tank lining. All steel tanks up to 48 in diameter are hot-quench phosphatized prior to the application of a 4- 6 mil thick exterior epoxy coating for further protection against rust and corrosion, providing years of good appearance on the job. Tanks over 48 diameter are coated with a zinc oxide-rich protective coating, suitable for eld painting where desired. Fiberglass tanks are available for applications where environmental conditions or budgetary constraints prevail. They are especially useful in providing rust and corrosion protection. All FRP tanks are provided with a minimum of 5 year warranties. Electronic Demand Programmable (ED) Controls ED controls offer precise control over water softener operation. All controls have state-of-the-art electronics, and are microprocessor-based and completely programmable. Operating efciency combines with ease of use -- a 4-button keypad and alphanumeric LCD display permit easy programming and observation of system functions (no complicated jumper pins or dip switches to set). Simple programming prompts the operator through set-up. Model code programming makes set-up as easy as selecting model, pipe size, salt dosage, water hardness, and time. Controls perform all calculations to minimize set-up errors. An EEPROM memory retains all programmed and accumulated data, eliminating the need to re-program the
Softeners
Versatile Control Valve: Each softener control valve is a low-lead brass, mechanically actuated, hydraulically balanced, self-cleaning six (6) position type to accomplish the regeneration steps of backwash, brine draw, slow rinse, fast rinse, and tank rell. Separate rinse and timed rell positions are used to reduce regeneration water use. The valve is tted with a xed orice eductor nozzle and self-adjusting backwash ow control. The bypass body, like the main control valve, is actuated by a mechanical drive. The valve is capable of stepping through all regeneration phases without electrical power. Brine System and Salt Storage Positive action brine piston eliminates the need for constant line pressure at the salt storage tank, minimizing brine tank overows. Timed tank rell provides highly reliable brine levels and salt usage. Salt dosage is easily changed from the system control, eliminating the need to empty salt tanks or change ll-plug locations to make minor adjustments. Simple protected brine well design eliminates the need for gravel subll and minimizes brine tank maintenance. High density FDA approved polyethylene tank and cover provide maximum strength and corrosion resistance. High Quality Softener Resins All water softeners contain a high-quality, high-capacity, solvent-free synthetic ion exchange resin, that exchanges the hardness minerals of calcium and magnesium ions with soluble sodium ions, a soft and non-scaling mineral that does not build up on pipes to cause hot spots and weaknesses. All resins have a minimum exchange capacity of 30,000 grains per cubic foot when regenerated with 15 pounds of salt per cubic foot. Resins provide efcient exchange capacity at lower salt dosages (20,000 grains per cubic foot at 5 pounds of salt per cubic foot). In addition to softening water, resins also provide iron and manganese removal from the water. Softener resins are stable over the entire pH range. They are suitable for high ow rates and high hardness waters, and are physically stable at high temperatures. Resins feature low attrition loss, and minimum backwash water is required.
Feedwater Systems
All resins are in solid bead form with uniform particle size, clean and free of dirt and extraneous matter which might interfere with the ion exchange process. All resins rest on a bed of quartz particles that have been screened not to exceed 16 mesh size by 3/16-inch particle size. The quartz bed is at least two inches in depth and is placed above the softened water distributor mounted in the bottom of the tank. The quartz is washed and dried to remove debris and nes. Automatic Self-Adjusting Backwash and Rinse Controls This feature assures maximum cleansing of the resin bed during backwash, and prevents loss of resin across the entire operating range of 30-100 PSIG. The ow control eliminates the need for troublesome and time-consuming eld adjustments. Availability: All softener systems are available from stock, with short lead times. Optional Skid Mounting: Tanks may be ordered skid-mounted for easy handling and easier and lower-cost eld installation. Efficient Water Distributors: Inlet water distributors are designed to produce uniform ow through the entire resin bed and thus ensure maximum exchange capacity with low pressure loss.
MODELS SMR FEATURES AND BENEFITS

Automatic Control Center Engineered for Efficient TroubleFree Service Includes: Industrial grade multi-valve with integral brine injector. Electrically operated cycle controller with position indicator. Automatic backwash ow control. The exclusive multi-valve design, features ve hydraulicallyoperated diaphragm valve assemblies conveniently arranged. The valve seats are positioned vertically in the valve casting, reducing the possibility of dirt or debris lodging in the seat area. This design provides a positive shut-off with no leaking or dripping, as is often the case with horizontally-positioned valve seats.
H8-4
02-02
Feedwater Systems
Single unit softeners are provided with an automatic bypass valve that provides service water during regeneration. Cycling of the diaphragm assemblies is smooth and entirely free of water hammer. Automatic Self-Regulating Brine Injector: Assures efcient brining without time-consuming eld adjustments. Automatic Brine Maker, Includes Heavy Gauge Polyethylene Brine Tank for Maximum Strength and Corrosion Resistance: Platform brine system allows use of pure, clean, efcient salt pellets or nuggets, eliminating costly and time consuming brine tank cleaning. The system eliminates need for gravel sublls, reducing shipping weight and freight costs. Automatic brine valve provides reliable rell of the brine system with fresh water and is fully serviceable. All critical seal areas of the brine valve are designed to prevent corrosion or scaling to assure trouble-free operation. High Capacity Resin, Adaptable to Wide Range of Applications: High exchange capacity (30,000 grains per cubic foot at 15 lbs. salt dosage). Efcient exchange capacity at lower salt dosages (20,000 grains per cubic foot at 6 lbs. salt). Iron and manganese removal. Stability over entire pH range. Suitable for high ow rates. Suitable for high hardness waters. Physically stable at high temperatures. Low attrition loss. Minimum backwash water required. Automatic Self-Adjusting Backwash And Flush Controls: Assures maximum cleansing of the resin bed during backwash and prevents loss of costly resin across the entire operating range of 30-100 psig. Eliminates the need for troublesome and time consuming eld adjustments because the ow control is pre-sized at the factory. Available From Stock: Short lead time or minimum down time. Optional Equipment - SSE & FSE ASME Code tank construction. Optional Skid Mounting:
Softeners
Ease of installation in the eld; lower installation cost. System of Non-Clogging Strainers Arranged in a Radial Network: Assures uniform ow through the entire resin bed, resulting in maximum exchange capacity from the resin with low pressure loss. Eliminates wasted capacity in the bottom area of the resin tank.
PRODUCT OFFERING
Water softeners require periodic regeneration with salt brine. Standard Equipment - SSE & FSE Single, duplex, triplex, or quadraplex unit systems include resin tank(s), brine tank, resin, piping, multi-position piston valves, owmeters and electronic demand controller. Single tank exchange capacities: 30,000 to 1,200,000 grains. Tank sizes: 9 to 48 diameter standard (larger diameters available). Operating temperatures: 40 to 100 F. Water meter for automatic regeneration. 24 Volt operation. Heat fused polyethylene lined steel or FRP tanks. Standard Equipment - SMR Single, twin, or triple unit system includes resin tank(s), brine tank, resin, face-piping, diaphragm, valve nest and cycle controller. Size range in capacities: 30,000 to 2,100,000 grains. Tank sizes: 20" to 42" dia. Operating temperatures: 40 F to 100 F.
Alternating Parallel or Variable Flow operation. Skid mounting, pre-wired and pre-piped. High temperature operation. Alternate linings and external coatings.
H8-5
02-02
Softeners
Optional Equipment - SMR ASME Code tank construction. Water meter for automatic regeneration. Alternating operation. Skid mounting, pre-wired and pre-piped. External corrosion protection. Operating Specifications Pressure Range: 25 to 100 psig. Temperature: Standard equipment suitable for water up to 100 F. Above 100 F, special tted valves are available. Specify water temperature when ordering. Electrical: 120 Volt, 60 Hz is standard. Alternate voltages and frequencies available. Specify electrical requirements when ordering. Transformers for control operation voltage will be supplied with the SSE &FSE, SMR with MX controls. Power: 6 Watts per cycle controller. 2. Time On-Line
Feedwater Systems
Single softeners should be sized to stay on-line for at least one day. For continuous usage when an alternating twin softener is used, each tank should be sized to stay on-line for 8-12 hours. 3. Water Hardness To size the softener, the total water hardness must be determined in grains per gallons. If the analysis report is in terms of parts per million or milligrams per liter (these are equal), divide by 17.1 to correct to grains per gallon. 4. Water Usage When the ow rate is constant, multiply the ow rate (gpm) by minutes on line. For example, 50 gpm for 480 minutes (8 hours) = 24,000 gallons. When the ow rate is not in constant use, use actual gallons used, or calculate gallons used based on boiler make-up rates. 5. Exchange Capacity Exchange rate is expressed in grains, and varies with salt dosage as follows: 15 pounds of salt per cu-ft = 30,000 grains capacity (best water quality, least efcient). 10 pounds of salt per cu-ft. = 25,000 grains capacity (good water quality, medium efciency). 6 pounds of salt per cu-ft. = 20,000 grains capacity (poorest water quality, most efcient). For boiler make-up water, the higher water quality - 15 pounds salt dosage per cu-ft. - is recommended.
DIMENSIONS, RATINGS AND SIZING

Dimensions
Dimensions for the SSE Model Polybond lined Steel Softeners (sizes 30 - 1200) are shown in Figure H8-1. Dimensions for the FSE Model FRP Softeners (sizes 30 - 600) are shown in Figure H8-2. Dimensions for the Model SMR Softeners (sizes 150-1050) are shown in Figure H8-4.
Sizing Calculations
l. Single Softener. (Water usage per day x water hardness = capacity required.) For example: 10,000 gallons per day x 15 gpg hardness = 150,000 grains per day capacity required. Select a Model (SSE 150) from the literature. Then select the pipe size to meet ow rate requirements. 2. Alternating Twin Softeners Flow rate x hardness x minutes on line = capacity required. For example: Flow rate = 40 gpm. Hardness = 15 gpg. 40 x 15 x 480 minutes on line = 288,000 grains. Select a Model (SSE 300) from the literature. Then select pipe size based on ow rate requirements. When the gallons of make-up is not known, use Figure H8-5 to calculate softener capacity required per hour. When less than 6 hours is expected between regeneration of a twin softener, two brine makers are required.
Ratings
Softener capacity and ow ratings are shown in Table H8-1, Table H8-2, Table H8-3 and Table H8-4.
Sizing
Five things are required to size a softener: 1. Flow Rate/Pressure Loss Softeners have two published ow rates: Continuous - Used for sizing when actual ows are known. This rating of a softener will generally produce a pressure loss of 15 psig. Peak - Used to establish the absolute upper limits of a softener. This rating of a softener will produce a pressure loss of 25 psig.
H8-6
02-02
Feedwater Systems
Softeners
C B A
BRINE
F PLAN VIEW
FRONT VIEW OF 36" TANK SHOWN REDUCED
RAW WATER
TREATED WATER
C A D E B
FRONT VIEW
RIGHT SIDE VIEW
Figure H8-1: (1 of 2)SSE Models (Size 30-1200) Softener Dimensions
H8-7
02-02
Softeners
Feedwater Systems
MODEL NUMBER
SSE 30-1 60-1 90-1 90-11/2 120-11/2 120-2 150-1 150-11/2 210-11/2 210-2 300-11/2 300-2 450-2
A (in.)
B (in.)
C (in.)
D (in.) SINGLE
E (in.) SINGLE
F (in.) SINGLE
TWIN 10 12 14 40 52 66 46 58 72 72 18 66 77 72 18 66 77 72 24 6 77 72 24 66 77 77 30 66 81 82 36 71 86 42 71 71 71 86 86 86 39 39 52 39 30 24 24 24 24 18 18 18
TRIPLE QUAD
TWIN 38 38 38
TRIPLE QUAD
TWIN 46 50 54
TRIPLE
QUAD
INLET/ OUTLET (in.)
DRAIN SIZE
(in.). 3/4 3/4 3/4
18 18 24
38 38 41*
32 34 36
58 66 75
71 82 124
1 1 1 11/2 11/2 2 1
24*
41
41
46
68
74
112
3/4
24
41
41
46
68
90
112
11/2 11/2 2
3/4
24
50
50
52
80
108
136
24
50
50
52
80
108
136
11/2 2
450-3 600-2 600-3 750-2 750-3 900-3 1200-2 42 48
30*
50
50*
2 64 98 132 166 3 2 79 119 159 242 3 2 85 85

104
1 1/2
39*
48
48*
1 1/2
39* 39* 52*
48 48 60
48* 48* 60
*
131 131 156
177 177 212
266 3 266 316 3 3
2 2 2
* denotes Dual brine tank on a quadruple unit.
Figure H8-1 (2 of 2)SSE Models (Size30-1200) Softener Dimensions
H8-8
02-02
Feedwater Systems
Softeners
BRINE
RAW WATER
TREATED WATER
A C B D E
FRONT VIEW
RIGHT SIDE VIEW
Figure H8-2: (1 of2) Model FSE (Size 30-600) Softener Dimensions
H8-9
02-02
Softeners
Feedwater Systems
MODEL NUMBER A (in.) B (in.) C (in.)
D (in.) SINGLE TRIPLE QUAD
E (in.) SINGLE TRIPLE QUAD SINGLE
F (in.)
PIPE SIZE (in.) INLET/ DRAIN OUTLET SIZE
FSE 30-1 60-1 90-1 90-11/2 120-11/2 120-2 150-1 150-11/2 210-11/2 210-2 300-11/2 300-2 450-2 600-2 37.1 600-3 81 96 30.9 75 24 75 87 92 92 17.6 73 84 82 24 75 87 82 17.6 9.2 12.8 14 48 53 54 59
TWIN 18 18
TWIN 38 38
TWIN 46 52
TRIPLE
QUAD
18 18 24*
38 38 41*
32 35
58 66
71 82
1 1 1
3/ 4 3/ 4
64
71
18
38
36
54
75
124
1 2 46 68 89 111 11/2 2 1
1/
3/ 4
66 59 71 80 24 24 41 41 46 68 89 111 24 24 41 41
3/ 4
11/2 11/2 2
3/ 4
24
24
50
50
52
80
108
136
24 30 39
24 30* 39*
50 50 48
50 50 48*
52 65 80
80 100 122
108 135 163
136 170 245
11/2 2 2 2 3 11/2 1 1
* denotes Dual brine tank on a quadruple unit.
Figure H8-2 (2 of 2) Model FSE (Size 130-600) Softener Dimensions
H8-10
02-02
Feedwater Systems
Softeners
BRINE TANK
F PLAN VIEW
RAW WATER
TREATED WATER
C A B
FRONT VIEW MODEL NUMBER
RIGHT SIDE VIEW
PIPE SIZE (in.) A (in.) B (in.) C (in.) D (in.) E (in.) F (in.)
FSE 30-1 60-1 90-1 14 90-11/2 120-11/2 150-11/2 210-11/2 300-11/2 17.6 17.6 24 24 59 73 75 75 66 80 82 82 24 24 24 24 41 41 50 50 64 71
18
INLET/ OUTLET 1 1 1
DRAIN 3/ 4 3/ 4
9.2 12.8
48 52
54 59
18 18
38 38
49 52 54
38 64 68 68 80 80 11/2 11/2 11/2 11/2 11/2
/4
3/ 4 3/ 4
1 1
Figure H8-3: FSE-CRS Crossover Twin Dimensions (Size 30-300) H8-11

02-02
Softeners
Feedwater Systems
1
MODEL NUMBER SMR-150-1 SMR-150-1 1/4 72 SMR-150-1 1/2 SMR-150-2 SMR-210-1 1/4 SMR-210-1 1/2 73 SMR-210-2 SMR-210-2 1/2 SMR-300-1 1/2 SMR-300-2 76 SMR-300-2 1/2 SMR-300-3 SMR-450-1 1/2 SMR-450-2 82 SMR-450-2 1/2 SMR-450-3 SMR-600-1 1/2 SMR-600-2 89 SMR-600-2 1/2 SMR-600-3 SMR-750-2 SMR-750-2 1/2 SMR-750-3 SMR-900-2 SMR-900-2 1/2 SMR-900-3 SMR-1050-2 SMR-1050-2 1/2 SMR-1050-3 106 94 101 HEIGHT (IN) WIDTH (IN) 29 30 30 34 32 32 36 37 38 42 43 44 38 42 43 44 44 48 49 50 48 49 50 54 55 56 54 55 56 90 150 218 90 150 218 81 135 189 81 135 189 66 114 162 60 108 156 54 96 138 50 88 126 SINGLE LL1 TWIN L2 TRIPLE L3
Figure H8-4: SMR Dimensions (Size 150-1050) H8-12

02-02
Feedwater Systems
Softeners
Table H8-1. SSE Water Softener Ratings Polybond Lined Steel
MODEL NUMBER
EXCHANGE CAPACITY
RESIN QYT
CONT SERV FLOW
PRESS DROP
PEAK SERV FLOW
BACKPRESS WASH DROP FLOW
TANK DIMENSIONS
MANIF PIPE SIZE (in.)
FLOW SENSOR SIZE (in.)
SALT STORAGE CAPACITY (lbs)
SSE 30-1 60-1 90-1
MAX GR 30,000 60,000 90,000
MIN GR 20,000 40,000 60,000
CU-FT
GPM
PSI 4 10 15 9 12 7 13 6 15 8 15 15 15 12 15 15 15 13 15 15
GPM
PSI 7 20 25
GPM 2 3 5
SOF R BRINE
(in.) (in.)
1 2 3
8 16 21 24 32
12 24 29 36 48 48 58 60 60 84 58 107 118 180 125 240 120 270 270 280
10x40 12x52 14x66
18x38 18x38 18x38
1 1 1
1 1 1
400 400 400
90-1-1/2 120-1-1/2 120,000 120-2 150-1 150,000 150-11/2 210-11/2 210-2 300-11/2 300-2 450-2 450,000 450-3 600-2 600,000 600-3 750-2 750,000 750-3 900-3 1200-3 900,000 600,000 30 40 500,000 25 400,000 20 300,000 15 300,000 200,000 10 210,000 140,000 7 100,000 5 80,000 4
16 22 7 18x66 24x41 12 25 7 18x66 24x41 11 25 15 24x66 24x50 15 25 15 24x66 24x50 25 25 20 30x66 30x50 18 25 25 36x71 39x48 25 25 40 42x71 42x71 48x71 39x48 22 25 25 40 50 39x48 52x60
1-1/2 1-1/2 2 1 1-1/2 1-1/2 2 1-1/2 2 2 3 2 3 2 3 3 3 11/2 1 1 700 11/2 11/2 2 11/2 2 2 1,500 3 2 1,500 3 2 2,500 3 3 3 2,500 2,500 1,000 1,000 700
32 40 40 45 56 45 77 87 120 94 160 85 200 200 210
1,200,000 800,000
Flow rates and resin capacities are based on a single tank.
H8-13
02-02
Softeners
Feedwater Systems
Table H8-2. FSE Water Softener Ratings, Fiberglass Softeners
MODEL NUMBER
EXCHANGE CAPACITY
RESIN QYT CU-FT
CONT SERV FLOW GPM
PRESS DROP PSI
PEAK SERV FLOW GPM
PRESS BACKDROP WASH FLOW PSI GPM
TANK DIMENSIONS
FSE 30-1 60-1 90-1
MAX GR 30,000 60,000 90,000
MINGR 20,000 40,000 60,000
SOF R BRINE
(in.) (in.)
1 2 3
10 16 21 24 32
4 10 15 9 12 7 13 6 15 8 15 15 15 15 15
20 24 29 36 48 48 52 60 60 84 58 107 118 125 240
9 30 25
2 3 5
9X48 12x52 14x65
18x38 18x38 18x38
1 1 1 11/2
1 1 1
400 400 400
90-1-1/2 120-1-1/2 120,000 120-2 150-1 150,000 150-11/2 210-11/2 210-2 300-11/2 300-2 450-2 600-2 600,000 600-3 400,000 20 450,000 300,000 15 300,000 200,000 10 210,000 140,000 7 100,000 5 80,000 4
16 20 7 17X58 24x41 10 25 7 17X71 24x41 15 25 15 24x71 24x50 15 25 15 24x71 24x50 25 25 25 25 36x72 39x48 25 20 30x72 30x50
11/2 11/2 1 1 700 11/2 11/2 2 11/2 2 2 2 1,500 3 1,500 1,000 1,000 700
11/2 2 1 11/2 11/2 2 11/2 2 2 2 3
32 38 40 45 56 45 77 87 94 160
Flow rates and resin capacities are based on a single tank.
H8-14
02-02
Feedwater Systems
Softeners
Table H8-3. FSE Water Softener Ratings, Fiberglass Softeners with Crossover Controls
MODEL NUMBER EXCHANGE CAPACITY RESIN QYT CU-FT CONT SERV FLOW GPM PRESS DROP PSI PEAK SERV FLOW GPM PRESS BACKDROP WASH FLOW PSI GPM TANK DIMENSIONS
FSE 30-1 60-1 90-1 90-11/2 12011/2 150-11/2 210-11/2 300-11/2
MAX GR 30,000 60,000 90,000 90,000 120,000 150,000 210,000 300,000
MINGR 20,000 40,000 60,000 60,000 80,000 100,000 140,000 200,000
SOF R BRINE
(in.) (in.)
1 2 3 3 4 5 7 10
16 16 17 24 32 35 40 45
15 15 15 10 14 15 15 15
22 22 23 36 46 48 54 52
25 25 25 18 23 25 25 25
2 3 5 5 7 7 15 15
9x48 12x52 14x65 14x65 17x58 17x71 24x71 24x71
18x38 18x38 18x38 18x38 24x41 24x41 24x50 24x50
1 1 1 11/2 11/2 11/2 11/2 11/2
1 1 1 11/2 11/2 11/2 11/2 11/2
400 400 400 400 700 700 1,000 1,000
Flow rates and resin capacities are based on a single tank. (FSE-CRS Crossover Systems Are Only Available In Twin Alternating Configurations.)
H8-15
02-02
Softeners
Feedwater Systems
Table H8-4. SMR Water Softener Ratings

MODEL NUMBER EXCHANGE CAPACITY MANIF PIPE SIZE IN. CONT SERV FLOW GPM PEAK SERV FLOW GPM BACKWASH FLOW GPM TANK DIMENSIONS SALT CAPACITY BRINE MAKER (LBS) SALT PER REGEN REC WATER METER SIZE (in.)
RESIN CU-FT
SMR 150-1 150-1-1/4 150-1-1/2 150-2 210-1-1/4 210-1-1/2 210-2 210-2-1/2 300-1-1/2 300-2 300-2-1/2 300-3 450-1-1/2 450-2 450-2-1/2 450-3 600-1-1/2 600-2 600-2-1/2 600-3 750-2 750-2-1/2 750-3 900-2 900-2-1/2 900-3 1050-2 1050-2-1/2 1050-3
MAX GR
MIN GR
SOFR BRINE
(in.) (in.)
MAX LBS 75
MIN LBS 30
DRAIN PIPE SIZE (in.)
150,000 100,000
1 1-1/4 1-1/2 2 1-1/4 1-1/2 2 2-1/2 1-1/2 2 2-1/2 3 1-1/2 2 2-1/2 3 1-1/2 2 2-1/2 3 2 2-1/2 3 2 2-1/2 3 2 2-1/2 3
33 37 58 70 41 64 77 115 63 81 140 163 67 79 122 140 71 85 140 175 81 140 160 90 150 185 86 145 175
43 51 82 98 56 86 105 160 91 113 190 230 89 110 170 190 93 120 190 250 110 190 230 130 215 270 120 200 250
10.0
20x54
24x60
700
1 1 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 2T 1-1/2 1-1/2 2T 2T 1-1/2 1-1/2 2T 2T 1-1/2 2T 2T 2T 1-1/2 2T 2T 2T 2T 2T 2T 3 3
210,000 140,000
13.5
24x54
24x60
700
105
42
300,000 200,000
10
20.0
30x54
24x60
600
150
60
450,000 300,000
15
20.0
30x60
30x60
900
225
90
1 1/2
600,000 400,000
20
30.0
36x60
39x60
1500
300
120
1 1/2
750,000 500,000
25
30.0
36x72
39x60
1500
375
150
900,000 600,000
30
45.0
42x60
42x60
1800
450
180
1050K
700K
35
45.0
42x72
50x60
2500
525
210
A. Continuous service flow at a pressure loss not exceeding 15 psig. B. Peak service flow at a pressure loss not exceeding 25 psig. T denotes turbo type water meter.
H8-16
02-02
Feedwater Systems
Softeners
ITEMS THAT MUST BE KNOWN 1. Capacity of generator in lbs of steam per hour. 2.% Make-up. 3. Water hardness. 4. Hours operated each day. PROCEDURE 1. Lay a straight edge from lbs steam/hour (line A) to the% make-up (line D) and obtain the DBMS make-up flow from line B. 2. Lay a straight edge from the gpm make-up (line B) to the water hardness (Line E) and obtain the hardness removal required for each hour of generator operation from line C. 3. Calculate the hardness removal required each day by multiplying the value obtained in step 2 by the hours operated each day. NOTE: In situations where softened water is required for loads in addition to boiler requirements, the total gpm flow for the softener is the total of both requirements. Then using lines B and E, the required grain removal per hour can be determined. EXAMPLE 10,000 lbs steam/hour 15% make-up 8 hours daily operation Water hardness 10 grains per gallon FROM NOMOGRAPH Feedwater make-up is 3 gpm. Hardness removal required is 1800 grains per hour. Hardness removal required each day - 8 x 1800 - 14,400 grains. SOFTENER SELECTION Select a softener that will meet both flow rate and exchange requirements. For 24 hour operation and to provide a continuous supply of soft water, a twin unit is required. For the above example, An ACC-SAB-60-1 Twin could be used to provide 24 hour operation. This model would provide 1 day operation between regeneration periods. To provide 8 hour a day operation, the ACC-SAB-60-1 single unit would permit 3 days between regeneration periods.
Figure H8-5: Water Softener Sizing Chart H8-17

02-02
Softeners
Feedwater Systems
The following sample specications are provided to you by Cleaver-Brooks to assist you in meeting your customers requirements. 1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 Skid Mounting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 General Furnish, install, and place in operation an Automatic Water Softener System similar or approved equal to Cleaver-Brooks Model (SSE: lined steel tank/ FSE: berglass reinforced plastic tank)_______________, having ______tank(s) with ______cu-ft. of ion exchange resin per tank. Soft water output to be ___________gallons (cu-meters) per tank per regeneration with______lbs(kg) of salt, based on _______ grains per gallon compensated hardness. Service ow rate per tank_______ gpm (lpm) at a pressure loss through softener system not exceeding _______ psig (bar). 2.0 Equipment H8-18 H8-18 H8-20 H8-23 H8-23 H8-23
2.1 Tanks 10 Through 36 Diameter (Steel Polybond: Standard SSE) Softener tanks shall be made of butt-welded industrial grade carbon steel designed for a working pressure of 125 psi (____bar) dynamic and hydrostatically tested at 50% excess of the working pressure. Each tank shall be _______ m) diameter with a _______ m) overall tank height. Tank support(s) shall be of a skirt-ring type welded to the tank(s) lower head. The tank(s) shall be equipped with a resin loading port and a drain/resin removal port (14 and larger). Steel tank(s) shall be provided with a Polybond lining of inert non-leachable virgin polyethylene material at least 40-60 mils thick permanently bonded to the tank interior by heat fusion. The tank lining shall meet the requirements of the United States Food and Drug Administration (USFDA). The tank lining shall be chemically inert so as not to react with water, media, acids, caustic soda, chemicals or water-borne contaminants. The tank exterior shall be degreased, pre-cleaned, and phosphatized and shall have an exterior coating of high gloss epoxy enamel 4 to 6 mils thick. Tank openings shall be tted with O-ring seals that seat rmly on the tank interior lining to prevent holidays due to thread tapping and eliminate water to thread contact. Steel tank linings shall be tested for lining integrity by a 2,500-volt spark test, and the test certied with the shipping papers for the system (if requested at the time of order). The spark test shall be capable of detecting the most minute imperfection. The tank(s), with linings in place, shall be water tested under pressure for leaks. 2.1 Tanks 42 Through 48 Diameter (Steel Polybond: Standard SSE) Softener tanks shall be made of butt-welded industrial grade carbon steel designed for a working pressure of 100 psi (____bar) dynamic and hydrostatically tested at 50% excess of the working pressure. Each tank shall be _______ m) diameter with a _______ m) overall tank height. Tank support(s) shall be strap-type steel legs permanently welded to the lower tank head. The tank(s) shall be equipped with a resin loading port and a drain/resin removal port. Steel tank(s) shall be provided with a Polybond lining of inert non-leachable virgin polyethylene material at least 40-60 mils thick permanently bonded to the tank interior by heat fusion. The tank lining shall meet the requirements of the United States Food and Drug Administration (USFDA). The tank lining shall be chemically inert so as not to react with water, media, acids, caustic soda, chemicals or water-borne contaminants. The tank exterior shall be degreased, precleaned, and phosphatized and shall have an exterior coating of high gloss epoxy enamel 4 to 6 mils thick. Tank openings shall be tted with O-ring seals that seat rmly on the tank interior lining to prevent holidays due to thread tapping and eliminate water to thread contact.
H8-18
02-02
Feedwater Systems
Softeners
Steel tank linings shall be tested for lining integrity by a 2,500-volt spark test, and the test certied with the shipping papers for the system if requested at the time of order. The spark test shall be capable of detecting the most minute imperfection. The tank(s), with linings in place, shall be water tested under pressure for leaks. 2.1 Tanks 9 Through 36 Diameter (Fiberglass Reinforced Plastic: Standard FSE) Softener tank(s) shall be made of berglass reinforced ABS plastic. The exterior sideshell shall be reinforced by a continuous roving glass lament overwrap of the same color as the tank shell. The tank(s) shall be supported by a molded polypropylene structural base. Including the base, each vessel shall have the dimensions of _______ inches diameter and _______ inches height. 2.1 Tanks 20 Through 42 Diameter (SMR Standard) 2.2 Tank Option Pressure vessels shall be provided in accordance with ASME Section VIII. Working pressure will be 100, 125 or 150 psig and hydrotested to 150% of stamped and certied rating. 2.3 Tank Option Provide tank with high temperature internal epoxy lining at 8-10 mil DFT. Exterior tank surface will be cleaned and coated with a corrosion-resistant zinc-rich primer suitable for epoxy coating in the eld.
2.4 Tank Option Provide tank with a baked phenolic internal epoxy lining at 8-10 mil DFT. Exterior tank surface will be cleaned and coated with a corrosion-resistant zinc-rich primer suitable for epoxy coating in the eld.
2.5 Tank Option Provide tank with an external coating of a high gloss epoxy paint 2-4 mil DFT.
2.6 Distribution System - Models SSE & FSE The soft water collector and backwash water distributor shall be non-clogging design with slot size slot 0.010 inch in width. Single point and hub radial laterals will be used to ensure adequate distribution of ow during service, backwash and regeneration. Laterals will be made of Schedule 80 PVC and designed for low pressure drop-in service. The distributor system will be fully covered by a minimum of 2 inches of quartz underbedding. The quartz shall be washed and dried to remove debris and nes, and screened not to exceed 16 mesh size by 3/16-inch particle size. 2.6 Distribution System - SMR 2.7 Main Operating Valve SSE / FSE 30 to 1200
The control valve shall have _______inch _______ cm) NPT (BSP) inlet and outlet connections. It shall be a low lead brass mechanically-actuated, hydraulically-balanced, self-cleaning piston six-position type to accomplish the regeneration steps of backwash, brine draw, slow rinse, fast rinse, and rell. Separate rinse and timed rell positions will be provided to reduce regeneration water use. The valve shall contain xed orice eductor nozzle and self-adjusting backwash ow control. The valve will be capable of being manually stepped through regeneration without electrical power.
H8-19
02-02
Softeners
2.8 Brine System and Salt Storage
Feedwater Systems
The brine system shall be designed to minimize possible overow conditions by eliminating line pressure to the salt storage tank at all times except during rell. Timed tank rell will be used to utilize salt and regeneration water efciently and the regeneration salt dosage shall be adjustable from 5 to 20 lbs _______ to___ kg) per cubic ft. (m) from the system control without the need for emptying salt tanks or moving ll plugs. A combination salt storage tank with cover and brine tank well shall be supplied as part of the system. The tank shall be sufcient size to hold salt for at least _______ regenerations between rells. The tank(s) shall be made of corrosion-free one-piece molded polyethylene or berglass reinforced plastic material. The tank(s) shall have a nominal diameter of _______ inches (_____cm) and a height of _______ inches (_____cm) and have a storage capacity of ______lbs (kg). All brine systems will include a oat operated plastic brine pick up designed to provide positive shut off to prevent air from entering the system. 2.9 Brine System Option A pressurized brine control system will be provided to introduce brine into the softener vessels. A timed brine controller, non-corrosive self-adjusting ow controls and pilot-operated diaphragm valve will be provided for integration into the facilities pressurized brine source. Salt dosage shall be eld adjustable through the timed brine module. 2.10 Resin Each softener tank shall be provided with _______ cubic feet of high capacity sulphonated styrene divinylbenzene based synthetic ion exchange resin having a minimum exchange capacity of 30,000 grains per cubic foot when regenerated with 15 pounds of salt per cubic foot. The resin shall be solid, with uniform particle size, clean and free of dirt and extraneous matter that might interfere with ow of water through the resin or that might interfere with the ion exchange process. All resin shall be FDA compliant under the Code of Federal Regulation No.21 paragraph 173.25. 2.11 Flow Control Automatic backwash and brine rell ow control shall be provided to maintain proper backwash, rinse and brine ow rates over wide uctuations of operating pressure. The controller will contain no moving parts and require no eld adjustment. All ow controls will be connected for ease of removal for inspection and service as needed. 2.12 Piping Contractor shall furnish and install all interconnecting pipe and isolation valves. Drain connections from the control valve shall have an air gap conforming to local codes and to permit observation and sampling of backwash and regeneration water. 2.13 Gauge and Sample Valve Option Manufacturer shall provide two pressure gauge and sample valve assemblies or contractor installation in the inlet and outlet piping. Pressure gauges and sample valves will be stainless steel or other non-corrosive design. 3.0 Control Options 3.1 Single Units EDS Control The softener system will be controlled by a single computer-based demand (meter) initiated controller. The controller shall be capable of operating either 1 or 2 units in single, twin alternating, or parallel congurations allowing easy expansion as soft water demand increases without the need for rewiring or adding additional controllers. The control will utilize alphanumeric, selfprompting programming for simple start up. EEPROM memory shall store program data eliminating need for battery back-up or conguration input after power loss. The control shall be pre-wired and includes twist lock electrical end connectors for installation ease.
H8-20
02-02
Feedwater Systems
Softeners
The controller will constantly monitor current operating condition and be capable of displaying instantaneous ow rate through the system. A resettable totalizing ow counter will be included to measure total water processed. The control shall be self-diagnostic and capable of emitting an audible signal and error specic messages if it detects a system problem. Control diagnostics can be transmitted over telephone lines for troubleshooting or review of historical operational data to allow system optimization through evaluation of actual water usage. Valve and control operation will be 24V, 60Hz, 1ph A suitably sized UL/CSA listed transformer(s) will be provided to convert 120V, 60Hz, 1ph power for system operation. Control printed wiring assemblies will be conformally coated to MIL specications suitable for use in humid environments. A water-tight enclosure will be used to house the control. 3.2 Duplex Twin Alternating Units EDT Control The softener system will be controlled by a single computer-based demand (meter) initiated controller. The controller shall be capable of operating 2 units in twin alternating, or parallel congurations allowing the units to easily both be put on-line to handle peak start up ows and returned to alternating operation during normal use periods without the need for rewiring, or extensive reprogramming or adding additional controllers. Although the control will allow two units to be put on-line simultaneously, a builtin lockout prevents both units from regenerating at the same time. The control will utilize alphanumeric, self-prompting programming for simple start up. EEPROM memory shall store program data eliminating need for battery back-up or conguration input after power loss. The control shall be pre-wired and includes twist lock electrical end connectors for installation ease. The controller will constantly monitor current operating condition and be capable of displaying instantaneous ow rate through the system. A resettable totalizing ow counter will be included to measure total water processed. The control shall be self-diagnostic and capable of emitting an audible signal and error-specic messages if it detects a system problem. Control diagnostics can be transmitted over telephone lines for trouble shooting or review of historical operational data to allow system optimization through evaluation of actual water usage. Valve and control operation will be 24V, 60Hz, 1ph A suitably sized UL/CSA listed transformer(s) will be provided to convert 120V, 60Hz, 1ph power for system operation. Control printed wiring assemblies will be conformally coated to MIL specications suitable for use in humid environments. A water-tight enclosure will be used to house the control. 3.3 Variable Flow Multiple Tank Systems VF Control The system will be supplied with a single computer-based demand (meter) initiated controller capable of operating systems with 2 to 4 units. In addition to traditional parallel or alternating operating conditions, the control can operate in a variable ow mode which has the ability to bring units on and off-line depending on current service ow. The control will utilize alphanumeric, selfprompting programming for simple start-up. EEPROM memory shall store program data eliminating need for battery back-up or conguration input after power loss. It is pre-wired and includes twist lock electrical end connectors for installation ease. The controller will constantly monitor current operating condition and be capable of displaying instantaneous ow rate through the system. On multiple vessel systems ow and operational data for each unit shall be independently displayable. A resettable totalizing ow counter will be included to measure total water processed. The control shall be self diagnostic and capable of emitting an audible signal and error-specic messages if it detects a system problem. Control diagnostics can be transmitted over telephone lines for troubleshooting or review of historical operational data to allow system optimization through evaluation of actual water usage. If an error is detected the controller will be capable of automatically readjusting the operating program to place the maximum number of tanks on-line and recalculate regeneration frequency to provide optimum treatment ow capacity until service is provided. Valve and control operation will be 24V, 60Hz, 1ph A suitably sized UL/CSA listed transformer(s) will be provided to convert 120V, 60Hz, 1ph power for system operation. Control printed wiring assemblies will be conformally coated to MIL specications suitable for use in humid environments. A water tight enclosure will be used to house the control. This meter-initiated system allows all units to be in service at the same time. Regeneration is immediate based on a batch count. A built in interlock does not allow more than one unit to be in regeneration at a time.
H8-21
02-02
Softeners
3.4 Cross Over Twin Units CSR Control
Feedwater Systems
The softener system will be supplied with a computer-based demand (meter) initiated controller. The control will utilize alphanumeric, self-prompting programming for simple start-up. EEPROM memory shall store program data eliminating need for battery back-up or conguration input after power loss. The controller will constantly monitor current operating condition and be capable of displaying instantaneous ow rate through the system. A resettable totalizing ow counter will be included to measure total water processed. The control shall be self-diagnostic and capable of emitting an audible signal and error specic messages if it detects a system problem. Control diagnostics can be transmitted over telephone lines for troubleshooting or review of historical operational data to allow system optimization through evaluation of actual water usage. Valve and control operation will be 24V, 60Hz, 1ph A suitably sized UL/CSA listed transformer(s) will be provided to convert 120V, 60Hz, 1ph power for system operation. Control printed wiring assemblies will be conformally coated to MIL specications suitable for use in humid environments. The control will be mounted directly in the valve cover. Electrical installation will only require plugging in the transformer and connecting the owsensor cable.
3.5 Time Clock Units TC Control The softener(s) will be provided with a 7 day timer allowing recharge to occur at a user adjustable time of day or night. The timer shall be capable of being set to skip one or more days between regenerations. Electrical operation is 120V, 60Hz, 1ph. 3.6 Flowsensors 1 Models _______ Hall effect tubo ow sensor(s) will be provided. These sensor(s) shall be made with no packing glands or rotating shaft seals and will be solid state proximity transducer-type with a self-lubricated shaft riding on a sapphire bearing. The sensor shall be made in such a way that it can be installed and removed with simple hand tools. Pipe size of the sensor(s) shall be 1 inch (_______cm). It shall have a minimum ow of 1 gpm (___lpm), and a peak ow of 50 gpm (____lpm). The owmeter housing shall be brass.
3.7 Flowsensors 1.5 x 2 Models _______ Hall effect tubo ow sensor(s) will be provided. These sensor(s) shall be made with no packing glands or rotating shaft seals and will be solid state proximity transducer-type with a self-lubricated shaft riding on a sapphire bearing. The sensor shall be made in such a way that it can be installed and removed with simple hand tools. Pipe size of the sensor(s) shall be 1.5 inch (_______cm) x 2 inch _______ cm). It shall have a minimum ow of 2 gpm (____lpm), and a peak ow of 100 gpm (_____lpm). The owmeter housing shall be brass.
3.8 Flowsensors 3 and larger _______ Hall effect paddle wheel ow sensor(s) will be provided. These sensor(s) shall be made with no packing glands or rotating shaft seals and will be solid state proximity transducer type with a self lubricated PVDF paddlewheel riding on a titanium shaft The sensor shall be made in such a way that it can be installed and removed with simple hand tools. Pipe size of the sensor(s) shall be 3 inch (_______cm). It shall have a minimum ow of 7 gpm (____lpm), and a peak ow of 231 gpm (_____lpm) [for 3 ]. _____12 gpm (____lpm) 394 gpm (_____lpm) [for 4] 25 gpm (____lpm) 999 gpm (_____lpm) [for 6]
H8-22
02-02
Feedwater Systems
4.0 Instructions A complete set of instructions for installation and operation of the softener system will be included. 5.0 Skid Mounting Options
Softeners
The softener system will be provided skid-mounted with all units pre-piped by the manufacturer. Each unit will be isolatable and a system bypass valve shall come installed in the plumbing header. Inlet and outlet connections will terminate in convenient locations near the skid edge. All plumbing shall be supported by Unistrut or equivalent anchors and members. Inter-tank hydraulic tubing and ttings will be installed as part of the skid package. All mineral tanks will be bolted to the skid members to allow removal. Permanent mounting or welding is not acceptable. All skids will be completely assembled, and hydraulically and electrically tested before shipment. Prior to shipping, the system will be drained before packaging. Partial disassembly may be required for shipment. All assemblies will be marked to allow simple reconnection.
5.1 Steel Softeners Model 30 to 300 Tanks 10 to 24 diameter will be mounted on a 4 channel iron skid (5.4 lb. per foot, ASTM grade A-36) The skid will be crossbraced with similar 4 channel or angle iron. All steel surfaces will be cleaned and painted with a high gloss epoxy top coat matching the softener vessel color.
5.2 Steel Softeners Model 450 to 600 Tanks 30 to 36 diameter will be mounted on a 6 channel iron skid (8.2 lb. per foot, ASTM grade A-36) The skid will be crossbraced with similar 6 channel or angle iron. All steel surfaces will be cleaned and painted with a high gloss epoxy top coat matching the softener vessel color.
5.3 Steel Softeners Model 750 to 1200 Tanks 42 to 48 diameter will be mounted on a 6 channel iron skid (8.2 lb. per foot, ASTM grade A-36) The skid will be crossbraced with similar 8 channel (11.5 lb. per foot) channel or angle iron. All steel surfaces will be cleaned and painted with a high gloss epoxy top coat matching the softener vessel color.
6.0 Guarantee Attrition loss of mineral is guaranteed not to exceed 3% per year for a period of 3 years. All mechanical equipment is guaranteed for 1 year against any defects in workmanship or materials. All EDS, EDT, and VF controls are guaranteed for 3 years against M & W. Consult specic product warranty for mineral and brine tank information. The manufacturer guarantees that under actual operating conditions, the mineral shall not be washed out of the system during service or backwash cycles when operated under the instructions and guidelines set forth in the operation manual.
H8-23
02-02
Softeners
Feedwater Systems
The following sample specications are provided by Cleaver-Brooks to assist you in meeting your customers requirements.
1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-24 2.0 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-24 3.0 Regeneration Initiation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-25 4.0 Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-26 5.0 Skid Mounting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-26 6.0 Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-27 1.0 General Furnish, install, and place in operation an Automatic Water Softener System similar or approved equal to Cleaver-Brooks Model SMR_______, having tank(s) with _______ cu-ft. of ion exchange resin per tank. Soft water output to be _______ gallons per tank per regeneration with _______ lbs of salt, based on _______ grains per gallon compensated hardness. Service ow rate per tank _______ gpm at a pressure loss through softener system not exceeding _______ psig. 2.0 Equipment 2.1 Tanks Softener tank(s) shall be of welded construction of tank quality carbon steel. Each tank shall be _______ diameter with a _______ straight side shell height. The tank(s) shall have threaded openings for pipe connections and an 11" x 15" manhole in the top head (for tanks 30" diameter and smaller; two 4 x 6 handholes should be provided in the top head and lower side shell). The tank(s) shall be rated for 100 psig working pressure and 150 psig test pressure. Support legs will be the strap-type permanently welded to the lower tank head. The tank(s) shall have their exterior and interior protected with a hot dipped galvanized application after fabrication. A minimum freeboard of 50% shall be provided for backwash expansion above the normal ion exchange resin bed level. 2.2 Tank Option Provide pressure vessel in accordance with ASME Section VIII. Working pressure to be 100, 125 or 150 pounds, hydrotested to 150, 187.5, or 225 psig, stamped and certied.
2.3 Tank Option Provide cold-set epoxy internal lining 8-10 mils DFT, with rust resistant prime coat, external coating 2-3 mils DFT.
2.4 Tank Option Provide baked phenolic internal lining 4-5 mils DFT, with rust resistant prime coat, external coating 2-3 mils DFT.
2.5 Tank Option Provide Safety Blue epoxy nish paint 6-8 mils DFT over exterior tank and valve surfaces. To be applied on channel iron surface if applicable.
H8-24
02-02
Feedwater Systems
2.6 Upper Distributor
Softeners
The upper distribution system shall be a single point bafe constructed of Schedule-40 galvanized steel pipe and ttings. 2.7 Lower Distributor The lower distribution system shall be of the hub end radial type constructed of PVC with slotted full ow non-clogging replaceable ABS strainers and covered with a subll of 1/8 x 1/16 gravel.
2.8 Main Operating Valves The main operating valves shall be a nest of individual diaphragm valves. The valves shall have cast iron bodies with Buna-N diaphragm and stainless steel and brass internal parts. The valves shall be slow opening and closing, and free of water hammer. There shall be no contact of dissimilar metals within the valves and no special tools shall be required to service the valves. Valves can be operated either hydraulically or pneumatically.
2.9 Brine System The brine system shall be platform type with dry salt storage compartment, sufcient for at least four regenerations at full salting and a saturated brine compartment. The tank shall be of polyethylene construction. It shall be equipped with a oat operated plastic brine valve and allow for simple adjustment of salt dosage without removing the brine valve. It shall be _______ diameter x _______ shell height and have a storage capacity of lbs of salt.
2.10 Resin Resin shall be of a premium grade high capacity synthetic sulfonated styrene divinylbenzene type, to be furnished in the sodium form. It shall be stable over the entire pH range, have good resistance to bead fracture, and be insoluble in all common solvents. The resin shall be capable of 30,000 grains per cubic foot capacity when regenerated with 15 lbs NaCl.
2.11 Flow Control An automatic backwash control shall be provided to maintain a proper backwash and fast ush ows over wide variations of operating pressure. Controller to contain no moving parts, and requires no eld adjustment.
2.12 Piping The main operating valves and manifold piping shall be Schedule 40 galvanized steel. Galvanized ttings shall be standard class 150 threaded malleable iron. 3.0 Regeneration Initiation 3.1 Control A NEMA 12rated factory mounted and wired electrical enclosure with all timing and sequencing controls for each softener shall be manufactured and provided by the same vendor providing the water treatment hardware. The controls shall include an automatic regeneration sequencer having the capability of providing site adjustable regeneration steps of backwash brine injection, brine displacement, ush and return to service. An indicator on the pilot stager points to the cycle of operation at all times. Complete function and control of all regeneration steps can be performed by manual operation of the pilot stager. The 12-Day electrical time clock controller shall be fully adjustable to initiate regeneration at any hour of the day and any day of the week.
H8-25
02-02
Softeners
3.2 Control Option Single Automatic Reset Meter and Alternator (Twin Softeners Only)
Feedwater Systems
The twin water softener shall be equipped with a single _______ (disc) (turbo) water meter, AWWA rated, in the common outlet header. At a pre-set gallonage the automatic reset head of the meter will send a 120 volt signal to an alternator that will direct the signal to regenerate the unit presently on-stream. Upon completion of regeneration, that softener will remain off stream in the stand-by position. This sequence will repeat on an alternating basis each time the preset gallonage of soft water has passed through the meter. A lockout shall be provided to allow only one unit to regenerate at any one time.
3.3 Control Option MX Electronic Programmable Controls (Two or Three Tanks) The system will operate with two or three media tanks each having a dedicated paddle wheel type ow sensor and operate in either of these modes, one of which will be on-line while the other is regenerated and user selected modes.
*Alternating One media tank will be in the standby or regeneration and one (1) or two (2) media tanks will be on-line. At a user specied volume the standby tank will go on line and the exhausted tank will go into regeneration. After regeneration this tank will go into standby until its rotation to go back on-line
*Parallel - All media tanks are on-line simultaneously. As each media tanks user specied volume is reached it shall immediately be taken off-line, regenerated, and placed immediately back on-line. *Additive Flow - One (1) media tank, designated as the primary, will remain on-line at all times. Variation of treated water ow demand shall automatically cause (one additional media tank) (up to two additional media tanks) to change status from standby to on-line and back to standby as needed. When the primary media tank regenerates the next media tank in sequence shall become the primary. As each media tanks user set volume is reached it will immediately be taken off-line, regenerated, and placed immediately back on-line or standby depending on treated water ow demand. The controller shall be capable of continuously determining the exhaustion rate of each media tank thus automatically avoiding the possibility of a simultaneous regeneration attempt. Simultaneous regenerations are not possible. The exchange capacity of each softener can be the same or different. Flow or peak ow rate indication shall be continuously displayed for each unit. The continuous ow range is 0-999 ow units per minute (gallons, cu.ft., liters, cu-m, etc.). Cumulative volume totalization to eight (8) digits shall be continuously displayed for each unit.
4.0 Instructions
A complete set of installation instructions and operating instructions shall be furnished.
5.0 Skid Mounting (Pre-pipe and Pre-wire) 5.1Mineral Tank skid mount Option. The softener mineral tanks shall be shall be mounted on a 4" channel iron skid (7.25 lbs per foot, ASTM grade A-36). The skid shall be cross-braced with a 4" channel or angle iron,. All steel surfaces shall be prime coated. All interconnecting piping shall be the same material as the valve nest manifold piping and shall be assembled by the manufacturer. This shall include inlet and outlet bronze isolation valves for each tank, and a bronze system bypass valve. Inlet and outlet headers shall be installed and terminate at the skid edge. All piping shall be suitably supported by Unistrut supports anchored to the skid. Electric wiring, where applicable,
H8-26
02-02
Feedwater Systems
Softeners
shall be complete between all inter unit controls and require only a single power source connection. The inter unit wiring shall be contained in Flextite exible, waterproof conduit. All inter-tank hydraulic or pneumatic tubing shall be installed as part of the skid package. The mineral tanks are to be bolted to the skid. Permanent attachment, or welding, will not be acceptable. The entire skid mounted system shall be both leak and electrically tested as a unit by the manufacturer before shipment 5.1Mineral Tank skid mount Option. The softener mineral tanks shall be shall be mounted on a 4" channel iron skid (7.25 lbs per foot, ASTM grade A-36). The skid shall be cross-braced with a 4" channel or angle iron. The entire area under the polyethylene briner shall be covered with a 1/4 steel plate All steel surfaces shall be prime coated. All interconnecting piping shall be the same material as the valve nest manifold piping and shall be assembled by the manufacturer. This shall include inlet and outlet bronze isolation valves for each tank, and a bronze system bypass valve. Inlet and outlet headers shall be installed and terminate at the skid edge. All piping shall be suitably supported by Unistrut supports anchored to the skid. Electric wiring, where applicable, shall be complete between all inter unit controls and require only a single power source connection. The inter unit wiring shall be contained in Flextite exible, waterproof conduit. All inter-tank hydraulic or pneumatic tubing shall be installed as part of the skid package. The mineral tanks are to be bolted to the skid. Permanent attachment, or welding, will not be acceptable. The entire skid mounted system shall be both leak and electrically tested as a unit by the manufacturer before shipment
6.0 Guarantee Attrition loss of mineral is guaranteed not to exceed 3% per year for a period of 3 years. All mechanical equipment is guaranteed for 1 year against any defects in workmanship or materials. Any part proving defective will be replaced or repaired within this period. The manufacturer guarantees that under actual operating conditions the mineral shall not be washed out of the system during the service run or backwashing period; that the turbidity and color of the efuent, by reason of passing through the softener system, shall not be greater than that of the incoming water; and that the under-drain system, gravel and mineral shall not become fouled, either with turbidity or by dirt, rust, or scale from the softening system, or present in the soft water, while operating as noted on manufacturers instructions.
H8-27
02-02
Softeners
Feedwater Systems
Notes
H8-28
02-02
Section H9
DEALKALIZERS
CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIMENSIONS, RATINGS AND SIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sizing Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ILLUSTRATIONS H9-3 H9-3 H9-3 H9-3 H9-3 H9-3 H9-4 H9-7
Figure H9-1. Dealkalizer Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-5 TABLES Table H9-1. Automatic Dealkalizer Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-4 Table H9-2. Dealkalizer Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-6
H9-1
02-02
Dealkalizers
Feedwater Systems
Information in this section applies directly to Cleaver- Brooks dealkalizers ranging from 10,000 to 980,000 grain capacity. Cleaver-Brooks chloride cycle dealkalizers are similar to water softeners except that, instead of cation resin, they use a strong anion resin to remove selective negatively charged ions from the raw water supply. Dealkalizers require use of softened water, and are installed down stream from the water softener, and before the deaerator. Dealkalizers remove more than 90% of the bicarbonate alkalinity from the softened water supply. This effectively controls formation of carbon dioxide in the boiler, the major cause of condensate line corrosion. Dealkalization reduces the need for neutralizing chemicals by as much as 90%, and cuts fuel costs by minimizing blowdown.
H9-2
02-02
Feedwater Systems
Dealkalizers
ASME code tank construction. Water meter for automatic or semi-automatic regeneration.

Reduces Bicarbonate Alkalinity, Thereby Minimizing CO2 Production: Decreased chemical consumption. Decreased condensate line corrosion. Lower blowdown rates. Reduces fuel consumption. Increased cycles of concentration. Uses a Strong Base Anion Resin With a Combination of Salt/Caustic Soda Regeneration: Produces a higher operating capacity and a more consistent efuent quality. Provides some silica reduction. Increases feed water pH.
Skid mounting. NEMA 12 or 4 control panels. External corrosion protection. Operating requirements include a continuous source of softened water at 30 to 100 psig, 40 F to 100 F. Electrical service, 120 Vac, 60 Hz, 5A.
DIMENSIONS, RATINGS AND SIZING

Dimensions
Dealkalizer dimensions are shown in Figure H9-1.
Ratings
Dealkalizer ratings are shown in Table H9-2.
PRODUCT OFFERING
Information in this section applies directly to Cleaver-Brooks dealkalizers ranging from 10,000 to 980,000 grain capacity (Table H9-1). Cleaver-Brooks chloride cycle dealkalizers are similar to water softeners except that, instead of cation resin, they use a strong anion resin to remove negatively charged ions from the raw water supply. Dealkalizers replace bicarbonate, sulfate, nitrate, and silica with chloride ions. Dealkalizers require use of softened water, and are installed down stream from the water softener, and before the deaerator. Dealkalizers remove more than 90% of the bicarbonate alkalinity from the softened water supply. This effectively controls formation of carbon dioxide in the boiler, the major cause of condensate line corrosion. Dealkalization reduces the need for neutralizing chemicals by as much as 90%, and cuts fuel cost by minimizing blowdown. Dealkalizers offer best payback when: 1. 2. 3. 4. Cycles of concentration in the boiler can be doubled. Chloride content is below 120 ppm. Sulfate count is below 50% of total exchangeable anions. Bicarbonate alkalinity is 100 ppm or more.
Sizing
Five things are required to size a dealkalizer: 1. Flow rate/pressure loss - because of a slower rate of exchange than softeners, dealkalizers should be operated at a ow rate not exceeding 2 gpm per cubic foot of resin. Peak ow could exceed this for very short periods of time without affecting capacity or water quality. 2. Time on line - Single dealkalizers should be sized to stay on line for at least one day. For continuous usage when an alternating twin dealkalizer is used, each tank should be sized to stay on line for 8 - 12 hours. 3. Water analysis - In addition to alkalinity, a dealkalizer will remove sulfate, nitrate, and carbon dioxide from water and these must all be considered to determine the total load. The alkalinity, sulte, nitrate, and carbon dioxide should be reported as CaCO3. To correct an analysis from the ion to CaCO3 equivalents use the following conversion factors: Bicarbonate HCO3 = ______ x .82 =_________ as CaC03 Sulfate SO4 = _________ x 1.04 = __________ as CaCO Nitrate NO3 = __________ x .81 = __________ as CaCO Carbon Dioxide CO2 = ______ x 1.14 =_______ as CaCO The total of the above is the total load on the dealkalizer. If the total is in terms of parts per million or milligrams per liter, convert to grains per gallon by dividing by 17.1. 4. Water usage - when the ow rate is constant, multiply the ow rate in gpm x minutes on line. For example: 50 gpm x 480 minutes (8 hours) = 24,000 gallons. When the ow rate is not
Dealkalizers are regenerated with salt brine and sodium hydroxide and have an operating temperature range of between 40 and 120 F. Optional equipment includes:
H9-3
02-02
Dealkalizers
constant, use actual gallons used or calculate gallons based on boiler make-up rates. 5. Exchange capacity - does not vary with salt usage like a water softener. Use a capacity of 10,000 grains per cubic foot and regenerate consumption of 4 pounds salt and 0.4 pounds caustic per cubic foot.
Feedwater Systems
Single Dealkalizer - Water usage per day x total load = capacity required. For example: 10,000 gallons per day x 20 gpg total load = 200,000 grain capacity required. Select a Model ACC-DAB 200 from the literature. Then select the pipe size to meet the ow rate required.
Sizing Calculations
NOTICE
Check to assure the continuous flow rate does not exceed 2 gpm per cubic foot of resin.
Table H9-1. Automatic Dealkalizer Selection Chart

MODEL NUMBER ACC-DAB10-3/4 20-1 30-1 40-1-1/4 50-1-1/4 80-1-1/4 140-1-1/2 200-2 250-2 330-3 420-3 550-3 680-3 980-4
D
PIPE SIZE IN. 3/4 1 1 1-1/4 1-1/4 1-1/4 1-1/2 2 2 3 3 3 3 4
RESIN CU-FT 1 2 3 4 5 8 14 20 25 33 42 55 68 98
CAPA GR 10000 20000 30000 40000 50000 80000 140000 200000 250000 330000 420000 550000 680000 980000
Resin Tank Size IN 9x48 12x54 14x60 16x60 20x54 24x54 30x60 36x60 36x72 42x72 48x72 54x72 60x72 72x72
FLOW RATE NORM GPM 2 4 6 8 10 16 28 40 50 66 88 110 136 196
FLOW RATE B MAX GPM 4 8 12 16 20 32 56 80 100 132 176 220 272 300
BACKWASH RATE GPM 1.0 1.4 2.0 2.4 4.3 6.5 10.0 15.0 15.0 20.0 25.0 32.0 40.0 60.0
BRINE TANK SIZE IN. 18x31 18x31 18x31 22x36 22x36 22x36 24x54 24x60 24x60 30x60 39x60 39x60 42x60 50x60
SALT SALT CAP BRINER REGEN LBS 200 200 200 375 375 300 550 700 600 900 1800 1500 1800 3000 LBS 4 8 12 16 20 32 56 80 100 132 168 220 272 392
CAUSTIC REGEN LBS .4 .8 1.2 1.6 2.0 3.2 5.6 8.0 10.0 13.2 16.8 22.0 27.2 39.2
WATER METER C SIZE IN. 3/4 3/4 3/4 1 1 1 1-1/2 1-1/2 1-1/2 2T 2T 2T 3T 3T
NOTES: A. Capacity based on 10,000 grains/cubic foot of resin. This decreases with chloride content over 30 ppm. B. Maximum flow reduces capacity by 20%. Pressure drop at max flow is less than 15psi. C. T denotes turbo type water meter. D. Valve manifold factory assembled on the tank, removed for shipment.
H9-4
02-02
Feedwater Systems
Dealkalizers
MODEL NO. ACC-DAB-10-3/4 ACC-DAB-20-1 ACC-DAB-30-1 ACC-DAB-40-1-1/4 ACC-DAB-50-1-1/4 ACC-DAB-80-1-1/4 ACC-DAB-140-1-1/2 ACC-DAB-200-2 ACC-DAB-250-2 ACC-DAB-330-3 ACC-DAB-440-3 ACC-DAB-550-3 ACC-DAB-680-3 ACC-DAB-980-4
DS 9 12 14 16 20 24 30 36 36 42 48 54 60 72
DB 18 18 18 22 22 22 24 24 24 30 39 39 42 48
G 37 43 49 49 43 43 43 43 43 43 38 39 40 42
H 54 60 66 66 76 79 85 91 103 106 98 99 101 105
W 22 22 22 22 30 34 41 45 45 53 64 70 76 90
L 61 64 66 72 76 80 88 94 94 106 112 126 132 148
L1 88 94 98 106 114 122 136 148 148 166 178 198 210 238
Figure H9-1. Dealkalizer Dimensions
H9-5
02-02
Dealkalizers
Feedwater Systems
Table H9-2. Dealkalizer Ratings

RESIN TANK DATA MODEL NO TANK PIPE RESIN FRRE GRAVEL (ACCSIZE SIZE BOARD 1/8X1/16 FT3 DAB) (DIA X HT) (IN.) (IN.) (LBS) FLOW RATES BACK SERVI CAPACITY WASH (GPM) (GRAINS) (GPM) SLOW RINSE (GPM) FAST RINSE (GPM) BRINE TANK DATA TANK SIZEA CAUSTIC DATA SALT SALT/ BRINE NaOH/ NaOH CAP. REGN RATE REGN RATE (LBS) (LBS) (GPM) (LBS) (GPM)
10 20 30 40 50 80 140 200 250 330 420 550 680 980
9x48 12x54 14x60 16x60 20x54 24x54 30x60 36x60 36x72 42x72 48x72 54x72 60x72 72x72
3/4 1 1 1-1/4 1-1/4 1-1/4 1-1/2 2 2 3 3 3 3 3
1 2 3 4 5 8 14 20 25
33
16 18 21 20 25-1/2 20-1/2 23 24-1/2 28

29
15 30 45 60 100 200 300 400 400

600
2 5 4 10 6 15 8 20 10 25 16 40 28 70 40 100 50 125 66 165 88 210 110 275 136 340 196 490
10000 8000 20000 16000 30000 24000 40000 32000 50000 40000 80000 64000 140000 112000 200000 160000 250000 200000 330000 264000 420000 336000 550000 440000 680000 544000 980000 784000
1.0 1.4 2.0 2.4 4.3 6.5 10 15 15 20 25 32 40 60
0.71 0.99 1.38 1.95 2.38 3.45 6.90 8.5 13.9 15.5 21.4 30 37.5 53.4
2.0 2.8 4.4 5.9 7.5 12.0 21.5 30 40 50 65 85 100 150
18x31 18x31 18x31 22x36 22x36 22x36 24x50 24x60 24x60 30x60 38x60 38x60 42x60 48x60
225 225 225 375 375 375 550 650 650 850 1650 1350 1700 2200
4 8 12 16 20 32 56 80 100 132 168 220 272 392
0.17 0.22 0.30 0.43 0.52 0.76 1.52 1.87 3.05 3.4 4.7 6.6 8.3 10.0
0.4 0.8 1.2 1.6 2.0 3.2 5.6 8.0 10.0 13.2 16.8 22.0 27.2 39.2
0.42 0.54 0.76 1.08 1.33 1.88 3.77 4.72 7.85 8.91 12.18 17.3 21.4 26.4
42
29
1000
55 68 98
27-1/2 27-1/2 27-1/2
1300 1800 2600
A. Tank size = diameter x height.
H9-6
02-02
Feedwater Systems
Dealkalizers
The following sample specications are provided by Cleaver-Brooks to assist you in meeting your customers requirements. 1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-7 2.0 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-7 3.0 Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-9 4.0 Test Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-10 5.0 Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-10 6.0 Skid Mounting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-10 7.0 Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-10 1.0 General Furnish, install, and place in operation an Automatic Chloride Cycle Dealkalizer system, similar or approved equal to CleaverBrooks Model ACC-DAB ________, having tank(s) with ________ cu-ft of ion exchange resin per regeneration with ________ lbs of salt and ________ lbs of caustic, based on grains per gallon total anion load. Service ow rate per tank ________ gpm at a pressure loss through the dealkalizer system not exceeding _______ psig. The dealkalizer shall be supplied by a boiler manufacturer that will be responsible for the total boiler room system. 2.0 Equipment 2.1 Tanks 9" Through 16" Diameter Dealkalizer tank(s) shall be of welded construction, tank quality carbon steel. Each tank shall be _______ " diameter with a _______ " straight side shell height. The tank(s) shall have reinforced openings for pipe connections and a 4" diameter access opening in the top head. The tank(s) shall be rated for 100 psig working pressure and 150 psig test pressure. Tank support(s) shall be of a skirt ring type design, welded to the tank(s) lower head. The tank(s) shall have the exterior protected with a nish coat of polyurethane and the interior protected with an epoxy-polyamide coating. A minimum freeboard of 50% shall be provided for backwash expansion above the normal ion exchange resin bed level. 2.2 Tanks 20" Through 42" Diameter Dealkalizer tank(s) shall be of welded construction, tank quality carbon steel. Each tank shall be __________ " diameter with a ___________" straight side shell height. The tank(s) shall have reinforced openings for pipe connections and an 11" x 15" manhole in the top head (for tanks 30" diameter and smaller; two 3" spin off handhole should be provided in the top head and lower sideshell). The tank(s) shall be rated for 100 psig working pressure and 150 psig test pressure. Support legs will be the strap type permanently welded to the lower tank head. The tank(s) shall have the exterior prime coated and the interior protected with an epoxy lining 4-6 mils DFT after fabrication. A minimum freeboard of 50% shall be provided for back wash expansion above the normal ion exchange resin bed level. 2.3 Tanks 48" Through 72" Diameter Dealkalizer tank(s) shall be of welded construction, tank quality carbon steel. Each tank shall be _______ " diameter with a ________ " straight side shell height; the tanks shall have reinforced openings for pipe connections and 12" x 16" manhole in the top head. The tank(s) shall be rated for 100 psig working pressure and 150 psig test pressure. Support legs will be the adjustable jack type. The tank(s) shall have the exterior protected with a rust inhibiting primer and the interior shall have an epoxy lining 4-6 mils DFT, prior to shipment. A minimum freeboard of 50% shall be provided for backwash expansion above the normal ion exchange resin bed level. 2.4 Tank Option Provide pressure vessel in accordance with ASME Section VIII. Working pressure to be 100, 125 or 150 pounds, and hydrotested to 150, 187.5 or 225 psig, stamped and certied. 2.5 Tank Option Provide high-temperature epoxy internal lining 10-12 mils DFT, with rust resistant prime coat, external coating 2-3 mils DFT. 2.6 Tank Option Provide baked phenolic internal lining 4-5 mils DFT, with rust resistant prime coat, external coating 2-3 mils DFT. H9-7
02-02
Dealkalizers
2.7 Upper Distributor
Feedwater Systems
The upper distribution system shall be a single point bafe or four-point cross-arm type (9" through 60" diameter, single point), (66" through 72" diameter, four point), constructed of Schedule-40 galvanized steel pipe and ttings. 2.8 Lower Distributor The lower distribution system shall be of a single ne slotted PVC lateral design with a single layer of washed 1/8" x 1/16" gravel sub-ll to support the resin bed (9" through 16" diameter). The lower distributor system be the Hub and Radial type or header-lateral type constructed of Schedule-80 PVC with a sub-ll 1/8" x 1/16" gravel covering the slotted full ow non-clogging replaceable polypropylene strainers (20" through 60" diameter, hub and radial), (66" through 72" diameter, header-lateral). 2.9 Main Operating Valve Each Dealkalizer shall have an automatic multiport diaphragm type, slow opening and closing, and free of water hammer. The valve shall consist of ve (5) individual diaphragm valves housed in a compact casing. These valves are to be pressure actuated by an external pilot valve, automatically or manually. The valves shall be manufactured by the same manufacturer as the entire dealkalizer system. The valve guides, seats and diaphragm shall be constructed of Noryl plastic. The valve shall have inlet and outlet pressure gauges and sample cocks. 2.10 Brining System The brining system shall be Flexi-trol type with dry salt storage compartment, sufcient for at least six regenerations at full salting and a saturated brine compartment. It shall be equipped with a oat operated plastic tted brine valve and allow for simple adjustment of salt dosage without removing the brine valve. The tank shall be of polyethylene construction. It shall be _______ " diameter x ______ " shell height, and have storage capacity of lbs of salt. 2.11 Caustic System The caustic system shall be designed to pump directly from customer-purchased drums or carboys of 50% liquid caustic soda with no caustic handling necessary. Components of the caustic system shall be as follows: One (1) caustic feed metering pump One (1) moveable pump stand One (1) pressure switch One (1) 30 minute automatic reset timer mounted in protective box One (1) blend valve for adjustment of concentration The metering pump shall be of the diaphragm type for corrosion resistance and have a capacity of _______ gallons per minute. 2.12. Resin Resin shall be of a premium grade high capacity synthetic quaternary ammonium devinylbenyene type, to be furnished in the chloride form. It shall be stable over the entire pH range, have good resistance to bead fracture, and be insoluble in all common solvents. The resin shall be capable of 10,000 grains per cubic foot capacity when regenerated with 4 lbs of NaCl and 0.4 lbs of NaOH. 2.13 Piping Manufacturer to furnish dealkalizer tank, with assembled valve manifold piping. Contractor shall furnish and install interconnecting piping. Drain shall have an air gap conforming to local codes to permit observation of discharge backwash water and manufacturer shall provide a valved drain at the lowest point of the dealkalizer system. 2.14 Flow Control An automatic backwash control shall be provided to maintain a proper backwash and fast ush ows over wide variations of operating pressure. Controller to contain no moving parts and requires no eld adjustment. The ow controls shall be manufactured by the same manufacturer as the entire dealkalizer system.
H9-8
02-02
Feedwater Systems
3.0 Control Options
Dealkalizers
Regeneration shall be controlled by a fully automatic time clock control which is fully adjustable or can be controlled by a remote manual controller. For fully automatic operating the regeneration shall be initiated by calendar clock. A pointer indicates the cycle of operation at all times. 3.1 Standard Gallon Register Meter Each Dealkalizer tank shall be equipped with a ______ " (disc), or (turbo), standard gallon register meter to record the amount of dealkalized water produced. The time clock will initiate the regeneration sequence. 3.2 Signal Register Meter Each dealkalizer tank shall be equipped with a _________ " (disc), or (turbo) meter with a signal register head. The head shall send a ___ volt electrical signal to an audible alarm upon reaching the hand set gallonage. The signal will continue until reset by the operator. Regeneration will be initiated by a push-button on the cycle controller of the exhausted unit. 3.3 Automatic Reset Register Meters Each dealkalizer tank shall be equipped with a _____ " (disc), or (turbo) meter with automatic reset head. The head shall send a 120 volt signal to the dealkalizer cycle controller to initiate regeneration at a preset gallonage. The head will automatically reset to this gallonage. 3.4 Single Automatic Reset Meter and Altwinator (Twin Dealkalizers Only) The twin chloride cycle dealkalizer shall be equipped with a single _____ " (disc), or (turbo) water meter in the common outlet header. At a preset gallonage the automatic reset head of the meter will send a 120 volt signal to an altwinator that will direct the signal to regenerate the unit presently on stream. Upon completion of regeneration, that dealkalizer will remain off stream in the standby position. This sequence will repeat on an alternating basis each time the preset gallonage of dealkalized water has passed through the meter. 3.5 Two Tanks - Alternating The system will operate with two media tanks each having a dedicated ow sensor, one of which will be on-line while the other is regenerated and standing by. Each tank can regenerate several times per day. The on-line media tank shall regenerate immediately upon reaching a user specied volume of treated water. Simultaneous regenerations are not possible. The exchange capacity of each dealkalizer can be the same or different. Flow rate indication shall be continuously displayed for each unit. The ow range is 0-999 ow units per minute (gallons, cu-ft, liters, cu-m, etc.). Cumulative volume totalization to eight (8) digits shall be continuously displayed for each unit. 3.6 (Two) (Three) Tanks - Parallel The system shall consist of (two) (three) media tanks each having a dedicated ow sensor, congured for parallel ow and operate in either of these user selected modes: All media tanks are on-line simultaneously. As each media tank s user specied volume is reached it shall immediately be taken off-line, regenerated, and placed immediately back on-line. One (1) media tank, designated as the primary, will remain on-line at all times. Variation of treated water ow demand shall automatically cause (one additional media tank) (up to two additional media tanks) to change status from standby to on-line and back to standby as needed. When the primary media tank regenerates the next media tank in sequence shall become the primary. As each media tank user set volume is reached it will immediately be taken off-line, regenerated, and placed immediately back on-line or standby depending on the treated water ow demand. The networked controls shall be capable of continuously determining the exhaustion rate of each media tank, thus automatically avoiding the possibility of a simultaneous regeneration attempt. Simultaneous regenerations are not possible. The exchange capacity of each dealkalizer can be the same or different.
H9-9
02-02
Dealkalizers
Feedwater Systems
Flow rate indication shall be continuously displayed for each unit. The ow range is 0-999 ow units per minute (gallons, cu-ft, liters, cu-m, etc.). Cumulative volume totalization to eight (8) digits shall be continuously displayed for each unit. A regeneration start delay time interval can be user programmed for 0 to 16 hours to allow for brine make-up or regeneration feedwater recovery. 4.0 Test Kit A test kit shall be furnished to measure the dealkalizer performance. It shall be of the methylorange type to detect alkalinity. 5.0 Instructions A complete set of installation instructions and operating instruction shall be furnished. 6.0 Skid Mounting Options The dealkalizer system shall be completely skid mounted. Tanks 9" through 16" diameter shall be mounted on a 3" channel iron skid (9 lbs per foot, ASTM Grade A-36). The skid shall be cross-braced with 3" channel or angle iron, and the entire skid covered with a 1/4" steel plate. All steel surfaces shall be prime coated. Tanks 20" through 30" diameter shall be mounted on a 3" channel iron skid (9 lbs per foot, ASTM Grade A-36). The skid shall be cross-braced with a 3" channel or angel iron, and the entire area under the polyethylene briner shall be covered with a 1/4" steel plate. All steel surfaces shall be prime coated. Tanks 36" through 42" diameter shall be mounted on a 4" channel iron skid (13.8 lbs per foot, ASTM Grade A-36). The skid shall be cross-braced with 4" channel or angel iron, and the entire area under the polyethylene briner shall be covered with a 1/4" steel plate. All steel surfaces shall be prime coated. Tanks 48" through 72" diameter shall be mounted on a 6" channel iron skid (15.3 lbs per foot, ASTM Grade A-36). The skid shall be cross-braced with 6" channel or angle iron, and the entire area under the polyethylene briner shall be covered with 1/4" steel plate. All steel surfaces shall be prime coated. All interconnecting piping shall be assembled by the manufacturer. This shall include inlet and outlet isolation valves for each tank and a system bypass valve. Inlet and outlet headers shall be installed and terminate at the skid edge. All piping shall be suitably supported by Unistrut supports anchored to the skid. Electric wiring, where applicable, shall be complete between all inter unit controls and require only a single power source connection. The inter unit wiring shall be contained in Flextite, exible, waterproof conduit. All inter tank hydraulic or pneumatic tubing shall be installed as part of the skid package. All polyethylene briners shall be supported on the skid by a 12" high steel band welded to the skid. The mineral tanks are to be bolted to the skid. Permanent attachment, or welding, will not be acceptable. Lifting lugs, rings, etc., will be suitably located for single point lifting of the entire skid mounted system. The entire skid mounted system shall be both hydro and electrically tested as a unit by the manufacturer before shipment. The system shall be completely drained after hydro testing. 7.0 Guarantee The manufacturer of the dealkalizer equipment shall guarantee his equipment as follows: A. All parts found defective in material or workmanship within a period of one year after installation shall be repaired or replaced. B. The dealkalizer shall reduce the alkalinity of the water to 10 ppm or to 10% of the inuent alkalinity. C. Loss of resin by attrition shall not exceed 3% per year for 3 years. The manufacturer of the dealkalizer equipment must have been engaged in the manufacturing of this size equipment for a period of not less than ve (5) years and be able to furnish locations of like-sized equipment installed and operating in the general area of this job. A complete set of operating instructions covering the installation, care and operation of the dealkalizer system shall be furnished in bound booklet form.
H9-10
02-02
Section H10
BLOWDOWN SEPARATORS
CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-3 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-3 Standard and Optional Equipment Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-3 DIMENSIONS, RATINGS, SIZING AND SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-5 ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-5 SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-10 ILLUSTRATIONS Figure H10-1. Blowdown Separator Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure H10-2. Automatic Drain Water Aftercooler (18DF) Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure H10-3. Automatic Drain Water Aftercooler (20AO) Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure H10-4. Model 5D Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure H10-5. Separator Floor Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure H10-6. Separator Wall Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TABLES Table H10-1. Boiler Blowdown Separator Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-4 Table H10-2. Cooling Water Line and Valve Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-6 H10-4 H10-5 H10-6 H10-7 H10-8 H10-9
H10-1
02-02
Blowdown Separators
Feedwater Systems
This section contains information on blowdown separators, which are used to provide safe and economical ash purication to enhance blowdown effectiveness.
H10-2
02-02
Feedwater Systems
Blowdown Separators
Cleaver-Brooks blowdown separators are compact, and can be quickly installed with few connections. Accessories include leg or wall brackets, drain tempering tting, strainer, temperature regulating valve, thermometer, pressure gauge and anges. Pressure ranges: 0 to 300 psig, standard.

Fast, Safe, Low-Cost Way to Separate Steam and Water and Remove Harmful Dissolved Solids. Protects boiler surfaces from severe scaling or corrosion problems. Economical Flash Purification Process for Enhancing Blowdown Effectiveness. Reduce drain water temperature to meet state and local requirements. The Design is Quiet, with Noise Levels Held Below 90 dBA, so no Exhaust Head is Required. CB Blowdown Separators are Compact, and Can Be Quickly Installed with Few Connections. Stainless steel striking plate greatly extends separator life. Momentum of Water is Speeded by Spiral Baffle Centerwise to Drain. Drain is Completely Filled - No Center Void. Tangential inlet and small diameter prompt high velocity spinning for release of steam. All Interior Surfaces Slant Toward Drain, Making Unit SelfDraining, Self-Drying for Longer Life. Proven Performance. Demonstrated Durability. Universal Adaptability.
301 to 1600 psig, special. Available with ASME U stamp.
Standard and Optional Equipment Selection

For dimensions and sizing of blowdown separators, refer to Figure H10-1 and Table H10-1. For manual drain water tempering, use Aftercooler model 5D and specify drain diameter. For automatic control of drain water temperature, use 18DF___ or 20AO___ Aftercooler. 20AO Aftercooler is required in some areas to automatically regulate the temperature of the water to the drain. Check local codes to ascertain if it is required in your area. A temperature regulating valve should be used when the blowdown temperature going to the drain needs to be less than 212 F. (See Table H10-2 to select cooling water line and valve size.) Use a solenoid valve and thermostat when the cooling water pressure exceeds 80 psig. 1. Model 18 DF Aftercooler (Figure H10-2). Nonclogging automatic drain tempering tting with stainless steel mixing tongue (on 4" and larger) to provide thorough mixing of inuent cold water with drain water. The middle ange permits rotation for various pipe tting requirements and also serves as a dismantling ange. Two bulb-wells for mounting control valve and thermometer are furnished. When ordering, state cold water inlet size. 2. Model 20AO Jacket Type After Cooler (Figure H10-3). Required in some areas. Has mixing holes corresponding to the cold water inlet size. The lower portion is designed with wells to accommodate automatic control bulb and thermometer. When ordering state cold water inlet size. 3. Temperature Regulator Valves (Figures H10-2 and H10-3). Automatically control the ow of cold water by responding to temperature changes at the thermostatic bulb. The 6" capillary tube allows installation in the cold water line while the 11" bulb is mounted in the lower portion of the aftercooler. The valve size should correspond to the cold water inlet. 4. Thermometer. Bi-metal, drawn steel case, rust resistant and nished in oven baked enamel. Six inch brass stem with 1/4" NPT bushing provided for use with Model 18 DF and Model 20 AO Aftercoolers. H10-3
02-02
PRODUCT OFFERING
Boilers that supply steam for power, process or heating applications require periodic and more often, frequent, blowdowns to prevent buildup of harmful solids. Blowdown protects boiler surfaces from severe scaling or corrosion problems that would otherwise result. Cleaver-Brooks blowdown separators use a safe, economical ash purication process for enhancing blowdown effectiveness. Steam is rapidly separated from blowdown water and vented out the top of the blowdown separator in a cyclonic spinning action. Water and dissolved solids are ushed out the bottom drain. The design is quiet, with noise levels held below 90 dBA, so no exhaust head is required. Internal pressures do not exceed 5 psig. Blowdown water is cooled to 120 F by a drain tempering device, designed to meet state and local codes.
Blowdown Separators
Feedwater Systems
INSPECTION PORT V VENT
A 1/4 SS WEAR PLATE 9 H 1/2 A MODEL NO. A20B A34B A56B H Dimension 22 34 56 A Dimension 9-3/4 10-1/4 11 I Inlet size Determined by blowdown valve size. :V Vent size Select from Table H10-1. D Drain size Select from Table H10-4. PL Plate size 5/16 or 3/8. May be determined by codes. 14 I INLET
PL A
D DRAIN
HEADS
SA 516-70 SA 53B SA 105 SA 240-304 SA 240-304 SA 53B, SA 106-B RED OXIDE PRIMER
SECTION A-A MODEL NO. ________ MAWP 250 PSIG AT 450 F
SHELL COUPLINGS WEAR PLATE BAFFLES NOZZLES FINISH
Figure H10-1. Blowdown Separator Dimensions Table H10-1. Boiler Blowdown Separator Sizing
VALVE SIZE Model H Separator Dim. 1" Model H 1-1/4" Model H 1-1/2" Model H 2" Model H 2-1/2"
Generator Op psig 0-15 16-50 51-100 101-125 126-150 151-175 176-200 201-225 226-300
14 20 20 34 34 34 34 34 56
1 1 1 1 1 1 1 1 1
2 2 3 3 3 3 3 4 4
2-1/2 2-1/2 2-1/2 3 3 4 4 4 4
20 20 34 34 34 34 34 56 56
1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4
3 3 4 4 4 4 4 4 4
4 4 4 4 4 4 5 5 5
20 34 34 34 34 34 56 56 56
1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2
3 3 4 4 4 4 5 5 5
4 4 4 4 5 5 5 5 6
20 34 34 34 56 56 56 56 56
2 2 2 2 2 2 2 2 2
4 4 5 5 5 5 6 6 6
5 5 5 5 6 6 6 6 8
34 34 34 56 56 56 56 56 56
2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2
5 5 6 6 6 6 6 8 8
6 6 6 6 6 8 8 8 8
251-300 psig U. Symbol Construction and Stamping is required. To use this chart: 1.Select separator size from this table by matching operating pressure and blow-down valve size. 2.Select Plate Thickness (PL) as local regulations require or as desired for maximum pressure stamped on Separator 3/16", 150 psig, 5/16", 225 psig, 3/8", 250 psig. 3.If local regulations require, indicate ASME or Standard. Separator size is now determined and discharge piping may follow these sizes with no calculation necessary. Separators are designed to exhaust at less than 5 psig.
H10-4
02-02
(Rev 7/97)
Feedwater Systems
5. Solenoid Valve. Automatically controls cooling water to aftercooler. Non-magnetic stainless steel body; micro-nished, hardened pilot valve ball. Has two-wire control circuit (120/ 60). Well immersion hot water control provided for actuating solenoid valve. 6. The Model 5D Drain Tempering Fitting (Figure H10-4). Simple type of aftercooler for adding cooling water with manual control. It has cold water inlet for adding cooling water to drain for tempering to 120 F. Inlet is sized for minimum inuent water conditions of 60 F water at 40 psig pressure with 100 sq-ft of supply. When ordering, state Model 5 D (Drain Diameter); i.e. for 4" drain use Model 5D 4. 7. Armstrong Strainer. Cast iron with .045 stainless steel screen. Install in cold water line to protect temperature regulator valve or solenoid valve shown in adjacent column. 8. Separator Floor Stand (Figure H10-5). Provides and excellent means for supporting separators. Constructed of sturdy angle iron. They come attached to the separator to provide an
Blowdown Separators
easy and expedient means of installation. Standard height raises separator 18 inches from oor, or when aftercoolers are provided, additional height is provided. 9.Separator Wall Brackets (Figure H10-6). For wall mounting where oor space is limited, or where desired installation is at a level higher than leg height of 18 inches.
DIMENSIONS, RATINGS, SIZING AND SELECTION

Dimensions, ratings, sizing, and selection information are presented in Table H10-2.
ENGINEERING DATA
Engineering data are shown in Figure H10-1 and Table H10-2.
A 2-1/2 2-1/2 2-1/2 4 4 4 4 4 4 4-1/2 4-1/2
D 2 2 2-1/2 3 3 4 4 5 5 6 6
F 6 6 7 7-1/2 7-1/2 9 9 10 10 11 11
H 18 18 18 20 20 20 20 20 20 20 20
CWI 1/2 3/4 3/4 3/4 1 1 1-1/4 1-1/4 1-1/2 1-1/2 2

F D A CWI COLD WATER INLET STAINLESS STEEL MIXING TONGUE SUPPLIED ON MODELS 18DF4 AND LARGER H 1/4 NPTF CONNECTION TO ACCOMODATE BIMETALLIC THERMOMETER
NOTES: 1. Temperature regulator valve bulb is installed in lower section of the aftercooler so that the bulb senses mixed water temperature. Valve is modulating so that the right amount of cold water is added to cool the drain water to the desired temperature set on the valve. Valve range is 110 to 150 F. 2. Regulator Valve has composition seat to ensure tight shut-off when not blowing down. Valve should be protected with C.1. Strainer with .045 mesh. 3. CWI = cold water inlet size.
D
1 NPTF CONNECTION TO ACCOMODATE TEMPERATURE REGLUATOR VALVE SENSING BULB
Figure H10-2. Automatic Drain Water Aftercooler (18DF) Dimensions
H10-5
02-02
Blowdown Separators
Feedwater Systems
D1 2 2 2-1/2 3 3 4 4 5 5 6 6
D2 3 3 4 4 4 5 5 6 6 8 8
CWI 1/2 3/4 3/4 3/4 1 1 1-1/4 1-1/4 1-1/2 1-1/2 2
CWI COLD WATER INLET NPTF 5-1/4 D2 1/4 NPTF CONNECTION TO ACCOMODATE BIMETALLIC THERMOMETER
D2 20
NOTES: 1. Temperature regulator valve bulb is installed in lower section of the aftercooler so that the bulb senses mixed water temperature. Valve is modulating so that the right amount of cold water is added to cool the drain water to the desired temperature set on the valve. Valve range is 110 to 150 F. 2. Regulator Valve has composition seat to ensure tight shut-off when not blowing down. Valve should be protected with C.1. Strainer with .045 mesh. 3. CWI = cold water inlet size.
D1 1 NPTF CONNECTION TO ACCOMODATE TEMP REGULATOR VALVE SENSING BULB
Figure H10-3. Automatic Drain Water Aftercooler (20AO) Dimensions
Table H10-2. Cooling Water Line and Valve Sizing

SEPARATOR INLET SIZE COOLING WATER PRESS. (PSIG) 40 1 1-1/4" 1-1/2 2" 2-1/2"
60
80
40
60
80
40
60
80
40
60
80
40
60
80
GENERATOR OPERATING PRESSURE (50 TO 70 F COOLING WATER TEMPERATURE) 0-50 51-100 101-125 126-175 176-225 226-250 251-300 1/2 1 1 1 1 1-1/4 1-1/4 1/2 3/4 3/4 1 1 1-1/4 1-1/4 1/2 3/4 3/4 1 1 1 1 1 1 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1 1 1 1-1/4 1-1/4 1-1/4 1-1/4 3/4 1-1/2 1 1 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/2 1-1/2 1-1/2 1 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1 1 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/2 2 2 2 2 2 1-1/4 1-1/4 1-1/2 2 2 2 2 1-1/4 1-1/4 1-1/4 1-1/2 2 2 2 1-1/2 2 2 2-1/2 2-1/2 2-1/2 2-1/2 1-1/2 2 2 2 2 2 2-1/2 1-1/4 2 2 2 2 2 2
GENERATOR OPERATING PRESSURE (71 TO 80 F COOLING WATER TEMPERATURE) 0-50 51-100 101-125 126-175 176-225 226-250 251-300 3/4 1 1 1 1 1-1/4 1-1/4 1/2 3/4 1 1 1 1-1/4 1-1/4 1/2 3/4 3/4 1 1 1 1-1/4 1 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/2 1 1 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1 1 1 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/2 1-1/2 1-1/2 2 1 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/2 1 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/2 1-1/4 2 2 2 2 2-1/2 2-1/2 1-1/4 1-1/2 2 2 2 2 2 1-1/4 1-1/4 1-1/2 2 2 2 2 2 2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 1-1/2 2 2 2 2-1/2 2-1/2 2-1/2 1-1/2 2 2 2 2 2 2-1/2
Use the chart as follows: 1. Depending upon the temperature of the cooling water used, locate the section of the chart which applies, 50-70 F or 71 - 80 F. 2. At the top of chart locate Separator inlet size and in left column under the section selected in step one, locate Boiler Operating pressure. You now have a selection of three valve sizes. 3. From the top of chart select the cooling water line pressure either 40, 60 or 80 and read the desired valve and line size.
H10-6
02-02
Feedwater Systems
Blowdown Separators
B 2-1/2 2-1/2 4 4 4 4-1/2
D 2 2-1/2 3 4 5 6
H 5 5 7 7 7 7
CWl 3/4 3/4 1 1-1/4

D COLD WATER INLET - NPTF
1-1/2 2
Furnish and install a manual drain water aftercooler Model 5D ____ and with a ____ cold water connection. NOTE: 1. Temperature regulator valve bulb is installed in lower section of the aftercooler so that the bulb senses mixed water temperature. Valve is modulating so that the right amount of cold water is added to cool the drain water to the desired temperature set on the valve. Valve range is 110 to 150 F. 2. Regulator Valve has composition seat to ensure tight shut-off when not blowing down. Valve should be protected with C.1. Strainer with .045 mesh. 3. CWI = cold water inlet size. 4. 16DS Same as 18DF Without Flanges.
Figure H10-4. Model 5D Dimensions
H10-7
02-02
Blowdown Separators
Feedwater Systems
For Screwed or Beveled Connections, Factory Fabricated 2" x 2" x 1/4" Angle Permissible Load 6000 lbs If 18DF, 16DS, or 20AO Aftercooler is furnished with separator, see dimension chart for separator height A. A dimension is determined by separator drain size D. This provides adequate height for the aftercooler and elbow when required. A dimension will always be 18" when separator is furnished without an aftercooler.
D 2 2-1/2 3 4 5 6
A 22 23 24 25 30 34
For Flanged Connections Factory Fabricated 2" x 2" x 1/4" Angle Permissible Load 6000 lbs. If 18DF, 16DS, or 20AO Aftercooler is furnished with flanged connections on both ends, use dimension chart to determine separator height "A". "A" dimension will always be 18" when separator is furnished without an aftercooler.
D 2 2-1/2 3 4 5 6
A 28 30 31 32 33 35
Figure H10-5. Separator Floor Stand
H10-8
02-02
Feedwater Systems
Blowdown Separators
SEPARATOR WALL BRACKET 2 X 2 X 1/4" ANGLE USE MODEL 20 W/20" SEPARATOR USE MODEL 34 W/34" SEPARATOR USE MODEL 56 W/56" SEPARATOR
MODEL 20 34 56
A 21 21 35
B 14 14 28
C 14
D 13 -
NOTE: 1. DIMENSION C IS FOR MODEL 56 ONLY. 2. DIMENSION D IS FOR MODEL 20 ONLY.
Figure H10-6. Separator Wall Bracket
H10-9
02-02
Blowdown Separators
Feedwater Systems
The following sample specication is provided by Cleaver-Brooks to assist you in meeting your customers requirements. 1.0 Blowdown Separator Furnish and install Cleaver-Brooks Model _____ blowdown separator with I=______, D=_____, V=______, and _______ plate thickness. The separator shall be manufactured in accordance with ASME Code for 250 psig design and tested to 375 psig. Provide separator with National Board stamping and "U" symbol. (Necessary in Michigan and Utah, optional elsewhere.) The separator shall be furnished with ______________ (screwed, weld bevel, 150# anged or 300# anged) connections. The separator shall include a stainless steel striking plate at the point of inlet impingement and shall be furnished by CleaverBrooks. 2.0 Accessories Provide a ________ solenoid valve to automatically control the ow of cold water by responding to temperature changes sensed at the thermostatic bulb in the aftercooler tting. Furnish a bi-metal thermometer with necessary adaptor bushing for use with _________ (18DF or 20AO) aftercooler. Furnish a ______ cast iron strainer with .045 stainless steel screen ahead of the ________ (TRV or solenoid valve) to protect said valve against foreign matter. Furnish and install an automatic drain water aftercooler, Model ________ (18DF or 20AO) with a ______ cold water connection for a _________________ (TRV or solenoid valve and thermostat) (See Figure H10-2 or H10-3). Provide a ___________ temperature regulator valve to automatically control the ow of cold water by responding to temperature changes sensed at the thermostatic bulb in the aftercooler tting. The accessory separator oor stand and wall mounting bracket are shown in Figures H10-5 and H10-6.
H10-10
02-02
Section H11
BLOWDOWN HEAT RECOVERY SYSTEMS
CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-3 BHR-S and BHR-M Series (High Pressure Steam Applications) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-3 BHR-LPS Series (Low Pressure Steam Applications) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-3 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-3 BHR-S and BHR-M Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-3 BHR-LPS Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-4 BHR-LPS Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-4 DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-4 SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-13 ILLUSTRATIONS Figure H11-1. Blowdown Heat Recovery System Selection and Payback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-5 Figure H11-2. Model BHR S Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-8 Figure H11-3. Model BHR-S Ratings/Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-9 Figure H11-4. Model BHR-M Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-10 Figure H11-5. Model BHR-M Ratings/Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-11 Figure H11-6. Model BHR-LPS Dimensions and Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-12
H11-1
02-02
Blowdown Heat Recovery Systems
Feedwater Systems
This section contains information on Cleaver-Brooks Blowdown Heat Recovery Systems used to recover energy from blowdown water and use the energy to preheat make-up water. Cleaver-Brooks heat recovery systems encompass the following models: Model BHR-S Series for single boiler applications. Model BHR-M Series for multiple boiler applications. Model BHR-LPS Series for low pressure steam applications.
H11-2
02-02
Feedwater Systems

Cools Blowdown Before Discharging Into Sewer: Helps comply with local codes on high temperature liquids to drain without adding cooling water to drain. Specifically Designed for Low Pressure Boiler Applications:

BHR-S and BHR-M Series (High Pressure Steam Applications)
Integrated System Automatically Adjusts to Changing Demands: Recovers 90% of heat normally lost. Automatically controls surface blowdown ow to maintain the desired concentration of dissolved solids within the boiler. Automatically controls boiler dissolved solids. Compact Size for Convenient Placement: Reduced installation costs. Removable Shell for Easy Inspection and Cleaning: Reduces maintenance costs. Significant Fuel Savings for Any Size Boiler: It transfers the blowdown heat to the make-up, thereby decreasing fuel costs. Saves chemical costs by reducing blowdown. Blowdown is Cooled Before Discharging Into the Sewer: Complies with discharge water codes.
No need to modify or redo high pressure systems to try and make them work in a low pressure application.
PRODUCT OFFERING
BHR-S and BHR-M Series
Continuous boiler surface blowdown is the most effective method of purging destructive solids from any steam boiler system. However, this protective procedure also results in a constant and costly heat loss, unless a blowdown heat recovery system is used. Cleaver-Brooks blowdown/heat recovery systems adjust automatically to changing system demands, and recover 90% or more of the heat normally lost during boiler surface blowdown operation. The blowdown/heat recovery systems will usually result in a payback in a few short months from fuel savings alone. Refer to Figure H11-1 for selection and payback calculations. The Cleaver-Brooks Packaged Blowdown Heat Recovery System serves two primary functions. 1. It automatically controls the surface blowdown to maintain the desired level of total dissolved solids (TDS) in the boiler, reducing the amount of blowdown to a minimum. 2. It recovers the heat from the high temperature blowdown, and transfers it to the incoming cold make-up water, maximizing boiler efciency. Use of BHR also improves deaerator efciency by reducing surges caused by adding large amounts of cold make-up water to the system. The control valve within the unit performs two functions. The valve senses the ow of make-up, and positions itself to maintain the desired ratio of blowdown and make-up ows. As a result, the dissolved solids concentration within the boiler is maintained automatically. The proportioning control also provides for very effective heat recovery since hot blowdown ows only when there is a corresponding ow of cold water (make-up). Model BHR-M Systems for multiple boiler installations include a ow control valve for each boiler. This allows for proportioning the overall system blowdown between different boilers, which may be operating at different loads. A strainer and sampling valve are also provided for each boiler, with a sample cooler mounted on the system. Thus, all boilers can be
BHR-LPS Series (Low Pressure Steam Applications)

Blowdown Flow Concurrent With and Proportional to Makeup Flow: Higher heat transfer, greater efciency. Each Boiler Has Its Own Heat Exchanger, Sample Valve, Throttling Valve, and Make-Up Flow Switch: Easier to adjust and monitor each boiler individually. Level of Dissolved Solids or Specific Conductance Can Be Adjusted: Prevents foaming, priming or scaling without wasting excess energy. Packaged for Easy Installation: Saves money on installation costs.
H11-3
02-02

sampled at one convenient location. The heavy duty blowdown heat exchangers are uniquely designed to handle the blowdown on the tube side. This allows many tube side passes, which ensures maximum heat transfer, and maintains high uid velocities preventing scaling and fouling. Due to the severe service, tubes are stainless steel, and because of the abrasive nature of the uid, return bends are fabricated of extra thick material. Since vibration is a common problem with blowdown exchangers, hold down devices are provided to clamp the tube bundle in place. Each system is equipped with a blowdown outlet thermometer so that performance can be monitored. By logging data regularly, a cleaning schedule can be established for each exchanger.
Feedwater Systems
BHR-LPS Series
Cleaver-Brooks Model BHR-LPS systems are designed for boilers operating up to 30 psig and features a brazed plate exchanger - dedicated to each boiler - up to a maximum of three boilers. The plate exchanger is designed to improve thermal exchange efciency. The BHR-LPS also features an on/off ow switch that is synchronized to each boiler feed pump. The BHR-LPS includes plate exchanger, on/off ow switch, outlet thermometer and interconnecting piping.
BHR-LPS Selection
Make-up = minimum ow (total - all boilers) - 3-1/2 gpm (The make-up valve to feedwater tank should be on/off type to ensure minimum 3-1/2 gpm ow). Maximum ow (each boiler) - 15 gpm. Maximum pressure - 65 psig. Blowdown, maximum ow (each boiler) - 3 gpm Design pressure -30 psig at 274 F

Dimensions and ratings for Model BHR-S are shown in Figures H11-2 and H11-3. Dimensions and ratings for Model BHR-M are shown in Figures H11-4 and H11-5. Dimensions and ratings for Model BHR-LPS are shown in Figure H11-6. .
H11-4
02-02
Feedwater Systems
Figure H11-1. Blowdown Heat Recovery System Selection and Payback (Sheet 1 of 3) H11-5
02-02
Feedwater Systems
02-02
Feedwater Systems
02-02
Feedwater Systems
MODEL BHR-S SERIES DIMENSIONS MODEL NO. A REF B C REF D REF E REF F EF G H + 1/8 J REF K L M N P R S + 1/8 BHR-2S 54-1/2 20-1/2 8 28 7 5-1/2 7-1/2 16-1/2 9 35-3/4 33 4-1/2 16-1/2 7 1/2 5 BHR-4S 81-1/2 20-1/2 8 64 7 5-1/2 7-1/2 38-1/2 22-3/4 62-5/8 60 4-1/2 16-1/2 7 1/2 5 CONNECTIONS 1 2 3 4 1-1/2 FPT 1-1/2 FPT 3/4 FPT 3/4 FPT 1-1/2 FPT 1-1/2 FPT 3/4 FPT 3/4 FPT 2 FPT 2 FPT 3/4 FPT 3/4 FPT 2 FPT 2 FPT 3/4 FPT 3/4 FPT 3FLG 3 FPT 1 FPT 1 FPT BHR-9S 84 23-1/2 10 64 9-1/8 5-1/2 8 38-1/2 22-3/4 62-5/8 60 4-3/8 19-1/2 7 * 7-1/8 BHR-14S 127 23-1/2 10 100 9-1/8 5-1/2 8 64-1/2 33-1/2 107-1/2 105 4-3/8 19-1/2 7 * 7-1/8 BHR-22S 128 33 12-1/2 100 11-1/8 6 9-1/2 64-1/2 31-1/2 105 96-1/2 4 24-1/2 7-1/2 3/4 9-1/8
Figure H11-2. Model BHR -S Dimensions H11-8

02-02
Feedwater Systems
MAXIMUM CAPACITIES (GPM) Model No. BHR-2S BHR-4S BHR-9S BHR-14S BHR-22S Blowdown 2 4 9 14 22 Make up 48 48 130 130 180
Figure H11-3. Model BHR-S Ratings/Capacities
H11-9
02-02
Feedwater Systems
MODEL BHR-M SERIES DIMENSIONS MODEL MAX NO.OF BOILERS A REF B REF C REF D REF E EF F REF G H + 1/8 J REF K L M N P R S T + 1/8 V W BHR-2M 4 54-1/2 22 19-1/4 28 7 5-1/2 7-1/2 16-1/2 9 35-3/4 33 4-1/2 14 13-1/2 11-1/2 20-1/2 5 25-1/2 15-1/2 BHR-4M 4 81-1/2 22 17-1/4 64 7 5-1/2 7-1/2 38-1/2 22-3/4 62-5/8 60 4-1/2 14 13-1/2 11-1/2 20-1/2 5 61-1/4 15-1/2 BHR-9M 5 84 24 18-1/2 64 9-1/8 5-1/2 8 38-1/2 22-3/4 62-5/8 60 4-3/8 16 15-1/2 11-1/2 23-1/2 7-1/8 61-1/4 18 BHR-14M 5 127 24 18-1/2 100 9-1/8 5-1/2 8 64-1/2 33-1/2 107-1/2 105 4-3/8 16 15-1/2 11-1/2 23-1/2 7-1/8 92-1/4 18 BHR-22M 6 128 28 19-1/2 100 11-1/8 6 9-1/2 64-1/2 31-1/2 105 96-1/2 4 20 21 11-1/2 33 9-1/8 95-3/4 22-1/2
CONNECTIONS 1 2 3 4 6 1-1/2 FPT 1-1/2 FPT 3/4 FPT 3/4 FPT 1/4 FPT 1/1/2 FPT 1-1/2 FPT 3/4 FPT 3/4 FPT 1/4 FPT 2 FPT 2 FPT 3/4 FPT 3/4 FPT 1/4 FPT 2 FPT 2 FPT 3/4 FPT 3/4 FPT 1/4 FPT 3 FPT 3 FPT 3/4 FPT 1 FPT 1/4 FPT
Figure H11-4. Model BHR-M Dimensions H11-10

02-02
Feedwater Systems
MAXIMUM CAPACITIES (GPM) MODEL BHR-2M BHR-4M BHR-9M BHR-14M BHR-22M BLOWDOWN 2 4 9 14 22 MAKE-UP 48 48 130 130 180
Figure H11-5. Model BHR-M Ratings/Capacities
H11-11
02-02
Feedwater Systems
MODEL NO. BHR-3LPS BHR-6LPSA BHR-9LPS
A 15 26 37
B 11 22
A. Two-boiler system is shown.
Figure H11-6. Model BHR-LPS Dimensions and Ratings
H11-12
02-02
Feedwater Systems
The following sample specications are provided by Cleaver-Brooks to assist you in specifying your customers requirements. 1.0 BHR-S Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-13 2.0 BHR-M Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-13 3.0 BHR-LPS Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-14 1.0 BHR-S Series Furnish ______ Cleaver-Brooks Model BHR-S Package blowdown heat recovery system designed to handle a maximum blowdown rate of _______ gpm (2 to 22) and a maximum make-up rate of _______ gpm (48 to 180). The heat recovery system shall be designed for a boiler of _______ hp (150 - 1500), hp operating at _______ psig (35 to 250). The unit shall be designed to cool the blowdown to within 30 F of the make-up water temperature. The unit shall have a 250 psig rating at 400 F. The heat recovery system shall consist of a differential temperature control valve that shall automatically regulate the blowdown of make-up ow. The ow of blowdown shall be regulated by the thermal expansion of the inner brass tube pressing against a valve seat. The inner tube will contract only when cold make-up water passes through the brass jacketed steel outer tube shell, allowing the blowdown to cool and go out the exchanger. The system shall also have a heat exchanger, including a removable U-tube bundle manufactured of 19 gauge, 304 stainless steel tubes and steel sideshell with hold down clamps to stop tube bundle vibration. The vessel shall be ASME code stamped for 250 psig at 400 F. The system shall have interconnecting piping of steel and stainless steel. The exchanger shall have a minimum sq-ft of surface area. The ow of the blowdown make-up shall ow in opposite directions for a maximum heat transfer efciency of _______ percent. A heat treated stainless steel valve seat and plunger shall manually control the blowdown ow by a handwheel. A blowdown thermometer Weksler Type 152 shall be furnished at the blowdown outlet. The entire system shall be supported by steel channel legs with 3/4" diameter holes for customer-supplied 5/8" diameter anchor bolts. The system will be painted with a hard enamel coating. 2.0 BHR-M Series The following sample specications are provided by Cleaver-Brooks to assist you in specifying your customers requirements. Furnish ______ Cleaver-Brooks Model BHR-M package blowdown heat recovery system designed to handle a maximum blowdown rate of _______ gpm (2 to 22) and a maximum make-up rate of _______ gpm (48 to 180). The heat recovery system shall be designed for boilers of ______ hp (250 - 1500), hp operating at _______ psig (35 to 250). The unit shall be designed to cool the blowdown to within 30 F of the make-up water temperature. The unit shall have a 250 psig rating at 400 F The heat recovery system shall consist of a differential temperature control valve that shall automatically regulate the blowdown and make-up ow. The ow of blowdown shall be regulated by the thermal expansion of the inner brass tube pressing against a valve seat. The inner tube will contract only when cold make-up water passes through the brass jacketed steel outer tube shell allowing the blowdown to cool and go out the exchanger. The system shall also have a heat exchanger, including a removable U-tube bundle manufactured of 19 gauge, 304 stainless steel tubes and steel sideshell with hold down clamps to stop tube bundle vibration. The vessel shall be ASME code stamped for 250 psig at 400 F. The system shall have interconnecting piping of steel and stainless steel. The exchanger shall have a minimum sq-ft of surface area. The ow of the blowdown make-up shall ow in opposite directions for a maximum heat transfer efciency of _____ percent.
H1102-02
Feedwater Systems
A heat treated stainless steel valve seat and plunger shall manually control, the blowdown ow by means of a handwheel. A blowdown outlet thermometer Weksler Type 152 shall be furnished at the blowdown outlet. A ow control assembly shall be furnished for each boiler. The assembly shall consist of a _____ inch Hancock #4595 ow control valve rated at 300 psig, bronze construction and a _____ inch cast steel strainer with a stainless steel screen and have a 250 psig pressure rating. A SC-22 sample cooler with isolation valves and interconnecting piping will be supplied. The entire system shall be supported by steel channel legs with 3/4" diameter holes for customer-supplied 5/8" diameter anchor bolts. The system will be painted with a hard enamel nish coating. 3.0 BHR-LPS Series The following sample specications are provided by Cleaver-Brooks to assist you in specifying your customers requirements. Furnish _______ Cleaver-Brooks Model BHR-LPS blowdown heat recovery system, designed to handle a maximum make-up rate of 3 gpm (per boiler) and a maximum make-up rate of 15 gpm (per boiler). The system shall be designed for boiler(s) of hp _____ (50 - 250) operating at psig _____ (10 -30). The unit shall be ASME stamped and rated for 30 psig at 274 F. The system shall consist of a brazed plate heat exchanger (one for each boiler) capable of recovering at least 90% of the available heat. The exchanger shall be constructed of copper with a 1" FPT inlet and outlet connections for the make-up and a 3/4" FPT inlet and a 1" FPT outlet connection for the blowdown. All other connections shall be sweat-soldered for strength. The system shall be designed to operate with on/off boilers. The system shall be electronically tied to the on/off circuit for the boiler feed pumps through a ow switch to the (each) boiler. Sampling of blowdown from the (each) boiler shall be by an on/off valve located on the blowdown outlet. A blowdown outlet thermometer, Weksler Type 152, shall be furnished at the blowdown outlet to monitor the cooled blowdown temperature. The system shall be pre-piped and mounted on channel legs for ease of assembly in the eld. The legs shall have 9/16" diameter holes for customer-supplied anchor bolts. The system will be painted with a hard enamel nish coating.
H11-14
02-02
Section H12
FLASH TANK HEAT EXCHANGERS
CONTENT FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-3 PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-3 Standard Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-3 Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-3 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-3 ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-3 SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-10 ILLUSTRATIONS Figure H12-1. Model FTE Flash Tank Heat Exchanger Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-4 Figure H12-2. Model AHR Flash Tank Heat Exchanger Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-5 Figure H12-3. Flash Tank Exchanger Blowdown System Selection & Payback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-6 This section contains information on Cleaver-Brooks Flash Tank Heat Exchangers. Flash tank heat exchangers are used on applications when operating pressures exceed 25 psig and continuous blowdown heat recovery is desired.
H12-1
02-02
Flash Tank Heat Exchangers
Feedwater Systems
Notes
H12-2
02-02
Feedwater Systems

steel, is integral with the ASME approved ash tank. The space saving system includes oor supports, liquid level control, three indicating thermometers, and a safety valve as standard equipment.

Flashing: Hot, high-pressure blowdown water from each boiler is piped to individual ow control valves on the inlet manifold. Pressure drops across the ow control valve to 5-20 psig, causing the blowdown water to ash into a mixture of steam and water. Separation Steam/Water: An entrainment bafe directs the mixture around the inside of the tank in a centrifugal motion. Efcient bafing separates the dirty blowdown water from the clean steam. Discharge: Steam then rises through the top of the ash tank and is piped to the feedwater heater, or wherever low pressure steam is required. The remaining hot, dirty water ows out the bottom of the ash tank to a heat exchanger for additional heat recovery, or to a blow-off tank or sewer. Heat Recovery: In addition to the heat recovered as ashed steam, the heat exchanger will transfer the remaining heat normally lost during blowdown, to the cold make-up water as it ows to the feedwater heater.
Standard Offering
Flash separator with stainless steel coil heat exchanger. Floor supports. Liquid level controller. Liquid level indicator, brass body Michigan gauge. Temperature control panel with three indicating thermometers (drain temperature, make-up inlet, make-up outlet). Safety Valve. ASME Code Construction (150# Design). Major Components Blowdown system. Flashtank. Heat exchanger. Stand. Optional Equipment Drain valve and level control. Sample coolers and assembly. Flow control valve and assembly. Manifold. Safety valve. Gauge glass. Pressure gauge. Gauge panel. Level alarm. Level alarm control panel. Thermometers for exchanger operation.
PRODUCT OFFERING
Flash tank heat exchangers are used when operating pressures exceed 25 psig and continuous blowdown heat recovery is desired for cost savings. They consist of an ASME approved and stamped ash tank and a blowdown heat exchanger. Water from continuous blowdown enters the tank and separates into steam and water. The steam, normally at 5 psig, can be returned to the deaerator to help meet heating needs. Hot water leaves the ash tank at temperatures of 220 F, or more. It goes into the heat exchanger, where it heats cold makeup water entering the system. The systems quickly pay for themselves with fuel savings resulting from recycled heat that would otherwise be wasted. The Model FTE (Figure H12-1) is a conventional plate and frame type blowdown heat recovery system available in sizes ranging from 10 to 20 gpm blowdown and 10 to 200 gpm makeup. The Model AHR (Figure H12-2) is available in sizes ranging from 3 to 30 gpm blowdown and 9 to 150 gpm makeup. The model AHR is a coil type ash tank heat exchanger. It is a compact, low cost alternative to the shell and tube design. The basic difference is the heat exchanger, constructed of stainless
ENGINEERING DATA
Engineering data, system selection, and payback are shown in Figure H12-3.
H12-3
02-02
Feedwater Systems
73
37
CAPACITY (MAX) MODEL NO. FTE-10I A FTE-20I A FTE-10E B FTE-20E B A BLOWDOWN 10 gpm 20 gpm 10 gpm 20 gpm MAKE-UP 100 gpm 200 gpm 100 gpm 200 gpm 48" 48" 72" 72"
NOTE: A. Internal type float assembly (shown). B. External type float assembly.
Figure H12-1. Model FTE Flash Tank Heat Exchanger Dimensions
H12-4
02-02
Feedwater Systems
MODEL ACC-AHR-39 ACC-AHR-315 ACC-AHR-612 ACC-AHR-630 ACC-AHR-1020 ACC-AHR-1050 ACC-AHR-2040 ACC-AHR-3060 ACC-AHR-20100 ACC-AHR-30150
BLOWDOWN (GPM) 3 3 6 6 10 10 20 30 20 30
MAKEUP (GPM) 9 15 12 30 20 50 40 60 100 150
A 96 97 110 111 100 106 140 172 140 132-1/2
B 44 50 49 53 44 50 67 76 67 67
C 44-1/4 36 50 46 42 44 62 85 62 52-1/2
D 8 10 10 12 16 16 18 18 18 24
E 1 1 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2
F 2-1/2 2-1/2 3 3 4 4 6 6-8 6 6-8
G 1-1/2 1 1-1/2 1 2 2 2 2 2 2
H 3/4 1 3/4 1-1/4 1-1/4 1-1/2 1-1/2 1-1/2 2 2-1/2
NOTE: Dimensions in inches.
Figure H12-2. Model AHR Flash Tank Heat Exchanger Dimensions
H12-5
02-02
Feedwater Systems
Figure H12-3. Flash Tank Exchanger Blowdown System Selection & Payback (Sheet 1 of 4)
H12-6
02-02
Feedwater Systems
H12-7
02-02
Feedwater Systems
H12-8
02-02
Feedwater Systems
H12-9
02-02
Feedwater Systems
The following sample specication is provided by Cleaver- Brooks to assist you in specifying your customers requirements. Model FTE 1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-10 2.0 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-10 Model AHR 1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-11 2.0 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-11 3.0 Multiple Boiler Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-11 Model FTE 1.0 General Provide Cleaver-Brooks Model FTE-_____________ packaged ash tank heat exchanger system designed to handle a maximum blowdown rate of 10 to 20 gpm, and a maximum makeup rate of 100 to 200 gpm. The heat recovery system shall be designed for boilers of 300-3600 hp operating at 25 to 250 psig. The unit shall be designed to cool the blowdown to within 25 F of the makeup water temperature. The tank shall have a 100 psig rating at 300 F. The heat recovery systems ash tank shall have an ASME Code design pressure at 100 psig and an internal ash tank pressure of _____ psig (5 to 15). The ash tank shall be 18" diameter x 30" high, and shall be complete with a blowdown inlet manifold, stainless steel wear plate, centrifugal entrainment bafe, steam outlet, Armstrong 3LD level control at and drain valve, 1/2" drain connections, gauge glass assembly, and a 1/2" Consolidated # 1543H safety valve. The system shall also have a plate and frame heat exchanger, consisting of plates manufactured of AISI 316 stainless steel. These plates shall be assembled in packs and bolted in a frame, with each adjacent pair of plates forming a channel with the liquid owing in alternate channels. Between the plates shall be a one piece gasket made of EPDM. The exchanger shall have a maximum temperature limitation of 100 psig at 300 F. The system shall have interconnecting piping of steel and stainless steel. A ow control assembly shall be furnished for each boiler. The assembly shall consist of a _____" Hancock #4595 ow control valve rated at 300 psig, bronze construction, and a ______" cast steel strainer with a stainless steel screen, and have a 250 psig pressure rating. A 0-100 psig ash tank pressure gauge shall be furnished. The entire system shall be supported by steel channel legs with 3/4" diameter holes for customer-supplied 5/8" diameter anchor bolts. A high level alarm switch Mercoid # 123, rated at 125 psig, shall be furnished. The switch shall be mounted and piped on the unit, and shall include two (2) isolation valves. The system shall be painted with Cleaver-Brooks nish paint. 2.0 Optional Equipment 2.1 A SC-22 Sample Cooler with isolation valves and interconnecting piping shall be supplied for a single boiler application. With each additional boiler, a sample valve assembly shall be added and manifolded to the sample cooler. 2.2 An alarm panel, including an audio and visual alarm for high level, shall be provided. The alarm panel shall be complete with a silencing switch and a push-to-test switch. The alarm panel shall be prepiped, wired, and mounted on the unit. 2.3. A gauge panel shall be provided, and shall include thermometers for makeup in, makeup out, and blowdown drain. Each thermometer shall have a 3" diameter dial with reading of 50-300 F. A tank pressure gauge shall also be included in the gauge panel. The tank pressure gauge shall have a 4-1/2" diameter dial with reading of 0-100 psig. The panel shall be prepiped and mounted on the unit. 2.4 A Warren 377 external oat control shall be provided, with Warren 320L valve and a 1-1/2" mechanical drain control valve. H12-10
02-02
Feedwater Systems
Model AHR 1.0 General
Furnish Cleaver-Brooks Model ACC-AHR ____ packaged ash tank coil type heat exchanger system, designed to handle a maximum blowdown rate of ____ gpm (3 to 30) and a maximum makeup rate of _____ gpm (9 to 150). The system shall be designed for boilers of (130-2200) hp operating at (0-600) psig. The unit shall be designed to cool the blowdown to within 30 F of the makeup water temperature. The unit shall have a 150 psig rating at 365 F. The systems ash tank shall have an ASME code design pressure of 150 psig and an internal ash pressure of ____ psig (5 to 15). The ash tank shall be ____" diameter and ____" high and shall be complete with a ______" tangential blowdown inlet, stainless steel wear plate, steam outlet, ball type oat trap with all working parts constructed of stainless steel, tank stand, brass-bodied Michigan site glass, and a safety relief valve set at 150 psig. The ash tank shall have a anged bottom section for quick access to the sludge area and to the coil. The system shall also have a vertical coil-type heat exchanger. The exchanger shall be constructed of stainless steel and shall be integral with the ash tank. The coil shall be complete with ______" threaded connections for the makeup water inlet and outlet. A gauge panel shall be furnished and shall include dial thermometers for indicating makeup inlet temperature, makeup outlet temperature and blowdown outlet temperature. The gauge panel shall be prepiped and mounted on the unit. The entire system shall be supported by steel legs with 3/4" diameter holes for customer-supplied 1/2" diameter bolts. The system will be painted with Cleaver-Brooks blue nish paint. 2.0 Optional Equipment A SC-325 Sample Cooler with isolation valves and interconnecting piping shall be supplied for a single boiler application. With each additional boiler, a sample valve assembly shall be added and manifolded to the sample cooler. 3.0 Multiple Boiler Operation A manifold assembly shall be necessary for multiple boiler installations and shall consist of the necessary piping with threaded connections for the customer-supplied continuous blowoff valves.
H1202-02
Feedwater Systems
NOTES
H12-12
02-02
Section H13
SAMPLE COOLERS
CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ILLUSTRATIONS H13-3 H13-3 H13-3 H13-3 H13-6
Figure H13-1. Sample Cooler (SC-22) Dimensions 4 Figure H13-2. Performance Curves for Hot Water Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H13-4 Figure H13-3. Sample Cooler (SC-42) Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H13-5 Figure H13-4. Performance Curves for Steam Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H13-5 TABLES Table H13-1. Sample Cooler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H13-3
H13-1
02-02
Sample Coolers
Feedwater Systems
This section contains information on Cleaver-Brooks sample coolers. The Model SC22 and SC42 Sample Coolers are used to cool boiler water samples under pressure so that an accurate sampling can be made. When boiler water samples are taken without being properly cooled (while under boiler pressure), as much as 20% of the sample can ash to steam, causing inaccurate measurement of boiler water quality.
H13-2
02-02
Feedwater Systems
Sample Coolers
tem. The Model SC-22 sample cooler is simple, compact and designed to cool boiler samples with minimum disturbance to system pressure. The 316 stainless steel tubing is a continuous, jointless, coil arrangement. The tubing is maintenance-free, rated for 850 F at 2000 psig. The shell is also 316 stainless steel, rated at 450 F, 250 psig. The design has bafing on the shell side to achieve high cooling water ow which minimizes pressure drop, vibration and scaling. The shell can be easily removed for inspection and/or cleaning without disconnecting sample or water lines.

Heavy Duty All Stainless Steel Wetted Parts: SC-22 cools hot water samples up to 850 F and 2000 psig. SC-42 cools steam or water samples up to 1000 F and 5000 psig. True Counterflow Cooling: Effective bafing on the shell side produces full counter ow with high cooling water ow and minimum pressure drop, vibration and scaling. Proper temperature achieved. Compact Design: SC-22 3-1/2" square x 5-1/2" long compact size. Easily mounted in cooling water piping without using brackets or special supports. SC-42 3-1/2 square x 11-1/4 long mounted in cooling water piping without using brackets or special supports. Stainless Steel Coil: Single continuous tube with no joints assures long, maintenance free operation. Removable Shell: Shell can be easily removed for inspection and/or cleaning without disconnecting sample water lines. Lowest Cost: Largest heat transfer surface per unit of cost of any sample coolers.
NOTICE
The Model SC-22 Sample Cooler is not generally recommended for steam samples. Use SC-42 for steam sample cooler information.

Dimensions for Model SC-22 are shown in Figure H13-1, and in Figure H13-3 for Model SC-42. Ratings are shown in Table H13-1.
ENGINEERING DATA
Refer to Figures H13-2 (hot water) and H13-4 (steam) for performance curves. For example, the hot water samples show the relationship of outgoing sample temperature to incoming cooling water temperature for various sample temperatures (diagonal lines) and ow rates (Scale at left). Example: If the water sample is 1/4 gpm (946 cc/min) at 400 F and is to be cooled to less than 100 F and the cooling water is 95 F. Follow the dotted line at 0.25 gpm to 400 F inlet temperature. Read 18 F temperature approach. Sample pressure drop will be approximately 6.5 psig. Sample will cool to 88 F, (70 F coolant + 18 F approach).
PRODUCT OFFERING
The sample cooler is a low-pressure-drop system for monitoring boiler water quality without shutting down the boiler sys-
Table H13-1. Sample Cooler Ratings

MODEL NO. SC-22 SHELL DESIGN 250 psig @ 450oF 450 psig @ 650oF TUBE DESIGN 2000 psig @ 850oF 5000 psig @ 1000oF TUBE MATERIAL 1/4" OD SSA 1/4 OD 316 SS SHELL & HEAD MATERIAL 304 Stainless AREA 1.2 sq-ft WEIGHT 9 lbs
SC-42
304 SS
2.4 sq-ft
12 lbs
A. Tubing is 300 series stainless steel with chemical and physical properties equal to, or better than T304.
H13-3
Sample Coolers
Feedwater Systems
Figure H13-1. Sample Cooler (SC-22) Dimensions
MODEL SC-22 (2.4 SQ-FT) 3 GPM COOLING WATER 1PSIG PRESSURE DROP
SAMPLE PRESS. DROP (PSIG)
APPROACH TEMPERATURE F
Figure H13-2. Performance Curves for Hot Water Samples
H13-4
Feedwater Systems
Sample Coolers
Figure H13-3. Sample Cooler (SC-42) Dimensions
SAMPLE DATA LB/ GPM HR CC/ MIN
MODEL SC-42 3 GPM COOLING WATER 1 PSIG PRESSURE DROP
SAMPLE PRESS. DROP (PSIG)
APPROACH TEMPERATURE F
Figure H13-4. Performance Curves for Steam Samples
H13-5
Sample Coolers
Feedwater Systems
The following sample specications are provided by Cleaver-Brooks to assist you in specifying your customers requirements. Furnish _______ Cleaver-Brooks Model SC-22 sample cooler(s) consisting of 304 stainless steel head and shell, jointless coiled T304 stainless steel tubing, and a carbon steel mounting bracket. The sample cooler shall be of compact bolted design and shall require no larger space than 3-1/2" square x 5-1/2". The tubing and shell shall be removable for cleaning without disturbing connections. The cooling water connections shall be 3/8" FPT and the sample tube connections shall be 1/4" OD. The tubing shall be rated at 2000 psig at 635 F. The surface area shall be 1.2 sq-ft. Furnish _______ Cleaver-Brooks Model SC-42 sample cooler(s) consisting of 304 stainless steel head and shell, jointless coiled T304 stainless steel tubing, and a carbon steel mounting bracket. The sample cooler shall be of compact bolted design and shall require no larger space than 3-1/2" square x 11". The tubing and shell shall be removable for cleaning without disturbing connections. The cooling water connections shall be 3/8" FPT and the sample tube connections shall be 1/4" OD. The tubing shall be rated at 5000 psig at 1000 F. The surface area shall be 2.4 sq-ft.
H13-6
02-02
Section I
SYSTEM FUNDAMENTALS
Boiler Selection Considerations Hot Water Systems Steam Systems General Engineering Data I1 I2 I3 I4
Ia
02-02
General
System Fundamentals
Notes
Ib
Section I1
BOILER SELECTION CONSIDERATIONS
CONTENTS BOILER TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1- 3 Scotch Marine - The Classic Firetube Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-3 Firebox boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4 Commercial Watertube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4 Industrial Watertube Boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4 Flexible Watertube (Bent Tube) Boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4 Membrane Watertube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4 Cast Iron Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4 Electric Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4 BOILER SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4 Codes and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-5 Steam or Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-6 System Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-6 Heating Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-6 Process Load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-6 Combination Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-7 Defining Load Variations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-7 System Load Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-7 Load Tracking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-7 Number of Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-8 Back-Up Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-8 Type of Load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-8 Downtime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-8 Boiler Turndown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-8 Performance Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9 Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9 Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9 Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9 Combustion Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9 Thermal Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9 Boiler Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9 Fuel-to-Steam Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9 Stack Temperature and Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9 Excess Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9 Radiation and Convection Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10 Heating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10 Flue Gas Passes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10 Integral Boiler/Burner Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10 Special Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10 Replacement Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10 PAYBACK ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10 Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-12
I1-1
02-02
Boiler Selection Considerations
System Fundamentals
ILLUSTRATIONS Figure I1-1. Annual Gas Cost as a Function of Gas Use and Unit Price . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure I1-2. Annual Gas Cost as a Function of Gas Use and Unit Price (Expansion of Figure I1-1) . . . . . . . . . . . . . . . . . Figure I1-3. Annual Fuel Oil Cost as a Function of Fuel Oil Use and Unit Price . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure I1-4. Annual Fuel Oil Cost as a Function of Fuel Oil Use and Unit Price (Expansion of Figure I1-3) . . . . . . . . . . Figure I1-5. System Efficiency Improvement as a Function of Incremental Component Efficiency Gain . . . . . . . . . . . . . Figure I1-6. Annual Savings as a Function of Annual Fuel Cost and System Efficiency Improvement . . . . . . . . . . . . . . . Figure I1-7. Annual Savings as a Function of Annual Fuel Cost and System Efficiency Improvement (Expansion of Figure I1-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I1-14 I1-15 I1-16 I1-17 I1-18 I1-19 I1-20
TABLES Table I1-1.Common Boiler Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-3 Table I1-2. Considerations for Selecting a Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-5 Table I1-3. Load Demand Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-7 Table I1-4.Typical Firetube Boiler Fuel Consumption Rates - Natural Gas (MM/Btu/hr) . . . . . . . . . . . . . . . . . . . . . . . . . I1-11 Table I1-5. Typical Firetube Boiler Fuel Consumption Rates - No. 6 Oil (gal/hr) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-12 Table I1-6. Typical Firetube Boiler Fuel Consumption Rates - No. 2 Oil (gal/hr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-13 Perhaps no other piece of equipment is more important to a facility than the boiler. Proper boiler selection, to meet the needs of the application, is a critical factor in the design of any steam or hot water system. This section provides information to consider when selecting a boiler. This information is divided into three main subsections: 1. Boiler Types Typical boiler types are dened, including: retube, rebox, industrial watertube, and commercial watertube boilers. General information is provided on the differences in boiler types (sizes, ranges, pressures, etc.). For more detailed information on boiler products, refer to the specic boiler product section. 2. Boiler Selection Provides information on codes and standards; when to use steam or hot water boilers; denes load requirements; denes the number of boilers needed; discusses performance issues; and addresses special requirements. 3. Payback Analysis There are many factors that affect the decision to purchase a particular piece of boiler room equipment. This section addresses economic considerations only, and provides a procedure that can be applied to individual equipment selection or evaluation of alternative systems. Definitions To assist with understanding information in this section, it will be necessary to understand the following denitions. Boiler horsepower(BHP) is a measure of boiler energy output. One boiler horsepower (from and at 212 F): BHP = 34.5 lbs/hr BHP = 33,472 Btu/hr BHP = 9.8 kW BHP should not be confused with other horsepower measurements. Boiler Trim: Accessories added to the boiler, such as auxiliary low water cutoff, special tappings, special gas trains, etc. Btu: Amount of energy required to raise one pound of water one F. Input: Total amount of fuel input to the burner in Btu/hr. Output: Total amount of energy released from a steam or hot water boiler measured in boiler horsepower, lbs/hr of steam, or Btu/ hr. For additional denitions, refer to the glossary at the end of The Boiler Book. I1-2
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System Fundamentals
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System Fundamentals
be necessary to use very thick shell and tube sheet material. For this reason, a watertube boiler is generally used if pressure above 350 psig design is needed. Firetube boilers are usually built similar to a shell and tube heat exchanger. A large quantity of tubes results in more heating surface per boiler horsepower, which greatly improves heat transfer and efciency. Firetube boilers are rated in boiler horsepower (BHP), which should not be confused with other horsepower measurements. The furnace and the banks of tubes are used to transfer heat to the water. Combustion occurs within the furnace and the ue gases are routed through the tubes to the stack outlet. Firetube boilers are available in two, three and four pass designs. A single pass is dened as the area where combustion gases travel the length of the boiler. Generally, boiler efciencies increase with the number of passes. Firetube boilers are available in either dryback or wetback design. In the dryback boiler, a refractory-lined chamber, outside of the vessel, is used to direct the combustion gases from the furnace to the tube banks. Easy access to all internal areas of the boiler including tubes, burner, furnace, and refractory, is available from either end of the boiler. This makes maintenance easier and reduces associated costs. The wetback boiler design has a water cooled turn around chamber used to direct the ue gases from the furnace to the tube banks. The wetback design requires less refractory maintenance; however, internal pressure vessel maintenance, such as cleaning, is more difcult and costly. In addition, the wetback design is more prone to water side sludge buildup, because of the restricted ow areas near the turn around chamber.
BOILER TYPES
The boilers discussed in this book are packaged boilers. This concept has been around for more than 60 years. The packaged boiler originated with Cleaver-Brooks, when a pre-engineered assembly was supplied to a customer to eliminate his need to purchase separate components, and then try to make them work together. The packaged boiler has proven to be a successful concept - with more than 150,000 Cleaver-Brooks units around the world. There are many types of packaged boilers available. Table I1-1 compares common boiler types and their features. The following is an overview of different types of boilers. Scotch Marine - The Classic Firetube Boiler The Scotch Marine style of boiler has become so popular in the last 40 years that it frequently is referred to simply as a retube boiler. Firetube boilers are available for low or high pressure steam, or for hot water applications. Firetube boilers are typically used for applications ranging from 15 to 1500 horsepower. A retube boiler is a cylindrical vessel, with the ame in the furnace and the combustion gases inside the tubes. The furnace and tubes are within a larger vessel, which contains the water and steam. The retube construction provides some characteristics that differentiate it from other boiler types. Because of its vessel size, the retube contains a large amount of water, allowing it to respond to load changes with minimum variation in steam pressure. Steam pressure in a retube boiler is generally limited to approximately 350 psig. To achieve higher pressure, it would
Table I1-1. Common Boiler Types

CAST IRON Efciency Floor Space Required Low Low MEMBRANE WATERTUBE Medium Very Low Medium Low/Medium Medium ELECTRIC High Very Low Medium/High High Medium FIREBOX Medium Medium Low Low Low/Medium HW/LPS FIRETUBE High Medium/ High Low Medium/ High High HW/LPS HPS to 350 psig Typical Sizes Typical Applications Comments To 200 hp Heating/ Process Field Erectable To 250 hp Heating/ Process To 300 hp Heating/ Process To 300 hp Heating To 1500 hp Heating/ Process To 250 hp Heating Field Erectable Process FLEXIBLE INDUSTRIAL WATERTUBE WATERTUBE Medium Low Medium Low/Medium Medium HW/LPS Medium High High High High High Temp HW HPS to 900 psig VERTICAL FIRETUBE Low/Medium Very Low Low Low Low HW/LPS HPS to 150 psig To 100 hp Heating/ Process
Maintenance Medium/High Initial Cost No. of Options Available Pressure Range Medium Low HW/LPS
HW/LPS HPS HW/LPS HPS to 600 psig to 900 PSIG
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System Fundamentals
For more information on specic retube boiler products, refer to Section A. Firebox boilers The rebox boiler uses similar tube attachment techniques as the retube boiler. Its combustion chamber is not round, like the retubes cylindrical furnace. The rebox boiler is typically manufactured to low pressure steam or hot water applications. The rebox boiler is a compact, economical unit and serves as a good t for seasonal use and when efciency is not the driving factor. Sizes range from 12 to 337 horsepower. Commercial Watertube Boilers Commercial watertube boilers typically produce steam or hot water for commercial, or modest-size applications. There are a wide variety of types, sizes, capacities, and design pressures available. Commercial watertube boilers can be membrane type, straight tube, modular, etc. They can be either atmospherically red or utilize power burners. For more information on commercial watertube boilers, refer to Section B. Industrial Watertube Boilers The industrial watertube boiler typically produces steam or hot water primarily for industrial process applications, and is used less frequently for heating applications. In the watertube design, tubes contain steam and/or water and the products of combustion pass around the tubes. Typically, watertube designs consist of multiple drums. A steam drum (upper) and mud drums (lower) are connected by the tubes, which form both the convection section and the furnace area. Packaged industrial watertube boilers are typically rated in pounds of steam per hour output at operating conditions and range from 10,000 to 134,000 lbs/hr. Industrial watertube boilers are noted for their fast steaming capability. Steam is generated very rapidly because of the relatively low water content. This allows them to respond quickly to changing load demands. The industrial watertube boiler design makes it capable of generating either saturated or superheated steam. When applications dictate superheated steam usage, large or uctuating steam loads, or high pressures (greater than 350 psig), an industrial watertube boiler should be considered. For more information on industrial watertube boilers, refer to Section C. Flexible Watertube (Bent Tube) Boilers Flexible watertube boilers are a common type of boiler used for heating applications because of their resistance to thermal

shock. Flexible watertube boilers are available in size ranges from 2 to 9 MMBtu/hr input. Flexible watertube boilers are available for low pressure steam or hot water applications. Field erectable packages are also available. For more information on exible watertube boilers, refer to Section B. Membrane Watertube Boilers The membrane watertube boiler is available for low or high pressure steam or hot water applications. High outputs are available in a compact design and should be considered where space is limited. Sizes range from 34 to 143 horsepower. For more information on membrane type commercial watertube boilers, refer to Section B. Cast Iron Boilers Cast iron boilers are limited to low-pressure steam or hot water applications, and typically range in size from 25 to 200 horsepower. One advantage of the cast iron boiler is its modular design, which includes sections for eld erection. For more information on cast iron boiler products, contact your local Cleaver-Brooks authorized representative. Electric Boilers Electric boilers are noted for being clean, quiet, easy to install, and compact. Because there are no combustion considerations, an electric boiler has minimal complexity (no fuels or fuel handling equipment) with easily replaceable heating elements. An electric boiler may be the perfect alternative to supply low or high pressure steam or hot water where the customer is restricted by emission regulations. In areas where the cost of electric power is minimal, the electric boiler could be the best choice. Sizes range from 9 kW to 3,375 kW output. For more information on electric boilers, refer to Section B.
BOILER SELECTION
Six criteria should be considered when selecting a boiler to meet the application needs. The criteria are: 1. Codes and standards requirements 2. Steam or Hot Water 3. Boiler load 4. Number of boilers 5. Performance considerations 6. Special considerations
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Codes and Standards
There are a number of codes and standards, laws, and regulations covering boilers and related equipment that should be considered when designing a system. Regulatory requirements are dictated by a variety of sources and are all focused primarily on safety. For more information on how the various rules affect boiler selection and operation, you may want to contact your local Cleaver-Brooks authorized representative. Here are some key rules to consider: The boiler industry is tightly regulated by the American Society of Mechanical Engineers (ASME) and the ASME Codes, which governs boiler design, inspection, and quality assurance. The boilers pressure vessel must have an ASME stamp. (Deaerators, economizers, and other pressure vessels must also be ASME stamped). The insurance company insuring the facility or boiler may dictate additional requirements. Boiler manufacturers provide special boiler trim according to the requirements of the major insurance companies. Special boiler trim items usually pertain to added safety controls. Some industries, such as food processing, brewing, or pharmaceuticals, may also have additional regulations that have an impact on the boiler and the boiler room. A UL, ULC, cUL, CSA or CGA listing, or Canadian Registration Number (CRN) may be required. State, local, or provincial authorities may require data on the boiler controls or basic design criteria.
System Fundamentals
Most areas have established a maximum temperature at which water can be discharged to the sewer. In this case, a blowdown separator aftercooler is required. Most state, local or provincial authorities require a permit to install and/or operate a boiler. Additional restrictions may apply in non-attainment areas where air quality does not meet the national ambient air quality standards and emission regulations are more stringent. For all new boilers with inputs over 10 MMBtu/hr, U.S. Federal emission standards apply, including permitting and reporting procedures. Limits on fuel sulfur content are frequently set at 0.5% maximum. A full-time boiler operator may be required. Operator requirement depends on the boilers size, pressure, heating surface or volume of water. Boilers can be selected which minimize the requirements, either by falling under the requirements and being exempt or with special equipment that gives the operator more freedom in the facility. Most states or provinces require an annual boiler inspection. There may be other requirements on piping as well. Before beginning the selection process, refer to Table I1-2, which shows multiple considerations for selecting a packaged boiler.
Table I1-2. Considerations for Selecting a Boiler

BOILER SELECTION COMMERCIAL WATERTUBE WATERTUBE CAST IRON REQUIREMENT OR APPLICATION FLEXTUBE FIRETUBE ELECTRIC VERTICAL FIREBOX OHIO SPECIAL
High Efciency Space Factor Emissions Factor Low Cost Low Operating Cost Boiler Operator Factor Low Maintenance High Turndown Field Erectable Fuel Limitations Low Usage, No Stack High Pressure, Over 350 psig, or Superheat
X X X X
X X X X X X X
X X X X X X
X X
X X X
A. With Flue Gas Recirculation/ Model CB (LE) Option.
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System Fundamentals
Steam or Hot Water
Now that you have a general overview of the types of boilers and code and standards requirements, its time to look at the facilitys application in order to see how the boiler will be used. Keep in mind, the primary purpose of the boiler is to supply energy to the facilitys operations - for heat, manufacturing process, laundry, kitchen, etc. The nature of the facilitys operation will dictate whether a steam or hot water boiler should be used. Hot water is commonly used in heating applications with the boiler supplying water to the system at 180 F to 220 F. The operating pressure for hot water heating systems usually is 30 psig to 125 psig. Under these conditions, there is a wide range of hot water boiler products available. If system requirements are for hot water of more than 240 F, a high temperature water boiler should be considered. For more information on application considerations for hot water boilers and hot water systems, refer to Hot Water Systems, Section I2. Steam boilers are designed for low pressure or high pressure applications. Low pressure boilers are limited to 15 psig design, and are typically used for heating applications. High pressure boilers are typically used for process loads and can have an operating pressure of 75 to 700 psig. Most steam boiler systems require saturated steam. Steam and hot water boilers are dened according to design pressure and operating pressure. Design pressure is the maximum pressure used in the design of the boiler for the purpose of calculating the minimum permissible thickness or physical characteristics of the pressure vessel parts of the boiler. Typically, the safety valves are set at or below design pressure. Operating pressure is the pressure of the boiler at which it normally operates. The operating pressure usually is maintained at a suitable level below the setting of the pressure relieving valve(s) to prevent their frequent opening during normal operation. Some steam applications may require superheated steam. It should be noted that superheated steam has a high enthalpy, so there is more energy per pound of steam and higher (drier) steam quality. One example of an application where superheated steam may be required is with a steam turbine. The turbines blades require very dry steam because the moisture can destroy the blades. When very high pressure or superheated steam is required, an industrial watertube boiler should be selected. For more information on application considerations for steam boilers and steam systems, refer to Section I3, Steam Systems.

System Load
In addition to the system load considerations provided in this section, many excellent reference manuals are available to help further dene specic load details and characteristics. For more information, refer to the ABMA Firetube Engineering Guide, the ASHRAE Handbook, or contact your local Cleaver-Brooks authorized representative. System load is measured in either Btus or pounds of steam (at a specic pressure and temperature). When discussing the system load, we will include references to both steam and hot water. However, not all situations or criteria apply to both. It would be nearly impossible to size and select a boiler(s) without knowing the system load requirements. Knowing the system load provides the following information: The boiler(s) capacity, taken from the maximum system load requirement. The boiler(s) turndown, taken from the minimum system load requirement. Conditions for maximum efciency, taken from the average system load requirement. Determining the total system load requires an understanding of the type(s) of load in the system. There are three types of loads: heating, process, and combination. Heating Load A heating load is typically low pressure steam or hot water, and is relatively simple to dene because there is not a great deal of instantaneous changes to the load. And, once a heating load is computed, the number can easily be transferred into the equipment size requirements. A heating load is used to maintain building heat. Cooling loads, using steam to run an absorption chiller, also are included when computing a heating load. Characteristics of a heating load include large seasonal variations but small instantaneous demand changes. The boiler should be sized for the worst possible weather conditions, which means that true capacity is rarely reached. Process Load A process load is usually a high pressure steam load. A process load pertains to manufacturing operations, where heat from steam or hot water is used in the process. A process load is further dened as either continuous or batch. In a continuous load, the demand is fairly constant - such as in a heating load. The batch load is characterized by short-term demands. The batch load is a key issue when selecting equipment, because a batchtype process load can have a very large instantaneous demand that can be several times larger than the rating of the boiler. For
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example, based on its size, a heating coil can consume a large amount of steam simply to ll and pressurize the coil. When designing a boiler room for a process load with instantaneous demand, a more careful boiler selection process should take place. Combination Load Many facilities have a mixture of loads - different types of process loads and combinations of heating and process loads. The information just given on heating and process loads should be taken into consideration when dealing with a combination load. Defining Load Variations Loads vary and a power plant must be capable of handling the minimum load, the maximum load, and any load variations. Boiler selection is often dictated by the variation in load demand, rather than by the total quantity of steam or hot water required. There are three basic types of load variations: seasonal, daily, and instantaneous. Seasonal Variations. For a heating system, seasonal variations can mean no demand in the summer, light demand in the fall and spring, and heavy demand in the winter. Manufacturing operations often have seasonal variations, because the demand for production may vary. When selecting boiler equipment, the minimum and maximum load for each season should be determined.
System Fundamentals
Daily Variation. Daily variation can occur due to variations in the work hours, or the heat required at various times of the day or weekend. Minimum and maximum seasonal variations mentioned earlier may already reect these changes if they occur daily. If not, the minimum and maximum daily loads should be included. The seasonal and daily variations dene the size of the load that the boiler(s) must handle. Seasonal and daily variations also help dene the number of boilers and turndown requirements. Instantaneous Demand. Instantaneous demand is a sudden peak load change that is usually of short duration. These types of loads are sometimes hidden. Many machines or processes are rated in pounds of steam per hour or Btu/hr as running loads, under balanced operating conditions, and there is no recognition given to cold startup, peak or pickup loads. The instantaneous load demand is important to consider when selecting a boiler to ensure that these load variations are taken into account. If the instantaneous demand is not included in the system load calculations, the boiler(s) may be undersized. System Load Summary The load demand matrix shown in Table I1-3 can be used as a work sheet in determining the minimum, maximum, and average system loads. Load Tracking Load tracking is the ability of a boiler to respond to changes in steam or hot water demand. Most often associated with pro-
Table I1-3. Load Demand Matrix

MINIMUM WEIGHTED AVERAGE MAXIMUM
Heating Load 1 Heating Load 2 Heating Load 3 Total Heating Load Process Load 1 Process Load 2 Process Load 3 Total Process Load Instantaneous Load Total Load Utilize a load demand matrix to analyze each load and determine minimum, average, and maximum load requirements.
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System Fundamentals
cess loads, load tracking focuses on the boilers ability to supply a constant volume of steam at the required pressure. The ability of the boiler to track a variable load depends on the boiler type, burner turndown capability, feedwater valve control, and combustion control design. If the analysis of the load shows highly variable load conditions, a more complex control package may be necessary. This type of control is achieved with sophisticated boiler management systems. For more information on these types of systems, refer to Controls, Section D, or contact your local Cleaver-Brooks authorized representative. If the application has instantaneous load demands, whereby a large volume of steam is required for a short period of time, a boiler with a large energy storage reserve, such as a retube, should be considered. If the application dictates large variances in load demand, where the load swings frequently for long periods of time, the best choice is probably a watertube type boiler, because it contains less water and can respond to the variances more rapidly. In all cases, operation of the burner should be taken into account in selecting a boiler(s) to meet system demand. The burner will require proper operating controls that can accurately sense the varying demands and be capable of the turndown requirements. The boiler feedwater valve and control design are also critical if load swings are expected. Downtime
Another way to determine whether a backup boiler is a wise decision is to compute the cost of downtime to the owner or the user, as shown in the following three examples: A chemical company manufactures dry cell battery compound in a batch process. The process temperature must be maintained within 2 degrees. The boiler shuts down on a ame failure. They have 20 minutes to recover steam or the batch is scrap. The value of the product is $250,000. A Midwestern insurance company building has comfort heat supplied by one boiler. There are over 2000 workers in the building. The boiler shuts down due to a failed gas valve. Outside, its 11F. Inside, the temperature continues to drop and, at 1:30 in the afternoon, all 2,000 workers are sent home. A meat processing company makes its entire packaged ham line in a Southern plant. It operates 24 hours a day, every day. A single boiler provides heat for curing, sterilizing, and cleaning. The boiler goes down due to a lack of feedwater. Each hour of steam loss results in four hours of lost production. Boiler Turndown Boiler turndown is the ratio between full boiler output and the boiler output when operating at low re. Typical boiler turndown is 4:1. For example, a 400 horsepower boiler, with a 4:1 turndown burner, will modulate down to 100 horsepower before cycling off. The same boiler with a 10:1 turndown burner will modulate down to 40 horsepower. The ability of the burner to turn down reduces frequent on and off cycling. Fully modulating burners are typically designed to operate down to 25% of rated capacity. At a load that is 20% of the rated capacity, the boiler will turn off and cycle frequently. A boiler operating at low load conditions can cycle as frequently as 12 times per hour, or 288 times per day. With each cycle, pre- and post-purge air ow removes heat from the boiler and sends it out the stack. The energy loss can be eliminated by keeping the boiler on at low ring rates. Every time the boiler cycles off, it must go through a specic start-up sequence for safety assurance. It requires about one to two minutes to place the boiler back on line. And, if theres a sudden load demand, the start-up sequence cannot be accelerated. Keeping the boiler on line assures the quickest response to load changes. Frequent cycling also accelerates wear of boiler components. Maintenance increases and, more importantly, the chance of component failure increases. As discussed earlier, boiler(s) capacity requirement determined by many different types of load variations in the system. Boiler over-sizing occurs when future expansion and safety factors are added to assure that the boiler is large enough for the application. If the boiler is oversized, the ability of the boiler to han-
Number of Boilers
Back-Up Boilers When selecting the boiler(s), consideration should be given to back-up equipment to accommodate future expansion, emergency repairs, and maintenance. There are a number of considerations for a backup boiler. Type of Load Heating systems and non-critical loads that do not result in a sudden loss of production generally have little or no backup. While this is not recommended, it is still common practice. These types of applications rely on the ability to make repairs quickly to reduce downtime. The risk involved in having no backup is a total loss of heat when the boiler is not in service. When process or heating loads use multiple boilers during peak times, and one boiler during most other times, the availability of an additional boiler to provide full backup during maximum demand should be considered. In applications with critical steam or hot water requirements, laws or codes may require a backup. Even if laws or codes do not require a backup, there are many cases where the operation cannot tolerate downtime. For example, a hotel uses hot water 24 hours a day, seven days a week. During periods of maintenance or in an emergency, a backup boiler is required.
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dle minimum loads without cycling is reduced. Therefore, capacity and turndown should be considered together for proper boiler selection to meet overall system load requirements.
System Fundamentals
has little bearing on combustion efciency. A well- designed burner will operate with as little as 15 to 20% excess air, while converting all combustibles in the fuel to thermal energy. Thermal Efficiency
Performance Considerations
Three important considerations pertain to fuels, emissions, and efciency. All three have important impact on boiler performance, and can affect long-term boiler operating costs. Fuels Remember, from an operating perspective, fuel costs typically account for approximately 10% of a facilitys total operating budget. Therefore, fuel is an important consideration. Normally, the fuels of choice are natural gas, propane, or light oil. Increasingly stringent emission standards have greatly reduced the use of heavy oil and solid fuels such as coal and wood. Of the fossil fuels, natural gas burns cleanest and leaves less residue; therefore less maintenance is required. It can be advantageous to supply a boiler with a combination burner that can burn two fuels independently - for example, oil or natural gas. A combination burner allows the customer to take advantage of peak time rates, which substantially reduces the costs of a therm of gas when operating off peak by merely switching to the back up fuel. Dual fuel capability also is benecial if the primary fuel supply must be shut down for safety or maintenance reasons. Some waste streams can be used as fuel in the boiler. In addition to reducing fuel costs, ring an alternate fuel in a boiler can greatly reduce disposal costs. Waste streams are typically used in combination with standard fuels to ensure safe operation and to provide additional operating exibility. Emissions Emission standards for boilers have become very stringent in many areas, because of the new clean air regulations. The ability of the boiler to meet emission regulations depends on the type of boiler and burner options. For more information, refer to Emissions, Section E.
Thermal efciency is the effectiveness of the heat transfer in a boiler. It does not take into account boiler radiation and convection losses - for example, from the boiler shell, water column piping, etc. Boiler Efficiency The term boiler efciency is often substituted for combustion or thermal efciency. True boiler efciency is the measure of fuel-to-steam efciency. Fuel-to-Steam Efficiency Cleaver-Brooks guaranteed boiler efciencies are fuel-tosteam efciencies. Fuel-to-steam efciency is the correct denition to use when determining boiler efciency. Fuel-to-steam efciency is calculated using either of two methods, as prescribed by the ASME Power Test Code, PTC 4.1. The rst method is inputoutput. This is the ratio of Btu output divided by Btu input x 100. The second method is heat balance. This method considers stack temperature and losses, excess air levels, and radiation and convection losses. Therefore, the heat balance calculation for fuel-to-steam efciency is 100 minus the total percent stack loss and minus the percent radiation and convection losses. Stack Temperature and Losses Stack temperature is the temperature of the combustion gases (dry and water vapor) leaving the boiler. A well-designed boiler removes as much heat as possible from the combustion gases. Thus, lower stack temperature represents more effective heat transfer and lower heat loss up the stack. The stack temperature reects the energy that did not transfer from the fuel to steam or hot water. Stack temperature is a visible indicator of boiler efciency. Any time efciency is guaranteed, predicted stack temperatures should be veried. Stack loss is a measure of the amount of heat carried away by dry ue gases (unused heat) and the moisture loss (product of combustion), based on the fuel analysis of the specic fuel being used, moisture in the combustion air, etc. Excess Air Excess air provides safe operation above stoichiometric conditions. A burner is typically set up with 15 to 20% excess air. Higher excess air levels result in fuel being used to heat the air
Efficiency
Efciency is used in the measure of economic performance of any piece of equipment. In the boiler industry, there are four common denitions of efciency, but only one true measurement. Following are the denitions and how to measure efciency. Combustion Efficiency Combustion efciency is the effectiveness of the burner only and relates to its ability to completely burn the fuel. The boiler
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System Fundamentals
instead of transferring it to usable energy, increasing stack losses. Radiation and Convection Losses Radiation and convection losses will vary with boiler type, size, and operating pressure. The losses are typically considered constant in Btu/hr, but become a larger percentage loss as the ring rate decreases. Boiler design factors that also impact efciencies of the boiler are heating surface, ue gas passes, and design of the boiler and burner package. Heating Surface Heating surface is one criterion used when comparing boilers. Boilers with higher heating surface per boiler horsepower tend to be more efcient and operate with less thermal stress. Many packaged boilers are offered with ve square feet of heating surface per boiler horsepower as an optimum design for peak efciency. Flue Gas Passes The number of passes that the ue gas travels before exiting the boiler is also a good criterion when comparing boilers. As the ue gas travels through the boiler it cools and, therefore, changes volume. Multiple pass boilers increase efciency because the passes are designed to maximize ue gas velocities as the ue gas cools. Integral Boiler/Burner Package Ultimately, the performance of the boiler is based on the ability of the burner, the boiler, and the controls to work together. When specifying performance, efciency, emissions, turndown, capacity, and excess air all must be evaluated together. The efciency of the boiler is based, in part, on the burner being capable of operating at optimum excess air levels. Burners not properly designed will produce CO or soot at these excess air levels, foul the boiler, and substantially reduce efciency. In addition to the boiler and burner, the controls included on the boiler (ame safeguard, oxygen trim, etc.) can enhance efciency and reduce overall operating costs for the customer. A true packaged boiler design includes the burner, boiler, and controls as a single, engineered unit.
Floor space required. Total space requirements. Access space for maintenance. Size and characteristics of the boiler to be replaced, including location of existing piping, the boiler stack and utilities. Boiler weight limitations. With little or no access to the boiler room, the cast iron boiler and some bent-tube type boilers can be carried into the boiler room in sections or pieces and easily assembled, with no welding required. Electric boilers should also be considered, especially since they do not require a stack. Vertical retube boilers have a small oor space requirement.
PAYBACK ANALYSIS
There are many factors that affect the decision to purchase a particular piece of boiler room equipment. This subsection addresses some of the economic considerations in the decision process. The procedure presented can be applied to equipment selection and the economic evaluation of alternative systems. The effect of a single piece of equipment can be a signicant part of the overall transfer of energy from the fuel burned to the thermal energy of the steam or hot water delivered. The performance of equipment, such as the boiler, stack gas recovery systems (economizers), condensate recovery systems (deaerators, etc.), oxygen trim systems, and blowdown heat recovery systems, should be considered. Efciency gains from each piece of equipment need to be evaluated individually in the context of the overall system to determine the incremental fuel cost savings. Savings from efciency gains are used to evaluate the payback potential of the equipment. Payback simply refers to the time period that will elapse before the cumulative cost savings will equal the incremental capital cost of the equipment selected. In summary, this section provides a procedure and a set of tables and gures to assist in assessing the economic justication of purchasing higher performance equipment or additional energy savings equipment (e.g., economizers, oxygen trim controls, etc.). This procedure may also be used to evaluate the operating cost impact of different system congurations. The tables and gures provided are not unique to CleaverBrook products. Therefore, the procedures may be applied to any thermal energy consuming system. Before proceeding, product related information (e.g., efciency and fuel consumption rates) should be obtained for each specic product.
Special Considerations
Replacement Boilers If the boiler is to be placed in an existing facility, there are a number of considerations:
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Having dened a basic system conguration, and having identied equipment that would yield incremental performance improvement (and investment), the payback analysis sequence is straight forward and can be summarized as follows: 1. Estimate boiler fuel consumption rate. 2. Estimate annual fuel use. 3. Estimate annual fuel cost. 4. Determine potential incremental efciency improvement. 5. Estimate potential annual fuel savings. 6. Determine the payback period for the investment. 7. Rene the analysis. The remainder of this section outlines the step-by-step procedure to be used in conjunction with the gures and tables. Remember, the lowest cost product is not necessarily the most economic choice. In fact, most often it is not the best choice! Step 1: Boiler Fuel Consumption Rate Use Tables 11-4, I1-5, and I1-6 to compare the fuel consumption rates of two boiler congurations with different fuel-tosteam efciency or, as a base fuel rate for a given boiler conguration. Find the appropriate boiler size and the efciency on the table to nd the associated fuel consumption. Step 2: Annual Fuel Usage Multiply the hourly fuel consumption rates by the annual hours of operation to determine the annual fuel usage rate. Step 3: Annual Fuel Cost Figures I1-1 and I1-2 are used to determine annual fuel cost for natural gas based on annual gas use (billion Btu/yr) and gas
System Fundamentals
cost ($/MMBtu). Figure I1-2 provides a more detailed graph for lower gas usage applications. Save the annual fuel cost value for Step 5. (Note that the gures referenced in this discussion are located at the end of this section.) Figures I1-3 and I1-4 are used to determine annual fuel cost for oil fuels based on annual oil use (thousand gal/yr) and oil cost ($/gal). Figure I1-4 provides a more detailed graph for lower oil usage application. Save the annual fuel cost value for Step 5. Step 4: Incremental Efciency Improvement If an improvement is being added to a boiler (economizer, oxygen trim, etc.) that is designed to improve the efciency of the boiler by x percent (incremental efciency gain). Use Figure I1-4 to take the base system efciency (bottom) and the incremental efciency gain (right side) to determine the actual improvement in the system efciency to be used for the cost savings in Step 5. Step 5: Annual Fuel Savings Use Figure I1-6 to determine the annual fuel savings based on the annual fuel cost and system efciency improvement (right side of graph). Figure I1-7 provides for a more detailed graph for lower fuel cost applications. Step 6: Payback Period The payback period is the years required to recover the capital investment. To determine payback simply divide the capital cost of the equipment by the annual savings. To determine the amount of capital available based on a known payback period, multiply the annual savings by the payback period required.
Table I1-4. Typical Firetube Boiler Fuel Consumption Rates - Natural Gas (MM/Btu/hr)
AVERAGE OUTPUT 86% BHP 100 200 300 400 500 600 700 800 900 1000 3.89 7.78 11.67 15.56 19.45 23.34 27.23 31.12 35.01 38.90 3.99 7.98 11.97 15.96 19.95 23.94 27.93 31.92 35.91 39.90 4.08 8.16 12.24 16.32 20.40 24.48 28.56 32.64 36.72 40.80 4.18 8.36 12.54 16.72 20.90 25.08 29.26 33.44 37.62 41.80 4.29 8.58 12.87 17.16 21.45 25.74 30.03 34.32 38.61 42.90 4.41 8.82 13.23 17.64 22.05 26.46 30.87 35.28 39.69 44.10 84% BOILER EFFICIENCY 82% 80% 78% 76%
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Table I1-5. Typical Firetube Boiler Fuel Consumption Rates - No. 6 Oil (gal/hr) A
AVERAGE OUTPUT 86% BHP 100 200 300 400 500 600 700 800 900 1000 26 52 78 104 130 156 182 208 234 260 27 53 80 106 133 159 186 213 239 266 27 54 82 109 136 163 191 218 245 272 28 56 84 112 140 168 196 224 252 280 29 57 86 114 143 172 200 229 257 286 29 59 88 117 147 176 206 235 264 294 84% BOILER EFFICIENCY 82% 80% 78% 76%
A. Based on 150,000 Btu/gallon.
Table I1-6. Typical Firetube Boiler Fuel Consumption Rates - No. 2 Oil (gal/hr) A
AVERAGE OUTPUT 86% BHP 100 200 300 400 500 600 700 800 900 1000 28 56 83 111 139 167 195 222 250 278 28 57 85 114 142 171 199 228 256 285 29 58 87 117 146 175 204 233 262 292 30 60 90 120 149 179 209 239 269 299 31 61 92 123 153 184 215 245 276 307 31 63 94 126 157 189 220 252 283 315 84% BOILER EFFICIENCY 82% 80% 78% 76%
A. Based on 140,000 Btu/gallon.
Step 7: Rene the Analysis It should be recognized that the tools provided herein are intended to provide a quick mechanism to focus on an appropriate equipment conguration and scope. The graphs provided should permit you to quickly identify candidate equipment options that economically qualify and, therefore, merit more serious evaluation. Additional economic issues (maintenance, necessity of equipment, etc.) should be considered by nal conclusions are reached. Contact your local Cleaver-Brooks authorized representative for additional information.
Example
Consider the following payback analysis example. Assume that a project requires a three-year payback for any incremental capital investment. Also assume that an 800 hp retube boiler ring No. 2 oil and operating at 85% efciency has a cost of $1/gal. Assume the average load is 50% of rated capacity for the anticipated 5000 hours per year of operation. The questions are: What is the yearly savings attributable to adding an oxygen trim control system designed to improve efciency 1.3% to the boiler? How much capital may be allocated to purchase this equipment and fall within the three-year payback guideline? I1-13
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Step 1: Estimate Boiler Fuel Consumption Rate Using Figure I1-4, an average output of 400 hp at 85% efciency will use approximately 112.5 gal/hr (interpolated between 86% at 11 gal/hr and 84% at 114 gal/hr) of No. 2 fuel oil. Step 2: Estimate Annual Fuel Use 112.5 gal/hr x 5000 hr/yr = 562,500 gal/yr annual fuel consumption or approximately 560,000 gal/yr Step 3: Estimate Annual Fuel Cost Refer to Figure I1-5 and nd the intersection of 560,000 gal/yr (bottom scale) and the $1/gal fuel price line (right scale). Looking to the left, the annual fuel cost (left scale) is shown to be $560,000. Step 4: Determine Potential Incremental Efciency Improvement Based on an average efciency improvement attributable to the trim control of 1.3% for No. 2 oil. Refer to Figure I1-3 and nd the intersection of the boiler system base efciency of (85%) and the 1.3% incremental efciency gain curve (right scale). Referring to the left scale, the system efciency improvement is shown to be 1.6%. Step 5: Estimate Potential Annual Fuel Savings Refer to Figure I1-7 and nd the intersection of $560,000 annual fuel cost (bottom scale) and the 1.6% system efciency improvement (right scale) identied in Step 4. Looking across to the left scale, annual savings are shown to be approximately $9,000. Step 6: Determine the Payback Period for the investment (or the Allowable Incremental Capital) Multiply $9,000 times the three years required to get $27,000. Step 7: Rene the Analysis If there are other economic factors to be considered as a result of adding oxygen trim controls, add these savings (or costs) to the $9,000 annual fuel savings determined in Step 5. Then repeat Step 6 with the combined savings gure. Assuming there are no other economic factors to be considered, the analysis has shown that the project payback criteria can be met provided the installed oxygen trim control will cost no more than $27,000. Clearly, purchase of the added control is this example would be a good investment. The equipment purchase cost would be recouped in less than three years and the customer would enjoy $9,000 annual savings thereafter that will grow with fuel price increases and escalation.
System Fundamentals
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Figure I1-1. Annual Gas Cost as a Function of Gas Use and Unit Price
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Figure I1-2. Annual Gas Cost as a Function of Gas Use and Unit Price (Expansion of Figure I1-1)
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Figure I1-3. Annual Fuel Oil Cost as a Function of Fuel Oil Use and Unit Price
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Figure I1-4. Annual Fuel Oil Cost as a Function of Fuel Oil Use and Unit Price (Expansion of Figure I1-3)
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Figure I1-5. System Efciency Improvement as a Function of Incremental Component Efciency Gain
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Figure I1-6. Annual Savings as a Function of Annual Fuel Cost and System Efciency Improvement
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Figure I1-7. Annual Savings as a Function of Annual Fuel Cost and System Efciency Improvement (Expansion of Figure I1-6)
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Notes
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Section I2
HOT WATER SYSTEMS
CONTENTS MECHANICAL CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-3 Code Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-3 Boiler Selection Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-3 Air Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-3 Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4 Pumping Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4 Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4 Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-6 Domestic Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-6 Heating/Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-7 Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-7 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-8 High Temperature Water Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2- 8 CONTROL CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-8 Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-8 Lead/Lag Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-9 Temperature Setbacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-10 Heat Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-10 WATER CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-13 Water Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-13 Chemical Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-13 Make-up Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-13 Ethylene Glycol as Heat Transfer Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-14 SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-14 ILLUSTRATIONS Figure I2-1.Typical Expansion Tank Piping Arrangement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-5 Figure I2-2. Typical Pump Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-6 Figure I2-3. Pressure Temperature Chart for Firetube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-6 Figure I2-4. Plug Cock or Gate Valve (Manual Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-11 Figure I2-5. Two-Position Valve (Electric or Pneumatic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-11 Figure I2-6. Throttling or Modulating Valve (Electric or Pneumatic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-11 Figure I2-7. Three-Way Mixing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-11 Figure I2-8. Three-Way Mixing Valve (Bypass Arrangement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-12 Figure I2-9. Three-Way Diverting Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-12 Figure I2-10. Intermittent Secondary Pump Operation (On-Off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-12 Figure I2-11. Water Temperature Constant Thru Zone By-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-12 Figure I2-12. Continuous Secondary Pump Operation with Two-Position Valve (Valve Open) . . . . . . . . . . . . . . . . . . . . I2-13 Figure I2-13. Continuous Pump Operation with Two -Position Valve (Valve Closed) . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-13 Figure I2-14. Primary Loop Circuit, Constant Speed Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-16
I2-1
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Hot Water Systems
System Fundamentals
Figure I2-15. Primary Loop Circuit with Secondary Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-17 Figure I2-16. Individual Zone Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-18 Figure I2-17. Primary Loop Circuit with Three-Way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-19 Figure I2-18.Four-Way Valve System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-20 Figure I2-19. Multiple Boiler Lead/Lag, Primary/Secondary Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-21
TABLES Table I2-1.Circulation Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-5
This section provides design considerations for boiler applications in hot water systems. The information provided is intended to create an awareness of the various considerations that should be evaluated to ensure a successful installation and long boiler life.
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Hot Water Systems

Specic load mix, often caused by early fall or late spring heating loads, can require additional considerations. When the minimum heating load is 10% of the maximum heating load, the heating load is: 9,300,900Btu/hr. Heating Load @ 10% = 930,090Btu/hr Domestic Water = 1,000,000Btu/hr TOTAL LOAD = 1,930,090Btu/hr When the light heating load only is imposed, the demand on the boiler is only 14% of its rated capacity. A third, smaller unit should be considered for light load conditions, unless the boiler has a burner with a 10:1 turndown ratio. When multiple boilers are used, care must be taken to assure proper proportional ow through each of the units. If ow is not properly balanced, wide variations in boiler ring rates can occur and, in extreme cases, the resulting outlet water temperatures may not be at the desired point. In summary, the seasonal and daily variations dene the size of the load that the boilers must handle. The maximum load will be used, along with backup requirements, to set the plant capacity. Seasonal and daily variations are used to help select the number of boilers and turndown requirements. In some applications, there is a mixture of loads. These may be different types of process loads or combinations of heating and process loads. It is usually best to analyze them individually, and then combine them for each season.
MECHANICAL CONSIDERATIONS
Code Considerations
Boilers constructed in accordance with Section IV, Heating Boilers, of the ASME Boiler and Pressure Vessel Code can be operated with water temperature up to 250 F with a maximum design pressure of 160 psig. Boilers for operation over 250 F or 160 psig must be constructed in accordance with Section I, Power Boilers, of the ASME Boiler and Pressure Vessel Code. Due to limitations of control and safety settings, desired operating temperatures between 240 F and 250 F may require the use of a Section I boiler. System operating pressure must not exceed 90% of the relief valve pressure setting. Consideration should be given to system piping to ensure it meets all applicable codes. For example, when Section I boilers are used, the piping must be in accordance with B31.1 ASME Power Piping Code.

When a hot water system is laid out, all of the components must be selected to work together to achieve the design intent. The design intent could include criteria such as: system exibility, maximum efciency, heating/cooling, domestic hot water, heat storage, fuel capability, etc. Selection and operation of the boiler(s) in relation to the other system components, and in support of the design intent, are important considerations. Selection of a boiler to support the design intent of the hot water system is dependent on several site-specic variables, such as those just listed. In addition, one of the most important selection factors is the maximum continuous rating of the boilers, which is dependent on the load imposed by the heat users and the nature of the load. For example, consider an installation with a maximum load of 10,300,900 Btu/hr. Of this, 9,300,900 Btu/hr are the peak winter heating load and 1,000,000 Btu/hr are domestic hot water load, which are provided through means of a heat exchanger. Based on the maximum load conditions just described, consideration might be given to a 310 horsepower retube boiler (1 boiler horsepower = 33,472 Btu/hr). However, to ensure system exibility, and to provide some degree of stand-by for unscheduled outage, common practice would dictate the installation of two units, each with a capacity of 65% of the maximum load. That is; two 200 horsepower units, or 6,695,000 Btu/hr each. Based on the example just mentioned, it is apparent that boiler capacity selection, based on peak loading, is fairly straight forward.
Air Removal
Air removal in a hot water boiler is important for two main reasons. Air contains oxygen, which can cause corrosion of metal surfaces. And, air acts as an insulator and can affect heat transfer as well the operation of temperature controls. All Cleaver-Brooks hot water outlet connections include a dip tube, which extends 2 to 3 inches into the boiler. The dip tube does not allow any air, which may be trapped at the top of the drum, to get back into the system. Because any oxygen or air which is released in the boiler will collect or be trapped at the top of the boiler drum, the air vent tapping on the top center line of the boiler should be piped into the expansion or compression tank or tted with an automatic air vent valve. Any air that is trapped at the top of the boiler will nd its way out of the boiler through this tapping. Dip tube assemblies furnished for external mounting into the boiler return connection, or system air separators, may also be equipped with an air vent tapping. These devices will remove air from the system, however, they do not remove air from the top of the boiler. To avoid trapped air at the top of the boiler drum, it is still necessary to pipe the boiler air vent into the expansion or compression tank or into an automatic air vent valve.
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Hot Water Systems

Expansion Tank
An expansion tank serves one primary function in a hot water system. It provides a means for the system water to expand, as it is heated, without signicantly increasing system pressure. Expansion tanks are also often used as the receiver for the air removed from the boiler. This is convenient if the expansion tank does not have a bladder or diaphragm. If the expansion tank has a bladder or diaphragm, the air from the boiler must be removed by an automatic type air vent piped directly to the air vent tapping on the top of the boiler. Proper expansion tank design will account for the desired system pressure and changes in the specic volume of water from 60 F (ambient temperature) to the maximum operating temperature of the boiler and related system. To design the expansion tank, you must rst know the total volume of water in the ooded boiler and system. For ooded values for a CleaverBrooks boiler, refer to the boiler products section. You will need to estimate the water volume in the system by considering the diameter and length of system piping and including the volume of water contained in system heat exchangers. Expansion tanks are usually charged with air or an inert gas such as nitrogen. Nitrogen is often used in high temperature water applications due to its low corrosive nature. Regardless of the charging media, expansion tanks are charged at a pressure slightly higher than the static pressure on the tank with the system at ambient temperature. As the water in the system is heated, the air or gas cushion in the expansion tank compresses, allowing the water to expand without signicant variations to the system pressure. For more information on sizing expansion tanks, refer to the ASHRAE Guide Book, or contact your local Cleaver-Brooks authorized representative. A typical expansion tank piping arrangement is shown in Figure I2-1.
System Fundamentals
Select a pump that meets both the ow and feet of head requirements for the system. The operating or design point of the pump is the point at which the vertical and horizontal lines intersect the pump curve. This point is also commonly referred to as the duty point. Pump Location It is recommended that the system circulating pumps take suction from the outlet connection on the boiler and that they discharge to the system load in order to put the boiler and the expansion tank on the suction side of the pump. This location is preferred because it decreases potential for air entry into the system and does not impose the system head on the boiler. It is common practice to install a standby system circulating pump, to accommodate scheduled pump maintenance without shutting the system down. Usually, both the main and standby circulating pumps are located adjacent to the boilers in the boiler room. Pump Operation Pumps are normally started and stopped by manual switches. It is also desirable to interlock the pump with the burner so that the burner cannot operate unless the circulating pump is running. Pump Capacity Table I2-1 can be used to determine the maximum gpm circulating rate in relation to full boiler output and system temperature drop. Knowing the boiler size and expected system temperature drop, the maximum circulation rate can be selected.
Circulation
The system should be piped and the controls congured to ensure continuous ow of system water through the boiler under all operating conditions. Constant circulation through the boiler results in a more even water temperature and eliminates the possibility of stratication within the boiler and system. Constant circulation reduces the possibility of thermal stresses to the boiler and subsequent pressure vessel failure. Minimum Circulation As a rule of thumb, the minimum continuous circulation rate through the boiler under operating conditions is one gallon per minute per boiler horsepower. Maximum Circulation The maximum circulation in gallons per minute through the boiler is based on system design temperature drop, and maximum Btu output rating of the boiler. Table I2-1 shows the max-
Pumping Equipment
Pump Type Centrifugal type pumps are typically used for system circulating pumps, because of their proven durability, efciency, and ability to pump the required ow and pressure. Although there are many types of centrifugal pumps available with varying characteristics, most applications use a pump with a curve similar to Figure I2-2. When using this type of pump curve, draw a horizontal line at the feet-of-head requirement for the system (2.31 feet of water at 60 F = 1 psig). At the point where the line intersects the pump curve, draw a vertical line to determine the gallon per minute ow the pump will pump at the given feet-of-head.
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System Fundamentals
Hot Water Systems
Table I2-1. Circulation Rates

BOILER HP 15 20 30 40 50 60 70 80 100 125 150 200 250 300 350 400 500 600 700 800 BOILER OUTPUT (X 1000) BTU/HR 500 670 1005 1340 1675 2010 2345 2680 3350 4185 5025 6695 8370 10045 11720 13400 16740 20080 23450 26780 SYSTEM TEMPERATURE DROP - DEGREES F 10 20 30 40 50 60 70 80 90 100
MAXIMUM CIRCULATING RATE - GPM 100 134 200 268 335 402 470 536 670 836 1005 1340 1675 2010 2350 2680 3350 4020 4690 5360 50 67 100 134 168 201 235 268 335 418 503 670 838 1005 1175 1340 1675 2010 2345 2680 33 45 67 89 112 134 157 179 223 279 335 447 558 670 784 895 1120 1340 1565 1785 25 33 50 67 84 101 118 134 168 209 251 335 419 503 587 670 838 1005 1175 1340 20 27 40 54 67 80 94 107 134 168 201 268 335 402 470 535 670 805 940 1075 17 22 33 45 56 67 78 90 112 140 168 224 280 335 392 447 558 670 785 895 14 19 29 38 48 58 67 77 96 120 144 192 240 287 336 383 479 575 670 765 12 17 25 33 42 50 59 67 84 105 126 168 210 251 294 335 419 502 585 670 11 15 22 30 37 45 52 60 75 93 112 149 186 223 261 298 372 448 520 595 10 13 20 27 33 40 47 54 67 84 100 134 167 201 236 268 335 402 470 535
Figure I2-1. Typical Expansion Tank Piping Arrangement
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Hot Water Systems
System Fundamentals
tem pressure drop calculation. As a rule of thumb, there is a pressure drop of less than 3 feet of head (1 psi = 2.31 feet of head) through Cleaver-Brooks boilers. Pressure Requirements In a hot water boiler, the pressure/temperature relationship is critical. Unlike a steam boiler, where the pressure and temperature relationship corresponds to the laws of nature, a hot water boiler design purposely prevents the water from turning to steam. To prevent steaming, a certain amount of over pressure is required to keep the water from ashing to steam. Figure I23 shows a typical pressure/temperature relationship for Firetube and Model 4 hot water boilers. Similar charts are provided in the specic boiler product sections. To use the chart, locate the maximum system operating temperature (High Limit Control Setting) on the bottom line. Draw a straight line to the minimum recommended boiler operating pressure curve. At the point where the lines intersect, draw a horizontal line to the left of the chart and nd the necessary pressure.
Figure I2-2. Typical Pump Curve imum circulation rates for retube boilers. For information on specic boiler circulation rates, refer to the boiler products section.
Pressure Drop
When sizing the system circulating pump, it is necessary to account for the system line losses. Proper sizing will allow the pump to overcome the system pressures in order to deliver the proper ow through the system. The boiler is part of the sys-
Domestic Hot Water

Hot water systems are often used as the energy source to provide domestic hot water. The hot water for personal washing (showers, laundry, etc.) and, in some cases, light industrial pro-
Figure I2-3. Pressure Temperature Chart for Firetube Boilers I2-6

04-02
System Fundamentals
cess, is often provided through the incorporation of a heat exchanger in the system. Physically, the heat exchanger provides a separation of the hot water system water from the domestic water which, in turn, allows the uids to be of different chemical make-up. This provides integrity and proper water treatment for the hot water system, and proper water treatment, while providing potable water in the secondary loop. Space requirements for the domestic water heat exchanger vary considerably based on specic application. However, typically, the required space is quite small. For example, CleaverBrooks can provide domestic water coils integral to the boiler that require no additional oor space, and only need room for the associated domestic water loop piping. In this type of system, typically, there is a low volume of domestic water stored. The heat exchanger system must be sized to maintain minimum desired temperature at maximum load conditions. This is an excellent application for fairly continuous domestic water loads. In many cases, domestic hot water can, and should, be provided by including a shell and tube (or plate and frame) heat exchanger as part of the hot water system. Isolation and services of the heat exchanger can be performed without removing the hot water heating system from service. When it is apparent that large domestic water demands are required for a short period of time, consideration should be given to incorporating a storage tank in the domestic water loop. In most applications of this type, the heat exchanger is incorporated into the storage tank and the hot water system uid is pumped through the tube side of the exchanger and the domestic hot water is on the shell side. Domestic water heat exchangers provide physical separation of the two media and, therefore, considerable exibility with respect to ow and temperature. Such systems, however, are not trouble free. Scaling or fouling of the heat exchanger surface can occur, process controls can fail, etc. To maintain optimum operating efciency of the domestic water circuit, serviceability of the equipment should always be considered during system design.
Hot Water Systems

are critical issues of design consideration that will dictate success or failure of the installation. The overall system design intent must be the comfort heating, or cooling, of the individuals who occupy the building. However, if either the boiler or chiller cannot be used because they are being repaired, the system intent has failed. Why would a boiler or chiller fail? With respect to the boiler, consider a scenario where heating is required in the early morning and early evening. During the day, cooling is required. To meet the demand, the boiler is maintained in a hot stand-by mode. When the system demands heat, the pumps and control valves shift to send boiler water to the system. What comes back to the boiler is the chilled water (relatively cold) from the system. The result - THERMAL SHOCK. It is assumed that a similar, but opposite, phenomenon exists within the chiller. What can the system designer do to minimize the potential problem when single pipe systems are designed? Provide slow acting valves that slowly bleed the system water into the boiler during the cooling/heating mode changeover. Specify boilers that minimize problems resulting from Thermal Shock. Refer to the Cleaver-Brooks Flextube Boiler product section, Section B1. Select and specify boiler operating controls and system controls that maximize equipment protection without sacricing the heating/cooling comfort needs of the individuals. Possibly include accumulator tanks into the system.
Accumulators
Hot water systems inherently have considerable energy capacity. Once the heating system is on-line, the ywheel affect has a tendency to smooth out the minor spikes and valleys that occur during the typical heating load. However, some systems dictate the requirement for load, or heat shedding, to maximize operating efciency or the availability of additional heat to satisfy load demand peaks. When load shedding or heat storage needs exist within the same system, an accumulator tank or heat accumulator, is an ideal t. When hot water systems include large demand heat users that are brought into service quickly through controls and valving, the increased load demand is immediately realized by the boiler. To minimize the impact of the condition and to add to the total available energy for the system, accumulators or storage tanks can be used. Proper sizing of accumulator tanks requires careful analysis of the load peaks that are to be addressed and the minimum/maximum temperature swings that can be tolerated in the system.
Heating/Cooling
Heating/cooling systems are often called single pipe systems. In a single pipe system, the water is either heated by a boiler or cooled by a chiller to meet the comfort demand. Special care and consideration must be given to system design when the heating (hot water) and cooling (chilled water) systems share common distribution piping. The type of boilers selected; control systems for both heating and cooling; and type of load - heat in the morning, cooling in the afternoon -
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Hot Water Systems

The control system, including circulating pumps, will be dependant on the specic application of the accumulator and the design of the storage tank, such as stratication tanks and bafe tanks. Although accumulators are not common in most heating systems, they do provide heat storage capacity and equipment protection and should be considered in complex hydronic system designs.
System Fundamentals
CONTROL CONSIDERATIONS
Temperature Control
Boiler Water Temperature Control As with all pieces of mechanical equipment, rapid changes in temperature will cause thermal stress to a boiler pressure vessel. The degree of stress and subsequent failure is directly related to the frequency and degree at which the thermal stresses are applied. Also, in hot water applications, too low of a boiler water outlet temperature can cause condensation of ue gases and subsequent reside corrosion. In order to avoid these types of problems, certain parameters must be considered when designing a hot water control system. 1. Minimum Outlet Temperature Fireside corrosion occurs when ue gases are cooled below the dew point. Cooling of the ue gases occurs when hot ue gases come in contact with cool pressure vessel surfaces. To prevent this, minimum operating temperatures must be maintained to keep the ue gases above the dew point. The minimum water outlet temperature is typically 170 F. The minimum return water temperature is typically 150 F. For exact temperatures refer to the specic boiler section. Maintaining minimum outlet temperatures will help prevent harmful condensing of ue gases. 2. Maximum Outlet Temperature The maximum temperature rating for all Cleaver-Brooks ASME Section IV boilers is 250 F. Due to limitations of control and safety settings, desired operating temperatures above 240 F may require the use of a Section I boiler and a high temperature hot water system. For high temperature water, ASME Section I, the boilers maximum outlet temperature depends upon its design pressure. For information on high temperature water applications, contact your local Cleaver-Brooks authorized representative for further information. 3. Temperature Drop Across the Boiler The maximum temperature drop from supply to return is directly related to the circulation rate through the boiler and boiler capacity. These factors must be evaluated to ensure they meet the intent of the system design. Refer to Table I2-1 for ow rate versus temperature drop charts. Even though design temperature drops can be up to 100 F, care must be taken when applying boilers into these systems. At no time should the system temperature drop provide return water at a temperature that could cause ue gas condensation and subsequent reside corrosion. 4. Boiler Warm-up The controls that maintain the boiler water temperature should be designed and set in such a way as to allow a slow warm-up
Safety
The highest level of consideration in any system design should be the safety of personnel. Good safety practices are essential in hot water, as well as in steam systems. For example, consideration for safe discharge of water from the relief valves is important. For hot water heating boilers (ASME Section IV; 160 psig/250 F maximum) a exible connection between the safety valve and the discharge pipe is recommended. The discharge piping must be properly arranged and supported so that its weight does not bear upon the valve.
High Temperature Water Boilers

As required by ASME Boiler and Pressure Vessel Code, boilers for operation over 250 F or 160 psig must be constructed in accordance with ASME Section I, Power Boilers. Due to limitations of control and safety settings, an operating temperature above 240 F will required the use of a Section I boiler. Design pressures above 125 psig will require Cleaver-Brooks review, regardless of the operating temperature. Use Figure I23 for the operating temperature and recommended minimum boiler operating pressure. Also, please ensure that there is continuous water ow trough the boiler. Depending on horsepower requirements, operating temperature, design pressure, and water ow rate, there could be some limitations that affect recommended boiler size or maximum Btu rating. Cleaver-Brooks is in a better position to review and comment on the design criteria if the evaluation is performed at the design stage of the project. Contact your local CleaverBrooks authorized representative on any high temperature water applications. Provide the following details for review: Supply and return temperatures. Flow rate (is it constant or variable?). Operating pressure. Describe load characteristics. Provide detail of system and sequence of operation. If a system schematic is available, forward a copy to your local Cleaver-Brooks authorized representative.
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System Fundamentals
of a cold boiler. To prevent damage to the pressure vessel and refractory, a warm-up from a cold (ambient) boiler to operating temperature is normally accomplished through manual operation at the low-re rate. Automatic operation from a cold start is not recommended without proper control sequencing, as is available with the CB-HAWK control. In multiple boiler installations when a second cold boiler is being brought into the system, a means should be provided to slowly introduce ow of system water into the return. The boilers temperature should not be increased any quicker than 1 F per minute. Even when the boiler has reached return water temperature, a means must be provided for a slow warm-up of the boiler from a stand-by to an operational condition. This will provide proper warm-up of the refractory within the boiler as well as ensure that the pressure vessel is at operating temperature. Under these conditions, a means should be provided to hold the burner in the low-re position a minimum of 30 minutes if the burner has not operated within the last 4 hours. 5. Rapid Replacement of Boiler Water The most common causes of cold water slugs returning to a boiler are: 1) cycling of individual zone pumps and, 2) the main circulating pump cycling off, allowing the boiler to continue to operate. These situations cause a boiler that is operating between 170 and 250 F to experience high ow rates of possibly ambient temperature water, thus causing excessive thermal stress. To determine the rate at which cold water can be introduced into an operating boiler, refer to the specic boilers temperature drop/ow rate charts. 6. One additional item that must be considered when deciding upon boiler outlet water temperatures is boiler auxiliaries, which may require certain temperatures. For example, a hot water boiler ring a No. 6 fuel oil may require temperatures in excess of 200 F, when heating the oil in an oil preheater with boiler water. The operating temperatures needed will depend upon the fuel oil temperatures required for proper atomization of the fuel. If water temperatures cannot be maintained at the required levels, an electric preheater must be sized accordingly to provide the additional heat. System Temperature Control Since the minimum outlet temperature for a boiler is limited, it is sometimes desirable to regulate the water temperature going to the heat users. This is normally done by regulating the temperature of the main supply and/or the water temperature at the heat users. The most common way to vary the system supply temperature is through the use of a three- or four-way control valve. These control valves will blend a portion of return water with boiler supply water to maintain the desired system supply temperature. When applying these types of valves, care must be taken
Hot Water Systems

to ensure that the minimum ow requirements for the boiler will be met at all times. These valves must be slow moving to ensure that rapid temperature changes are not taking place in the boiler return water temperature. Temperature control at the heat users is normally accomplished through diverting or two-position valves controlled by a room or duct thermostat. Temperature control of heat users will be discussed in more detail later in this section.
Lead/Lag Systems
A Lead/Lag system sequences the on-off ring and modulation of multiple boilers to meet the system load demand. The key to the design of a lead/lag control in a hot water system is the realization that temperature changes in a hot water system are inherently slow. This also means that a change in boiler output does not result in immediate changes in overall system temperature. The control system must be designed to take into account the lag times and allow for ne tuning. Lead/lag systems are available in two basic types. Lead/lag start - unison modulation and lead/lag start - lead/lag modulation. Please refer to Controls, Section 8, for a more detailed description of these two systems. In general, with hot water systems, lead/lag start - unison modulation would be the most practical system. This is due to the fact that with hot water boilers, the load imposed on a particular boiler is directly related to the rate of water ow through it. If the ow rate through two boilers is equal, they must have the same Btu output to maintain a constant supply header temperature. The following example illustrates the problem associated with not having unison modulation with two equally sized boilers in a lead/lag sequence. Boiler #1 200hp Flow = 500gpm Firing rate = 100% Boiler #2 200hp Flow = 500gpm Firing rate = 25%
Return temperature = 160 F Required header temperature = 190 F The Btu output of a 200hp boiler at 100% ring rate is 6,695,000 Btu/hr. The same boilers output at 25% is 1,673,750 Btu/hr. Each boiler has a ow of 500 gpm or 4071 lb/min. Since it takes 1 Btu to change 1 pound of water 1 F, we can determine the outlet temperature of each boiler. Boiler #1 6,695,000 Btu/hr 60 min/hr = 111,583 Btu/min 111,583 Btu/min output divided by the 4071 lbs/min ow rate yields a temperature rise of 27.4 F.
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Hot Water Systems

Boiler #2 1,673,750 Btu/hr 60 min/hr = 27,895 Btu/min 27,895 Btu/min output divided by the 4071 lbs/min ow rate yields a temperature rise of 6.9 F. With a return temperature to both boilers at 160 F, it can be seen that the outlet temperature of boiler #1 would be approximately 187 F and the outlet temperature of boiler #2 would be almost 167 F. Since the ow through both boilers is equal, the mixed temperature to the header would be approximately 177 F. This scenario becomes even further complicated when more than two boilers are in a system, and when they are of varying sizes. When the boilers are different sizes, the ow through the boilers must be proportional to the capacity and ring rate of the boilers. For example, the load on a smaller boiler may exceed rated capacity while the larger boiler is cycling off, resulting in inefciencies and potential thermal shock damage to the pressure vessel and refractory. To ensure the ow through a particular boiler is proportional to its size and ring rate, controls and motorized valves should be incorporated. The control system required to perform this can become quite sophisticated; however, reliable operation and a savings in repair and maintenance costs will be realized. The stand-by boiler must be kept in mind when designing a system with lead/lag operation. If there is continuous ow through all boilers, regardless of whether or not they are ring, the stand-by boiler will have an outlet temperature equal to the return temperature. This, again, will create a situation where a blended temperature is getting to the common supply header. This is normally avoided by installing a motorized valve at the outlet or return to each boiler. The position of the valve is dictated by the status of the boiler. The valve will generally have two positions. When the boiler is at header temperature and supplying hot water to the system, the valve would be at its position for maximum design ow through the boiler. When the boiler is in stand-by, the valve would be positioned for the minimum ow rate required by the boiler. Maintaining the minimum ow rate will prevent stratication of temperatures within the boiler. The valve positions become more complicated and numerous when boilers of unequal sizes are applied in the same system. Keep in mind, ow through the boilers must be proportional to the output of the boilers. Provisions should be made in the lead/lag control system to maintain a boiler in a hot standby condition. This normally requires intermittent ring at low re to maintain a set point slightly lower than the main supply set point. To ensure that refractory as well as the pressure vessel are at a proper operating temperature, all lead/lag controls must ensure that the burners return to low re prior to turning the burners off. It is recommended that once a boiler is brought into the
System Fundamentals
system after being off for a period of time (standby hot condition), that it be operated at its lowest ring rate for a minimum of 30 minutes.
Temperature Setbacks
In the interest of conserving energy, it is sometimes desirable to set back the system supply temperatures based on time of day, day of week, or outdoor air temperature. Since the boiler water temperature requires that a minimum outlet temperature be maintained, resetting the boiler temperature is normally not practical. Resetting the supply water temperature is normally accomplished through a three- or four-way control valve. One important item to keep in mind when setting back temperatures, is how the control valve reacts when returning the system to the higher temperature. Control valve operation should not be instantaneous. It is extremely important to ensure that the valve does not travel from a fully closed to a fully open position instantaneously. This would cause high ow rates of relatively cold water to return to the boiler, causing thermal stress and possible pressure vessel damage. Individual zones should not normally be set back by turning off individual circulating pumps. In determining whether or not this practice would be acceptable, the ow rate of the zone versus the entire system ow rate must be considered. If the zone has a high ow rate compared to other zones, cycling of pumps can cause serious problems with cold slugs of water being returned to the boiler, resulting in thermal stress and subsequent pressure vessel failure.
Heat Users
Selection of the type, size, quantity and location of heat users is job specic, and is usually determined by the project design engineer. Typical load groupings are shown on the hot water system layouts shown in Figures I2-14 thru 12-19. The groupings will naturally be varied, depending on actual job layout and the individual load and temperature requirements. The following heat users are most commonly used in hot water heating systems: 1. Radiators 2. Convectors 3. Coils in Ducts 4. Fin Coils 5. Blast Coils 6. Unit Heaters 7. Unit Ventilators 8. Unit Ventilators with Face and Bypass Dampers
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System Fundamentals
Hot Water Systems
Figure I2-4. Plug Cock or Gate Valve (Manual Operation)
Figure I2-6. Throttling or Modulating Valve (Electric or Pneumatic)
Sometimes an oriced gate valve is used in a non-critical area. The oriced gate valve is recommended to ensure ow to the heat user, because it allows ow back to the boiler under all system conditions. Two-position Valve (Electric or Pneumatic) Two-position (fully open or fully closed) valves are commonly used to control water ow to all types of heat users. See Figure I2-5. The electric or pneumatic signal to the valve is usually controlled by a room thermostat or manual on-off switch in the area adjacent to the heat user. Figure I2-5. Two-Position Valve (Electric or Pneumatic) 9. Radiant Panel - Inside 10. Process Heating Manufacturers installation recommendations should be closely followed to avoid special problems such as coil freezeup, water hammer, and noise factors. Control of Water Flow Through Heat Users Common methods of controlling water ow through heat users are shown on the hot water layouts found later in this section and are described later. Plug Cock or Gate Valve (Manual Operation) Figure I2-4 is the simplest form of control and is directly related to physical comfort in the area adjacent to the heat user. It is commonly used on radiators, convectors, unit heaters or ventilators, and blast coils. It is sometimes used on coils and unit ventilators with face and by-pass dampers. The room thermostat or manual on-off switch in the area adjacent to the heat user will also start the fan on devices such as unit heaters.
Figure I2-7. Three-Way Mixing Valve
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Hot Water Systems
System Fundamentals
Figure I2-8. Three-Way Mixing Valve (Bypass Arrangement) Throttling or Modulating Valve (Electric or Pneumatic) Throttling or modulating valves are used to control water ow to heat users such as: blast coils, unit heaters, and unit ventilators. See Figure I2-6. Throttling or modulating valves are preferred to two-position valves since they provide more uniform heating and a relatively constant ow of return water. Three-way mixing valve Three-way mixing valves (two inlets, one outlet) are used to control water temperatures going to inside radiant panels or process loads. See Figure I2-7. If a pump is used, its capacity governs the quantity of water owing through the heat user. The pump usually operates (on-off) in response to a high limit room thermostat (without heat anticipation feature). When used on inside radiant panels, the three-way valve is usually controlled by a room thermostat or by the temperature of the water going to the panel. When used on process loads, the three-way valve is usually Figure I2-10. Intermittent Secondary Pump Operation (On-Off) controlled by the temperature of the process itself. Three-way Mixing Valve (By-pass Arrangement) The three-way mixing valve with bypass arrangement (Figure I2-8) is commonly used on n coils, coils, panels, and process loads and is preferred to the three-way mixing valve arrangement, since it assures a ow of return water. When n coils or coils are controlled by a three-way valve, a room or duct thermostat usually operates the valve. Three-way Diverting Valve A three-way diverting valve (one inlet, two outlets) arrangement can be used in the same manner as the three-way mixing valve (by-pass arrangement). See Figure I2-9. In either case, the position of the valve allows more or less water to ow through the coil or through the by-pass. Either position of the valve assures return water ow to the boiler.
Figure I2-9. Three-Way Diverting Valve
Figure I2-11. Water Temperature Constant Thru Zone By-Pass
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System Fundamentals
Hot Water Systems

In Figure I2-11, the 5 gpm at 250 degrees entering the zone bypass leaves the zone by-pass at approximately the same temperature. If desired, the supply water temperature could be varied with an indoor-outdoor system. 2. Continuous Secondary Pump Operation (with 2-position valve) In Figure I2-12, when the 2-position valve is open (admits 250 F water), the 5 gpm at 250 F mixes with the 10 gpm at 190 F to supply 15 gpm at 210 F to the pump and the heat users.
NOTICE
There is 0 gpm in the common piping and the return water (5 gpm) is at 190 F. Thus, there is a 60 degree drop from supply to return, and a 20 degree drop across the heat user. The 2-position valve could be controlled by a room thermostat or by the temperature of the water entering or leaving the heat user. When the 2-position valve is closed, (Figure I2-13) the continuously operating secondary pump is circulating 15 gpm at approximately 210 F. As long as this satises the load requirements, the valve remains closed. The 5 gpm at 250 F entering the zone by-pass line leaves the zone by-pass at approximately the same temperature. Continuous secondary pump operation provides continuous controlled heat input into each zone.
Figure I2-12. Continuous Secondary Pump Operation with Two-Position Valve (Valve Open) Primary-Secondary Pumping 1. Intermittent Secondary Pump Operation (on-off) The secondary pump operates in response to a high limit room thermostat (without heat anticipation feature), a duct thermostat, or actual temperature of the water entering or leaving the heat user. See Figure I2-10. A tee can actually be used as a mixing valve with this system. Also, wide ranges and good control of temperature drops are available to the designer. (In the example just given, there is a 60 degree drop from supply to return, but only a 20 degree drop across the heat user). When the pump is off, there is no ow in the secondary zone. The amount of water entering the zone by-pass ows through the zone by-pass to the return header.
WATER CONSIDERATIONS
Water Conditioning
Boiling Out: Initial Cleaning Every new system will have certain harmful substances which remain in the boiler and piping after construction. It is common to nd oils, greases, weld slag, and other contaminates within the system. If the foreign materials remain, the boiler could be affected by loss of heat transfer on heat exchanger surfaces and/or an acidic water condition. Boiler life may be reduced as a result of an unclean system. Your authorized Cleaver-Brooks representative or water treatment company will be able to recommend a chemical cleaning or boil-out procedure. Also, refer to the boiler operating and instruction manual for more details.
Chemical Treatment
Figure I2-13. Continuous Pump Operation with Two -Position Valve (Valve Closed) It is recommended that chemical treatment be provided for the initial ll of the system. Generally, chemicals will be required
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Hot Water Systems

to prevent scale formation, promote elimination of dissolved gases and control pH. Most hot water boilers operate in a closed system and are considered to require little attention for water treatment. Experience has shown, however, few systems can be considered completely closed. Loss of water can occur from pump packing, glands, air venting devices, and threaded or anged pipe connections. A means must be provided to chemically treat the raw water make-up. This is generally accomplished through the use of a shot-type chemical feeder. For information on shot type chemical feeders refer to Section 19.
System Fundamentals
ene glycol and water is commonly used. When using ethylene glycol certain design limitations are important, due to the characteristics of the uid versus the characteristics of water. These characteristics are: Elevated saturation temperature, decreased thermal conductivity and specic heat, and increased viscosity and density. In addition, ethylene glycol degrades when it is heated above the manufacturers specied maximum lm temperature. The following design parameters must be considered when operating with ethylene glycol solutions. For industrial watertube boiler parameters, or for conditions not covered in the following, contact your local Cleaver-Brooks authorized representative. 1. Maximum Glycol Concentration Firetube:60% Flexible Watertube: 60% Model 4 Watertube: 50% 2. Maximum Outlet Temperature Firetube: up to 300 F Flexible Watertube: 200 F Model 4 Watertube: 200 F 3. Internal Circulation A. For retube boilers, the size of the supply and return connections are decreased based on the design temperature drop and the system pump gpm. B. A minimum continuous gpm ow rate through the boiler corresponding to a 40 F system drop is recommended. For retube boilers operating between 250 300 F, use a ow rate based on a 30 F system drop. 4. Expansion Tank a. An inert gas pressurizing blanket is preferred due to the overpressure requirements. 5. Over-Pressure Required: A. Firetube 170 - 250 F operating temperature - recommend 40 psig minimum operating pressure. 250 - 300 F operating temperature - recommend 100 psig minimum operating pressure. B. Flexible Watertube - recommend 50 psig minimum operating pressure. C. Model 4 Watertube - recommend 50 psig minimum operating pressure. 6. Depending upon the application, process boilers may need to be sized to limit continuous duty to 80% of maximum boiler rating.
Make-up Water
It has been generally accepted in system design that hot water boilers are in a closed system and, therefore, no make-up water is needed. This is not always the case. Untreated makeup water is a leading cause for failures of hot water boilers. In the design stage of a hot water system, provisions must be made for properly introducing, metering, and treating make-up water. Introducing Make-up Water A recommended means for introducing make-up water to a hot water system is shown in Figure I2-1. This method ensures all air is removed from the make-up water. It also ensures the water temperature is tempered prior to being introduced to the boiler, thus reducing the risk of thermal shock. Metering Make-up Water The purpose of metering the make-up water to a hot water system is to prevent potential problems that can tend to damage an otherwise well planned installation. Figure I2-1 shows the recommended location for a water meter, which is used to measure the amount of make-up water used by the system. The meter is necessary, as it may be the only means to identify a system loss of water. Knowledge of make-up water usage will alert the operator to investigate the cause of the system water loss. This allows the operator to x the problem and properly treat the make-up water prior to experiencing any additional problems. In some cases, depending on the preference of the customer, no automatic means for make-up water is provided. Instead, a low water alarm is used in the expansion tank to alert the operator of a loss in system water and a need for system make-up. The operator can then diagnose the system loss and properly treat the make-up water. A low water alarm is only practical where full- time operators are employed.
Ethylene Glycol as Heat Transfer Medium

On applications requiring freeze protection, a mixture of ethyl-
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System Fundamentals
Hot Water Systems

Individual expansion tanks are shown for clarity. One expansion tank for multiple boilers is typically sufcient when sized properly.
NOTICE
Generally, Firetube boilers up to 350 horsepower and a maximum operating temperature of 200 F can be operated without consideration of Btu de-rating. 7. A means should be provided to routinely monitor the condition of the system uid. Frequent analysis during the rst six months of operation and semi-annual checks thereafter are recommended. 8. Excessive use of inhibitors can create precipitation of solids causing reduced circulation and reduced heat transfer. 9. Always alert your local Cleaver-Brooks authorized representative of a system to be designed for glycol mix. Additional product modications may be necessary, based on size, boiler model and operating temperature. 10. The temperature rating of the glycol is also important. In general, use a product with a minimum temperature rating of 175 F above the boiler operating temperature.
NOTICE
When working with individual zone circuits, where one zone may have a large quantity of water, and where the zone circulating pump has a high gpm compared to other zones, cooling down of the water can cause a serious problem in rapid replacement of boiler water when the pump is started. For this reason, it is recommended that all circulating pumps run continuously to permit constant circulation through the relief or bypass device.
SYSTEM DIAGRAMS
Hot Water System Layout Schematics: The system layouts (Figures I2-14 through 12-19) are intended to be used as a general guide for use with CleaverBrooks products. Many system layout combinations have not been shown. Typical load groupings have been shown and will naturally vary, depending on actual job layout and individual load temperature requirements. Reverse returns are shown, since they help equalize the paths of water ow and simplify balancing of the circuits. Centrifugal system circulating pumps are shown. It is assumed that these pumps are manually started and stopped and that they are electrically interlocked with the burner control circuit. The boiler cannot re unless the circulating pumps are running. Balancing cocks are shown in the supply lines from each boiler to the pumps in order to help equalize or proportion ow through the boilers. The number and location of balancing cocks, shutoff valves, etc., to be used in the system will vary with the particular application. A make-up water meter must be installed in any raw water feed to the system. A means for introducing chemicals to the system water must be provided.
I2-15
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Hot Water Systems
System Fundamentals
Figure I2-14. Primary Loop Circuit, Constant Speed Pumps
I2-16
04-02
System Fundamentals
Hot Water Systems
Figure I2-15. Primary Loop Circuit with Secondary Pumping
I2-17
04-02
Hot Water Systems
System Fundamentals
Figure I2-16. Individual Zone Circuits
I2-18
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System Fundamentals
Hot Water Systems
Figure I2-17. Primary Loop Circuit with Three-Way Valve
I2-19
04-02
Hot Water Systems
System Fundamentals
Figure I2-18. Four-Way Valve System
I2-20
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System Fundamentals
Hot Water Systems
Figure I2-19. Multiple Boiler Lead/Lag, Primary/Secondary Pumping
I2-21
04-02
Hot Water Systems
System Fundamentals
NOTES
I2-22
04-02
Section I3
STEAM SYSTEMS
CONTENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-3 THE STEAM-GENERATING FACILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-3 Type of Application/Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-3 Operating Conditions, Requirements and Constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-3 Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-3 Condensate Return/Make-up Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-5 Water Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-5 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-5 Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-5 Stack Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-5 Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-5 Facility Requirements and Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-5 Codes and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-5 Other Federal, State, Provincial and Local Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-6 EQUIPMENT CONSIDERATIONS AND HARDWARE DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-6 Steam Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-6 Boiler Piping and Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-8 Low Pressure Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-8 High Pressure Boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-8 Boiler Feed Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-10 Boiler Feed System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-10 Surge Tanks (Condensate Receiver Tanks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-11 Deaerators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-11 Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-11 Water Treatment Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-13 The Objectives of Feedwater Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-13 Raw Water Make-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-14 Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-14 Water Softeners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-15 Dealkalizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-15 Chemical Feed Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-15 Economizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-15 Blowdown Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-15 Types of Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-16 SYSTEM INTEGRATION AND OPTIMIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-16 EXAMPLE - STEAM SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-17 Boiler Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-18 Condensate Return and Feedwater System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-19 Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-19 Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-19 Efficiency Enhancement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-20 System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-20
I3-1
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Steam Systems
System Fundamentals
ILLUSTRATIONS Figure I3-1. Typical Steam System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-4 Figure I3-2. Schematic Diagram of a Generic Steam-Generating Facility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-4 Figure I3-3. Summary of Application/Energy-Use Audit Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-6 Figure I3-4. Recommended Safety Valve Discharge Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-9 Figure I3-5. Example of System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-20 TABLES Table I3-1. Removal of Harmful Elements with Various Types of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-14 Table I3-2. Makeup Water Impurities, Limits and Treatment Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-14 Table I3-3. Recommended Limits for Total Suspended Solids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-16 Table I3-4. Water Test Results and Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-19
I3-2
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System Fundamentals
Steam Systems
draw from that information in order to address design of integrated steam systems. Ultimately, the objective is to design a steam-generating facility which is economically optimal for the demands of the steam-use facility. The following is a step-by-step procedure which assists in the design of steam-generating facilities for industrial and commercial use. These items are typically addressed during an application/energy-use audit of the facility.
INTRODUCTION
A steam system consists of a steam-supply/generating facility, a steam and condensate return/water piping system, and a steam-use facility (Figure I3-1). In this section, the discussion is focused on the integration of the various equipment within the steam-generating facility. Information is offered which need be considered when designing a steam-supply system. A general guideline is provided which identies major issues to be addressed, leading to the evaluation of system solutions and ultimately to equipment considerations for selection and design. Finally, an example of an audit and system design are provided for demonstration purposes. The reader is encouraged to review the specic product sections for additional information. The discussion in this section applies primarily to new systems and new boiler installations. When modifying existing systems, other considerations may apply.
Type of Application/Load
1. Categorize the application and load as heating/cooling, process or combination (see Section I1, System Load). There are a number of institutional applications which demand not only heating/cooling, but other steam or hot water requirements for the purpose of cooking, washing, etc. Generally speaking, these institutional loads are classied as heating applications since the requirement typically deals with heating and cooling of air and potablewater. At this juncture, a determination is made whether the boiler should be steam- or hot water-generating (see Section I1). For the remainder of this section, it is assumed that a steam- generating facility is appropriately chosen. (For more information on application considerations for hot water boilers and hot water systems, please refer to Section I2, Hot Water Systems.)
THE STEAM-GENERATING FACILITY

The steam-generating facility, located in the boiler room, consists of boilers, feedwater systems, heat exchangers (e.g., economizers), boiler and system controls, fuel and gas handling equipment (e.g., fuel trains, stacks), and steam/water treatment equipment and piping (Figure I3-2). The purpose of the steam-generating facility is to provide energy (in the form of thermal energy of the steam) to drive other processes in the steam-use facility. In turn, typical steam-use facilities are designed to meet various industrial and commercial needs such as comfort heating, food processing, paper corrugation, etc. Steam-generating facility design is unique to the specic application and it is dictated by good engineering practice, the ASME code, applicable national, state, provincial and local codes, and utility and insurance requirements. System design and selection depend on job specic operating requirements, boiler room structure and venting, fuel storage, and utility service considerations. There is therefore no simple mathematical expression to correlate steam boiler room design and application. However, there are several characteristics which help dene the application and its relevant requirements. For a steam-generating facility, these characteristics include: 1. 2. 3. 4. 5. Type of Application/Load Operating Conditions, Requirements and Constraints Facility Requirements and Limitations Codes and Standards Other Federal, State, Provincial and Local Requirements 4.
Operating Conditions, Requirements and Constraints

Steam 2. Determine the desired operating pressure. For existing steam-use facilities, the operating pressure has typically been set in the past and now acts as a constraint on the system design at hand. For new facilities, slightly more exibility exists and yet operating characteristics of equipment in the steam-use facility either set or limit the range of operating pressure of the boiler. Determine the steam load characteristics and ultimately the prole of the steam-use facility in its entirety (see Section I1). It is important to understand both the steadystate load prole as well as the transient and instantaneous demands. Determine the desired or necessary steam quality (dryness) or degree of superheat. Steam quality ranges from 0 to 100% and is dened as the ratio of the amount of saturated steam vapor to the total steam amount (which may consist of both saturated steam vapor and liquid). A 100% steam quality translates to zero amount of saturated steam liquid and, in this condition, the steam is termed to be dry.
3.
Many of these characteristics have been thoroughly discussed in other sections of The Boiler Book. The objective here is to
I3-3
02-02
Steam Systems
System Fundamentals
STACK GASES
STEAM-SUPPLY/GENERATING FACILITY
FUEL AND COMBUSTION AIR BOILERS CONTROLS STACKS ECONOMIZERS FUEL TRAINS HEAT EXCHANGERS FEEDWATER SYSTEMS SEPARATORS BLOWDOWN SYSTEMS WATER TREATMENT PUMPS
STEAM
STEAM AND CONDENSATE RETURN PIPING SYSTEM
STEAM-USE FACILITY
COMMERCIAL AND INDUSTRIAL HEATING, PROCESS, AND COMBINATION APPLICATIONS
PIPING STEAM TRAPS PUMPS
CONDENSATE RETURN
MAKE-UP WATER
Figure I3-1. Typical Steam System
STACK GAS MAKE-UP WATER
ECONOMIZER WATER TREATMENT SYSTEM

STEAM
STEAM-USE FACILITY
FEEDWATER SYSTEM
BOILER(S)
BLOWDOWN SYSTEM
BOILER FEEDWATER
CONTROLS
CONDENSATE RETURN
TO SEWER
Figure I3-2. Schematic Diagram of a Generic Steam-Generating Facility
I3-4
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System Fundamentals
The degree of superheat refers to the amount of thermal energy (heat) added to the steam relative to the saturated steam vapor point of reference, typically expressed in units of degrees Fahrenheit. For example, a degree of superheat of 50 oF means that an additional amount of heat has been added to the steam so that the nal steam temperature is 50 oF greater than the saturation temperature of the steam at the given operating pressure. Condensate Return/Make-up Water 5. 6. 7. Determine the condensate return conditions, primarily focusing on temperature, pressure and ow rate (% return). Calculate the make-up water requirement based on the % condensate return. Determine the water charges for the specic facility under analysis.
Steam Systems
16. Determine the physical lengths and ow areas of stack/ breeching, most importantly any constraints imposed in this area. These physical attributes will affect the stack gas pressure which can, in turn, have an impact on combustion characteristics and ring rates. Electrical Power 17. Understand the electrical power overall demand and seasonal proles. 18. Determine the electrical power costs for the facility. A review of 2-3 year historical data of electric power billing from the local power company will assist in this area. It is important to understand the demand charges separate from the actual electrical energy charges. Facility Requirements and Limitations 19. In regard to boiler room design, understand the physical limitations of the facility. This understanding should include oor space or footprint for both installation and maintenance considerations as well as height limitations for equipment sizing. 20. Determine noise level requirements. These twenty audit items are summarized in Figure I3-3.
Water Discharge 8. Determine the maximum temperature for water discharge, which is usually mandated by the local environmental governing authorities. Determine the sewer charges for the specic facility under analysis.
9.
Fuel 10. Determine the type(s) of fuel to be combusted within the boiler. Generally speaking, the fuels are limited to natural gas, propane, and fuel oil (although some other alternate fuels may be used). 11. Obtain a composition analysis for each fuel, which will be necessary for calculating fuel usage for a given load. 12. Determine the fuel costs; this is necessary for the economical optimization of boiler room design. For new boiler(s) installation into an existing system, a two-three year history of fuel billing data would be helpful in the eventual design of the steam-generating facility. Combustion Air 13. Determine the ambient air conditions in the boiler area and determine current fresh air supply (e.g., louvre area). Primarily, the intention is to understand typical air temperatures and humidity and their variance during the necessary time of boiler operation. Stack Gas 14. Determine any temperature limitations imposed on the stack gas. 15. Understand the local emission requirements, which will affect the allowable stack gas composition.
Codes and Standards

Various Codes and Standards govern the design, fabrication and installation of many of the boiler room components. Of primary importance is the American Society of Mechanical Engineers' (ASME) Boiler and Pressure Vessel Code. The different sections of this Code specify the rules by which steam boilers, pressure vessels and connecting piping are to be designed, constructed and installed. Section I of the ASME Code contains rules for Power Boilers which, for the case of steam boilers, are boilers designed for a maximum allowable operating pressure (MAWP) greater than 15 psig. Section IV of the ASME Code would provide rules for steam boilers with a MAWP of 15 psig or lower. B31.1 Power Piping Code provides rules for most of the piping systems involved in a typical steam plant, but has special signicance relative to Section I in that it contains Certication and Stamping requirements for boiler external piping (BEP). BEP is dened as piping from the rst circumferential joint leaving the boiler up to and including the required stop valve or valves. Most, if not all, of the piping included with a packaged boiler is within the scope of BEP. This generally includes steam, feedwater, blowdown, water column and instrument piping. Section VIII of the ASME Code contains rules for unred pressure vessels, which may apply to deaerators, blowdown separators, etc.
I3-5
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Steam Systems
System Fundamentals
STACK GAS
14. TEMPERATURE LIMITATIONS 15. EMISSION REQUIREMENTS 16. STACK/BREECHING PHYSICAL ATTRIBUTES
COMBUSTION AIR
13. TEMPERATURE HUMIDITY VARIANCE
STEAM STEAM-GENERATING FACILITY

17. ELECTRICAL POWER DEMANDS AND PROFILE 18. ELECTRICAL COSTS 19. PHYSICAL LIMITATIONS 20. NOISE LEVEL REQUIREMENTS 2. OPERATING PRESSURE 3. LOAD PROFILE 4. QUALITY/DEGRE OF SUPERHEAT
STEAM-USE FACILITY
1. TYPE OF APPLICATION/LOAD
FUEL
10. TYPE(S) OF FUEL 11. COMPOSITION ANALYSIS 12. FUEL COSTS
CONDENSATE RETURN
5. TEMPERATURE PRESSURE PERCENT RETURN
WATER DISCHARGE
8. MAXIMUM TEMPERATURE 9. SEWER CHARGES
MAKE-UP WATER
6. PERCENT MAKE-UP 7. WATER CHARGES
Figure I3-3. Summary of Application/Energy-Use Audit Items
Other Federal, State, Provincial and Local Requirements

There are many other Codes and Standards which apply to other aspects of the design and installation of steam room equipment. For a listing of standards organizations of relevance to the design of steam systems, please refer to Section I4. Local jurisdictions, insurance companies and individual contracts often impose special requirements above and beyond Code requirements, or may require compliance with special Codes and Standards. It is essential that those responsible for the planning of a boiler room installation be familiar with such requirements.
to each subsection of the overall system, categorized as: steam boilers, boiler piping and valves, feedwater systems, water treatment systems, heat exchangers and economizers, and blowdown systems. Stacks and controls are not discussed since the intention here is to concentrate on the steam side of the system. For information concerning controls and stacks, please refer to sections D and F, respectively. Considerations concerning sizing of piping, steam traps, etc. are also not covered in this section; those items are considered as a part of the steam/condensate return handling and piping system design and many references concerning these issues are available.
Steam Boilers
The boiler selection process is based on an evaluation of the system and load requirements as described above, and a comparison with the different boiler types that are available. This section denes a process and the considerations that can be used to select a boiler for a steam system application, based on the requirements discussed in Section I1. The steam-use facility will have certain operating requirements that are used to establish the boiler design pressure. For example, heating systems often operate at low pressure (a steam pressure of 8 - 10 psig), and would use a boiler that is designed for 15 psig. The boiler design pressure must be higher than the operating pressure, and is usually based on common design pressures. Steam quality, or the moisture content in the steam, may also be a requirement of the facility. The rst step in determining the required boiler size is to deter-
EQUIPMENT CONSIDERATIONS AND HARDWARE DESIGN

Having dened the application and obtained an understanding of the requirements and constraints of the steam system, it is now important to consider basic equipment needs and hardware design. Here the concern deals with potential equipment problems of the steam-generating facility in terms of performance and life. Specically, the issues to be addressed when designing and integrating equipment into a workable system are: (1) equipment capacity, (2) operating characteristics and constraints of equipment, (3) maintenance issues and the tradeoff with design/initial cost, and (4) the operational effects of each piece of hardware on the overall system operation. The following is a discussion concerning considerations given I3-6
02-02
System Fundamentals
mine the number of boilers. Multiple boilers can be used to divide a seasonal load into more manageable segments, even using different boiler sizes to better match the load. Additional boilers can be used to provide backup and minimize potential down time. Hospitals usually require a substantial amount of backup capability. Increasing the number of boilers also adds to the initial cost, on-going maintenance costs and complexity of the system. Once the number of boilers have been selected, the capacity of the boilers can be determined. This task should not be limited to matching the peak load and the total capacity of the boilers. For example, the base capacity or number of boilers should be increased if there can be a high instantaneous demand. Some consideration should also be given to how multiple boilers are cycled to minimize the cycling and number of units in use at any one time. Increasing the number of boilers will: Minimize down time and maximize reliability. Provide the highest efciency by matching load to boiler capacity. Increase the total installed cost of the boiler room. Allow the use of smaller boilers and support components. Increase maintenance cost. Increase the size and complexity of the boiler room. Minimizing the number of boilers will: Decrease total installed cost. Reduce overall efciency because of low-load operation. Minimize maintenance costs. Provide a less complex and smaller boiler room. Different sized boilers can be used for the large variation in seasonal loads. Total boiler capacity should include future expansion considerations. Emission regulations may require special controls above a certain total capacity. At this stage of the selection process, some boiler types can be eliminated based on the operating pressure and capacity requirements. (Table I1-1 in Section I1 can be used as a guide in this process). In addition, the load type may also impact the selection process. For example, watertube boilers are better suited to swing loads while retube boilers are better for loads with upset conditions. Also, bent tube boilers can be used when quick warm up is required.
Steam Systems
Watertube boilers are the preferred choice for pressures above 350 psig. Higher turndown rates improve the boiler load response because the boiler remains on line at low loads. Bent tube and electric boilers can provide quick warm-up without thermal shock. Steam superheat is generally only available on the IWT boiler. There are numerous regulatory requirements in the boiler industry. Many boilers are listed by Underwriters Laboratories or a similar agency, which has tested the product to ensure that it meets their minimum standards for safety and performance. Emission regulations have become more common in recent years. Finally, there may be other organizations that will mandate requirements for an installation, such as the city, state or insurance carrier. These requirements may prevent the use of some boiler types. Check insurance carrier for requirements. A Package listing helps insure boiler/burner compatibility. Construction and operating permits are usually required by local authorities. Federal NSPS regulations, permits and recording applies over 200 hp. The nal stage in the selection process will be the consideration of the operating features and efciency of the boilers. Initial cost is always a factor, but it should not be the only factor. For example, the boiler efciency, turndown and maintenance requirements can result in much higher or lower operating costs, and can easily change the cost analysis. Some common considerations that impact overall efciency and fuel costs are: Multiple fuel capabilities, including future conversions. More ue gas passes in a retube boiler will increase heat transfer. Heating surface area, usually 5 square feet per boiler hp in a retube boiler. Higher turndown increases boiler efciency and provides quicker load response. Lower excess air operation increases boiler efciency. Economizers can be added to most boilers, which will increase efciency. Maintenance and down time can be important considerations in the boiler selection. Using multiple boilers helps reduce the potential for loss of steam generating capability. Higher turndown reduces component wear and failure due to on-off cycling.
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Steam Systems
Critical operations should include controls to keep the standby boiler hot. Always use duplex pumps and lters to allow maintenance without shut down. Consider rental boilers as potential backup, and include required piping in the plant. Generally boilers with large water volumes and surface areas are more tolerant of feedwater treatment variations and load surges. The moisture content in steam from a steam generator is normally very small. There are conditions that can upset the normal operation and result in some relatively high amounts of water carry-over. In addition, there are some applications which require extremely dry steam for proper operation. There are some guidelines for maintaining high quality steam, and methods to improve the steam quality. Feedwater quality is the single most important element in steam quality. General feedwater guidelines are given in this book and others. Special considerations need to be given to the type of boiler. There may be additional requirements based on the boiler type and the conditions of the local water supply. A water specialist should be consulted for specic requirements of an installation. The steam quality from a boiler can be improved by adding an external separator or an equalizing line similar to a Hartford Loop. Such special steam piping arrangements are sometimes used on low pressure steam boilers with small steam chambers. The industrial watertube boiler offers some additional options for improving the steam quality. One option uses special drum components to further remove solids, resulting in higher steam quality. The other option is to add a superheater to provide superheated steam. Water maintenance programs can help insure reliable steam quality. Boiler concentrations may need to be adjusted for best steam quality. Special steam piping can be used with some boilers (such as the cast iron boiler) to reduce carry-over. An external separator will typically remove 90% of the moisture in a steam line. Superheated steam and special steam dryers are available on industrial watertube boilers.
System Fundamentals
Relevant highlights of the ASME Code are included. However, for complete details, the reader should review the applicable section of the ASME Code. In addition to the ASME Code, the reader should determine whether there are any special, local insurance or regulatory requirements. Low Pressure Boilers The ASME Code contains many recommendations for low pressure steam systems. Here are excerpts that apply to design consideration. Steam Line Expansion - Provisions shall be made for the expansion and contraction of steam and hot water mains connected to boilers by providing substantial anchorage at suitable points, and by providing swing joints when boilers are installed in batteries, so there will be no undue strain transmitted to the boilers. para. HG-703.1 Stop Valves for Single, Multiple, and Steam Boilers Steam Boilers - When a stop valve is used in the supply pipe connection of a single steam boiler, there shall be one used in the return pipe connection.para. HG-710.1 Multiple Boiler Installations - A stop valve shall be used in each supply and return pipe connection of two or more boilers connected to a common system. para. HG-710.3 Shutoff Valves - No shutoff of any description shall be placed between the safety relief valve and the boiler, nor on discharge pipes between such valves and the atmosphere. para. HG701.5 Safety and Safety Relief Valves - Safety and safety relief valves shall not be connected to an internal pipe in the boiler. para. HG-701.4 Safety Valve Discharge Piping - A discharge pipe shall be used. Its internal cross-sectional area shall be not less than the full area of the valve outlet or of the total of the valve outlets discharging there into and shall be as short and straight as possible and so arranged as to avoid undue stress on the valve or valves. When an elbow is placed on a safety or safety-relief valve discharge pipe, it shall be located close to the valve outlet. The discharge from safety or safety-relief valves shall be so arranged that there will be no danger of scalding attendants. Para. HG-701.6 Refer to Figure I3-4. Bottom Blowoff - Each boiler shall have a bottom blowoff or drain pipe connection tted with a valve or cock connected with the lowest water space practicable. The discharge piping shall be full size to the point of discharge. para. HG-715 High Pressure Boilers The ASME Code provides many recommendations for high pressure steam boilers. Here are some excerpts that apply to design considerations.
Boiler Piping and Valves

This section contains information on boiler piping and valve requirements for low and high pressure boilers.
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System Fundamentals
Steam Systems
Figure I3-4. Recommended Safety Valve Discharge Piping Steam Line Expansion - Provisions shall be made for the expansion and contraction of steam mains connected to boilers, by providing substantial anchorage at suitable points, so that there shall be no undue strain transmitted to the boiler. para. PG-59.1.2 Steam Stop Valves - Each boiler discharge outlet, except safety valves or safety relief valves, or preheater inlet and outlet connections, shall be tted with a stop valve located at an accessible point in the steam-delivery line and as near the boiler nozzle as is convenient and practicable. When such outlets are over NPS2, the valve or valves used on the connection shall be of the outside-screw-and-yoke rising-stem type so as to indicate from a distance, by the position of its stem whether it is closed or open, and the wheel may be carried either on the yoke or attached to the stem. para. 122.1.7 (A.1) (ASME B31.1) When boilers are connected to a common header, the connection from each boiler having a manhole opening, shall be tted with two stop valves having an ample free-blow drain between them. The discharge of this drain shall be visible to the operator while manipulating the valve. The stop valves shall consist preferably of one automatic non-return valve (set next to the boiler) and a second valve of the outside-screw-and-yoke type or two valves of the outside-screw-and-yoke type shall be used. Para. 122.1.7 (A.2) (ASME B31.1) Stop-Check Valves (Non-Code Recommendations) - A problem confronting the power piping designer is the selection of the best size of stop check valve for his service conditions. This type valve usually has a oating disc member, hence it is important that the valve be sized to provide full disc lift under ow conditions prevailing during the major portion of the service life of the installation. If the valve is too large for ow conditions, the disc will oat in a partially open position; this may result in uttering of the disc and rapid wear of valve parts. Conversely, if the valve is too small for ow conditions encountered, pressure drop will be excessive. Safety Valves - No valve of any description shall be placed between the required safety valve or valves and the boiler, nor the discharge pipe between the safety valve and the atmosphere. When a discharge pipe is used, the cross-sectional area shall be not less than the full area of the valve outlet or the total
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Steam Systems
of the areas of the valve outlets discharging there into and shall be as short and straight as possible and so arranged as to avoid undue stresses on the valve or valves. All safety valve or relief valve discharges shall be so located or piped as to be carried clear from running boards or platforms. Ample provision for gravity drain shall be made in the discharge pipe at or near each safety valve or safety relief valve, and where water of condensation may collect. Each valve shall have an opening gravity drain through the casing below the level of the valve seat. For iron-and-steel bodied valves exceeding 2-1/2 inch size, the drain hole shall be tapped not less than 3/8 inch pipe size. Para PG-71.3 Refer to Figure I3-4, Recommended Safety Valve Discharge Piping. Safety Valve Mounting - When a boiler is tted with two or more safety valves or safety relief valves on one connection, this connection to the boiler shall have a cross-sectional area not less than the combined area of inlet connections of all the safety valves with which it connects and shall also meet the requirements of Paragraph PG-71.3. Para. PG-71.5 Blowoff Valves - The blowoff valve or valves, the pipe between them, and the boiler connection shall be of the same size except that a larger pipe for the return of condensate may be used. For all boilers . . . with allowable working pressure in excess of 100 psig, each bottom blowoff pipe shall have two slowopening valves, or one quick-opening valve or cock; at the boiler nozzle followed by a slow-opening valve. A slow-opening valve is a valve which requires at least ve 360 degree turns of the operating mechanism from fully closed to fully opened. On a boiler having multiple blowoff pipes, a single master valve may be placed on the common blowoff pipe from the boilers, in which case only one valve on each individual blowoff is required. In such a case, either the master valve or the individual valves or cocks shall be of the slow-opening type. Para. 122.1.7 (ASME B31.1) Feedwater Valves - The feedwater piping for all [steam] boilers . . . shall be provided with a check valve . . . between the check valve and the boiler. Para 122.1 (B1) (ASME B31.1) When two or more boilers are fed from a common source, there shall also be a globe or regulating valve in the branch to each boiler located between the check valve and the source of supply. Para. 122.1.7 (B.5) (ASME B31.1)
System Fundamentals
An important factor in the condensate return and water makeup system is to ensure that contaminated condensate does not return to the boiler room and its associated equipment. Condensate contaminated with oil, dye, soap, etc. must be disposed of in a safe manner. Contaminated condensate will cause problems such as foaming, priming, unstable water level, and it will increase blowdown requirements. The collection of clean steam condensate is desirable for several economic reasons. Condensate generally is capable of being collected at temperatures higher than the temperature of raw water make-up. This results in signicant fuel cost savings and improved overall system efciency. Since condensate is formed from steam, it contains little or no dissolved solids. Therefore, using collected condensate reduces chemical usage and associated costs as well. Additionally, the cost of raw water make-up will be reduced by collecting condensate because the demand for raw water is limited. When considering installation costs, the expected condensate return may allow for down-sizing of the raw water makeup supply system and other components. Unfortunately, condensate ow from the system may be unpredictable. Unpredictability of returning condensate causes a problem for the boiler, since it should have a continuous and immediately available supply of water. However, there are several ways to collect and store condensate so it is readily available. A collection or storage tank can be incorporated to act as a reservoir. Products which serve this purpose include boiler feedwater systems, surge tanks, and deaerators. The function of these products in the overall condensate return and raw water make-up system is as follows. For further information on this equipment, refer to the specic product sections in The Boiler Book. Boiler Feed System Boiler feedwater systems help maintain maximum efciency and prolong the life of the boiler, when investment in a deaerator cannot be justied. Consisting of one or more feed pumps and a corrosion resistant receiver tank, the system automatically supplements condensate with make-up water to replace system losses. When equipped with an automatic preheater, feedwater temperatures can be maintained at temperatures up to 210 F (maximum). At this temperature, substantial amounts of oxygen and carbon dioxide are released, reducing the amount of chemicals required to protect the boiler and system from corrosion. Preheating is recommended if the return condensate constitutes 50% or less of the required feedwater. Boiler feed systems typically combine one or more boiler feed pumps with a tank to store condensate and make-up water. These components are typically furnished as a complete package with level, temperature, and pressure controls. Additional
Boiler Feed Systems

The transfer of heat from steam, regardless of process usage, will create condensate. The quantity of collectable condensate varies with the type of application. For instance, with humidication, the steam is released to the environment and the condensate is considered uncollectible. In industrial applications, condensate can typically be collected in large quantity.
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System Fundamentals
features such as deaeration hardware and more sophisticated controls may be considered. The purpose of the boiler feed system is to provide a reservoir with sufcient surge capacity to accommodate intermittent condensate owrates, and to provide stable suction conditions for the boiler feed pump(s). The selection of a boiler feedwater system is primarily driven by surge capacity. For this reason, it is necessary to accurately estimate peak condensate owrates from the steam-use facility, considering also factors due to transient conditions such as equipment startups, piping hydraulics, and system interactions. Once this information is obtained and understood, a boiler feed tank of sufcient size may be selected. The operating characteristics of the boiler and steam-generating system have an impact on the type of controls and features included in the boiler feed system. In particular, those factors inuencing pump selection will also have an effect on the height of the boiler feedwater system, the level control system, and suction piping design. The characteristics of the returning condensate should also be considered when selecting feedwater system components, corrosion resistant linings, and pressure/temperature controls. There are many cost/benet tradeoffs available when conguring a boiler feed system. A partial list includes: Feedwater Preheat reduces thermal shock. Premium Lining/Galvanizing reduces corrosion. Premium Level Control reduces overow losses. Code Rated Pressure Tank reduces ash steam losses. Deaeration Hardware reduces corrosion and thermal shock. Each of these options has a direct benet on the long-term operating costs of the system. Their increased initial costs must be balanced against the overall capital cost and the expected life of the system. For more information on boiler feed systems, please refer to Section H5. Surge Tanks (Condensate Receiver Tanks) Surge tanks can greatly reduce dependence on cold, untreated raw water to replace boiler system losses by collecting condensate by gravity return for re-use in the boiler feed system. Surge tanks are required when no other storage exists or when intermittent peak loads of condensate can exceed the storage capacity of the deaerator. Integrated control automatically introduces makeup water to supplement condensate only when necessary to meet boiler demand. Refer to Section H4 for more detailed information. Deaerators Deaeration is widely recognized as the most acceptable method for removing oxygen and carbon dioxide from makeup
Steam Systems
water and condensate. Without deaeration, the dissolved gases can cause serious corrosion in the boiler and other system hardware. Deaerators are considered essential for: All boiler plants operating at 75 psig or more. All boiler plants with little or no standby capacity. All boilers plants where production depends on continuous operation. All boiler plants operating with makeup water of 25% or more. In addition to removing oxygen and carbon dioxide, deaerators also heat boiler feedwater. The large storage capacity provides an effective means for recovering heat from exhaust steam and hot condensate. With a deaerator, further savings result from the reduced need for oxygen-scavenging chemical treatment. For further information, refer to Sections H1, H2, and H3. Pumps There are ve design criteria that must be considered before the proper boiler feed pump can be selected. 1. Will the pump run continuously or intermittently? 2. What is the temperature of the water being pumped? 3. What is the pump capacity requirement in gpm? 4. What is the pump discharge pressure requirement? 5. What is the NPSH (net positive suction head) required? Continuous or Intermittent Operation - Continuous or intermittent operation of a pump is determined by the critical nature of the desired water level control. The water level control requirements are primarily based on the type of boiler, but are also affected by the load, operating pressure, and feed water temperature. Continuous operation provides better water level control, but adds cost and components to the system. Boiler types with a relatively low water volume, such as watertube boilers, require more precise water level control than boiler types with a large water volume, such as retubes. This is due to the relationship between drum (vessel) size and gallons of water content. For example, a fty gallon change in a watertube boiler might represent a one inch change in water level, while the same fty gallon change in a retube boiler might only represent a fraction of an inch change in water level. Frequent load swings will require more accurate water level control to ensure the feedwater ow matches the steam ow requirement. Frequent load swings may require continuous feedwater control to maintain proper water level. The relationship between operating pressure and feedwater temperature can make water level control more critical if the
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Steam Systems
temperatures vary or if there is a large differential between saturation temperature and feed water temperature. Large temperature differentials could result in a reduction in boiler water level when feed water is added. The reduction is caused by a quenching effect, which lowers the boiler water temperature slightly, reducing the steam/water volume, thereby lowering the water level. This type of water level reduction is generally more common on smaller, low pressure boilers. Selection of Pump Type (Centrifugal or Turbine) - Once the criteria for water level control is determined, the type of feed pump can be selected. Highly accurate water level control can be achieved with a centrifugal type pump, running continuously, in conjunction with a modulating feed water valve on the boiler. An effective but less precise means of water level control can be provided using a turbine type pump, with intermittent (onoff) operation. With intermittent operation, larger swings in water level control will result. Although not common, turbine pumps have been used in conjunction with a modulating feedwater valve to provide water level control. In this application, a relief device must be included to discharge water back to the feedwater tank to protect the pump from dead head pressures. Dead head pressures can cause overheating, cavitation, and subsequent pump damage. A concern of this design is the use of a relief device as a control valve, and the inherent performance and reliability factors. Pump Water Temperature - The temperature of the pumped water must be specied to ensure proper design and construction. Pumps use packing or mechanical seals to seal the area between the pump shaft and the pump casing. These seals have temperature limitations and, if misapplied, the seals will fail. Standard pump seals are adequate up to temperatures of approximately 215 F. Higher temperature seals are available for temperatures up to 250 F and, for temperatures above 250 F, external water cooling is usually employed to protect the seals. For applications above 250 F, contact your local Cleaver-Brooks authorized representative. Pump Capacity Requirements - Determining pumping capacity requirements involves slightly different criteria for centrifugal and turbine type pumps. For both pump types, the maximum boiler capacity must be determined. The maximum boiler capacity, or evaporation rate, is usually calculated in pounds of steam per hour, and should be converted to gallons per minute, and have blowdown added to it for pump selection purposes. For assistance in this calculation, contact your local Cleaver-Brooks authorized representative. The pump capacity for turbine pumps, with intermittent operation, should be equal to 2 times the maximum evaporation rate of the boiler. The pump capacity for centrifugal pumps, with continuous operation, is equal to: evaporation rate times 1.15 (safety facI3-12
02-02
System Fundamentals
tor), plus by-pass ow requirement (in gpm) for the pump. The by-pass ow is usually regulated through a xed orice, and is of sufcient quantity to prevent cavitation within the pump under dead head conditions. The by-pass orice must be located between the pump discharge and the modulating feedwater valve to allow water to recirculate back to the storage tank. Pump Discharge Pressure Requirements - Pump discharge pressure requirements are calculated by determining the boiler operating pressure and calculating the line losses between the pump and the boiler. The pump discharge pressure needs to overcome the piping line losses, and boiler pressure in order to get water into the boiler. All calculations need to be converted to feet of head for pump selection purposes. Therefore, convert boiler operating pressure to feet of head, and add to that value the equivalent length (in feet of head) of the piping and associated valves between the pump discharge and the boiler. Net Positive Suction Head (NPSH) - Every pump design has a certain requirement for net positive suction head. This is the amount of liquid in feet that must be above the pump suction centerline in order to prevent cavitation and to provide proper pump operation. Net positive suction head required (NPSH-R) by the pump must be exceeded by the net positive suction head available (NPSH-A) from the system. Calculation: NPSH-A = HP + HZ - HF - HVP NPSH-A - Available NPSH expressed in feet of uid. HP - Absolute pressure on the surface of the liquid at the pump suction location, expressed in feet. This could be atmospheric pressure or vessel pressure (pressurized tank). HZ - Static elevation of the liquid above, or below the centerline of the impeller, expressed in feet. HF - Friction and entrance head loss in the suction piping, expressed in feet. HVP- Absolute vapor pressure of the uid at the pumping temperature, expressed in feet. Cleaver-Brooks makes selections that are based on pumps having the lowest possible NPSH-R. This is done to provide the lowest stand height and the lowest overall height of the tank. There are some sacrices which must be accepted in order to have low NPSH-R. Usually a selection with a low NPSH-R is a pump that is larger and usually requires a greater horsepower drive. Generally speaking, however, it is more important to keep the overall height to a minimum than to select a pump with a higher NPSH-R. Pumps (General) - The design criteria for transfer pumps (pumps which pump water to a deaerator) is the same as the criteria just covered for boiler feed pumps.
System Fundamentals
Cleaver-Brooks and our authorized representatives provide a full line of pumps, and pump selection services for application in both steam and hot water systems. For assistance, contact your local Cleaver-Brooks authorized representative.
Steam Systems
gen. Dissolved oxygen is not related to the combined oxygen contained in the water molecule H2O. All surface and rain water contain dissolved oxygen, because of their contact with the atmosphere. With enough contact, the dissolved oxygen content will reach saturation for the corresponding temperature. The solubility of oxygen is affected by solid content. Water with a higher solid content will contain less oxygen than distilled water. Surface water usually contains more oxygen than well water. As the raw water temperature rises, dissolved oxygen is released and can cause corrosion of iron and steel. Therefore, the problem caused by dissolved oxygen in boiler systems is corrosion in the boiler feedwater piping, economizer, boiler, and steam and condensate return piping. Hence, the generation of steam from naturally occurring water sources can be complicated by the presence of various chemical constituents in the water supply. The American Society of Mechanical Engineers has published guidelines on boiler water and boiler feedwater quality for steam boilers. Most boiler installations will require some form of water treatment in order to conform to these guidelines. A few methods of treatment are depicted in Tables I3-1 and I3-2. The Objectives of Feedwater Treatment Proper boiler feedwater treatment is an absolute necessity! Unless the boiler receives water of proper quality, the boilers life will be shortened. The water supply for a steam system may originate from rivers, ponds, underground wells, etc. Each water supply source requires a specic analysis. Depending upon the analysis, various pretreatment methods may be employed to prepare make-up water for the boiler feedwater system. The objectives of boiler water treatment in general are as follows: 1. Prevent hard scale deposits or soft sludge type deposits which would, if present, impair the rate of heat transfer and possibly result in overheating and damage to the pressure vessel. Prevent general corrosion or pitting to assure maximum life of the boiler at the lowest maintenance cost. Prevent intercrystalline cracking or caustic embrittlement of boiler metal. Prevent carryover to assure high quality steam at an economical rate of continuous and intermittent blowdown.
Water Treatment Systems

Harmful elements are contained in surface and well water. Surface and well water are also called raw water. A sample of the raw water should be analyzed early in the equipment planning stage. The analysis provides a clear denition of the particular threats posed by the water source. Your CleaverBrooks representative can assist you in dening the harmful elements, and can help in planning a water treatment program and in selecting the proper treatment equipment. The following is a discussion of the elements commonly found in raw water. Surface water usually has high suspended solids and dissolved gases and low dissolved solids. Well water normally has high dissolved solids and low suspended solids and dissolved gases. Suspended solids represent the undissolved matter in water, including dirt, silt, biological growth, vegetation, and insoluble organic matter. When minerals dissolve in water, ions are formed. The sum of all minerals or ions in the water is the total dissolved solids or TDS. Iron can be soluble or insoluble. Insoluble iron can clog valves and strainers and can cause excessive sludge build up in low lying areas of a water system. It also leads to boiler deposits that can cause tube failures. Soluble iron can interfere in many processes, such as printing or the dying of cloth. In domestic water systems, porcelain xtures can be stained by as little as 0.25 ppm of iron. Water hardness is the measure of calcium and magnesium content as calcium carbonate equivalents. Water hardness is the primary source of scale in boiler equipment. Silica in boiler feedwater can also cause hard dense scale with a high resistance to heat transfer. Alkalinity is a measure of the capacity of water to neutralize strong acid. In natural waters, the capacity is attributable to bases, such as bicarbonates, carbonates, and hydroxides; as well as silicates, borates, ammonia, phosphates, and organic bases. These bases, especially bicarbonates and carbonates, break down to form carbon dioxide in steam, which is a major factor in the corrosion of condensate lines. Alkalinity also contributes to foaming and carryover in boilers. pH is a measure of the degree of acid or base of a solution. The pH scale is from 0 to 14, with 0 being the most acidic and 14 being the most basic or alkaline. Dissolved oxygen is the amount of oxygen gas dissolved in the raw water and is caused by the solubility of atmospheric oxy-
2. 3. 4.
The accomplishment of these objectives will, in all cases, involve several forms of treatment including: Pretreatment of the make-up water before it enters the boiler feedwater system. Chemical treatment of the boiler water internally in the boiler.
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Steam Systems
System Fundamentals
Table I3-1. Removal of Harmful Elements with Various Types of Equipment
DISSOLVED CONSTITUENT Calcium CaB Magnesium MgB HardnessA Sodium Na Bicarbonate Alkalinity HCO3A Sulfate SO4 Chloride Cl Silica SiO2A Soluble Iron Fe Total Dissolved SolidsA Suspended SolidsA Dissolved GasesA
SOFTENER 98-100% 98-100% 98-100% Increases No Change No Change No Change No Change 100% No Change Must Be Removed No Change
CLORIDE CYCLE DEALKALIZER Must have soft water Must have soft water Must have soft water No Change 90% 90-95% Increases 20% Must have soft water No Change Must be removed Free CO2 Only
FILTERS No Change No Change No Change No Change No Change No Change No Change No Change No Change No Change Down to 10 Micron See Filter Section
DEAERATORS No Change No Change No Change No Change No Change No Change No Change No Change No Change No Change No Change To .005 cc/liter of O2
NOTE: All of the above packaged water systems can be readily integrated into existing Cleaver-Brooks boiler rooms. All are designed to accommodate boilers of any make. A. Specifically limited by ASME guidelines on boiler feedwater quality. B. The sum of calcium and magnesium equal the hardness. Hardness has been listed as a separate item for those analyses showing hardness only.
Table I3-2. Makeup Water Impurities, Limits and Treatment Methods

MAKE-UP WATER TEST Oxygen Hardness Suspended Matter pH Silica Alkalinity Dissolved Solids A. Limits for feedwater. B. Limits of boiler. TYPICAL IMPURITIES 6 ppm 86 ppm 0.1 ppm 6.87 10 ppm 100 ppm 500 -mho/cm TYPICAL LIMITS <.007 ppmA <1.0 ppmA 0.15 ppmA 7.0-10.5A <150 ppmB <700 ppmB <7000 mho/cmB TREATMENT METHOD Deaeration/Chemical Softener Blowdown Chemical Blowdown Blowdown/Dealkalizer Blowdown
In addition, the selection of pretreatment methods will depend upon the chemistry of the raw water and the plant operating characteristics. In most cases, pretreatment becomes more critical as the percentage of make-up to the system increases. Raw Water Make-up Impurities in raw water make-up can be removed and controlled either chemically or mechanically with various equipment. Mechanical means of removing or controlling impurities will result in less chemicals being added to the boiler and system. However, mechanical means will not remove or control all impurities. Chemicals will still be required to provide the desired results. I3-14
The following are descriptions of feedwater pretreatment equipment and a discussion of their functions in the overall feedwater pretreatment cycle. For further information on equipment, refer to the specic product sections. Filters The need for special lter equipment to remove impurities can be readily determined by a raw water analysis. Filters should be considered in order to remove sand, iron, chlorine, and some dissolved organics and sediments. Refer to Section H7.
02-02
System Fundamentals
Water Softeners Water softeners should be used whenever raw water hardness exceeds 5 ppm. A softener removes calcium and magnesium and exchanges them with highly soluble sodium ions. Removing hardness prevents scale buildup on heat transfer surfaces and helps maintain peak boiler efciency. A water softener also is the base for many sophisticated pretreatment processes that require the control of water hardness for proper operation. Refer to Section H8. Dealkalizers Dealkalizers use softened water and remove negatively charged ions of bicarbonate, carbonate, sulfate nitrate, and silica. They are replaced with chloride ions. Removal of bicarbonate alkalinity controls formation of carbon dioxide and reduces the corrosion of condensate piping. Dealkalization reduces the need for neutralizing chemicals by as much as 90% and cuts fuel costs by minimizing blowdown. Refer to Section H9. Chemical Feed Systems Chemical feed systems treat feedwater, boiler water, and condition blowdown sludge where an additional measure of protection against corrosion and scaling is required. Refer to Section H6. In summary, the benets of water treatment equipment include improved boiler efciency, corrosion reduction and therefore component life, and improved steam purity. The selection and sizing of water treatment equipment is dictated by the capacity of the steam system, the chemical constituents in the make-up water supply, and the operating characteristics of the overall system. Generally speaking, the greater the treatment load (in units of lb/hr removal), the larger the equipment. It is important when designing a water treatment system that a detailed water analysis be available as a guide. The design of the water treatment system is inuenced by cost/ benet tradeoffs in equipment selection. These inuences may include: Chemical Feed Systems which have low initial costs, but signicant operating costs. Component Duplexing which tends to ensure uninterrupted operation. Chloride Cycle Dealkalizers which reduce blowdown losses. Filters which also reduce blowdown losses and maintenance. Skid Mounting which decreases installation costs. Premium Regeneration Controls which may decrease operating costs.
Steam Systems
These equipment selection economic tradeoffs are inuenced by size, criticality, and operating environment of the steam system.
Economizers
During boiler operation in typical commercial and industrial applications, approximately 10-20% of the heating value of fuel is expelled with the stack gases to the atmosphere. Stack economizers are designed to recover signicant amounts of this stack gas energy loss, thereby vastly improving boiler system efciency, as shown in Section G, Tables G-5 and G-6. There are several considerations when selecting an economizer: Gas-side Pressure Drop. Added back-pressure on the boiler stack affects the combustion air fan throughput capability. The economizer and combustion air fan(s) must be sized properly in order to assure a suitable system operation and capacity. Feedwater Temperature. The feedwater to the economizer must be deaerated and the temperature setpoint minimally at 220oF to prevent tube corrosion. Water-side Pressure Drop. Feedwater pumps must be sized to accommodate the economizer pressure drop. Additionally, a continuous modulating feedwater system is required to ensure proper ow rates through the economizer. A full product line description of Cleaver-Brooks Boilermate Economizers, including sizing and performance information, is offered in Section G.
Blowdown Systems
A number of factors determine the need for boiler blowdown. As mentioned earlier, the amount of total dissolved solids (TDS) is one. The American Boiler Manufacturers Association (ABMA) has developed recommended limits for total and suspended solids for different boiler operating pressures. Refer to Table I3-3 for recommended limits for total and suspended solids. Other controlling factors for determining blowdown requirements are alkalinity, suspended solids, and other chemical factors. In boilers operating over 600 psig, silica content could be the limiting factor. Solids are brought into the boiler by the feedwater. Even though the water is treated, either mechanically or chemically, neither means of treatment is capable of removing all substances. A small amount of crystallized solids will be present in the boiler water, which can tend to encrust surfaces. That is, solids become less soluble in the high temperature of the boiler water and tend to crystallize and concentrate on heat-
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02-02
Steam Systems
Table I3-3. Recommended Limits for Total Suspended Solids
OPERATING PRESSURE PSIG 0-300 301-450 451-600 601-750 751-900 901-1000 TOTAL SOLIDS PPM 3500 3000 2500 2000 1500 1250 SUSPENDED SOLIDS PPM 300 250 150 100 60 40
System Fundamentals
A controlled orice valve is used to allow a continual, yet controlled, ow of concentrated water. Periodic adjustments are made to the valve in order to increase or decrease the amount of blowdown in accordance with test analysis. There are a few considerations when designing a blowdown system: Local Code Requirements: If necessary, a blowdown aftercooler should be incorporated to bring the blowdown water temperature to a level acceptable to the sewer system and local code requirements. Blowdown Heat Recovery: Since the blowdown water is discharged at the saturated steam temperature, a signicant amount of energy may be expelled during blowdown. A well-designed blowdown heat recovery system can control blowdown rates and dissolved solids concentration while recovering heat for make-up water preheating. When selecting a blowdown heat recovery system, two factors should be considered: (1) tube materials and construction, and (2) blowdown owrate control. The high velocities and abrasive nature of blowdown water necessitates quality construction materials such as stainless steel, as well as design for vibration damping. Secondly, it is important to control blowdown rate so as to match makeup water ow rates for optimal heat recovery. In most cases, the intermittent nature of bottom blowdown will preclude recovery of the blowdown energy losses. Moreover, the bottom blowdown can contain suspended matter or sludge that will tend to clog a heat exchanger. With a continuous blowdown system, heat may certainly be recovered, transferred to make-up water, before the blowdown is cooled and sent to sewer. Flash Tank Heat Exchangers: Flash tank heat exchangers are also designed to recover heat from blowdown water, but provide an added feature of producing low-pressure steam for deaeration. The portion of blowdown water which is not ashed either enters a blowdown heat recovery system for make-up water preheating or is discharged to sewer.
ing surfaces. Internal chemical treatment is therefore required in order to keep harmful scale and sludge from forming. Scale has a low heat transfer value and acts as an insulating barrier. Insulation retards heat transfer, which not only results in lower operating efciency but, more importantly, can cause overheating of boiler metal. Overheating of boiler metal results in tube failure or other pressure vessel metal damage. Scale is caused primarily by calcium and magnesium salts, silica, and oil. Any calcium and magnesium salts, along with organic materials in the boiler water, are generally precipitated by the use of sodium phosphate in order to maintain these precipitates or sludge in a uid form. Solids, such as sodium salts and suspended dirt, do not readily form scale. However, as boiler water boils, forming relatively pure steam, the remaining water becomes increasingly thicker with solids. If the concentration is permitted to accumulate, foaming and priming will occur and the sludge can cause harmful deposits that potentially result in overheating of the metal. Therefore, lowering or removing concentrated solids requires the use of boiler water blowdown. Types of Blowdown There are two principal types of blowdown: manual (intermittent) bottom blowdown and surface (continuous) blowdown. Manual (Intermittent) Bottom Blowdown - Bottom blowdown is necessary for the proper operation of the boiler. Bottom blowdown removes sludge and controls the level of TDS. On a manual system, the blowdown tappings are located at the bottom or lowest part of the boiler, so that the dissolved solids in the boiler water are lowered, and a portion of the sludge that accumulates in the lower portion of the boiler is removed. Surface (Continuous) Blowdown - Surface blowdown involves a continuous, low ow of boiler water extracted from the surface of the water level in order to skim off sediment, oil and other impurities. The blowdown is regulated by a ow control valve, which is adjusted as needed to control the TDS level. The surface blowdown opening is on the top center line of the pressure vessel and is provided with an internal collecting pipe terminating slightly below the working water level. I3-16
SYSTEM INTEGRATION AND OPTIMIZATION

The discussion in this section attempts to provide to the reader assistance to approach in designing and integrating various equipment into a workable system. A workable system is one that meets the requirements and purposes of the system, has satisfactory life and maintenance costs, and abides by all constraints such as pressures, temperatures, footprint, noise, emissions, etc. In summary, a workable system performs the assigned duty, given the imposed constraints and requirements. System optimization, on the other hand, is the process of determining system conguration and state point conditions which provide a maximization of some objec02-02
System Fundamentals
tive such as the net present value of overall life costs. Optimized design may offer the steam-user signicant savings over the life of the steam-generating facility. It is the design which maximizes protability for the owner over time. For a given application, there are many workable designs, but only one optimal design. The discussion in this section entails a search method to approaching the optimal design. Components/equipment are added arbitrarily and evaluated for effect on system performance and ultimately cost/benet to the steam system owner. Obtaining the optimum design is more involved than that presented in this section and is beyond the scope of this discussion. $68.04/month service charge $0.833/ccf consumption charge
Steam Systems
8. Water Discharge Max. Temp: 120 F 9. Sewer Charges: $13.72/month service charge $0.573/ccf use charge 10. Types of Fuel: Natural Gas Light Oil considered as a back-up 11. Fuel Analysis: Natural Gas Methane: 86.0% (vol.) Ethane: 7.2% (vol.) Nitrogen: 6.8% (vol.) SG: 0.619 HHV: 21,100 Btu/lb (1000 Btu/scf) No. 2 Oil Carbon: 85.8% (wt.) Hydrogen: 12.7% (wt.) Sulfur: 0.2% (wt.) HHV: 19,420 Btu/lb 12. Fuel Costs: Natural Gas: $4.50/MMBtu ($3.50 MMBtu interruptible) No. 2 Oil: $4.20/MMBtu 13. Combustion Air Conditions: Avg Temp1: 80 F Rel Hum: 60% 14. Stack Gas Temperature Limits: N/A 15. Emission Regulations: There are none currently, but requirements are in the expected future. Site is located in a non-attainment zone. 16. Stack/Breeching Physical Attributes: A new single stack is to be designed by the boiler supplier. 17. Electrical Power Demand: Not applicable in this case ______________
1. Boiler room combustion air temperature ranges from 60 F to 100 F.
EXAMPLE - STEAM SYSTEMS

The following is an example of a relatively simple low pressure steam heating system. The entire steam-generating facility of an existing heating system is evaluated for replacement. An application/energy-use audit results in the following information. 1. Type of Application/Load: Heating 2. Nominal Steam Pressure: 10 psig 3. Steam Load Characteristics/Prole: The steam system operates 5 months/year. During 3 months (2160 hours) Minimum load: 0 Maximum load: 5,600 kBtu/hr Average load:650 kBtu/hr During 2 months (1440 hours) Minimum load: 0 Maximum load: 8,100 kBtu/hr Average load: 2,500 kBtu/hr Transient loads, instantaneous demand, and sudden load swings do not exist. 4. Steam Quality Requirements: 98% steam quality at boiler pressure vessel exit 5. Condensate Return Conditions: Temperature: 200 F Pressure: 2 psig % Return: 90% 6. Make-up Water Requirement: 10% 7. Water Charges:
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Steam Systems
18. Electrical Power Costs: $0.0345/kWhr on-peak $0.0245/kWhr off-peak 19. Physical Limitations of Facility: None 20. Noise Level Requirements: <90 dBA When designing a steam generating facility, necessary system capacity and approximate fuel costs need to be considered. This will for allow both qualitative and quantitative economic analyses of different installation alternatives. First, required system capacity should be calculated. This is the maximum load. A total capacity of 241 horsepower is required for this applica8100 kBtu hour hp hour ) = 241 hp ( 33.475 kBtu
System Fundamentals
Boiler Selection
As this steam generating facility is replacing an existing one, pressure is already set at 10 psig. This system operating constraint allows the use of a 15 psi boiler which falls under Section IV of the ASME code. In addition to pressure requirements, steam quality requirements need to be met. The customers system/application requirement is 98%. Most boilers offer 98.5% steam quality at low pressure; therefore this is not a limitation. The large amount of idle time and low-load ring apparently suggest a two boiler installation (boilers operate most efciently near their rated capacity), with a large boiler for winter and a smaller model for spring and fall. Reviewing the fuel bill, however, indicates that an improvement in efciency would not justify increased installation, maintenance and capital costs that the customer wishes to minimize. Furthermore, there is no need for back-up in this application. Therefore, the recommendation is to install a single boiler. However, highturndown would be desirable to prevent excessive cycling. With the necessary capacity calculated, and the number of boilers to be installed decided, several boiler types can be ruled out immediately. Neither the Vertical Firetube nor the Model 4 Watertube Boilers are available in sufcient size for this system. At the opposite extreme, the load is far too small for an industrial watertube boiler. Remaining boilers include the rebox, retube, extube, electric and cast iron boilers. The cast iron boiler may be ruled out because of its higher initial cost; the electric may be ruled out because of higher operating costs. The remaining boilers, the rebox, retube and extube all are good choices for heating loads requiring low pressure steam. Instantaneous load is not an issue with a heating load. Likewise, there are no large load swings to consider. An application under federal emission regulations (NSPS) needs to be submitted because this installation is capable of using over 10 MMBTU/hr. There are no federal emissions requirements for this boiler because of the fuels selected. Local permits for construction and operation will also be required. Furthermore, it is desirable that the boiler be UL listed. There are no current local emission requirements, although they are expected to occur in the near future as the site is located in an ozone nonattainment area. To minimize maintenance, a boiler with 5 square feet of heating area per horsepower should be selected. The large water chamber and surface area reduce the need for cleaning, and minimize upsets caused in water treatment. A turndown capability increased from the standard 4-1 would further reduce maintenance and prolong boiler life. A 10-1 turndown, standard on the CB and CB (LE) [low emission] Firetube Boilers (250-800 hp), would result in signicant fuel savings in this
tion. Next, approximate fuel costs are calculated using the following:2
total load =
(loadi) (hoursi)
total load = 2160 hrs 650 kBtu/hr + 1440 2500 kBtu/hr = 5,004,000 kBtu total fuel cost = (total load) ($/MMBtu)
where = system efficiency (decimal) 1 $4.50 (5,004,000 MBtu) 0.6 MMBtu
( ) = $37,530
__________
2. Efciency should be set to 80% for process loads and 60% for heating loads. In a heating application such as this one, the operating efciency of the system may be much lower than the stack efciency of the boiler. The reason for this is that the boiler may re for only a few minutes in the morning. During the long off-cycle, heat is transferred from the boiler to its surroundings, allowing the steam contained within the boiler to cool and condense. When steam is again required, this lost heat must be replaced through several minutes of operation before steam may be supplied. Typical efciencies for this type of operation range from 50 to 75%.
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System Fundamentals
application. In a heating system such as this, eight to twelve cycles per hour are common. The 10-1 turndown drastically reduces such excessive cycling and decreases purge energy losses and cycling wear on components. Both the CB and CB (LE) Firetube Boilers guarantee steam quality above the system requirements. The certainty of a future tightening of emission regulations leads to a decision in favor of the 60 ppm CB (LE) Firetube Boiler3. Although both the rebox and extube boilers may be retrotted with low NOx burners, it is done at considerable cost. The CB (LE) Firetube Boilers ability to meet all future emission regulations, along with its fuel savings, 10-1 turndown, and low cost for emissions reduction, make it the best choice. The customer currently carries uninterruptable gas service, paying $4.50/MMBtu. The customer has the opportunity for savings by switching to a dual fuel burner, which would allow for interruptible service. With the gas cost reduced to $3.50/ MMBtu, and assuming that light oil at $4.20/MMBtu would be used 20% of the time, the resultant fuel bill is $30,490, or a $7,040 savings. The nal choice in this example will be a 250 horsepower 60 ppm CB (LE) Firetube Boiler with a dual fuel burner. As this is a heating load, and no expansion is foreseen, the 20% oversizing used in boiler selection for some systems is not necessary here. In this application, the CB (LE) Firetube Boiler was selected due to high turndown capability and the ability to meet future emissions regulations. These features compensate for the higher capital costs of other boiler choices which could meet demand.
Steam Systems
A rule of thumb for tanks is to have a fteen minute water supply for boiler feed systems and a ten minute supply for deaerating systems. A larger tank may be used for systems with high condensate return, and a smaller tank for systems with a high percentage of make-up. In this system, a fteen minute water supply corresponds to 2100 lb, or 253 gallons. A 270 gallon tank will be specied, allowing for the high percentage condensate return. In a heating system with a retube boiler there is neither a large load swing nor a necessity for precise boiler water level control. Therefore, an intermittent operation turbine style pump will be selected to minimize system cost. As the feedwater temperature is well below 215 F, there is no need for high temperature pump seals. Duplex pumps will be specied to minimize maintenance downtime.
Water Treatment
Water treatment options include chemical, deaeration, softening and ltering. A test result yielded the results in Table I3-4 The limits for silica, alkalinity and dissolved solids are all limits for the boiler water itself. These can be controlled through blowdown (described below). The decision to control oxygen through chemicals has already been made. It will be necessary to include a water softener in the water treatment system to remove hardness.
Blowdown
Manual bottom blowdown should be specied. The low fuel bills preclude the option of continuous blowdown with heat recovery. Additional equipment necessary includes a bottom blowdown separator and aftercooler. These are necessary to reduce the blowdown water temperature to the maximum 120F.
Condensate Return And Feedwater System

This system has 90% condensate return. This yields a makeup water requirement of 10%. If we assume a constant specic heat, and a make-up water temperature of 40 F, a direct mixing would result in a feedwater temperature of 184 F. It must rst be decided whether to use a boiler feed system or a deaerating system. In either case, this system must consist of a water reservoir, a stand (to provide sufcient net positive suction head for the pump) and a pump. In this system, the percentage of make-up water is low, and the feedwater mix temperature is relatively high. Oxygen in the system may be controlled by chemicals. These conditions, coupled with an already low annual fuel cost, decide against additional spending for a deaerating system. ________________
3. The 60 ppm CB (LE) Boiler may be converted to 30 or 20 ppm at low cost. The 60 ppm model has lower electric demands and is predicted to meet all future requirements.
Table I3-4. Water Test Results and Limits

SUBSTANCE Oxygen Hardness Suspended Matter pH Silica Total Alkalinity Dissolved Solids TEST RESULT 6 ppm 86 ppm 0.1 ppm 6.8 10 ppm 100 ppm 500 mho/cm LIMITS <0.007 ppm <5.0 ppm <0.15 ppm 7.0-10.5 <150 ppm <700 ppm <7000 mho/cm
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Steam Systems
Efficiency Enhancement
The small annual fuel bills rule out a reasonable return on investment for efciency enhancing equipment such as an economizer, oxygen trim or blowdown heat recovery. On large systems selecting such options may be the wise economic decision.
System Fundamentals
System Schematic
A schematic of the resulting system in shown in Figure I3-5.
MAKE-UP WATER 90% CONDENSATE RETURN 200 STACK
WATER SOFTENER
10 PSIG STEAM
STEAM HANDLING, HEATING AND CONDENSATE RETURN SYSTEMS
250 HP CB (LE) BOILER
PACKAGED BOILER FEED SYSTEM
BOTTOM BLOWDOWN
CHEMICAL FEED SYSTEM
COLD WATER SUPPLY
STEAM SEPARATOR/ BLOWDOWN AFTERCOOLER
TO DRAIN
Figure I3-5. Example of System Conguration
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Section I4
General Engineering Data
CONTENTS STEAM PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-3 Example for Steam Pipe Chart, Pounds per Minute to Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-3 Example for Steam Pipe Chart, Pounds per Minute to Feet per Minute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-3 WATER PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-3 Hot Water Boiler Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-3 Feedwater Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-3 NATURAL GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-3 FUEL OIL PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-3 EQUIVALENT LENGTHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-10 STACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-10 Why Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-10 Stack Draft on CB Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-10 Stack Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-10 Stack Condensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-10 Stack Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-11 Stack Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-11 Stack Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-11 Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-11 FACTORS OF EVAPORATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-12 THERMODYNAMIC PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-12 Fuel Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-12 Fuel Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-12 Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-18 Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-19 31 UNIT CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-31 UNIT CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-30 STANDARD ASSOCIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-43 ILLUSTRATIONS Figure I4-1. Steam Pipe Chart - Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-4 Figure I4-2. Steam Pipe Chart - Steam Velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-5 Figure I4-3. Pressure Drop for Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-6 Figure I4-4. Typical Stack Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-11 Figure I4-5. Typical Stack Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-11 Figure I4-6. Rain Cap Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-15 Figure I4-7. Fuel Oil Viscosity and Temperature Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-15
I4-1
02-02
System Fundamentals
TABLES Table I4-1. Gas Line Capacities, Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-7 Table I4-2. Oil Piping Pressure Drop (Viscosity = 40 SSU and Specific Gravity = 0.9) . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-8 Table I4-3. Oil Piping Pressure Drop (Viscosity = 100 SSU and Specific Gravity = 0.94) . . . . . . . . . . . . . . . . . . . . . . . . . .I4-8 Table I4-4. Oil Piping Pressure Drop (Viscosity = 500 SSU and Specific Gravity = 0.94) . . . . . . . . . . . . . . . . . . . . . . . . . .I4-8 Table I4-5. Oil Piping Pressure Drop (Viscosity = 1000 SSU and Specific Gravity = 0.96) . . . . . . . . . . . . . . . . . . . . . . . . .I4-9 Table I4-6. Oil Piping Pressure Drop (Viscosity = 5000 SSU and Specific Gravity = 0.96) . . . . . . . . . . . . . . . . . . . . . . . . .I4-9 Table I4-7. Equivalent Length of Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-10 Table I4-8. Single Boiler Vent or Stack Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-12 Table I4-9. Multiple Boilers Common Breeching and Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-12 Table I4-10. Pounds of Dry Saturated Steam per Boiler Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-13 Table I4-11. Typical Units for Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-13 Table I4-12. Detailed Requirements for Fuel Oils - Properties of Fuel Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-16 Table I4-13. Detailed Requirements for Fuel Oil Grade of Fuel Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-17 Table I4-14. Thermal Properties of Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-18 Table I4-15. Saturated Steam Properties, Temperature Table (Sheet 1 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-19 Table I4-16. Saturated Steam Properties, Pressure Table (Sheet 1 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-26 Table I4-17. Temperature Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-31 Table I4-18. Conversion Factors (Sheet 1 of 9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-32 Table I4-19. pH Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-40 Table I4-20. Salinity Indicating Readings Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-40 Table I4-21. Useful Physical Constants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-40 Table I4-22. Conversions Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-41 Table I4-23. Approximate Common Equivalents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-42 Table I4-24. Conversions Accurate to Parts per Million . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-42 This section consists of four primary areas. The first includes information to assist in sizing of steam, water, natural gas, and fuel oil piping. It also provides information on stacks. The second area, entitled Thermodynamic Properties, contains information on fuel oils, water, and steam, and covers viscosities, thermal properties of water, and steam tables covering the saturated region. The third area is Unit Conversion, which includes extensive unit conversion factors as well as an discussion of the difference between absolute and gauge pressure. Finally, the fourth area provides a list of standard associations.
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System Fundamentals
STEAM PIPING
Figure I4-1 allows pressure drop to be calculated given saturated steam pressure, ow rate and pipe diameter. Although the example covers calculating pressure drop, it is possible to work backwards to calculate pipe size, given pressure drop. Figure I4-2 is similar to Figure I4-1, but gives steam velocity instead of pressure drop. These illustrations are approximations for saturated steam only. Example for Steam Pipe Chart, Pounds per Minute to Pressure Drop A 500 hp boiler at 125 psig has a capacity of 17210 lbs/hr. Pressure drop will be found through 100 feet of 5" inside diameter pipe. First, convert pounds/hr to pounds/min by dividing by 60: 17210 60 = 285 Next, convert psig to absolute pressure by adding 14.7: 125 + 14.7 = 139.7 Now, plot 140 (the pressure) on its corresponding axis. This gives point A. Draw a line from A through B, which is the pipe diameter. Continue this line to the axis, X. This gives point C. A new line is plotted from point C, through the pounds of steam per minute axis (point D). This line ends at the pressure drop axis, for a drop of slightly more than 2.5 psi per 100 feet of pipe. Example for Steam Pipe Chart, Pounds per Minute to Feet per Minute The same specications will be used from the previous example. For this chart, begin with pounds/min. This gives point A. Draw the line through the proper point (in this case, point B) on the diameter axis to the X axis (point C). Next, plot from the X axis through the appropriate pressure (point D) to get steam velocity. In this example, that corresponds to 3200 feet per minute.
Hot Water Boiler Example In this example, pressure drop will be calculated for a 500 hp hot water boiler with a 20 F temperature differential. This corresponds to approximately 1700 gpm.
Btu 500 hp x 33472 hr x hp x 1 x lb x F x 1 hr x gallon = 1680 gallons 20 F 1 Btu 60 min 8.3 lb m in
The system will use 10" nominal size schedule 40 pipe. These two gures are plotted on their respective axis, giving points A and B. A line is drawn through these two points and the remaining two axis, giving a pressure drop of.57 psig (1.3 ft. of water) and a 6.4 feet per second velocity. Feedwater Example Now consider a 500 hp steam boiler. This requires approximately 40 gallons per minute of feedwater. A 2" nominal schedule 40 pipe will be used. Plotting these gure yields points C and D. Drawing a line through the points as before gives us a pressure drop of 2 psig, or 4.6 feet of water.
NATURAL GAS PIPING

Table I4-1 shows capacity of a natural gas line for a given initial pressure with a 5% pressure drop. For example, consider a 500 hp boiler, which requires 20,925 cu-ft / hr. A 5 psi initial pressure is available for 100 ft of pipe. To nd the correct pipe size, go to the line for initial gas pressure reading 5 pounds. Now move to the right, until a number larger than 20,925 appears. In this case, the rst greater number is 30,500. The number at the top of that column shows the appropriate pipe size, in this case 4". Table I4-1 assumes gas at 60 F, 1000 Btu/ cu-ft, and a specic gravity of 0.619.
FUEL OIL PIPING

Tables I4-2 through I4-6 show pressure drop for liquids with specic gravities and viscosities in the ranges found for numbers 2 through 6 fuel oils. To use these tables, select the table with the appropriate viscosity for the oil that is being used. (An oil viscosity chart is provided later in this section in Figure I4-7.) Select the line corresponding to the required ow, and the column corresponding to the nominal pipe size. The intersection will give the pressure drop in psi per 100 feet of equivalent pipe length. For example, a typical No. 2 fuel oil has a viscosity 40 SSU. A 500 hp boiler requires up to 115 gallons per hour of No. 2 oil. Using Table I4-2, and specifying a 1-inch nominal pipe size, gives 0.1 psi pressure drop at 100 gph, and 0.2 at 150 gph. Linear interpolation gives 0.13 psi pressure drop per 100 equivalent feet of pipe. Note that heavy oils require a return line, which increases total ow requirements.
WATER PIPING
Figure I4-3 allows pressure drop in psi or ft. of water to be calculated for a given ow and pipe size. Like Figures I4-1 and I4-2, working backwards will allow pipe size to be calculated for a target pressure drop. This gure will work with either water ow in a hot water system boiler or feedwater to a steam boiler. This assumes a constant viscosity and density for water over this range of temperatures, but should not cause signicant error.
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System Fundamentals
I4-4
02-02
Figure I4-1. Steam Pipe Chart - Pressure Drop
System Fundamentals
Illustration intentionally deleted.
Figure I4-2. Steam Pipe Chart - Steam Velocity
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02-02
Figure I4-3. Pressure Drop for Water
System Fundamentals
Table I4-1. 13
IINITIAL GAS PRESSUR E 4 water 5 water 6 water 7 water 8 water 9 water 10 water 11 water 12 water 1/2 psi 3/4 psi 1 psi 1-1/4 psi 1-1/2 psi 1-3/4 psi 2 psi 2-1/2 psi 3 psi 3-1/2 psi 4 psi 4-1/2 psi 5 psi 6 psi 8 psi 10 psi GAS LINE CAPACITIES (CU-FT/HR THROUGH 100 FT LENGTH) TOTAL PRESS .DROP 1/2 0.2 0.25 0.30 0.35 0.40 0.45 0.50 0.55 0.6 .025 psi .038 psi .050 psi .062 psi .075 psi .088 psi .100 psi .125 psi .150 psi .175 psi .200 psi .225 psi .250 psi .300 psi .400 psi .500 psi 23 26 28 31 33 35 37 38 40 43 53 62 70 77 84 91 103 114 125 135 146 155 174 211 246 3/4 52 58 64 69 74 79 83 87 91 98 121 141 159 175 191 205 233 259 283 307 330 352 395 477 556 1 104 117 128 139 148 158 166 175 183 197 243 282 319 351 382 412 467 519 568 615 661 706 792 957 1120 1-1/4 230 257 282 305 327 347 366 385 402 433 534 622 702 773 842 906 1030 1140 1250 1350 1460 1550 1740 2110 2460 DIAMETER OF PIPE IN INCHES 1-1/2 358 400 439 475 508 540 569 598 625 673 831 967 1090 1200 1310 1410 1600 1780 1940 2110 2260 2420 2710 3280 3820 2 724 811 889 962 1030 1090 1150 1210 1280 1360 1680 1960 2210 2440 2650 2850 3240 3600 3940 4270 4580 4890 5490 6640 7730 2-1/2 1180 1320 1450 1570 1680 1780 1880 1980 2060 2220 2750 3190 3600 3970 4320 4660 5280 5870 6420 6960 7480 7980 8960 10800 12600 3 2150 2410 2640 2860 3060 3250 3430 3600 3760 4050 5000 5820 6570 7240 7870 8480 9620 10700 11700 12700 13600 14500 16300 19700 23000 4 4510 5050 5540 5990 6410 6810 7180 7550 7890 8590 10500 12200 13800 15200 16500 17800 20200 22400 24500 26600 28500 30500 34200 41300 48200 5 8210 9190 10100 10900 11700 12400 13100 13700 14300 15400 19100 22200 25000 27600 30000 32300 36700 40800 44600 48300 51900 55400 62200 75200 87600 6 13400 14900 16400 17700 19000 20200 21300 22300 23300 25100 31100 36100 40800 44900 48900 52600 59000 66300 72600 78700 84500 90200 101000 122000 143000 8 27300 30600 33500 36300 38800 41200 43500 45700 47700 51400 63500 73800 83300 91800 99900 108000 122000 136000 148000 161000 173000 184000 207000 250000 292000
For total lengths other than 100 ft, multiply the capacity shown in the table by the factor corresponding to the desired length as follows:
Length of pipe in ft Multiplier
10 3.16
15 2.58
25 2.00
50 1.41
100 1.00
150 .817
200 .707
250 .632
300 .577
350 .535
400 .500
500 .447
For pressures and diameters not shown, consult you local Cleaver-Brooks authorized representative. This table shows gas ow capacities of pipes from 1/2 to 8 diameter, based upon a pressure drop of 5% of the initial gas pressure for 100-ft. length of pipe. Turbulent ow is assumed, hence the non-linear ratio of length to capacity.
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System Fundamentals
Table I4-2. Oil Piping Pressure Drop (Viscosity = 40 SSU and Specic Gravity = 0.9)
FUEL OIL FLOW RATE (GPH) 25 50 75 100 150 200 250 300 400 500 600 700 NOMINAL PIPE SIZE (INCHES) 0.5 0.3 0.6 0.9 1.1 3.6 6.0 8.9 12.3 20.3 30.5 42.2 55.6 0.75 0.1 0.2 0.3 0.4 0.9 1.6 2.3 3.2 5.3 7.9 11.0 14.5 1 0.0* 0.1 0.1 0.1 0.2 0.5 0.7 1.0 1.7 2.5 3.5 4.6 1.5 0.01 0.01 0.02 0.03 0.04 0.05 0.06 0.13 0.22 0.32 0.45 0.59 2 0.00* 0.00 0.01 0.01 0.01 0.02 0.02 0.03 0.007 0.10 0.13 0.18 2.5 0.001 0.002 0.003 0.005 0.007 0.009 0.011 0.014 0.018 0.042 0.058 0.076 3 0.000* 0.001 0.001 0.002 0.003 0.004 0.005 0.006 0.008 0.010 0.020 0.027 4 0.000* 0.000* 0.000* 0.001 0.001 0.001 0.002 0.002 0.003 0.003 0.004 0.007
NOTE: Pressure Drop (psig) per 100 equivalent ft of pipe for a fuel oil viscosity of 40 SSU, specic gravity of 0.9 * Negligible pressure drop.
FUEL OIL FLOW RATE (GPH) 25 50 75 100 150 200 250 300 400 500 600 700 NOMINAL PIPE SIZE (INCHES) 0.5 3.9 7.8 11.6 15.5 23.3 31.1 38.8 46.6 62.1 77.6 93.2 108.7 0.75 1.3 2.5 3.8 5.0 7.6 10.1 12.6 15.1 20.2 25.2 30.2 35.3 1 0.5 1.0 1.4 1.9 2.9 3.8 4.8 5.8 7.7 9.6 11.5 13.4 1.5 0.1 0.2 0.3 0.3 0.5 0.7 0.9 1.0 1.4 1.7 2.1 2.4 2 0.03 0.06 0.10 0.13 0.19 0.25 0.32 0.38 0.51 0.64 0.76 0.89 2.5 0.02 0.03 0.05 0.06 0.09 0.13 0.16 0.19 0.25 0.31 0.38 0.44 3 0.007 0.013 0.020 0.026 0.039 0.052 0.066 0.079 0.10 0.13 0.16 0.18 4 0.002 0.004 0.007 0.009 0.013 0.018 0.022 0.027 0.035 0.044 0.053 0.062
NOTE: Pressure Drop (psig) per 100 equivalent ft of pipe for a fuel oil viscosity of 100 SSU, specic gravity of 0.94
FUEL OIL FLOW RATE (GPH) 25 50 75 100 150 200 250 300 400 500 600 700 NOMINAL PIPE SIZE (INCHES) 0.5 7.8 15.6 23.5 31.3 46.9 62.6 78.2 93.9 125.1 156.4 187.7 219.0 0.75 2.5 5.1 7.6 10.2 15.2 20.3 25.4 30.5 40.6 50.8 69.9 71.1 1 1.0 1.9 2.9 3.9 5.8 7.7 9.7 11.6 15.5 19.3 23.2 27.1 1.5 0.2 0.3 0.5 0.7 1.0 1.4 1.7 2.1 2.8 3.5 4.2 4.9 2 0.06 0.13 0.19 0.26 0.38 0.51 0.64 0.77 1.03 1.28 1.54 1.80 2.5 0.03 0.06 0.019 0.13 0.19 0.25 0.32 0.38 0.50 0.63 0.76 0.88 3 0.013 0.026 0.040 0.053 0.079 0.106 0.132 0.159 0.21 0.26 0.32 0.37 4 0.004 0.009 0.013 0.018 0.027 0.036 0.045 0.053 0.071 0.089 0.107 0.125
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System Fundamentals
FUEL OIL FLOW RATE (GPH) 25 50 75 100 150 200 250 300 400 500 600 700 NOMINAL PIPE SIZE (INCHES) 0.5 16.0 32.0 48.0 64.0 96.0 128.0 160.1 192.1 256.1 320.1 384.1 448.1 0.75 5.2 10.4 15.6 20.8 31.2 41.6 52.0 62.4 83.1 103.9 124.7 145.5 1 2.0 4.0 5.9 7.9 11.9 15.8 19.8 23.7 31.7 39.6 47.5 55.4 1.5 0.4 0.7 1.1 1.4 2.1 2.9 3.6 4.3 5.7 7.1 8.6 10.0 2 0.13 0.26 0.39 0.52 0.79 1.05 1.31 1.57 2.10 2.62 3.15 3.67 2.5 0.06 0.13 0.19 0.26 0.39 .052 0.64 0.77 1.03 1.29 1.55 1.81 3 0.027 0.054 0.081 0.108 0.162 0.216 0.270 0.324 0.43 0.54 0.65 0.76 4 0.009 0.018 0.027 0.036 0.055 0.073 0.091 0.109 0.146 0.182 0.219 0.255
FUEL OIL FLOW RATE (GPH) 25 50 75 100 150 200 250 300 400 500 600 700 NOMINAL PIPE SIZE (INCHES) 0.5 80 160 240 320 480 641 801 961 1281 1601 1922 2242 0.75 26 52 78 104 156 208 260 312 416 520 624 728 1 10 20 30 40 59 79 99 119 158 198 238 277 1.5 2 4 5 7 11 14 18 21 29 36 43 50 2 1 1 2 3 4 5 7 8 11 13 16 18 2.5 0.3 0.6 1.0 1.3 1.9 2.6 3.2 3.9 5.2 6.5 7.7 9.0 3 0.1 0.3 0.4 0.5 0.8 1.1 1.4 1.6 2.2 2.7 3.2 3.8 4 0.05 0.09 0.14 0.18 0.27 0.36 0.46 0.55 0.73 0.91 1.09 1.28
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System Fundamentals
cic limitations on stack/breeching size criteria. Other typical pressure drops for the Model CB Boilers are as follows: A. A 4 inch to 12 inch WC drop is taken across the burner in order to provide high turbulence, good mixing of fuel and air, and high CO2 readings for most efcient combustion, B. A 2 inch to 6 inch WC drop is taken through the four (4) gas passes of the boiler in order to maintain high ue gas velocities and thus increase heat transfer. For other boiler types, the draft variation could be similar. Consult you local Cleaver-Brooks authorized representative. If the stack height is over 150 feet or if an extremely large breeching and stack combination cause excessive draft, a simple barometric damper can be located in the breeching close to the stack or chimney. This damper should only be considered after burner adjustment problems have been experienced and are serious enough to warrant corrective action. Automatic or special draft controls are not required and are not recommended for use with Cleaver-Brooks boilers. Stack Location An off-set type stack connection to the stub vent on the boiler is preferred and recommended. A direct vertical connection can also be made, if required. A typical stack location diagram is shown in Figure I4-4. Stack Condensation
EQUIVALENT LENGTHS
Table I4-7 shows equivalent lengths of pipe for various plumbing ttings. Find the nominal pipe size being used in the leftmost column. For each tting, read the value under the appropriate heading and add this to the length of piping. This allows total system pressure drop to be calculated. (This is valid for any uid.) Table I4-7. Equivalent Length of Pipe
EQUIVALENT LENGTH OF STRAIGHT PIPE (FEET) PIPE SIZE STANDARD STANDARD ELBOW TEE 4 5 6 8 9 11 13 16 20 25 30 35 9 11 13 16 18 21 26 32 42 55 65 75 GATE GLOBE ANGLE VALV E VALVE FULL VALVE FULL FULL OPEN OPEN OPEN 0.9 1.2 1.4 1.6 2.0 2.2 2.8 3.4 4.5 5.5 6.5 8.0 41 54 64 80 91 110 140 155 210 270 320 370 21 27 32 40 45 55 70 81 110 140 160 190
1-1/2 2 2-/1/2 3 3-1/2 4 5 6 8 10 12 14
This table contains the number of feet of straight pipe usually allowed for standard ttings and valves.
STACKS
NOTICE
For boilers over 800 hp, consult your local CleaverBrooks authorized representative. Why Used The only purpose of a vent stack on Cleaver-Brooks boilers is to conduct the products of combustion to a point of safe discharge (atmosphere). Forced draft design eliminates the need for a stack designed to create a draft. Stack Draft on CB Boilers Depending on the boiler model, draft variations of as much as 1/2 inch W.C. at the boiler vent outlet will have no appreciable effect on the Model CB burner operation. This is due to the high pressure drops which are taken from the burner inlet to the boiler vent outlet. See individual boiler sections for spe-
The amount of condensation in the stack will vary with the type of fuel and with the stack gas temperature. Normally, the temperature of the ue gas leaving the boiler is higher than the temperature of the steam or the water in the boiler. Stack condensation is most likely to occur on heating boiler installations where light loads and intermittent ring cause a cool stack condition, which results in condensation of the water vapor in the ue gas. This condensed water accelerates corrosion of steel stacks or breechings. The following items should be considered when planning to keep stack condensation to a minimum: A. The boiler should be sized as close as possible to the true heat load. Oversized boilers should be avoided. B. Masonry stacks have better heat holding characteristics than steel stacks. C. When steel stacks are used, stack insulation will help prevent heat loss. D. An off-set stack (recommended) with bottom clean-out and drain connection will prevent any condensed water from draining back into the boiler.
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System Fundamentals
STACK TIGHT-SEAL CLEANOUT
STACK
CLEANOUT
DRAIN CONNECTION
VERTICAL STACK CONNECTION
OFFSET STACK CONNECTION (RECOMMENDED)
Figure I4-4. Typical Stack Locations Stack Weight Boiler vent outlets will withstand a maximum direct vertical load of 2,000 pounds. This loading must include the effect of wind and guy wires. Stack Construction The stack can be terminated several feel above the top of the roof. (State and local codes may govern the stack height above the roof.) If down drafts are unavoidable, the stack outlet can be provided with a ventilator such as the Breidert Air-XHauster or equivalent. See Figure I4-5 for typical stack construction details. Stack Material Minimum 12 gauge steel is recommended for stack sections. If the stack will be inaccessible, the use of a non-corrosive material (e.g. glass lining) should be considered. A rain cap or hood should be used at the top of the stack to minimize the entrance of rain or snow. See Figure I4-6 for typical rain cap details. Stack/Breeching Size Criteria The design of the stack and breeching system must provide a draft at the boiler outlet(s) which is within the required limits. Consideration must be given to operation variations (including number of boilers), purge cycles, outside wind and air conditions, and the impact of other variables that may impact draft conditions. Safe and reliable burner performance requires good stack design.See Table I4-8 and further detail in the individual boiler sections.
(Rev 7/97)
02-02
RAIN CAP
2-0 MIN AS REQUIRED BY LOCAL CODE B A STACK DIA. C TOP OR ROOF
BOILER HP 15-20 25-40, 50A 50-60 70-100A, 125A 125-200 250-350 400-800
STACK DIAMETER (IN.) 6 8 10 12 16 20 24
A (IN.) 15 20 25 30 40 50 60
B (IN.) 15 20 25 30 40 50 60
C (IN.) 12 16 20 24 32 40 48
Figure I4-5. Typical Stack Construction Stack and breeching sizes should always be provided by a reputable stack supplier who will design the stack and breeching system based on the required system layout. Your local Cleaver-Brooks authorized representative is capable of assisting in your evaluation of the stack/breeching design.
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System Fundamentals
Table I4-9. Multiple Boilers Common Breeching and Stack
C D MINIMUM RECOMMENDED STACK DIAMETERA NUMBER OF BOILERS BOILER HP 2 3 4
100 FT 200 FT 100 FT 200 FT 100 FT 200 FT STACK DIA STACK A (IN.) DIAMETER (IN.) 6 8 10 12 16 20 24 24 5 6 8 9 12 15 18 21 B (IN.) 12 16 20 24 32 40 48 48 C (IN.) 3 4 5 6 8 10 12 12 D (IN.) 3 4 5 6 8 10 12 12 15-20 25-40 50A, 50-60 70-100. 100A 125-200 250-350 400-600 700-800 9" 11" 13" 16" 21" 26" 32" 38" 10" 12" 14" 17" 22" 28" 34" 42" 10" 13" 15" 19" 24" 32" 38" 44" 12" 14" 16" 20" 26" 34" 40" 48" 11" 14" 17" 21" 28" 34" 421" 48" 12" 16" 18" 23" 30" 40" 46" 52"
BOILER HP 15-20 25-40, 50A 50-60 70-100A, 125A 125-200 250-350 400-600 700-800
Notes: A. No barometric damper required.
Figure I4-6. Rain Cap Details Table I4-8. Single Boiler Vent or Stack Diameter
BOILER HP 15-20 25-40, 50A 50-60 70-100, 100A, 125A 125-200 250-350 400-800 STACK DIAMETER Same as Boiler Vent Outlet Size (Inches OD) 6 8 10 12 16 20 24
Referring to Table I4-10, at 100 F and 10 psig, the following factors can be obtained: 30.6 pounds of steam per boiler horsepower. This factor is used to convert the from and at 212 F rating basis: 3060 30.6 = 100 hp rated boiler should be selected.
THERMODYNAMIC PROPERTIES
Fuel Oils
The purpose of this section is to provide technical information on the various grades of fuel oils commonly used in the generation of steam and hot water. The American Society for Testing and Materials (ASTM) has established numerous tests to identify fuel oil properties and specications that allow the fuel to be identied by a grade, which can be No. 1, 2, 4, 5, or 6. Grades No. 1 and No. 2 are considered distillate oil, while grades No. 4 through No. 6 are considered residual oils. Distillate oils have a low viscosity and are relatively easy to burn. Residual oils have a high viscosity and often require heating to pump and atomize. Residual oils will also have much higher emission levels, and their use is frequently regulated because of this. The viscosity ranges of fuel oils are shown in Figure I4-7.
FACTORS OF EVAPORATION
The factor of evaporation is used to adjust rated boiler output (from and at 212 F) to actual job or operating conditions. Available feedwater temperature and expected boiler operating pressure (psig) affect the boiler output ratings which are based on from and at 212 F. Example: A boiler is to have an output of 3060 pounds of steam per hour when operating at 10 psig with feedwater at 100 F. What should the boiler rating be on the basis of from and at 212 F.
Fuel Oil Specifications

The limits on fuel oil properties are shown in Tables I4-11, I412, and I4-13. Denitions of these properties are discussed next.
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System Fundamentals
Table I4-10. Pounds of Dry Saturated Steam per Boiler Horsepower
Table I4-11. Typical Units for Fuels

ITEM No. 2 Oil No 5 Oil No. 6 Oil 1 Therm 1 kW GROSS HEATING VALUES 140,000 Btu/gal. 148,000 Btu/gal. 150,000 Btu/gal. 100,000 Btu 3,413 Btu
Ultimate Analysis - Ultimate analysis is a statement of the quantities of the various elements of which a substance is composed. For fuel oils, this will likely state higher heating values and specic gravity in addition to the percentages by weight of each element. Flash Point - The ash point of a fuel oil is an indication of the maximum temperature at which it can be stored and handled without serious re hazard. The minimum permissible ash point is usually regulated by federal, state or municipal laws and is based on accepted practice in handling and use. Pour Point - The pour point is an indication of the lowest temperature at which a fuel oil can be stored and still be capable of owing under very low forces. The pour point is prescribed in accordance with the conditions of storage and use. Higher pour
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point fuels are permissible where heated storage and adequate piping facilities are provided. An increase in pour point can occur when residual fuel oils are subjected to cyclic temperature variations that can occur in the course of storage or when the fuel is preheated and returned to storage tanks. To predict these properties, Test Method D 3245 may be required. Water and Sediment - Appreciable amounts of water and sediments in a fuel oil tend to cause fouling of facilities for handling it, and cause trouble in burner mechanisms. Sediment may accumulate in storage tanks and on lter screens or burner parts, resulting in obstructions to ow of oil from the tank to the burner. Water in distillate fuels can cause corrosion of tanks and equipment, and can cause emulsions in residual fuels. Carbon Residue - The carbon residue of a fuel is a measure of the carbonaceous material left after all the volatile components are vaporized in the absence of air. It is a rough approximation of the tendency of a fuel to form deposits in vaporizing burners, such as pot-type and sleeve burners, where the fuel is vaporized in an air-decient atmosphere. To obtain measurable values of carbon residue in the lighter distillate fuel oils, it is necessary to distill the oil to remove 90% of it in accordance with Section 9 of Test Method D 524, and determine the carbon residue concentrated in the remaining 10% bottoms. Ash - The amount of ash is the quantity of noncombustible material in an oil. Excessive amounts can indicate the presence of materials that cause high wear of burner pumps and valves, and contribute to deposits on boiler heating surfaces. Distillation - The distillation test shows the volatility of a fuel and the ease with which it can be vaporized. The test is of greater signicance for oils that are to be burned in vaporizing type burners than for the atomizing type. For example, the maximum 10% and 90% distilled temperatures are specied for grade No. 1 fuel. The limiting10% value assures easy starting in vaporizing type burner and the 90% limit excludes heavier fractions that would be difcult to vaporize. The limits specied for grade No. 2 heating oil dene a product that is acceptable for burners of the atomizing type in household heating installations. Distillation limits are not specied for fuel oils of grades No. 4, 5, and 6. Viscosity Limits for Grades Nos1214 1 and 2 - The viscosity of an oil is a measure of its resistance to ow. In fuel oil it is highly signicant since it indicates both the relative ease with which the oil will ow or can be pumped and the case of atomization. Viscosity limits for No. 1 and No. 2 grades are specied to help maintain uniform fuel ow in appliances with gravity ow, and to provide satisfactory atomization and constant ow rate through the small nozzles of household burners. For the
System Fundamentals
heavier grades of industrial and bunker fuel oils, viscosity is of major importance, so that adequate preheating facilities can be provided to permit them to be pumped to the burner and to provide good atomization. However, it is equally important that the maximum viscosity under the existing conditions be such that the oil can be pumped satisfactorily from the storage tank to the preheater. Density - Density alone is of little signicance as an indication of the burning characteristics of fuel oil. However, when used in conjunction with other properties, it is of value in mass-volume relationships and in calculating the specic energy (heating value) of an oil. Corrosion - The corrosion test serves to indicate the presence or absence of materials that could corrode copper, brass, and bronze components of the fuel system. This property is specied only for Nos. 1 and 2 distillate fuel oils. Limited sulfur content of fuel oil can be required to meet federal, state, or local legislation or regulations. Nitrogen - Nitrogen oxide emission regulations have been imposed on certain combustion facilities as a function of fuel nitrogen content. For purposes of these regulations, distillate fuels, low nitrogen residual fuels, and high nitrogen residual fuels have been dened by their nitrogen content. Installations are required to meet different emission standards according to the classication of the fuel being used. When regulations require such a distinction to be made, fuel nitrogen specications can be needed in the contractual agreement between the purchaser and the supplier.
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System Fundamentals
02-02
I4-15
Figure I4-7. Fuel Oil Viscosity and Temperature Curves
System Fundamentals
Table I4-12. Detailed Requirements for Fuel Oils - Properties of Fuel Oil
FUEL OIL GRADE PROPERTY ASTM TEST METHOD B No. 1 No. 2 No. 4 (Light) No. 4 No 5 (Light) No. 5 (Heavy) No. 6
Flash Point C min Water and sediment, % vol max Distillation temperature C 10% vol recovered, max 90% vol recovered, min max Kinematic viscosity at 40 C mm Minimum viscosity Maximum viscosity Kinematic viscosity at 100 C Minimum viscosity Maximum viscosity Ramsbottom carbon residue on 10% distillation residue % mass, max Ash, % mass, max Sulfur, % mass, max
E 2/s
D 93 D 1796 D 85 D 445 mm2/s D 524 D 482 D 129 D 130 D 1298
38 0.05 215 288 1.3 2.1
38 0.05 282 338 1.9 3.4
38 (0.50) 1.9 5.5

C
55 (0.50)C >5.5 24.0

D
55 (1.00)C
55 (1.00)C
60 (2.00)C
0.15 0.50 No. 3 850 -18
0.35 0.50 No. 3 876 -6
0.05 >876 -6
F
0.15 -6
5.0 8.9 0.10

D
9.0 14.9D 0.15
15.0 50.0D
H
Copper, strip corrosion rating, max, 3h at 50 C Density at 15 C, kg/m Minimum density Maximum density Pour Point C, ma
A G 3
D 97
It is the intent of these classications that failure to meet any requirement of a given grade does not automatically place an oil in the next lower grade unless in fact it meets all requirements of the lower grade. However, to meet special operating conditions modication of individual limiting requirements may be agreed upon among purchaser, seller, and manufacturer. test methods indicated are the approved referee methods.
B The C The
amount of water by distillation by Test Method D 95 plus the sediment by extraction by Test Method D 473 shall not exceed the value shown in the table. For Grade No.6 fuel oil, the amount of sediment by extraction shall not exceed 0.50 mass %, and a deduction in quantity shall be made for all water and sediment in excess of 1.0 mass %.
D Where low sulfur fuel oil is required, fuel oil falling in the viscosity range of a lower numbered grade down to and including No. 4 can be supplied by agreement between the purchaser and supplier. The viscosity range of the initial shipment shall be identied and advance notice shall be required when changing from one viscosity range and another. This notice shall be in sufcient time to permit the user to make the necessary adjustments. E
Other sulfur limits may apply in selected areas in the United States and in other countries. limit assures a minimum heating value and also prevents misrepresentation and misapplication of this product as Grade
F This
No. 2.
G
Lower or higher pour points can be specied whenever required by conditions of storage or use. When a pour point less than
-18 C is specied, the minimum viscosity at 40 C for grade No. 2 shall be 1.7 mm2/s and the minimum 90% recovered temperature shall be waived.
H Where low sulfur fuel oil is required, Grade No. 6 fuel oil will be classied as Low Pour (+15 C max) or High Pour (no max). Low Pour fuel oil should be used unless tanks and lines are heated.
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System Fundamentals
Table I4-13. Detailed Requirements for Fuel Oil Grade of Fuel Oil
CARBON POUR WATER & RESIDUE ON POINT F SEDIMENT % 10% MAX MAX RESIDUUM % MAX 0 trace 0.15 DISTILLATION TEMPERATURES, F ASH % MAX 10% POINT MAX 420 90% POINT MAX END POINT MAX 625
GRADE OF FUEL OIL
FLASH POINT F MIN
1. Distillate oil intended for vaporizing pot-type burners and other burners requiring this grade. 2. A distillate oil for general purpose domestic heating for use in burners not requiring No. 1. 4. An oil for burner installations not equipped with preheating facilities. 5.A residual type oil for burner installations equipped with preheating facilities. 6.An oil for use in burners equipped with preheaters permitting a high viscosity fuel,
100 or legal 100 or legal 130 or legal 130 or legal 130 or legal
20
0.10
0.35
675
20
0.50
0.10
1.00
0.10
2.00
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Water
The relevant properties of water are shown in Table I4-14.
System Fundamentals
Table I4-14. Thermal Properties of Water
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System Fundamentals
Steam
Steam properties are shown in Tables I4-15 and I4-16.
Table I4-15. Saturated Steam Properties, Temperature Table (Sheet 1 of 7)

ABS. PRESSURE TEMP F t 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 PSIA p 0.08854 0.09223 0.09603 0.09995 0.10401 0.10821 0.11256 0.11705 0.12170 0.12652 0.13150 0.13665 0.14199 0.14752 0.15323 0.15914 0.16525 0.17157 0.17811 0.18486 0.19182 0.19900 0.20642 0.2141 0.2220 0.2302 0.2386 0.2473 0.2563 0.2655 0.2751 0.2850 0.2951 0.3056 0.3164 0.3276 0.3390 0.3509 0.3631 0.3756 0.3886 0.4019 0.4156 0.4298 IN. HG p 0.1803 0.1878 0.1955 0.2035 0.2118 0.2203 0.2292 0.2383 0.2478 0.2576 0.2677 0.2782 0.2891 0.3004 0.3120 0.3240 0.3364 0.3493 0.3626 0.3764 0.3906 0.4052 0.4203 0.4359 0.4520 0.4686 0.4858 0.5035 0.5218 0.5407 0.5601 0.5802 0.6009 0.6222 0.6442 0.6669 0.6903 0.7144 0.7392 0.7648 0.7912 0.8183 0.8462 0.8750 SPECIFIC VOLUME (ft3/lb) SAT. LIQUID vf 0.01602 0.01602 0.01602 0.01602 0.01602 0.01602 0.01602 0.01602 0.01602 0.01602 0.01602 0.01602 0.01602 0.01602 0.01602 0.01603 0.01603 0.01603 0.01603 0.01603 0.01603 0.01603 0.01603 0.01603 0.01603 0.01603 0.01604 0.01604 0.01604 0.01604 0.01604 0.01604 0.01605 0.01605 0.01605 0.01605 0.01605 0.01605 0.01606 0.01606 0.01606 0.01606 0.01606 0.01607 EVAP. vfg 3306 3180 3061 2947 2837 2732 2632 2536 2444 2356 2271 2190 2112 2036.4 1964.3 1895.1 1828.6 1764.7 1703.2 1644.2 1587.6 1533.3 1481.0 1430.7 1382.4 1335.9 1291.1 1248.1 1206.6 1166.8 1128.4 1091.4 1055.7 1021.4 988.4 956.6 925.9 896.3 867.8 840.4 813.9 788.3 763.7 740.0 SAT. VAPOR vg 3306 3180 3061 2947 2837 2732 2632 2536 2444 2356 2271 2190 2112 2036.4 1964.3 1895.1 1828.6 1764.7 1703.2 1644.2 1587.6 1533.3 1481.0 1430.7 1382.4 1335.9 1291.1 1248.1 1206.7 1166.8 1128.4 1091.4 1055.7 1021.4 988.4 956.6 925.9 896.3 867.9 840.4 813.9 788.4 763.8 740.0 ENTHALPY (Btu/lb) SAT. LIQUID hf 0.00 1.01 2.02 3.02 4.03 5.04 6.04 7.04 8.05 9.05 10.05 11.06 12.06 13.06 14.06 15.07 16.07 17.07 18.07 19.07 20.07 21.07 22.07 23.07 24.06 25.06 26.06 27.06 28.06 29.06 30.05 31.05 32.05 33.05 34.05 35.05 36.04 37.04 38.04 39.04 40.04 41.03 42.03 43.03 EVAP. hfg 1075.8 1075.2 1074.7 1074.1 1073.6 1073.0 1072.4 1071.9 1071.3 1070.7 1070.1 1069.5 1068.9 1068.4 1067.8 1067.3 1066.7 1066.1 1065.6 1065.0 1064.4 1063.9 1063.3 1062.7 1062.2 1061.6 1061.0 1060.5 1059.9 1059.3 1058.8 1058.2 1057.6 1057.1 1056.5 1056.0 1055.5 1054.9 1054.3 1053.8 1053.2 1052.6 1052.1 1051.5 SAT. VAPOR hg 1075.8 1076.2 1076.7 1077.1 1077.6 1078.0 1078.4 1078.9 1079.3 1079.7 1080.2 1080.6 1081.0 1081.5 1081.9 1082.4 1082.8 1083.2 1083.7 1084.1 1084.5 1085.0 1085.4 1085.8 1086.3 1086.7 1087.1 1087.6 1088.0 1088.4 1088.9 1089.3 1089.7 1090.2 1090.6 1091.0 1091.5 1091.9 1092.3 1092.8 1093.2 1093.6 1094.1 1094.5 ENTROPY (Btu/lb,F) SAT. LIQUID sf 0.0000 0.0020 0.0041 0.0061 0.0081 0.0102 0.0122 0.0142 0.0162 0.0182 0.0202 0.0222 0.0242 0.0262 0.0282 0.0302 0.0321 0.0341 0.0361 0.0380 0.0400 0.0420 0.0439 0.0459 0.0478 0.0497 0.0517 0.0536 0.0555 0.0574 0.0593 0.0613 0.0632 0.0651 0.0670 0.0689 0.0708 0.0726 0.0745 0.0764 0.0783 0.0802 0.0820 0.0839 EVAP. sfg 2.1877 2.1821 2.1764 2.1709 2.1654 2.1598 2.1544 2.1489 2.1435 2.1381 2.1327 2.1274 2.1220 2.1167 2.1113 2.1060 2.1008 2.0956 2.0903 2.0852 2.0799 2.0747 2.0697 2.0645 2.0594 2.0544 2.0493 2.0443 2.0393 2.0343 2.0293 2.0243 2.0194 2.0145 2.0096 2.0047 1.9998 1.9950 1.9902 1.9854 1.9805 1.9757 1.9710 1.9663 SAT. VAPOR sg 2.1877 2.1841 2.1805 2.1770 2.1735 2.1700 2.1666 2.1631 2.1597 2.1563 2.1529 2.1496 2.1462 2.1429 2.1395 2.1362 2.1329 2.1297 2.1264 2.1232 2.1199 2.1167 2.1136 2.1104 2.1072 2.1041 2.1010 2.0979 2.0948 2.0917 2.0886 2.0856 2.0826 2.0796 2.0766 2.0736 2.0706 2.0676 2.0647 2.0618 2.0588 2.0559 2.0530 2.0502
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SPECIFIC VOLUME (ft3/lb) SAT. LIQUID vf 0.01607 0.01607 0.01607 0.01608 0.01608 0.01608 0.01608 0.01609 0.01609 0.01609 0.01609 0.01610 0.01610 0.01610 0.01610 0.01611 0.01611 0.01611 0.01612 0.01612 0.01612 0.01612 0.01613 0.01613 0.01613 0.01614 0.01614 0.01614 0.01615 0.01615 0.01615 0.01616 0.01616 0.01616 0.01617 0.01617 0.01617 0.01618 0.01618 0.01618 0.01619 0.01619 0.01620 0.01620 0.01620 0.01621 0.01621 0.01622 0.01622 0.01622 EVAP. vfg 717.1 694.9 673.6 653.0 633.1 613.9 595.3 577.4 560.1 543.4 527.3 511.7 496.6 482.1 468.0 454.4 441.2 428.5 416.2 404.3 392.8 381.7 370.9 360.4 350.3 340.6 331.1 321.9 313.1 304.5 296.1 288.1 280.3 272.7 265.3 258.2 251.3 244.6 238.2 231.9 225.8 219.9 214.2 208.6 203.25 198.02 192.93 188.01 183.23 178.59 SAT. VAPOR vg 717.1 694.9 673.6 653.0 633.1 613.9 595.3 577.4 560.2 543.5 527.3 511.7 496.7 482.1 468.0 454.4 441.3 428.5 416.2 404.3 392.8 381.7 370.9 360.5 350.4 340.6 331.1 321.9 313.1 304.5 296.2 288.1 280.3 272.7 265.4 258.3 251.4 244.7 238.2 231.9 225.8 219.9 214.2 208.7 203.27 198.03 192.95 188.02 183.25 178.61
System Fundamentals

ABS. PRESSURE TEMP F t 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 PSIA p 0.4443 0.4593 0.4747 0.4906 0.5069 0.5237 0.5410 0.5588 0.5771 0.5959 0.6152 0.6351 0.6556 0.6766 0.6982 0.7204 0.7432 0.7666 0.7906 0.8153 0.8407 0.8668 0.8935 0.9210 0.9492 0.9781 1.0078 1.0382 1.0695 1.1016 1.1345 1.1683 1.2029 1.2384 1.2748 1.3121 1.3504 1.3896 1.4298 1.4709 1.5130 1.5563 1.6006 1.6459 1.6924 1.7400 1.7888 1.8387 1.8897 1.9420 IN. HG p 0.9046 0.9352 0.9666 0.9989 1.0321 1.0664 1.1016 1.1378 1.1750 1.2133 1.2527 1.2931 1.3347 1.3775 1.4215 1.4667 1.5131 1.5608 1.6097 1.6600 1.7117 1.7647 1.8192 1.8751 1.9325 1.9915 2.0519 2.1138 2.1775 2.2429 2.3099 2.3786 2.4491 2.5214 2.5955 2.6715 2.7494 2.8293 2.9111 2.9948 3.0806 3.1687 3.2589 3.3512 3.4458 3.5427 3.6420 3.7436 3.8475 3.9539 ENTHALPY (Btu/lb) SAT. LIQUID hf 44.03 45.02 46.02 47.02 48.02 49.02 50.01 51.01 52.01 53.00 54.00 55.00 56.00 56.99 57.99 58.99 59.99 60.98 61.98 62.98 63.98 64.97 65.97 66.97 67.97 68.96 69.96 70.96 71.96 72.95 73.95 74.95 75.95 76.94 77.94 78.94 79.94 80.94 81.93 82.93 83.93 84.93 85.92 86.92 87.92 88.92 89.92 90.91 91.91 92.91 EVAP. hfg 1050.9 1050.4 1049.8 1049.2 1048.6 1048.1 1047.5 1046.9 1046.4 1045.8 1045.2 1044.7 1044.1 1043.5 1042.9 1042.4 1041.8 1041.2 1040.7 1040.1 1039.5 1038.9 1038.4 1037.8 1037.2 1036.6 1036.1 1035.5 1034.9 1034.3 1033.8 1033.3 1032.7 1032.1 1031.6 1031.0 1030.4 1029.8 1029.2 1028.7 1028.1 1027.5 1026.9 1026.3 1025.8 1025.2 1024.6 1024.0 1023.4 1022.9 SAT. VAPOR hg 1094.9 1095.4 1095.8 1096.2 1096.6 1097.1 1097.5 1097.9 1098.4 1098.8 1099.2 1099.7 1100.1 1100.5 1100.9 1101.4 1101.8 1102.2 1102.6 1103.1 1103.5 1103.9 1104.4 1104.8 1105.2 1105.6 1106.1 1106.5 1106.9 1107.3 1107.8 1108.2 1108.6 1109.0 1109.5 1109.9 1110.3 1110.7 1111.1 1111.6 1112.0 1112.4 1112.8 1113.2 1113.7 1114.1 1114.5 1114.9 1115.3 1115.8 ENTROPY (Btu/lb,F) SAT. LIQUID sf 0.0858 0.0876 0.0895 0.0913 0.0932 0.0950 0.0969 0.0987 0.1005 0.1024 0.1042 0.1060 0.1079 0.1097 0.1115 0.1133 0.1151 0.1169 0.1187 0.1205 0.1223 0.1241 0.1259 0.1277 0.1295 0.1313 0.1330 0.1348 0.1366 0.1383 0.1401 0.1419 0.1436 0.1454 0.1471 0.1489 0.1506 0.1524 0.1541 0.1559 0.1576 0.1593 0.1610 0.1628 0.1645 0.1662 0.1679 0.1696 0.1714 0.1731 EVAP. sfg 1.9615 1.9569 1.9521 1.9475 1.9428 1.9382 1.9335 1.9290 1.9244 1.9198 1.9153 1.9108 1.9062 1.9017 1.8972 1.8927 1.8883 1.8838 1.8794 1.8750 1.8706 1.8662 1.8618 1.8575 1.8531 1.8488 1.8445 1.8402 1.8359 1.8317 1.8274 1.8232 1.8190 1.8147 1.8106 1.8064 1.8023 1.7981 1.7940 1.7898 1.7857 1.7816 1.7776 1.7735 1.7694 1.7654 1.7614 1.7574 1.7533 1.7493 SAT. VAPOR sg 2.0473 2.0445 2.0416 2.0388 2.0360 2.0332 2.0304 2.0277 2.0249 2.0222 2.0195 2.0168 2.0141 2.0114 2.0087 2.0060 2.0034 2.0007 1.9981 1.9955 1.9929 1.9903 1.9877 1.9852 1.9826 1.9801 1.9775 1.9750 1.9725 1.9700 1.9675 1.9651 1.9626 1.9601 1.9577 1.9553 1.9529 1.9505 1.9481 1.9457 1.9433 1.9409 1.9386 1.9363 1.9339 1.9316 1.9293 1.9270 1.9247 1.9224
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02-02
System Fundamentals

ABS. PRESSURE TEMP F t 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 PSIA p 1.9955 2.0503 2.1064 2.1638 2.2225 2.2826 2.3440 2.4069 2.4712 2.5370 2.6042 2.6729 2.7432 2.8151 2.8886 2.9637 3.0404 3.1188 3.1990 3.281 3.365 3.450 3.537 3.627 3.718 3.811 3.906 4.003 4.102 4.203 4.306 4.411 4.519 4.629 4.741 4.855 4.971 5.090 5.212 5.335 5.461 5.590 5.721 5.855 5.992 6.131 6.273 6.417 6.565 6.715 IN. HG p 4.0629 4.1745 4.2887 4.4055 4.5251 4.6474 4.7725 4.9005 5.0314 5.1653 5.3022 5.4421 5.5852 5.7316 5.8812 6.0341 6.1903 6.3500 6.5132 6.680 6.850 7.024 7.202 7.384 7.569 7.759 7.952 8.150 8.351 8.557 8.767 8.981 9.200 9.424 9.652 9.885 10.122 10.364 10.611 10.863 11.120 11.382 11.649 11.921 12.199 12.483 12.772 13.066 13.366 13.671 SPECIFIC VOLUME (ft3/lb) SAT. LIQUID vf 0.01623 0.01623 0.01624 0.01624 0.01625 0.01625 0.01626 0.01626 0.01626 0.01627 0.01627 0.01628 0.01628 0.01629 0.01629 0.01630 0.01630 0.01631 0.01631 0.01632 0.01632 0.01633 0.01633 0.01634 0.01634 0.01635 0.01635 0.01636 0.01636 0.01637 0.01637 0.01638 0.01638 0.01639 0.01639 0.01640 0.01640 0.01641 0.01641 0.01642 0.01643 0.01643 0.01644 0.01644 0.01645 0.01645 0.01646 0.01647 0.01647 0.01648 EVAP. vfg 174.09 169.71 165.46 161.33 157.32 153.43 149.65 145.97 142.40 138.93 135.56 132.29 129.10 126.00 122.99 120.06 117.22 114.45 111.75 109.13 106.58 104.10 101.69 99.34 97.06 94.83 92.67 90.56 88.51 86.51 84.56 82.67 80.82 79.03 77.27 75.57 73.91 72.29 70.71 69.17 67.67 66.21 64.79 63.40 62.04 60.72 59.43 58.18 56.96 55.76 SAT. VAPOR vg 174.10 169.72 165.47 161.35 157.34 153.44 149.66 145.99 142.42 138.95 135.58 132.30 129.12 126.02 123.01 120.08 117.23 114.46 111.77 109.15 106.60 104.12 101.71 99.36 97.07 94.85 92.68 90.57 88.52 86.52 84.58 82.69 80.84 79.04 77.29 75.58 73.92 72.30 70.73 69.19 67.69 66.23 64.80 63.41 62.06 60.74 59.45 58.20 56.97 55.78 ENTHALPY (Btu/lb) SAT. LIQUID hf 93.91 94.91 95.91 96.90 97.90 98.90 99.90 100.90 101.90 102.90 103.90 104.89 105.89 106.89 107.89 108.89 109.89 110.89 111.89 112.89 113.89 114.89 115.89 116.89 117.89 118.89 119.89 120.89 121.89 122.89 123.89 124.89 125.89 126.89 127.89 128.89 129.89 130.89 131.89 132.89 133.89 134.89 135.90 136.90 137.90 138.90 139.90 140.90 141.90 142.91 EVAP. hfg 1022.3 1021.7 1021.1 1020.5 1020.0 1019.4 1018.8 1018.2 1017.6 1017.0 1016.4 1015.9 1015.3 1014.7 1014.1 1013.5 1012.9 1012.3 1011.7 1011.2 1010.6 1010.0 1009.4 1008.8 1008.2 1007.6 1007.0 1006.4 1005.8 1005.2 1004.7 1004.1 1003.5 1002.9 1002.3 1001.7 1001.1 1000.5 999.9 999.3 998.7 998.1 997.5 996.9 996.3 995.7 995.1 994.5 993.9 993.3 SAT. VAPOR hg 1116.2 1116.6 1117.0 1117.4 1117.9 1118.3 1118.7 1119.1 1119.5 1119.9 1120.3 1120.8 1121.2 1121.6 1122.0 1122.4 1122.8 1123.2 1123.6 1124.1 1124.5 1124.9 1125.3 1125.7 1126.1 1126.5 1126.9 1127.3 1127.7 1128.1 1128.6 1129.0 1129.4 1129.8 1130.2 1130.6 1131.0 1131.4 1131.8 1132.2 1132.6 1133.0 1133.4 1133.8 1134.2 1134.6 1135.0 1135.4 1135.8 1136.2 ENTROPY (Btu/lb,F) SAT. LIQUID sf 0.1748 0.1765 0.1782 0.1799 0.1816 0.1833 0.1849 0.1866 0.1883 0.1900 0.1917 0.1934 0.1950 0.1967 0.1984 0.2000 0.2016 0.2033 0.2049 0.2066 0.2083 0.2099 0.2116 0.2133 0.2149 0.2165 0.2182 0.2198 0.2214 0.2230 0.2246 0.2263 0.2279 0.2295 0.2311 0.2327 0.2343 0.2360 0.2376 0.2392 0.2408 0.2424 0.2440 0.2455 0.2472 0.2488 0.2503 0.2519 0.2535 0.2551 EVAP. sfg 1.7454 1.7414 1.7374 1.7335 1.7296 1.7257 1.7218 1.7179 1.7141 1.7102 1.7063 1.7024 1.6987 1.6948 1.6910 1.6873 1.6835 1.6797 1.6760 1.6722 1.6685 1.6648 1.6610 1.6573 1.6537 1.6500 1.6463 1.6427 1.6390 1.6354 1.6318 1.6282 1.6246 1.6210 1.6174 1.6138 1.6103 1.6067 1.6032 1.5997 1.5961 1.5926 1.5891 1.5857 1.5822 1.5787 1.5753 1.5718 1.5684 1.5649 SAT. VAPOR sg 1.9202 1.9179 1.9156 1.9134 1.9112 1.9090 1.9067 1.9045 1.9023 1.9002 1.8980 1.8958 1.8937 1.8915 1.8894 1.8873 1.8851 1.8830 1.8809 1.8788 1.8768 1.8747 1.8726 1.8706 1.8685 1.8665 1.8645 1.8624 1.8604 1.8584 1.8564 1.8545 1.8525 1.8505 1.8485 1.8466 1.8446 1.8427 1.8408 1.8388 1.8369 1.8350 1.8331 1.8312 1.8293 1.8275 1.8256 1.8237 1.8219 1.8200
I4-21
02-02
System Fundamentals

ABS. PRESSURE TEMP F t 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 202 204 206 208 210 212 214 216 218 220 222 224 226 228 230 232 234 236 238 240 242 244 246 248 250 PSIA p 6.868 7.024 7.183 7.345 7.510 7.678 7.850 8.024 8.202 8.383 8.567 8.755 8.946 9.141 9.339 9.541 9.746 9.955 10.168 10.385 10.605 10.830 11.058 11.290 11.526 12.011 12.512 13.031 13.568 14.123 14.696 15.289 15.901 16.533 17.186 17.861 18.557 19.275 20.016 20.780 21.567 22.379 23.217 24.080 24.969 25.884 26.827 27.798 28.797 29.825 IN. HG p 13.983 14.301 14.625 14.955 15.291 15.633 15.982 16.337 16.699 17.068 17.443 17.825 18.214 18.611 19.014 19.425 19.843 20.269 20.703 21.144 21.593 22.050 22.515 22.987 23.467 24.455 25.475 26.531 27.625 28.755 29.922 31.129 32.375 33.662 34.992 36.365 37.782 39.244 40.753 42.308 43.911 45.564 47.269 49.027 50.837 52.701 54.620 56.597 58.631 60.725 SPECIFIC VOLUME (ft3/lb) SAT. LIQUID vf 0.01648 0.01649 0.01650 0.01650 0.01651 0.01651 0.01652 0.01653 0.01653 0.01654 0.01654 0.01655 0.01656 0.01656 0.01657 0.01658 0.01658 0.01659 0.01659 0.01660 0.01661 0.01661 0.01662 0.01663 0.01663 0.01665 0.01666 0.01667 0.01669 0.01670 0.01672 0.01673 0.01674 0.01676 0.01677 0.01679 0.01680 0.01682 0.01683 0.01684 0.01686 0.01688 0.01689 0.01691 0.01692 0.01694 0.01696 0.01697 0.01699 0.01700 EVAP. vfg 54.60 53.46 52.35 51.27 50.21 49.18 48.18 47.19 46.24 45.29 44.39 43.50 42.62 41.77 40.94 40.13 39.34 38.57 37.81 37.07 36.35 35.64 34.95 34.28 33.62 32.35 31.14 29.97 28.86 27.80 26.78 25.81 24.88 23.99 23.13 22.31 21.53 20.78 20.06 19.365 18.703 18.067 17.456 16.869 16.306 15.765 15.245 14.745 14.265 13.804 SAT. VAPOR vg 54.61 53.48 52.37 51.29 50.23 49.20 48.19 47.21 46.25 45.31 44.40 43.51 42.64 41.79 40.96 40.15 39.36 38.58 37.83 37.09 36.37 35.66 34.97 34.30 33.64 32.37 31.15 29.99 28.88 27.82 26.80 25.83 24.90 24.01 23.15 22.33 21.55 20.79 20.07 19.382 18.720 18.084 17.473 16.886 16.323 15.782 15.262 14.762 14.282 13.821 ENTHALPY (Btu/lb) SAT. LIQUID hf 143.91 144.91 145.91 146.92 147.92 148.92 149.92 150.93 151.93 152.93 153.94 154.94 155.94 156.95 157.95 158.95 159.96 160.96 161.97 162.97 163.97 164.98 165.98 166.99 167.99 170.00 172.02 174.03 176.04 178.05 180.07 182.08 184.10 186.11 188.13 190.15 192.17 194.18 196.20 198.23 200.25 202.27 204.29 206.32 208.34 210.37 212.39 214.42 216.45 218.48 EVAP. hfg 992.7 992.1 991.5 990.8 990.2 989.6 989.0 988.4 987.8 987.2 986.6 986.0 985.4 984.8 984.1 983.4 982.8 982.2 981.6 981.0 980.4 979.7 979.1 978.5 977.9 976.6 975.4 974.2 972.9 971.6 970.3 969.0 967.8 966.5 965.2 963.9 962.6 961.3 960.1 958.8 957.4 956.1 954.8 953.5 952.2 950.8 949.5 948.2 946.8 945.5 SAT. VAPOR hg 1136.6 1137.0 1137.4 1137.7 1138.1 1138.5 1138.9 1139.3 1139.7 1140.1 1140.5 1140.9 1141.3 1141.7 1142.0 1142.4 1142.8 1143.2 1143.6 1144.0 1144.4 1144.7 1145.1 1145.5 1145.9 1146.6 1147.4 1148.2 1148.9 1149.7 1150.4 1151.1 1151.9 1152.6 1153.4 1154.1 1154.8 1155.5 1156.3 1157.0 1157.7 1158.4 1159.1 1159.8 1160.5 1161.2 1161.9 1162.6 1163.3 1164.0 ENTROPY (Btu/lb,F) SAT. LIQUID sf 0.2567 0.2583 0.2599 0.2614 0.2630 0.2645 0.2661 0.2676 0.2692 0.2708 0.2723 0.2739 0.2754 0.2770 0.2785 0.2801 0.2816 0.2831 0.2846 0.2862 0.2877 0.2892 0.2907 0.2923 0.2938 0.2969 0.2999 0.3029 0.3059 0.3090 0.3120 0.3149 0.3179 0.3209 0.3239 0.3268 0.3298 0.3328 0.3357 0.3387 0.3416 0.3444 0.3473 0.3502 0.3531 0.3560 0.3589 0.3618 0.3647 0.3675 EVAP. sfg 1.5615 1.5581 1.5547 1.5513 1.5480 1.5446 1.5412 1.5379 1.5346 1.5312 1.5279 1.5246 1.5213 1.5180 1.5147 1.5114 1.5082 1.5049 1.5017 1.4984 1.4952 1.4920 1.4888 1.4856 1.4824 1.4760 1.4697 1.4634 1.4571 1.4508 1.4446 1.4385 1.4323 1.4262 1.4201 1.4141 1.4080 1.4020 1.3961 1.3901 1.3842 1.3784 1.3725 1.3667 1.3609 1.3551 1.3494 1.3436 1.3379 1.3323 SAT. VAPOR sg 1.8182 1.8164 1.8146 1.8127 1.8109 1.8091 1.8073 1.8055 1.8038 1.8020 1.8002 1.7985 1.7967 1.7950 1.7932 1.7915 1.7898 1.7880 1.7863 1.7846 1.7829 1.7812 1.7795 1.7779 1.7762 1.7729 1.7696 1.7663 1.7630 1.7598 1.7566 1.7534 1.7502 1.7471 1.7440 1.7409 1.7378 1.7348 1.7318 1.7288 1.7258 1.7228 1.7199 1.7169 1.7140 1.7111 1.7083 1.7054 1.7026 1.6998
I4-22
02-02
(Rev 7/97)
System Fundamentals

ABS. PRESSURE TEMP F t 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 292 294 296 298 300 302 304 306 308 310 312 314 316 318 320 322 324 326 328 330 332 334 336 338 340 342 344 346 348 350 PSIA p 30.884 31.973 33.093 34.245 35.429 36.646 37.897 39.182 40.502 41.858 43.252 44.682 46.150 47.657 49.203 50.790 52.418 54.088 55.800 57.556 59.356 61.201 63.091 65.028 67.013 69.046 71.127 73.259 75.442 77.68 79.96 82.30 84.70 87.15 89.66 92.22 94.84 97.52 100.26 103.06 105.92 108.85 111.84 114.89 118.01 121.20 124.45 127.77 131.17 134.63 IN. HG p 62.880 65.098 67.378 69.723 72.134 74.612 77.159 79.775 82.463 85.225 88.062 90.974 93.963 97.031 100.18 103.41 106.72 110.12 113.61 117.19 120.85 124.61 128.46 132.40 136.44 140.58 144.82 149.16 153.60 _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ SPECIFIC VOLUME (ft3/lb) SAT. LIQUID vf 0.01702 0.01704 0.01705 0.01707 0.01709 0.01710 0.01712 0.01714 0.01715 0.01717 0.01719 0.01721 0.01722 0.01724 0.01726 0.01728 0.01730 0.01732 0.01733 0.01735 0.01737 0.01739 0.01741 0.01743 0.01745 0.01747 0.01749 0.01751 0.01753 0.01755 0.01757 0.01759 0.01761 0.01763 0.01765 0.01768 0.01770 0.01772 0.01774 0.01776 0.01778 0.01781 0.01783 0.01785 0.01787 0.01790 0.01792 0.01794 0.01797 0.01799 EVAP. vfg 13.360 12.933 12.522 12.127 11.746 11.379 11.026 10.687 10.359 10.044 9.739 9.446 9.163 8.891 8.628 8.374 8.129 7.892 7.664 7.444 7.231 7.025 6.827 6.635 6.449 6.269 6.096 5.928 5.766 5.609 5.457 5.310 5.167 5.030 4.896 4.767 4.642 4.521 4.403 4.289 4.179 4.072 3.968 3.868 3.770 3.675 3.584 3.495 3.408 3.324 SAT. VAPOR vg 13.377 12.950 12.539 12.144 11.763 11.396 11.043 10.704 10.376 10.061 9.756 9.463 9.181 8.908 8.645 8.391 8.146 7.910 7.682 7.461 7.248 7.043 6.844 6.652 6.466 6.287 6.114 5.946 5.783 5.626 5.474 5.327 5.185 5.047 4.914 4.785 4.660 4.538 4.421 4.307 4.197 4.090 3.986 3.886 3.788 3.693 3.602 3.513 3.426 3.342 ENTHALPY (Btu/lb) SAT. LIQUID hf 220.51 222.54 224.58 226.61 228.64 230.68 232.72 234.76 236.80 238.84 240.88 242.92 244.96 247.01 249.06 251.10 253.15 255.20 257.26 259.31 261.36 263.42 265.48 267.53 269.59 271.66 273.72 275.78 277.85 279.92 281.99 284.06 286.13 288.20 290.28 292.36 294.43 296.52 298.60 300.68 302.77 304.86 306.95 309.04 311.13 313.23 315.33 317.43 319.53 321.63 EVAP. hfg 944.2 942.8 941.4 940.1 938.7 937.3 936.0 934.5 933.2 931.8 930.3 929.0 927.5 926.1 924.7 923.3 921.8 920.4 918.9 917.5 916.0 914.6 913.1 911.6 910.1 908.6 907.2 905.6 904.1 902.6 901.0 899.5 898.0 896.5 894.9 893.3 891.8 890.2 888.6 887.0 885.4 883.8 882.2 880.6 879.0 877.4 875.7 874.1 872.4 870.7 SAT. VAPOR hg 1164.7 1165.3 1166.0 1166.7 1167.3 1168.0 1168.7 1169.3 1170.0 1170.6 1171.2 1171.9 1172.5 1173.1 1173.8 1174.4 1175.0 1175.6 1176.2 1176.8 1177.4 1178.0 1178.6 1179.1 1179.7 1180.3 1180.9 1181.4 1182.0 1182.5 1183.1 1183.6 1184.1 1184.7 1185.2 1185.7 1186.2 1186.7 1187.2 1187.7 1188.2 1188.7 1189.2 1189.6 1190.1 1190.6 1191.0 1191.5 1191.9 1192.3 ENTROPY (Btu/lb,F) SAT. LIQUID sf 0.3704 0.3732 0.3761 0.3789 0.3817 0.3845 0.3874 0.3902 0.3930 0.3958 0.3986 0.4014 0.4041 0.4069 0.4096 0.4124 0.4152 0.4179 0.4207 0.4234 0.4261 0.4288 0.4315 0.4343 0.4369 0.4397 0.4424 0.4450 0.4477 0.4504 0.4530 0.4557 0.4584 0.4611 0.4637 0.4664 0.4690 0.4717 0.4743 0.4769 0.4795 0.4821 0.4847 0.4873 0.4900 0.4926 0.4952 0.4978 0.5004 0.5029 EVAP. sfg 1.3266 1.3210 1.3154 1.3099 1.3043 1.2988 1.2933 1.2878 1.2824 1.2769 1.2715 1.2661 1.2608 1.2554 1.2501 1.2448 1.2395 1.2343 1.2290 1.2238 1.2186 1.2134 1.2083 1.2031 1.1980 1.1929 1.1878 1.1828 1.1777 1.1727 1.1677 1.1627 1.1577 1.1527 1.1478 1.1428 1.1379 1.1330 1.1281 1.1233 1.1184 1.1136 1.1088 1.1040 1.0992 1.0944 1.0896 1.0848 1.0801 1.0754 SAT. VAPOR sg 1.6970 1.6942 1.6915 1.6888 1.6860 1.6833 1.6807 1.6780 1.6753 1.6727 1.6701 1.6675 1.6649 1.6623 1.6597 1.6572 1.6547 1.6522 1.6497 1.6472 1.6447 1.6422 1.6398 1.6374 1.6350 1.6326 1.6302 1.6278 1.6254 1.6231 1.6207 1.6184 1.6161 1.6138 1.6115 1.6092 1.6069 1.6047 1.6024 1.6002 1.5979 1.5957 1.5935 1.5913 1.5891 1.5870 1.5848 1.5826 1.5805 1.5783
I4-23
02-02
System Fundamentals

ABS. PRESSURE TEMP F t 352 354 356 358 360 362 364 366 368 370 372 374 376 378 380 382 384 386 388 390 392 394 396 398 400 405 410 415 420 425 430 435 440 445 450 455 460 465 470 475 480 485 490 495 500 505 510 515 520 525 PSIA p 138.16 141.77 145.45 149.21 153.04 156.95 160.93 165.00 169.15 173.37 177.68 182.07 186.55 191.12 195.77 200.50 205.33 210.25 215.26 220.37 225.56 230.85 236.24 241.73 247.31 261.71 276.75 292.45 308.83 325.92 343.72 362.27 381.59 401.68 422.6 444.3 466.9 490.3 514.7 539.9 566.1 593.3 621.4 650.6 680.8 712.0 744.3 777.8 812.4 848.1 IN. HG p _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ SPECIFIC VOLUME (ft3/lb) SAT. LIQUID vf 0.01801 0.01804 0.01806 0.01808 0.01811 0.01813 0.01816 0.01818 0.01821 0.01823 0.01826 0.01829 0.01831 0.01834 0.01836 0.01839 0.01842 0.01844 0.01847 0.01850 0.01853 0.01855 0.01858 0.01861 0.01864 0.01871 0.01878 0.01886 0.01894 0.01902 0.01910 0.01918 0.01926 0.01935 0.0194 0.0195 0.0196 0.0197 0.0198 0.0199 0.0200 0.0201 0.0202 0.0203 0.0204 0.0205 0.0207 0.0208 0.0209 0.0210 EVAP. vfg 3.243 3.164 3.087 3.012 2.939 2.869 2.801 2.734 2.669 2.606 2.545 2.486 2.428 2.372 2.317 2.264 2.212 2.162 2.113 2.0651 2.0187 1.9734 1.9293 1.8864 1.8447 1.7448 1.6512 1.5635 1.4811 1.4036 1.3308 1.2623 1.1979 1.1371 1.0799 1.0258 0.9748 0.9266 0.8811 0.8380 0.7972 0.7586 0.7221 0.6874 0.6545 0.6233 0.5935 0.5653 0.5385 0.5130 SAT. VAPOR vg 3.261 3.182 3.105 3.030 2.957 2.887 2.819 2.752 2.687 2.625 2.564 2.504 2.446 2.390 2.335 2.282 2.231 2.180 2.131 2.0836 2.0372 1.9920 1.9479 1.9050 1.8633 1.7635 1.6700 1.5823 1.5000 1.4226 1.3499 1.2815 1.2171 1.1565 1.0993 1.0453 0.9944 0.9463 0.9009 0.8579 0.8172 0.7787 0.7423 0.7077 0.6749 0.6438 0.6142 0.5861 0.5594 0.5340 ENTHALPY (Btu/lb) SAT. LIQUID hf 323.74 325.85 327.96 330.07 332.18 334.30 336.42 338.54 340.66 342.79 344.91 347.04 349.18 351.31 353.45 355.59 357.73 359.88 362.02 364.17 366.33 368.48 370.64 372.80 374.97 380.39 385.83 391.29 396.77 402.27 407.79 413.34 418.90 424.49 430.1 435.7 441.4 447.1 452.8 458.6 464.4 470.2 476.0 481.9 487.8 493.8 499.8 505.8 511.9 518.0 EVAP. hfg 869.1 867.3 865.6 863.9 862.2 860.5 858.8 857.1 855.3 853.5 851.8 850.0 848.2 846.4 844.6 842.8 841.0 839.1 837.3 835.4 833.6 831.7 829.9 827.9 826.0 821.2 816.3 811.3 806.3 801.2 796.0 790.8 785.4 780.0 774.5 768.9 763.2 757.4 751.5 745.4 739.4 733.1 726.8 720.4 713.9 707.1 700.3 693.4 686.4 679.1 SAT. VAPOR hg 1192.8 1193.2 1193.6 1194.0 1194.4 1194.8 1195.2 1195.6 1196.0 1196.3 1196.7 1197.0 1197.4 1197.7 1198.1 1198.4 1198.7 1199.0 1199.3 1199.6 1199.9 1200.2 1200.5 1200.7 1201.0 1201.6 1202.1 1202.6 1203.1 1203.5 1203.8 1204.1 1204.3 1204.5 1204.6 1204.6 1204.6 1204.5 1204.3 1204.0 1203.7 1203.3 1202.8 1202.3 1201.7 1200.9 1200.1 1199.2 1198.2 1197.1 ENTROPY (Btu/lb,F) SAT. LIQUID sf 0.5055 0.5081 0.5106 0.5132 0.5158 0.5183 0.5209 0.5235 0.5260 0.5286 0.5311 0.5336 0.5362 0.5388 0.5413 0.5438 0.5463 0.5488 0.5514 0.5539 0.5564 0.5589 0.5614 0.5639 0.5664 0.5726 0.5788 0.5850 0.5912 0.5974 0.6035 0.6097 0.6158 0.6219 0.6280 0.6341 0.6402 0.6463 0.6523 0.6584 0.6645 0.6705 0.6766 0.6826 0.6887 0.6948 0.7008 0.7069 0.7130 0.7191 EVAP. sfg 1.0707 1.0660 1.0613 1.0566 1.0519 1.0473 1.0426 1.0380 1.0334 1.0287 1.0241 1.0196 1.0150 1.0104 1.0059 1.0013 0.9968 0.9923 0.9877 0.9832 0.9787 0.9742 0.9698 0.9653 0.9608 0.9497 0.9386 0.9276 0.9166 0.9056 0.8947 0.8838 0.8730 0.8622 0.8513 0.8406 0.8298 0.8190 0.8083 0.7976 0.7868 0.7761 0.7653 0.7546 0.7438 0.7331 0.7223 0.7115 0.7006 0.6897 SAT. VAPOR sg 1.5762 1.5741 1.5719 1.5698 1.5677 1.5656 1.5635 1.5615 1.5594 1.5573 1.5553 1.5532 1.5512 1.5492 1.5471 1.5451 1.5431 1.5411 1.5391 1.5371 1.5351 1.5331 1.5311 1.5292 1.5272 1.5223 1.5174 1.5126 1.5078 1.5030 1.4982 1.4935 1.4887 1.4840 1.4793 1.4746 1.4700 1.4653 1.4606 1.4560 1.4513 1.4466 1.4419 1.4372 1.4325 1.4278 1.4231 1.4184 1.4136 1.4088
I4-24
02-02
System Fundamentals

ABS. PRESSURE TEMP F t 530 535 540 545 550 555 560 565 570 575 580 585 590 595 600 605 610 615 620 625 630 635 640 645 650 655 660 665 670 675 680 685 690 695 700 702 704 705 705.4 PSIA p 885.0 923.2 962.5 1003.2 1045.2 1088.5 1133.1 1179.1 1226.5 1275.4 1325.8 1377.7 1431.2 1486.2 1542.9 1601.2 1661.2 1723.0 1786.6 1852.0 1919.3 1988.5 2059.7 2132.9 2208.2 2285.7 2365.4 2447.4 2531.8 2618.7 2708.1 2800.2 2895.1 2992.9 3093.7 3134.9 3176.7 3197.7 3206.2 IN. HG p _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ SPECIFIC VOLUME (ft3/lb) SAT. LIQUID vf 0.0212 0.0213 0.0215 0.0216 0.0218 0.0219 0.0221 0.0222 0.0224 0.0226 0.0228 0.0230 0.0232 0.0234 0.0236 0.0239 0.0241 0.0244 0.0247 0.0250 0.0253 0.0256 0.0260 0.0264 0.0268 0.0273 0.0278 0.0283 0.0290 0.0297 0.0305 0.0315 0.0328 0.0344 0.0369 0.0385 0.0410 0.0438 0.0503 EVAP. vfg 0.4886 0.4655 0.4434 0.4224 0.4022 0.3831 0.3647 0.3472 0.3304 0.3143 0.2989 0.2841 0.2700 0.2563 0.2432 0.2306 0.2185 0.2068 0.1955 0.1845 0.1740 0.1637 0.1538 0.1441 0.1348 0.1256 0.1165 0.1076 0.0987 0.0899 0.0810 0.0719 0.0625 0.0520 0.0392 0.0325 0.0234 0.0152 0 SAT. VAPOR vg 0.5098 0.4868 0.4649 0.4440 0.4240 0.4050 0.3868 0.3694 0.3528 0.3369 0.3217 0.3071 0.2931 0.2797 0.2668 0.2545 0.2426 0.2312 0.2201 0.2095 0.1992 0.1893 0.1798 0.1705 0.1616 0.1528 0.1442 0.1359 0.1277 0.1196 0.1115 0.1034 0.0953 0.0864 0.0761 0.0710 0.0645 0.0589 0.0503 ENTHALPY (Btu/lb) SAT. LIQUID hf 524.1 530.3 536.6 542.9 549.3 555.7 562.2 568.8 575.4 582.1 588.9 595.8 602.8 609.8 617.0 624.3 631.6 639.1 646.7 654.4 662.3 670.4 678.6 687.0 695.7 704.8 714.2 724.1 734.4 745.4 757.3 770.1 784.4 801.2 823.3 835.4 852.7 869.2 902.7 EVAP. hfg 671.8 664.3 656.6 648.8 640.8 632.6 624.2 615.5 606.7 597.7 588.4 578.8 569.0 558.9 548.5 537.7 526.7 515.3 503.6 491.4 478.8 465.6 452.0 437.7 422.8 406.9 390.2 372.4 353.2 332.6 309.9 284.7 256.0 220.7 172.1 145.2 106.0 69.1 0 SAT. VAPOR hg 1195.9 1194.6 1193.2 1191.7 1190.0 1188.3 1186.4 1184.3 1182.1 1179.8 1177.3 1174.6 1171.8 1168.7 1165.5 1162.0 1158.4 1154.4 1150.3 1145.8 1141.1 1136.0 1130.5 1124.7 1118.5 1111.7 1104.4 1096.4 1087.7 1078.0 1067.2 1054.8 1040.4 1021.9 995.4 980.6 958.7 938.4 902.7 ENTROPY (Btu/lb,F) SAT. LIQUID sf 0.7252 0.7313 0.7374 0.7435 0.7497 0.7559 0.7621 0.7683 0.7746 0.7809 0.7872 0.7936 0.8001 0.8066 0.8131 0.8197 0.8264 0.8331 0.8398 0.8467 0.8536 0.8607 0.8679 0.8752 0.8828 0.8906 0.8987 0.9071 0.9159 0.9251 0.9351 0.9459 0.9578 0.9719 0.9905 1.0006 1.0152 1.0293 1.0580 EVAP. sfg 0.6788 0.6679 0.6568 0.6458 0.6346 0.6234 0.6121 0.6007 0.5893 0.5777 0.5659 0.5541 0.5421 0.5299 0.5176 0.5051 0.4924 0.4795 0.4664 0.4530 0.4394 0.4254 0.4110 0.3962 0.3809 0.3651 0.3485 0.3311 0.3127 0.2931 0.2719 0.2487 0.2227 0.1911 0.1484 0.1249 0.0911 0.0593 0 SAT. VAPOR sg 1.4040 1.3991 1.3942 1.3893 1.3843 1.3793 1.3742 1.3690 1.3638 1.3585 1.3532 1.3477 1.3422 1.3365 1.3307 1.3248 1.3188 1.3126 1.3062 1.2997 1.2930 1.2861 1.2789 1.2715 1.2637 1.2557 1.2472 1.2382 1.2285 1.2183 1.2071 1.1946 1.1805 1.1630 1.1389 1.1256 1.1063 1.0886 1.0580
I4-25
02-02

ABS. PRESS PSIA p 14.696 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 48 49 50 51 52 53 54 55 56 57 58 59 60 61 TEMP SPECIFIC VOLUME (ft3/lb) SAT. LIQUID vf 0.01672 0.01672 0.01674 0.01677 0.01679 0.01681 0.01683 0.01685 0.01687 0.01689 0.01691 0.01692 0.01694 0.01696 0.01698 0.01699 0.01701 0.01702 0.01704 0.01705 0.01707 0.01708 0.01709 0.01711 0.01712 0.01714 0.01715 0.01716 0.01717 0.01719 0.01720 0.01721 0.01722 0.01723 0.01725 0.01726 0.01727 0.01725 0.01726 0.01727 0.01728 0.01729 0.01730 0.01731 0.01732 0.01733 0.01734 0.01736 0.01737 0.01738 0.01739 SAT. VAPOR vg 26.80 26.29 24.75 23.39 22.17 21.08 20.089 19.192 18.375 17.627 16.938 16.303 15.715 15.170 14.663 14.189 13.746 13.330 12.940 12.572 12.226 11.898 11.588 11.294 11.015 10.750 10.498 10.258 10.029 9.810 9.601 9.401 9.209 9.025 8.848 8.678 8.515 8.848 8.678 8.515 8.359 8.208 8.062 7.922 7.787 7.656 7.529 7.407 7.289 7.175 7.064 ENTHALPY (Btu/lb) SAT. LIQUID hf 180.07 181.11 184.42 187.56 190.56 193.42 196.16 198.79 201.33 203.78 206.14 208.42 210.62 212.75 214.83 216.86 218.82 220.73 222.59 224.41 226.18 227.91 229.60 231.26 232.89 234.48 236.03 237.55 239.04 240.51 241.95 243.36 244.75 246.12 247.47 248.79 250.09 247.47 248.79 250.09 251.37 252.63 253.87 255.09 256.30 257.50 258.67 259.82 260.96 262.09 263.20 SAT. VAPOR hg 1150.4 1150.8 1152.0 1153.1 1154.2 1155.3 1156.3 1157.2 1158.1 1159.0 1159.8 1160.6 1161.3 1162.0 1162.7 1163.4 1164.1 1164.7 1165.4 1166.0 1166.5 1167.1 1167.6 1168.2 1168.7 1169.2 1169.7 1170.2 1170.7 1171.1 1171.6 1172.0 1172.4 1172.9 1173.3 1173.7 1174.1 1173.3 1173.7 1174.1 1174.4 1174.8 1175.2 1175.6 1175.9 1176.3 1176.6 1176.9 1177.3 1177.6 1177.9 ENTROPY (Btu/lb,F) SAT. LIQUID sf 0.3120 0.3135 0.3184 0.3231 0.3275 0.3317 0.3356 0.3395 0.3431 0.3466 0.3500 0.3533 0.3564 0.3594 0.3623 0.3652 0.3680 0.3707 0.3733 0.3758 0.3783 0.3807 0.3831 0.3854 0.3876 0.3898 0.3919 0.3940 0.3960 0.3980 0.4000 0.4019 0.4038 0.4057 0.4075 0.4093 0.4110 0.4075 0.4093 0.4110 0.4127 0.4144 0.4161 0.4177 0.4193 0.4209 0.4225 0.4240 0.4255 0.4270 0.4285
System Fundamentals
INTERNAL ENERGY (Btu/lb) SAT. LIQUID uf 180.02 181.06 184.37 187.51 190.50 193.36 196.10 198.73 201.26 203.71 206.07 208.34 210.54 212.67 214.74 216.77 218.73 220.63 222.49 224.31 226.07 227.80 229.49 231.14 232.77 234.36 235.90 237.42 238.91 240.37 241.81 243.22 244.60 245.97 247.32 248.63 249.93 247.32 248.63 249.93 251.21 252.46 253.70 254.92 256.12 257.32 258.49 259.63 260.77 261.90 263.00 SAT. VAPOR ug 1077.5 1077.8 1078.7 1079.5 1080.4 1081.2 1081.9 1082.6 1083.3 1083.9 1084.6 1085.1 1085.7 1086.3 1086.8 1087.3 1087.8 1088.3 1088.7 1089.2 1089.6 1090.1 1090.5 1090.9 1091.3 1091.6 1092.0 1092.4 1092.7 1093.1 1093.4 1093.7 1094.1 1094.4 1094.7 1095.0 1095.3 1094.7 1095.0 1095.3 1095.5 1095.8 1096.1 1096.4 1096.7 1097.0 1097.2 1097.4 1097.7 1097.9 1098.2
Table I4-16. Saturated Steam Properties, Pressure Table (Sheet 1 of 5)
F t 212.00 213.03 216.32 219.44 222.41 225.24 227.96 230.57 233.07 235.49 237.82 240.07 242.25 244.36 246.41 248.40 250.33 252.22 254.05 255.84 257.58 259.28 260.95 262.57 264.16 265.72 267.25 268.74 270.21 271.64 273.05 274.44 275.80 277.13 278.45 279.74 281.01 278.45 279.74 281.01 282.26 283.49 284.70 285.90 287.07 288.23 289.37 290.50 291.61 292.71 293.79
EVAP. hfg 970.3 969.7 967.6 965.5 963.6 961.9 960.1 958.4 956.8 955.2 953.7 952.1 950.7 949.3 947.9 946.5 945.3 944.0 942.8 941.6 940.3 939.2 938.0 936.9 935.8 934.7 933.7 932.6 931.6 930.6 929.6 928.6 927.7 926.7 925.8 924.9 924.0 925.8 924.9 924.0 923.0 922.2 921.3 920.5 919.6 918.8 917.9 917.1 916.3 915.5 914.7
EVAP. sfg 1.4446 1.4415 1.4313 1.4218 1.4128 1.4043 1.3962 1.3885 1.3811 1.3740 1.3672 1.3606 1.3544 1.3484 1.3425 1.3368 1.3313 1.3260 1.3209 1.3159 1.3110 1.3063 1.3017 1.2972 1.2929 1.2886 1.2844 1.2803 1.2764 1.2726 1.2687 1.2650 1.2613 1.2577 1.2542 1.2508 1.2474 1.2542 1.2508 1.2474 1.2442 1.2409 1.2377 1.2346 1.2316 1.2285 1.2255 1.2226 1.2197 1.2168 1.2140
SAT. VAPOR sg 1.7566 1.7549 1.7497 1.7449 1.7403 1.7360 1.7319 1.7280 1.7242 1.7206 1.7172 1.7139 1.7108 1.7078 1.7048 1.7020 1.6993 1.6967 1.6941 1.6917 1.6893 1.6870 1.6848 1.6826 1.6805 1.6784 1.6763 1.6743 1.6724 1.6706 1.6687 1.6669 1.6652 1.6634 1.6617 1.6601 1.6585 1.6617 1.6601 1.6585 1.6569 1.6553 1.6538 1.6523 1.6509 1.6494 1.6480 1.6466 1.6452 1.6438 1.6425
EVAP. ufg 897.5 896.7 894.3 892.0 889.9 887.8 885.8 883.9 882.0 880.2 878.5 876.8 875.2 873.6 872.1 870.5 869.1 867.7 866.3 864.9 863.5 862.3 861.0 859.8 858.5 857.2 856.1 855.0 853.8 852.7 851.6 850.5 849.5 848.4 847.4 846.4 845.4 847.4 846.4 845.4 844.3 843.3 842.4 841.5 840.6 839.7 838.7 837.8 836.9 836.0 835.2
I4-26
02-02
System Fundamentals
ABS. PRESS PSIA p 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 TEMP SPECIFIC VOLUME (ft3/lb) SAT. LIQUID vf 0.01740 0.01741 0.01742 0.01743 0.01744 0.01745 0.01746 0.01747 0.01748 0.01749 0.01750 0.01751 0.01752 0.01753 0.01754 0.01754 0.01755 0.01756 0.01757 0.01758 0.01759 0.01760 0.01761 0.01761 0.01762 0.01763 0.01764 0.01765 0.01766 0.01767 0.01768 0.01768 0.01769 0.01770 0.01771 0.01772 0.01772 0.01773 0.01774 0.01775 0.01775 0.01776 0.01777 0.01778 0.01778 0.01779 0.01780 0.01781 0.01782 0.01782 0.01783 SAT. VAPOR vg 6.957 6.853 6.752 6.655 6.560 6.468 6.378 6.291 6.206 6.124 6.044 5.966 5.890 5.816 5.743 5.673 5.604 5.537 5.472 5.408 5.346 5.285 5.226 5.168 5.111 5.055 5.001 4.948 4.896 4.845 4.796 4.747 4.699 4.652 4.606 4.561 4.517 4.474 4.432 4.391 4.350 4.310 4.271 4.232 4.194 4.157 4.120 4.084 4.049 4.015 3.981 ENTHALPY (Btu/lb) SAT. LIQUID hf 264.30 265.38 266.45 267.50 268.55 269.58 270.60 271.61 272.61 273.60 274.57 275.54 276.49 277.43 278.37 279.30 280.21 281.12 282.02 282.91 283.79 284.66 285.53 286.39 287.24 288.08 288.91 289.74 290.56 291.38 292.18 292.98 293.78 294.56 295.34 296.12 296.89 297.65 298.40 299.15 299.90 300.64 301.37 302.10 302.82 303.54 304.26 304.97 305.66 306.37 307.06 SAT. VAPOR hg 1178.2 1178.5 1178.8 1179.1 1179.4 1179.7 1180.0 1180.3 1180.6 1180.8 1181.1 1181.3 1181.6 1181.9 1182.1 1182.4 1182.6 1182.8 1183.1 1183.3 1183.5 1183.8 1184.0 1184.2 1184.4 1184.6 1184.8 1185.1 1185.3 1185.5 1185.7 1185.9 1186.1 1186.2 1186.4 1186.6 1186.8 1187.0 1187.2 1187.4 1187.5 1187.7 1187.9 1188.1 1188.2 1188.4 1188.6 1188.7 1188.9 1189.0 1189.2

ENTROPY (Btu/lb,F) SAT. LIQUID sf 0.4300 0.4314 0.4328 0.4342 0.4356 0.4369 0.4383 0.4396 0.4409 0.4422 0.4435 0.4447 0.4460 0.4472 0.4484 0.4496 0.4508 0.4520 0.4531 0.4543 0.4554 0.4565 0.4576 0.4587 0.4598 0.4609 0.4620 0.4630 0.4641 0.4651 0.4661 0.4672 0.4682 0.4692 0.4702 0.4711 0.4721 0.4731 0.4740 0.4750 0.4759 0.4768 0.4778 0.4787 0.4796 0.4805 0.4814 0.4823 0.4832 0.4840 0.4849 SAT. VAPOR sg 1.6412 1.6399 1.6387 1.6374 1.6362 1.6350 1.6338 1.6326 1.6315 1.6303 1.6292 1.6281 1.6270 1.6259 1.6248 1.6238 1.6228 1.6217 1.6207 1.6197 1.6187 1.6177 1.6168 1.6158 1.6149 1.6139 1.6130 1.6121 1.6112 1.6103 1.6094 1.6085 1.6076 1.6068 1.6060 1.6051 1.6043 1.6035 1.6026 1.6018 1.6010 1.6002 1.5994 1.5986 1.5978 1.5971 1.5963 1.5956 1.5948 1.5941 1.5934 INTERNAL ENERGY (Btu/lb) SAT. LIQUID uf 264.10 265.18 266.24 267.29 268.34 269.36 270.38 271.39 272.38 273.37 274.34 275.30 276.25 277.19 278.12 279.05 279.96 280.86 281.76 282.65 283.52 284.39 285.26 286.11 286.96 287.80 288.63 289.45 290.27 291.08 291.88 292.68 293.47 294.25 295.03 295.80 296.57 297.33 298.08 298.82 299.57 300.30 301.03 301.75 302.47 303.19 303.90 304.61 305.30 306.00 306.69 SAT. VAPOR ug 1098.4 1098.6 1098.8 1099.1 1099.3 1099.5 1099.8 1100.0 1100.2 1100.4 1100.6 1100.8 1101.0 1101.2 1101.4 1101.6 1101.7 1101.9 1102.1 1102.2 1102.4 1102.6 1102.8 1102.9 1103.1 1103.2 1103.4 1103.6 1103.7 1103.9 1104.1 1104.2 1104.4 1104.5 1104.6 1104.7 1104.9 1105.0 1105.2 1105.3 1105.4 1105.6 1105.7 1105.9 1106.0 1106.1 1106.3 1106.4 1106.5 1106.6 1106.7
F t 294.85 295.90 296.94 297.97 298.99 299.99 300.98 301.96 302.92 303.88 304.83 305.76 306.68 307.60 308.50 309.40 310.29 311.16 312.03 312.89 313.74 314.59 315.42 316.25 317.07 317.88 318.68 319.48 320.27 321.06 321.83 322.60 323.36 324.12 324.87 325.61 326.35 327.08 327.81 328.53 329.25 329.96 330.66 331.36 332.05 332.74 333.42 334.10 334.77 335.44 336.11
EVAP. hfg 913.9 913.1 912.3 911.6 910.8 910.1 909.4 908.7 907.9 907.2 906.5 905.8 905.1 904.5 903.7 903.1 902.4 901.7 901.1 900.4 899.7 899.1 898.5 897.8 897.2 896.5 895.9 895.3 894.7 894.1 893.5 892.9 892.3 891.7 891.1 890.5 889.9 889.4 888.8 888.2 887.6 887.1 886.5 886.0 885.4 884.9 884.3 883.7 883.2 882.6 882.1
EVAP. sfg 1.2112 1.2085 1.2059 1.2032 1.2006 1.1981 1.1955 1.1930 1.1906 1.1881 1.1857 1.1834 1.1810 1.1787 1.1764 1.1742 1.1720 1.1698 1.1676 1.1654 1.1633 1.1612 1.1592 1.1571 1.1551 1.1530 1.1510 1.1491 1.1471 1.1452 1.1433 1.1413 1.1394 1.1376 1.1358 1.1340 1.1322 1.1304 1.1286 1.1268 1.1251 1.1234 1.1216 1.1199 1.1182 1.1166 1.1149 1.1133 1.1117 1.1101 1.1085
EVAP. ufg 834.3 833.4 832.6 831.8 831.0 830.2 829.4 828.6 827.8 827.0 826.3 825.5 824.7 824.0 823.3 822.5 821.7 821.0 820.3 819.6 818.9 818.2 817.5 816.8 816.1 815.4 814.8 814.1 813.4 812.8 812.2 811.5 810.9 810.2 809.6 808.9 808.3 807.7 807.1 806.5 805.9 805.3 804.7 804.1 803.5 802.9 802.4 801.8 801.2 800.6 800.0
I4-27
02-02

ABS. PRESS PSIA p 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 152 154 156 158 160 162 164 166 168 170 172 174 176 178 TEMP SPECIFIC VOLUME (ft3/lb) SAT. LIQUID vf 0.01784 0.01784 0.01785 0.01786 0.01787 0.01787 0.01788 0.01789 0.01790 0.01791 0.01791 0.01792 0.01792 0.01793 0.01794 0.01794 0.01795 0.01796 0.01797 0.01797 0.01798 0.01799 0.01800 0.01800 0.01801 0.01801 0.01802 0.01802 0.01803 0.01804 0.01804 0.01805 0.01806 0.01806 0.01807 0.01808 0.01808 0.01809 0.01810 0.01812 0.01813 0.01814 0.01815 0.01817 0.01818 0.01819 0.01820 0.01822 0.01823 0.01824 0.01825 0.01826 SAT. VAPOR vg 3.947 3.914 3.882 3.850 3.819 3.788 3.758 3.728 3.699 3.670 3.642 3.614 3.587 3.560 3.533 3.507 3.481 3.455 3.430 3.405 3.381 3.357 3.333 3.310 3.287 3.264 3.242 3.220 3.198 3.177 3.155 3.134 3.114 3.094 3.074 3.054 3.034 3.015 2.977 2.940 2.904 2.869 2.834 2.801 2.768 2.736 2.705 2.675 2.645 2.616 2.587 2.559 ENTHALPY (Btu/lb) SAT. LIQUID hf 307.75 308.43 309.11 309.79 310.46 311.12 311.78 312.44 313.10 313.75 314.40 315.04 315.68 316.31 316.94 317.57 318.19 318.81 319.43 320.04 320.65 321.25 321.85 322.45 323.05 323.64 324.23 324.82 325.40 325.98 326.56 327.13 327.70 328.27 328.83 329.39 329.95 330.51 331.61 332.70 333.79 334.86 335.93 336.98 338.02 339.05 340.07 341.09 342.10 343.10 344.09 345.06 SAT. VAPOR hg 1189.4 1189.5 1189.7 1189.8 1190.0 1190.1 1190.2 1190.4 1190.5 1190.7 1190.8 1190.9 1191.1 1191.2 1191.3 1191.5 1191.6 1191.7 1191.9 1192.0 1192.1 1192.2 1192.4 1192.5 1192.6 1192.7 1192.9 1193.0 1193.1 1193.2 1193.3 1193.4 1193.5 1193.6 1193.8 1193.9 1194.0 1194.1 1194.3 1194.5 1194.7 1194.9 1195.1 1195.3 1195.5 1195.7 1195.8 1196.0 1196.2 1196.4 1196.5 1196.7 ENTROPY (Btu/lb,F) SAT. LIQUID sf 0.4858 0.4866 0.4875 0.4883 0.4891 0.4900 0.4908 0.4916 0.4924 0.4932 0.4940 0.4948 0.4956 0.4964 0.4972 0.4980 0.4987 0.4995 0.5002 0.5010 0.5018 0.5025 0.5032 0.5040 0.5047 0.5054 0.5061 0.5069 0.5076 0.5083 0.5090 0.5097 0.5104 0.5111 0.5118 0.5124 0.5131 0.5138 0.5151 0.5165 0.5178 0.5191 0.5204 0.5216 0.5229 0.5241 0.5254 0.5266 0.5278 0.5290 0.5302 0.5313
System Fundamentals
INTERNAL ENERGY (Btu/lb) SAT. LIQUID uf 307.38 308.05 308.73 309.41 310.07 310.73 311.39 312.05 312.70 313.35 313.99 314.63 315.26 315.89 316.52 317.15 317.77 318.38 318.99 319.60 320.21 320.80 321.40 322.0 322.59 323.18 323.77 324.35 324.93 325.51 326.08 326.65 327.22 327.78 328.34 328.90 329.45 330.01 331.10 332.18 333.26 334.23 335.39 336.44 337.47 338.49 339.51 340.52 341.52 342.51 343.50 344.46 SAT. VAPOR ug 1106.8 1106.9 1107.1 1107.2 1107.3 1107.4 1107.5 1107.6 1107.7 1107.8 1107.9 1108.0 1108.1 1108.2 1108.3 1108.4 1108.5 1108.6 1108.7 1108.8 1108.9 1109.0 1109.1 1109.2 1109.3 1109.4 1109.5 1109.6 1109.7 1109.8 1109.8 1109.9 1110.0 1110.1 1110.2 1110.3 1110.4 1110.5 1110.6 1110.7 1110.9 1111.0 1111.2 1111.4 1111.5 1111.7 1111.8 1111.9 1112.0 1112.2 1112.3 1112.4
F t 336.77 337.42 338.07 338.72 339.36 339.99 340.62 341.25 341.88 342.50 343.11 343.72 344.33 344.94 345.54 346.13 346.73 347.32 347.90 348.48 349.06 349.64 350.21 350.78 351.35 351.91 352.47 353.02 353.57 354.12 354.67 355.21 355.76 356.29 356.83 357.36 357.89 358.42 359.46 360.49 361.52 362.53 363.53 364.53 365.51 366.48 367.45 368.41 369.35 370.29 371.22 372.14
EVAP. hfg 881.6 881.1 880.6 880.0 879.5 879.0 878.4 877.9 877.4 876.9 876.4 875.9 875.4 874.9 874.4 873.9 873.4 872.9 872.5 872.0 871.5 871.0 870.6 870.1 869.6 869.1 868.7 868.2 867.7 867.2 866.7 866.3 865.8 865.3 864.9 864.5 864.0 863.6 862.7 861.8 860.9 860.0 859.2 858.3 857.5 856.6 855.7 854.9 854.1 853.3 852.4 851.6
EVAP. sfg 1.1069 1.1053 1.1037 1.1022 1.1007 1.0992 1.0977 1.0962 1.0947 1.0933 1.0918 1.0903 1.0888 1.0874 1.0859 1.0845 1.0832 1.0817 1.0804 1.0790 1.0776 1.0762 1.0749 1.0735 1.0722 1.0709 1.0696 1.0682 1.0669 1.0657 1.0644 1.0631 1.0618 1.0605 1.0592 1.0580 1.0568 1.0556 1.0532 1.0507 1.0483 1.0459 1.0436 1.0414 1.0391 1.0369 1.0346 1.0324 1.0302 1.0280 1.0259 1.0238
SAT. VAPOR sg 1.5927 1.5919 1.5912 1.5905 1.5898 1.5891 1.5885 1.5878 1.5871 1.5865 1.5858 1.5851 1.5844 1.5838 1.5832 1.5825 1.5819 1.5812 1.5806 1.5800 1.5793 1.5787 1.5781 1.5775 1.5769 1.5763 1.5757 1.5751 1.5745 1.5740 1.5734 1.5728 1.5722 1.5716 1.5710 1.5705 1.5699 1.5694 1.5683 1.5672 1.5661 1.5650 1.5640 1.5630 1.5620 1.5610 1.5600 1.5590 1.5580 1.5570 1.5561 1.5551
EVAP. ufg 799.4 798.9 798.4 797.8 797.2 796.7 796.1 795.6 795.0 794.5 793.9 793.4 792.8 792.3 791.8 791.3 790.7 790.2 789.7 789.2 788.7 788.2 787.7 787.2 786.7 786.2 785.7 785.2 784.8 784.3 783.8 783.3 782.8 782.3 781.9 781.4 780.9 780.5 779.5 778.5 777.6 776.8 775.8 775.0 774.1 773.2 772.3 771.4 770.5 769.7 768.8 767.9
I4-28
02-02
System Fundamentals
ABS. PRESS PSIA p 180 182 184 186 188 190 192 194 196 198 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 310 320 330 340 350 360 370 380 390 400 410 420 430 440 450 460 470 480 490 SPECIFIC VOLUME (ft3/lb) SAT. LIQUID vf 0.01827 0.01829 0.01830 0.01831 0.01832 0.01833 0.01834 0.01835 0.01836 0.01838 0.01839 0.01842 0.01844 0.01847 0.01850 0.01852 0.01854 0.01857 0.01860 0.01863 0.01865 0.01868 0.01870 0.01873 0.01875 0.01878 0.01880 0.01883 0.01885 0.01887 0.01890 0.01894 0.01899 0.01904 0.01908 0.01913 0.01917 0.01921 0.01925 0.01930 0.0193 0.0194 0.0194 0.0194 0.0195 0.0195 0.0196 0.0196 0.0197 0.0197 SAT. VAPOR vg 2.532 2.505 2.479 2.454 2.429 2.404 2.380 2.356 2.333 2.310 2.288 2.234 2.183 2.134 2.087 2.0422 1.9992 1.9579 1.9183 1.8803 1.8438 1.8086 1.7748 1.7422 1.7107 1.6804 1.6511 1.6228 1.5954 1.5689 1.5433 1.4944 1.4485 1.4053 1.3645 1.3260 1.2895 1.2550 1.2222 1.1910 1.1613 1.1330 1.1061 1.0803 1.0556 1.0320 1.0094 0.9878 0.9670 0.9470

TEMP ENTHALPY (Btu/lb) SAT. LIQUID hf 346.03 347.00 347.96 348.92 349.86 350.79 351.72 352.64 353.55 354.46 355.36 357.58 359.77 361.91 364.02 366.09 368.13 370.14 372.12 374.08 376.00 377.89 379.76 381.60 383.42 385.21 386.98 388.73 390.46 392.16 393.84 397.15 400.39 403.56 406.66 409.69 412.67 415.59 418.45 421.27 424.0 426.8 429.4 432.1 434.6 437.2 439.7 442.2 444.6 447.0 SAT. VAPOR hg 1196.9 1197.0 1197.2 1197.3 1197.5 1197.6 1197.8 1197.9 1198.1 1198.2 1198.4 1198.7 1199.0 1199.3 1199.6 1199.9 1200.1 1200.4 1200.6 1200.9 1201.1 1201.3 1201.5 1201.7 1201.9 1202.1 1202.3 1202.4 1202.6 1202.7 1202.8 1203.1 1203.4 1203.6 1203.7 1203.9 1204.1 1204.2 1204.3 1204.4 1204.5 1204.5 1204.6 1204.6 1204.6 1204.6 1204.6 1204.6 1204.5 1204.5 ENTROPY (Btu/lb,F) SAT. LIQUID sf 0.5325 0.5336 0.5348 0.5359 0.5370 0.5381 0.5392 0.5403 0.5414 0.5425 0.5435 0.5461 0.5487 0.5512 0.5537 0.5561 0.5585 0.5608 0.5631 0.5653 0.5675 0.5697 0.5719 0.5740 0.5760 0.5781 0.5801 0.5821 0.5841 0.5860 0.5879 0.5916 0.5952 0.5988 0.6022 0.6056 0.6090 0.6122 0.6153 0.6184 0.6214 0.6243 0.6272 0.6301 0.6329 0.6356 0.6383 0.6410 0.6436 0.6462 SAT. VAPOR sg 1.5542 1.5532 1.5523 1.5514 1.5506 1.5497 1.5488 1.5479 1.5470 1.5462 1.5453 1.5432 1.5412 1.5392 1.5372 1.5353 1.5334 1.5316 1.5298 1.5280 1.5263 1.5246 1.5229 1.5212 1.5196 1.5180 1.5164 1.5149 1.5133 1.5118 1.5104 1.5075 1.5046 1.5019 1.4992 1.4966 1.4941 1.4916 1.4891 1.4867 1.4844 1.4821 1.4799 1.4777 1.4755 1.4734 1.4713 1.4693 1.4673 1.4653 INTERNAL ENERGY (Btu/lb) SAT. LIQUID uf 345.42 346.38 347.34 348.29 349.22 350.15 351.07 351.98 352.89 353.79 354.68 356.88 359.05 361.18 363.27 365.32 367.34 369.33 371.29 373.23 375.14 377.01 378.86 380.68 382.48 384.26 386.01 387.74 389.45 391.13 392.79 396.06 399.26 402.40 405.46 408.45 411.39 414.27 417.10 419.88 422.6 425.3 427.9 430.5 433.0 435.5 438.0 440.5 442.9 445.2 SAT. VAPOR ug 1112.5 1112.6 1112.8 1112.9 1113.0 1113.1 1113.2 1113.3 1113.5 1113.6 1113.7 1114.0 1114.2 1114.4 1114.6 1114.8 1115.0 1115.3 1115.4 1115.6 1115.8 1116.0 1116.1 1116.3 1116.4 1116.6 1116.7 1116.8 1116.9 1117.0 1117.1 1117.4 1117.6 1117.8 1117.9 1118.0 1118.2 1118.3 1118.4 1118.5 1118.5 1118.6 1118.7 1118.7 1118.7 1118.7 1118.7 1118.7 1118.6 1118.6
F t 373.06 373.96 374.86 375.75 376.64 377.51 378.38 379.24 380.10 380.95 381.79 383.86 385.90 387.89 389.86 391.79 393.68 395.54 397.37 399.18 400.95 402.70 404.42 406.11 407.78 409.43 411.05 412.65 414.23 415.79 417.33 420.35 423.29 426.16 428.97 431.72 434.40 437.03 439.60 442.12 444.59 447.01 449.39 451.73 454.02 456.28 458.50 460.68 462.82 464.93
EVAP. hfg 850.8 850.0 849.2 848.4 847.6 846.8 846.1 845.3 844.5 843.7 843.0 841.1 839.2 837.4 835.6 833.8 832.0 830.3 828.5 826.8 825.1 823.4 821.8 820.1 818.5 816.9 815.3 813.7 812.1 810.5 809.0 806.0 803.0 800.0 797.1 794.2 791.4 788.6 785.8 783.1 780.5 777.7 775.2 772.5 770.0 767.4 764.9 762.4 759.9 757.5
EVAP. sfg 1.0217 1.0196 1.0175 1.0155 1.0136 1.0116 1.0096 1.0076 1.0056 1.0037 1.0018 0.9971 0.9925 0.9880 0.9835 0.9792 0.9750 0.9708 0.9667 0.9627 0.9588 0.9549 0.9510 0.9472 0.9436 0.9399 0.9363 0.9327 0.9292 0.9258 0.9225 0.9159 0.9094 0.9031 0.8970 0.8910 0.8851 0.8794 0.8738 0.8683 0.8630 0.8578 0.8527 0.8476 0.8426 0.8378 0.8330 0.8283 0.8237 0.8191
EVAP. ufg 767.1 766.2 765.4 764.6 763.8 763.0 762.1 761.3 760.6 759.8 759.0 757.1 755.2 753.2 751.3 749.5 747.7 745.9 744.1 742.4 740.7 739.0 737.3 735.6 733.9 732.3 730.7 729.1 727.5 725.9 724.3 721.3 718.3 715.4 712.4 709.6 706.8 704.0 701.3 698.6 695.9 693.3 690.8 688.2 685.7 683.2 680.7 678.2 675.7 673.4
I4-29
02-02
System Fundamentals

ABS. PRESS PSIA p 500 520 540 560 580 600 620 640 660 680 700 720 740 760 780 800 820 840 860 880 900 TEMP SPECIFIC VOLUME (ft3/in2) SAT. LIQUID vf 0.0197 0.0198 0.0199 0.0200 0.0201 0.0201 0.0202 0.0203 0.0204 0.0204 0.0205 0.0206 0.0207 0.0207 0.0208 0.0209 0.0209 0.0210 0.0211 0.0212 0.0212 EVAP. vfg 0.9081 0.8717 0.8379 0.8065 0.7772 0.7497 0.7238 0.6995 0.6767 0.6553 0.6349 0.6156 0.5973 0.5800 0.5635 0.5478 0.5329 0.5186 0.5049 0.4918 0.4794 SAT. VAPOR vg 0.9278 0.8915 0.8578 0.8265 0.7973 0.7698 0.7440 0.7198 0.6971 0.6757 0.6554 0.6362 0.6180 0.6007 0.5843 0.5687 0.5538 0.5396 0.5260 0.5130 0.5006 ENTHALPY (Btu/lb) SAT. LIQUID hf 449.4 454.1 458.6 463.0 467.4 471.6 475.7 479.8 483.8 487.7 491.5 495.3 499.0 502.6 506.2 509.7 513.2 516.6 520.0 523.3 526.6 SAT. VAPOR hg 1204.4 1204.2 1204.0 1203.8 1203.5 1203.2 1202.9 1202.5 1202.1 1201.7 1201.2 1200.7 1200.2 1199.7 1199.1 1198.6 1198.0 1197.4 1196.8 1196.1 1195.4 ENTROPY (Btu/lb,F) SAT. LIQUID sf 0.6487 0.6536 0.6584 0.6631 0.6676 0.6720 0.6763 0.6805 0.6846 0.6886 0.6925 0.6963 0.7001 0.7037 0.7073 0.7108 0.7143 0.7177 0.7210 0.7243 0.7275 SAT. VAPOR sg 1.4634 1.4596 1.4560 1.4524 1.4489 1.4454 1.4421 1.4389 1.4358 1.4327 1.4296 1.4266 1.4237 1.4209 1.4181 1.4153 1.4126 1.4099 1.4072 1.4046 1.4020 INTERNAL ENERGY (Btu/lb) SAT. LIQUID uf 447.6 452.2 456.6 460.9 465.2 469.4 473.4 477.4 481.3 485.1 488.8 492.5 496.2 499.7 503.2 506.6 510.0 513.3 516.6 519.9 523.1 SAT. VAPOR ug 1118.6 1118.4 1118.3 1118.2 1118.0 1117.7 1117.5 1117.3 1117.0 1116.7 1116.3 1116.0 1115.6 1115.2 1114.8 1114.4 1114.0 1113.6 1113.1 1112.6 1112.1
F t 467.01 471.07 475.01 478.85 482.58 486.21 489.75 493.21 496.58 499.88 503.10 506.25 509.34 512.36 515.33 518.23 521.08 523.88 526.63 529.33 531.98
EVAP. hfg 755.0 750.1 745.4 740.8 736.1 731.6 727.2 722.7 718.3 714.0 709.7 705.4 701.2 697.1 692.9 688.9 684.8 680.8 676.8 672.8 668.8
EVAP. sfg 0.8147 0.8060 0.7976 0.7893 0.7813 0.7734 0.7658 0.7584 0.7512 0.7441 0.7371 0.7303 0.7237 0.7172 0.7108 0.7045 0.6983 0.6922 0.6862 0.6803 0.6744
UNIT CONVERSIONS
Note that pressures are typically given in gauge pressure. This is the difference between the absolute pressure in the boiler and the absolute pressure of the surroundings. A gauge reads pressure differences (in most cases, the difference between the pressure of the substance and that of the atmosphere). Therefore, gauge pressure may be positive or negative (vacuum). Gauge pressures, in U.S. (English Engineering) units, are referred to as psig (pounds per square inch gauge, although the g is frequently omitted). An absolute pressure is the pressure above zero pressure, which can only be positive. Most thermodynamic tables are based on absolute pressure. In U.S. units, absolute pressure is referred to as psia (pounds per square inch absolute). Absolute pressure is calculated by adding the absolute pressure of the surroundings (atmospheric pressure) to the gauge pressure. In general, for U.S. units (psig) to convert gauge pressure to absolute pressure, add 14.696. Conversely, to convert absolute pressure to gauge pressure, subtract 14.696.
The following information is included for your convenience. Temperature Conversion Conversions Factors 2 pH Values Salinity Indicating Readings Conversion Table Useful Physical Constants Conversions Table Approximate Common Equivalents Conversions Accurate to Parts per Million
I4-30
02-02
System Fundamentals
Table I4-17. Temperature Conversion
I4-31
02-02

Table I4-18. Conversion Factors (Sheet 1 of 9)
System Fundamentals
I4-32
02-02
System Fundamentals

Table I4-18. Conversions Factors (Sheet 2 of 9)
I4-33
02-02

System Fundamentals
I4-34
02-02
System Fundamentals
I4-35
02-02

System Fundamentals
I4-36
02-02
System Fundamentals

I4-37
02-02
System Fundamentals
.Table I4-18. Conversions Factors (Sheet 7 of 9)
I4-38
02-02
System Fundamentals

I4-39
02-02
System Fundamentals
Table I4-20. Salinity Indicating Readings Conversion Table
Table I4-21. Useful Physical Constants
Table I4-19. pH Values
I4-40
02-02
System Fundamentals
Table I4-22. Conversions Table
I4-41
02-02
System Fundamentals
Table I4-23. Approximate Common Equivalents
Table I4-24. Conversions Accurate to Parts per Million
I4-42
02-02
System Fundamentals

Factory Mutual System (FM) 1151 Boston-Providence Turnpike Norwood, MA 02062 617-762-4300 FM is an association of 4 mutual insurance companies dedicated to minimizing loss of insured property. Through its research arm, the Factory Mutual Research Corporation, it investigates means of preventing and minimizing re and other losses. FM laboratories provide product testing and approval. Industrial Risk Insurers (IRI) 85 Woodland Street Hartford, CT 06105 203-520-7412 IRI is composed of stock insurance companies providing indemnity for damage caused by such perils as re, explosion, and windstorm. To assist their policyholders, IRI provides an advisory engineering service. Part of this service is the development of recommendations which serve as standards for IRI itself and its policyholders. Kemper Insurance Company 1 Kemper Drive Long Grove, IL 60049 708-320-2000 The HPR (Highly Protective Risk) Department of Kemper has developed a set of recommendation for gas and oil red boiler furnaces. These recommendations are used to determine the underwriting acceptability of proposals and completed installations. National Board of Boiler and Pressure Vessel Inspectors 1055 Crupper Avenue Columbus, OH 43229-1183 614-888-8320 The National Board is an organization comprised of Chief Inspectors of states and cities of the US and provinces of Canada organized for the purpose of promoting greater safety in the construction, installation, inspection and repair of boilers and pressure vessels. National Electric Code (NEC) 1 Batterymarch Park Quincy, MA 02269-9101 The National Electric Code is a standard established for safe wiring procedures in the interest of personal safety and re protection. The code is adopted and copyrighted by the NFPA (see National Fire Protection Association). National Fire Protection Association (NFPA) 1 Batterymarch Park Quincy, MA 02269-9101 NFPA develops and promotes standards for the purpose of advancing the science and improving the methods of re protection and prevention. I4-43
02-02
STANDARD ASSOCIATIONS
American Gas Association (AGA) 1515 Wilson Blvd. Arlington, VA 22209 703-524-2000 American National Standards Institute (ANSI) 11 West 42nd Street New York, NY 10036 212-642-4900 ANSI acts as the national coordinating institution through which interested organizations voluntarily cooperate in establishing, recognizing, and improving standards. American Society of Heating Refrigerating and Air Conditioning Engineers (ASHRAE) 1791 Tullie Circle, NE Atlanta, GA 30329 American Society of Mechanical Engineers (ASME) 345 East 47th Street New York, NY 10017 212-705-8500 The ASME develops test codes for boilers and pressure vessels and for power applications, and serves as a sponsor for ANSI in developing safety codes and standards. American Society for Nondestructive Testing 3200 Riverside Drive Columbus, Ohio 43221 American Society for Testing and Materials (ASTM) 1916 Race Street Philadelphia, PA 19103-1187 ASTM is the largest voluntary standards development system in the world publishing standards for materials, products, systems and services. Canadian Standards Association (CSA) 178 Rexdale Blvd. Etobicoke, Ontario, Canada M9W 1R3 416-747-4044 CSA, a nonprot nongovernmental body, which promotes nationwide standards for product design, construction and performance for Canada. CSA is a recognized testing agency. Canadian Gas Association (CGA) 55 Scarsdale Road Don Mils, Ontario M3B 2R3 416-447-6465 CGA, a nonprot association of manufacturers of gas utilities, provides certication service based on standards established by CSA.

Underwriters Laboratories (UL and cUL) 333 Pngsten Road Northbrook, IL 60062 UL is a nonprot organization which operates laboratories for testing for public safety. They provide listings, classication, recognition and certicate. UL is a recognized testing agency for the U.S. and Canada. Underwriters Laboratories of Canada (ULC) 7 Crouse Road Scarborough, Ontario M1R 3A9 ULC is an agency sponsored by the Canadian Underwriters Association that tests and certies products and materials against ULC established standards. It has no relationship to UL of the U.S. United States Department of Energy (DOE) 100 Independence Avenue, SW Washington, DC 20585 United States Environmental Protection Agency (EPA) Ofce of Air Quality Planning & Standards Research Triangle Park, NC 27711
System Fundamentals
I4-44
02-02
Glossary
Section J
GLOSSARY AND INDEX
GLOSSARY
A
ABSOLUTE PRESSURE - Pressure above zero pressure; the sum of the gauge and atmospheric pressures. ACCUMULATOR - (STEAM) A pressure vessel containing water and/or steam, which is used to store the heat of steam for use at a late period and at some lower pressure. ACID CLEANING - The process of cleaning the interior surfaces of steam generating units by lling the unit with dilute acid accompanied by an inhibitor to prevent corrosion, and subsequently draining, washing and neutralizing the acid by a further wash of alkaline water. ACIDITY - Represents the amount of free carbon dioxide, mineral acids and salts (especially sulphates of iron and aluminum) which hydrolyze to give hydrogen ions in water and is reported as milliequivalents per liter of acid, or ppm acidity as calcium carbonate, or pH the measure of hydrogen ions concentration. ADIABATIC FLAME TEMPERATURE - The theoretical temperature that would be attained by the products of combustion provided the entire chemical energy of the fuel, the sensible heat content of the fuel and combustion above the datum temperature were transferred to the products of combustion. This assumes: No heat loss to surroundings and no dissociation. AIR - The mixture of oxygen, nitrogen, and other gases, which with varying amounts of water vapor, forms the atmosphere of the earth. AIR ATOMIZING OIL BURNER - A burner for ring oil in which the oil is atomized by compressed air, which is forced into and through one or more streams of oil which results in the breaking of the oil into a ne spray. AIR DEFICIENCY - Insufcient air, in an air-fuel mixture, to supply the oxygen required for complete oxidation of the fuel. AIR-FREE - The descriptive characteristic of a substance from which air has been removed. AIR-FUEL RATIO - The ratio of the weight, or volume, of air to fuel. AIR INFILTRATION - The leakage of air into a setting or duct. AIR, SATURATED - Air which contains the maximum amount of water vapor that it can hold at its temperature and pressure. AIR VENT - A valved opening in the top of the highest drum of a boiler or pressure vessel for venting air. ALARM - A suitable horn, bell, light or other device which when operated will give notice of malfunction or off normal condition. ALKALINITY - Represents the amount of carbonates, bicarbonates, hydroxides and silicates or phosphates in the water and is reported as grains per gallon, or ppm as calcium carbonate. ALLOWABLE WORKING PRESSURE - See design pressure. AMBIENT AIR - The air that surrounds the equipment. The standard ambient air for performance calculations is air at 80 F, 60% relative humidity, and a barometric pressure of 29.921 in. Hg, giving a specic humidity of 0.013 lb of water vapor per lb of dry air. AMBIENT TEMPERATURE - The temperature of the air surrounding the equipment. ANALYSIS - Quantitative determination of the constituent parts. ANALYSIS, ULTIMATE - Chemical analysis of solid, liquid or gaseous fuels. In the case of coal or coke, determination of carbon, hydrogen, sulfur, nitrogen, oxygen, and ash. AQUASTAT - Water limit temperature control, a safety device often used on boilers. ARRESTER - A device to impede the ow of large dust particles or sparks from a stack, usually screening at the top. AS-FIRED FUEL - Fuel in the condition as fed to the fuel burning equipment. ASH - The incombustible inorganic matter in the fuel. ASH-FREE BASIS - The method of reporting fuel analysis, whereby ash is deducted and other constituents are recalculated to total 100%. ASH PIT - A pit or hopper located below a furnace where refuse is accumulated and from which refuse is removed at intervals. ASME - The American Society of Mechanical Engineers. ASPIRATING BURNER - A burner in which the fuel in a gaseous or nely divided form is burned in suspension, the air for combustion being supplied by bringing into contact with the fuel, air drawn through one or more openings by the lower static pressure created by the velocity of the fuel stream. AS-RECEIVED FUEL - Fuel in the condition as received at the plant. ATMOSPHERIC AIR - Air under the prevailing atmospheric conditions. ATMOSPHERIC PRESSURE - The barometric reading of pressure exerted by the atmosphere. At sea level 14.7 lb per sq in. or 29.92 in. of mercury. ATOMIZER - A device by means of which a liquid is reduced to a very ne spray. AVAILABLE DRAFT - The draft which may be utilized to cause the ow of air for combustion or the ow of products of combustion. AVAILABILITY FACTOR - The fraction of time during which the unit is in operable condition. AXIAL FAN - Consists of a propeller or disc type of wheel within a cylinder that discharges air parallel to the axis of the wheel.
J-1
Glossary B
BAFFLE - A plate or wall for deecting gases or liquids. BAFFLE TILE - A tile for deecting gases. BAFFLE-TYPE COLLECTOR - A device in gas paths utilizing bafes so arranged as to deect dust particles out of the gas stream. BAG FILTER - A device containing one or more cloth bags for recovering particles from the dust laden gas or air which is blown through it. BAG-TYPE COLLECTOR - A lter in which the cloth ltering medium is made in the form of cylindrical bags. BAROMETRIC PRESSURE - Atmospheric pressure as determined by a barometer usually expressed in inches of mercury. BASE LOAD - Base load is the term applied to that portion of a station or boiler load that is practically constant for long periods. BEADED TUBE END - The rounded exposed end of a rolled tube when the tube metal is formed over against the sheet in which the tube is rolled. BLIND NIPPLE - A nipple, or a short piece of pipe or tube, closed at one end. BLOWDOWN - Boiler water that is removed from the boiler in order to maintain the desired concentration levels of suspended and dissolved solids in the boiler and removal of sludge. BLOWDOWNSAFETY VALVE - The difference between the pressure at which a safety valve opens and at which it closes. BLOWDOWN VALVE - A valve generally used to continuously regulate concentration of solids in the boiler, not a drain valve. (Often called continuous blowdown.) BLOW-OFF VALVE - A specially designed, manually operated, valve that connects to the boiler for the purpose of reducing the concentration of solids in the boiler or for draining purposes. (Often called bottom blowdown.) BLOWER - A fan used to force air under pressure. BOILER - A closed vessel in which water is heated, steam is generated, steam is superheated, or any combination thereof, under pressure or vacuum by the application of heat from combustible fuels, electricity or nuclear energy. BOILER EFFICIENCY - The term boiler efciency is often substituted for combustion or thermal efciency. True boiler efciency is the measure of fuel-to-steam efciency. BOILER HORSEPOWER - The evaporation of 34-1/2 lbs of water per hour from a temperature of 212 F into dry saturated steam at the same temperature. Equivalent to 33,475 Btu/hr. BOILER RATING - The heating capacity of a boiler expressed in boiler horsepower, Btu/hour, or pounds of steam/hour. BOILER SHELL- The outer cylindrical portion of a pressure vessel. BOILER WATER - A term construed to mean a representative sample of the circulating boiler water, after the generated steam has been separated and before the incoming feed water or added chemical becomes mixed with it so that its composition is affected. BOILING - The conversion of a liquid into vapor with the formation of bubbles. BOILING OUT - The boiling of highly alkaline water in boiler pressure parts for the removal of oils, greases, etc. BOOSTER FAN - A device for increasing the pressure or ow of a gas. BREECHING - A duct that transports the products of combustion between parts of a steam generating unit or to the stack. BRIDGEWALL - A wall in a furnace over which the products of combustion pass. BRITISH THERMAL UNIT (Btu) - The mean British Thermal Unit is 1/ 180 of the heat required to raise the temperature of 1 lb of water from 32 F to 212 F at a constant atmospheric pressure. A Btu is essentially 252 calories. BUCKSTAY - A structural member placed against a furnace or boiler wall to restrain the motion of the wall. BUNKER C OIL - Residual fuel oil of high viscosity commonly used in marine and stationary steam power plants. (No. 6 fuel oil) BURNER - A device for the introduction of fuel and air into a furnace at the desired velocities, turbulence and concentration. BURNER WINDBOX - A plenum chamber around a burner that maintains an air pressure sufcient for proper distribution and discharge of secondary air. BURNER WINDBOX PRESSURE - The air pressure maintained in the windbox or plenum chamber measured above atmospheric pressure. BY-PASS - A passage for a uid, permitting a portion of the uid to ow around its normal pass ow channel.
C
C - Carbon element, the principal combustible constituent of all fuels. CaCO3 - Calcium Carbonate. CALORIE - The mean calorie is 1/100 of the heat required to raise the temperature of 1 gram of water from Zero C to 100 C at a constant atmospheric pressure. It is about equal to the quantity of heat required to raise one gram of water 1 C. Another denition is: A calorie is 3600/860 joules. CALORIMETER - Apparatus for determining the caloric value of a fuel. CAPACITY FACTOR - The ratio of the average load carried to the maximum design capacity. CARBON - Element. The principal combustible constituent of all fuels. CARRYOVER - The chemical solids and liquid entrained with the steam from a boiler. CASING - A covering of sheets of metal or other material such as re resistant composition board used to enclose all or a portion of a steam generating unit. CENTRAL STATION - A power plant or steam heating plant that generates power or steam. CENTRIFUGAL FAN - Consists of a fan rotor or wheel within a housing that discharges air at a right angle to the axis of the wheel. CHEMICAL ANALYSIS - Determination of the principal chemical constituents. CHEMICAL FEED PIPE - A pipe inside a boiler drum through which chemicals for treating the boiler water are introduced. CHIMNEY - A brick, metal or concrete stack. CIRCULATION - The movement of water and steam within a steam generating unit.
J-2
Glossary
CIRCULATION RATIO - The ratio of water entering a circuit to the steam generated by that passes that circuit in a unit of time. CIRCULATOR - A pipe or tube to pass steam or water between upper boiler drums usually located where the heat absorption is low. Also used to apply to tubes connecting headers of horizontal water tube boilers with drums. CLEANOUT DOOR - A door placed so that accumulated refuse may be removed room a boiler setting. CO - Carbon monoxide. CO2 - Carbon dioxide. COLLECTOR - A device used for removing gas borne solids from ue gas. COLLOID - A nely divided organic substance which tends to inhibit the formation of dense scale and results in the deposition of sludge, or causes it to remain in suspension, so that it may be blown from the boiler. COMBUSTIBLE LOSS - The loss representing the unliberated thermal energy occasioned by failure to oxidize completely some of the combustible matter in the fuel. COMBUSTIBLES - The heat producing constituents of a fuel. COMBUSTION - The rapid chemical combination of oxygen with the combustible elements of a fuel resulting in the release of heat. COMBUSTION AIR - Air used in the combustion process. Air contains oxygen which is required to combust fuel. COMBUSTION CHAMBER - See Furnace. COMBUSTION EFFICIENCY - The effectiveness of the burner to completely burn the fuel. A well designed burner will operate with as little as 10 to 20% excess air, while converting all combustibles in the fuel to useful energy. COMPLETE COMBUSTION - The complete oxidation of all the combustible constituents of a fuel. CONCENTRATION - (1) The weight of solids contained in a unit weight of boiler or feed water. (2) The number of times that the dissolved solids have increased from the original amount in the feedwater to that in the boiler water due to evaporation in generating steam. CONDENSATE Condensed water resulting from the removal of latent heat from steam. CONDUCTION - The transmission of heat through and by means of matter unaccompanied by any obvious motion of the matter. CONDUCTIVITY - (1) A material property relating heat ux (heat transferred per unit area per unit time) to a temperature difference. In American units, it is typically dened as the amount of heat (Btu) transmitted in one hour through one square foot of material 1 inch thick, with a temperature difference of 1F between the two surfaces of the material. (2) The property of a water sample to transmit electric current under a set of standard conditions. Usually expressed as microhms conductance. CONTINUOUS BLOWDOWN - The uninterrupted removal of concentrated boiler water from a boiler to control total solids concentration in the remaining water. CONTROL - Any manual or automatic device for the regulation of a machine to keep it at normal operation. If automatic, the device is motivated by variations in temperature, pressure, water level, time, light, or other inuences. CONTROL VALVE - A valve used to control the ow of air, gas, water, steam or other substance. CONVECTION - The transmission of heat by the circulation of a liquid or gas. It may be natural, with the circulation caused by buoyancy affects due to temperature differences, or forced with circulation caused by a mechanical device such as a fan or pump. CORROSION - The wasting away of metal due to chemical action. In a boiler, usually caused by the presence of O2, CO2, or an acid. CROWN SHEET - In a rebox boiler, the plate forming the top of the furnace. CRUDE OIL - Unrened petroleum. CSD-1 - Abbreviation for the ASME standard for Controls and Safety Devices.
D
DAMPER - A device for introducing a variable pressure drop in a system used for regulating the volumetric ow of a gas, such as air. DAVIT - The structure on large retube boilers from which the front and rear doors are suspended when opened. DEAERATION - Removal of air and gases from boiler feed water prior to its introduction to a boiler. DEGASIFICATION - Removal of gases from samples of steam taken for purity test. Removal of CO2 from water as in the ion exchange method of softening. DELAYED COMBUSTION - A continuation of combustion beyond the furnace. (See also Secondary Combustion.) DESIGN LOAD - The load for which a steam generating unit is designed, considered the maximum load to be carried. DESIGN PRESSURE - The pressure used in the design of a boiler for the purpose of calculating the minimum permissible thickness or physical characteristics of the different parts of the boiler. DESIGN STEAM TEMPERATURE - The temperature of steam for which a boiler is designed. DEW POINT - The temperature at which condensation starts. DISENGAGING SURFACE - The surface of the boiler water from which steam is released. DISSOCIATION - The process by which a chemical compound breaks down into simpler constituents, as do CO2 and H2O at high temperature. DISSOLVED SOLID - Those solids in water which are in solution. DISTILLATE FUELS - Liquid fuels distilled usually from crude petroleum. DISTILLATION - Vaporization of a substance with subsequent recovery of the vapor by condensation. Often used in less precise sense to refer to vaporization of volatile constituents of a fuel without subsequent condensation. DISTILLED WATER - Water produced by vaporization and condensation with a resulting higher purity. DOWNCOMER - A tube or pipe in a boiler or waterwall circulating system through which uid ows downward. DOWNTIME - Amount of time a piece of equipment is not operational.
J-3
Glossary
DRAFT - The difference between atmospheric pressure and some lower pressure existing in the furnace stack or gas passages of a steam generating unit. DRAFT DIFFERENTIAL - The difference in static pressure between two points in a system. DRAFT GAUGE -A device for measuring draft, usually in inches of water. DRAIN - A valved connection at the lowest point for the removal of all water from the pressure parts. DRUM - A cylindrical shell closed at both ends designed to withstand internal pressure. DRY AIR - Air with which no water vapor is mixed. This term is used comparatively, since in nature there is always some water vapor included in air, and such water vapor, being a gas, is dry. DRYBACK BOILER - Firetube boiler with a refractory lined back door. Door opens to allow maintenance and/or inspection. DRY GAS - Gas containing no water vapor. DRY-GAS LOSS - The loss representing the difference between the heat content of the dry exhaust gases and their heat content at the temperature of ambient air. DRY STEAM - Steam containing no moisture. Commercially dry steam containing not more than one half of one percent moisture. DUCT - A passage for air or gas ow. EXCESS AIR - Air supplied for combustion in excess of that theoretically required for complete oxidation. EXPANSION JOINT - The joint to permit movement due to expansion without undue stress. EXPLOSION DOOR - A door in a furnace or boiler setting that is designed to be opened by a pre-determined gas pressure. EXTERNAL TREATMENT - Treatment of boiler feed water prior to its introduction into the boiler.
F
FAN - A machine consisting of a rotor and housing for moving air or gases at relatively low pressure differentials. FAN PERFORMANCE - A measure of fan operation in terms of volume, total pressures, static pressures, speed, power input, mechanical and static efciency, at a stated air density. FAN PERFORMANCE CURVES - The graphical presentation of total pressure, static pressure, power input, mechanical and static efciency as ordinates and the range of volumes as abscissa, all at constant speed and air density. FEED PUMP - A pump that supplies water to a boiler. FEEDWATER - Water introduced into a boiler during operation. It includes make-up and return condensate. FEEDWATER TREATMENT - The treatment of boiler feed water by the addition of chemicals to prevent the formation of scale or to eliminate other objectionable characteristics. FGR - Flue Gas Recirculation or the recirculation of ue gas with combustion air to reduce NOx emissions. FILTER - Porous material through which uids or uid - and solid mixtures are passed to separate matter held in suspension. FIN - A n is an extended surface, a solid, experiencing energy transfer by conduction within its boundaries, as well as energy transfer with its surroundings by convection and/or radiation, used to enhance heat transfer by increasing surface area. FIN TUBE - A tube with one or more ns. FIRED PRESSURE VESSEL - A vessel containing a uid under pressure exposed to heat from the combustion of fuel. FIRETUBE - A type of boiler design in which combustion gases ow inside the tubes and water ows outside the tubes. FIRING RATE CONTROL - A pressure temperature or ow controller which controls the ring rate of a burner according to the deviation from pressure or temperature set point. The system may be arranged to operate the burner on-off, high-low or in proportion to load demand. FIXED CARBON - The carbonaceous residue less the ash remaining in the test container after the volatile matter has been driven off in making the proximate analysis of a solid fuel. FLAME - A luminous body of burning gas or vapor. FLAME DETECTOR - A device which indicates if a fuel (liquid, gaseous, or pulverized) is burning, or if ignition has been lost. The indication may be transmitted to a signal or to a control system. FLAME PROPAGATION RATE - Speed of travel of ignition through a combustible mixture.
E
ECONOMIZER - Utilizes waste heat by transferring heat from ue gases to warm incoming feedwater. EDR - Equivalent direct radiation is the rate of heat transfer from a radiator or convector. It is equivalent to the square feet of surface area necessary to transfer heat at the same rate at which it is produced by a generator. A single boiler horsepower equals 140 ft2 EDR. EFFICIENCY - The ratio of output to input. See also Combustion, Fuelto-Steam and Thermal Efciency. EJECTOR - A device which utilizes the kinetic energy in a jet of water or other uid to remove a uid or uent material from tanks or hoppers. ELECTRIC BOILER - A boiler in which electric energy is used as the source of heat. ELECTROSTATIC PRECIPITATOR - A device for collecting dust, mist or fume from a gas stream, by placing an electrical charge on the particle and removing that particle onto a collecting electrode. ENTRAINMENT - The conveying of particles of water or solids from the boiler water by the steam. EQUALIZER - Connections between parts of a boiler to equalize pressures. EQUIVALENT EVAPORATION - Evaporation expressed in pounds of water evaporated from a temperature of 212 F to dry saturated steam at 212 F. EVAPORATION - The change of state from a liquid to a vapor. EVAPORATION RATE - The number of pounds of water that is evaporated in a unit of time.
J-4
Glossary
FLAME SAFEGUARD - A control that sequences the burner through several stages of operation to provide proper air purge, ignition, normal operation, and shutdown for safe operation. FLAMMABILITY - Susceptibility to combustion. FLASHING - The process of producing steam by discharging water into a region of pressure lower than the saturation pressure that corresponds to the water temperature FLASH POINT - The lowest temperature at which, under specied conditions, fuel oil gives off enough vapor to ash into a momentary ame when ignited. FLUE - A passage for products of combustion. FLUE GAS - The gaseous product of combustion in the ue to the stack. FOAMING - The continuous formation of bubbles which have sufciently high surface tension to remain as bubbles beyond the disengaging surface. FORCED CIRCULATION - The circulation of water in a boiler by mechanical means external to the boiler. FORCED-DRAFT FAN - A fan supplying air under pressure to the fuel burning equipment. FOULING - The accumulation of refuse in gas passages or on heat absorbing surfaces which results in undesirable restriction to the ow of gas or heat. FM - Factory Mutual. FREE ASH - Ash which is not included in the xed ash. FUEL - A substance containing combustible used for generating heat. FUEL-AIR MIXTURE - Mixture of fuel and air. FUEL-AIR RATIO - The ratio of the weight, or volume, of fuel to air. FUEL OIL - A liquid fuel derived from petroleum or coal. FUEL-TO-STEAM EFFICIENCY - The ratio of heat added to boiler feedwater to produce the output steam to the amount of energy inputted with fuel. FURNACE - An enclosed space provided for the combustion of fuel. FURNACE PRESSURE - Pressure occurring inside the combustion chamber; positive if greater than atmospheric, negative if less than atmospheric, and neutral if equal to atmospheric. FURNACE VOLUME - The cubic contents of the furnace or combustion chamber. FUSIBLE PLUG - A hollowed threaded plug having the hollowed portion lled with a low melting point material. GAUGE GLASS - The transparent part of a water gauge assembly connected directly or through a water column to the boiler, below and above the water line, to indicate the water level in a boiler. GAUGE PRESSURE - The pressure above atmospheric pressure. GRADE - Oil classication according to quality, generally based on ASTM specications. GRAINS PER CU-FT - The term for expressing dust loading in weight per unit of gas volume (7000 grains equals one pound). GRAINS (WATER) - A unit of measure commonly used in water analysis for the measurement of impurities in water (17.1 grains = 1 part per million - ppm). GRAVITY - Weight index of fuels: liquid, petroleum products expressed either as specic, Baume or A.P.I. (American Petroleum Institute) gravity; weight index of gaseous fuels as specic gravity related to air under specied conditions; or weight index of solid fuels as specic gravity related to water under specied conditions.
H
HANDHOLE - An access opening in a pressure part usually not exceeding 6" in its longest dimension. HANDHOLE COVER - A handhole closure. HARDNESS - A measure of the amount of calcium and magnesium salts in water. Usually expressed as grains per gallon or ppm as CaCO3. HARD WATER - Water which contains calcium or magnesium in an amount which require an excessive amount of soap to form a lather. HEAT AVAILABLE - The thermal energy above a xed datum that is capable of being absorbed for useful work. HEAT BALANCE - An accounting of the distribution of the heat input, output and losses. HEAT EXCHANGER - A vessel in which heat is transferred from one medium to another. HEAT RELEASE RATE - Rate that describes the heat available per square foot of heat-absorbing surface in the furnace or per cubic foot of volume. HEATING SURFACE - Those surfaces which are exposed to products of combustion on one side and water on the other. This surface is measured on the side receiving the heat. HEATING VALUE - The quantity of heat released by a fuel through complete combustion. It is commonly expressed in Btu per lb, per gallon, or cu-ft. HIGH GAS PRESSURE CONTROL - A control to stop the burner if the gas pressure is too high. HIGH OIL TEMPERATURE CONTROL - A control to stop the burner if the oil temperature is too high. HYDROCARBON - A chemical compound of hydrogen and carbon. HYDROSTATIC TEST - A strength and tightness test of a closed pressure vessel by water pressure.
G
GAS ANALYSIS - The determination of the constituents of a gaseous mixture. GAS BURNER - A burner that uses gas or fuel. GAS PRESSURE REGULATOR - A spring loaded, dead weighted or pressure balanced device which will maintain the gas pressure to the burner supply line. GAUGE COCK - A valve attached to a water column or drum for checking water level.
I
IGNITION - The initiation of combustion. IGNITION TEMPERATURE - Lowest temperature of a fuel at which combustion becomes self-sustaining.
J-5
Glossary
ILLUMINANTS - Light oil or coal compounds that readily burn with a luminous ame, such as ethylene, propylene and benzene. INCOMPLETE COMBUSTION - The partial oxidation of the combustible constituents of a fuel. INDUCED DRAFT FAN- A fan exhausting hot gases from the heat absorbing equipment. INERT GASEOUS CONSTITUENTS - Incombustible gases such as nitrogen which may be present in a fuel. INHIBITOR - A substance which selectively retards a chemical action. An example in boiler work is the use of an inhibitor, when using acid to remove scale, to prevent the acid from attacking the boiler metal. INJECTOR - A device utilizing a steam jet to entrain and deliver feed water into a boiler. INSULATION - A material of low thermal conductivity used to reduce heat losses. INTEGRAL BLOWER - A blower built as an integral part of a device to supply air thereto. INTEGRAL-BLOWER BURNER - A burner of which the blower is an integral part. INTERLOCK - A device to prove the physical state of a required condition, and to furnish that proof to the primary safety control circuit. INTERMITTENT BLOWDOWN - the blowing down of boiler water at intervals. INTERNAL TREATMENT - The treatment of boiler water by introducing chemicals directly into the boiler. ION - A charged atom or radical which may be positive or negative. IRI - Industrial Risk Insurers. LUG - Any projection, like an ear, used for supporting or grasping.
M
MAKE-UP - The water added to boiler feed to compensate for that lost through exhaust, blowdown, leakage, etc. MANHOLE - The opening in a pressure vessel of sufcient size to permit a man to enter. MANIFOLD - A pipe or header for collection of a uid from, or the distribution of a uid to a number of pipes or tubes. MANUAL GAS SHUTOFF VALVE - A manually operated valve in a gas line for the purpose of completely turning on or shutting off the gas supply. MANUFACTURED GAS - Fuel gas manufactured from coal, oil, etc., as differentiated from natural gas. MAXIMUM ALLOWABLE WORKING PRESSURE - The maximum gauge pressure permissible in a completed boiler. The MAWP of the completed boiler shall be less than or equal to the lowest design pressure determined for any of its parts. This pressure is based upon either proof tests or calculations for every pressure part of the boiler using nominal thickness exclusive of allowances for corrosion and thickness required for loadings other than pressure. It is the basis for the pressure setting of the pressure relieving devices protecting the boiler. MAXIMUM CONTINUOUS LOAD - The maximum load which can be maintained for a specied period. MAXIMUM INSTANTANEOUS DEMAND - The sudden load demand on a boiler beyond which an unbalanced condition may be established in the boiler's internal ow pattern and/or surface release conditions. MECHANICAL ATOMIZING OIL BURNER - A burner which uses the pressure of the oil for atomization. MECHANICAL DRAFT - The negative pressure created by mechanical means. MICRON - One millionth of a meter, or 0.000039 in. or 1/25400 in. The diameter of dust particles is often expressed in microns. MINIATURE BOILER - Fire pressure vessels which do not exceed the following limits: 16 in. inside diameter of shell; 42 in., overall length to outside of heads at center; 20 sq ft water heating surface; or 100 psi maximum allowable working pressure. MMBtu - Millions of Btus (British Thermal Units). MOISTURE - Water in the liquid or vapor phase. MOISTURE IN STEAM - Particles of water carried in steam, expressed as the percentage by weight. MOISTURE LOSS - The boiler ue gas loss representing the difference in the heat content of the moisture in the exit gases and that at the temperature of the ambient air. MULTIFUEL BURNER - A burner by means of which more than one fuel can be burned. MULTIPORT BURNER - A burner having a number of nozzles from which fuel and air are discharged.
L
LAGGING - A light gauge steel covering used over a boiler, usually combined with insulation, to provide a low temperature outer surface. LEAKAGE - The uncontrolled quantity of uid which enters or leaves through the enclosure of air or gas passages. LIBERATION - See Heat Release. LIMIT CONTROL - A switching device that completes or breaks an electrical circuit at predetermined pressures or temperatures. Also known as an interlock. See interlock. LINING - The material used on the furnace side of a furnace wall. It is usually of high grade refractory tile or brick or plastic refractory material. LOAD - The rate of output required; also the weight carried. LOAD FACTOR - The ratio of the average load in a given period to the maximum load carried during that period. LOW GAS PRESSURE CONTROL - A control to stop the burner if gas pressure is too low. LOW OIL TEMPERATURE CONTROL - (Cold Oil Switch) A control to prevent burner operation if the temperature of the oil is too low. LOW WATER CUTOFF - Safety device that shuts off the boiler/burner in the event of low water, preventing pressure vessel failure.
J-6
Glossary N
NATURAL CIRCULATION - The circulation of water in a boiler caused by differences in density. NATURAL GAS - Gaseous fuel occurring in nature. NET POSITIVE SUCTION HEAT (NPSH) - The liquid pressure that exists at the suction end of a pump. If the NPSH is insufcient, the pump can cavitate. NOx - Abbreviation for all of the family of oxides of nitrogen. NOZZLE - a short anged or welded neck connection on a drum or shell for the outlet or inlet of uids; also a projecting spout through which a uid ows. pH - The hydrogen ion concentration of a water to denote Acidity or Alkalinity. A pH of 7 is neutral. A pH above 7 denotes alkalinity while one below 7 denotes acidity. This pH number is the negative exponent of 10 representing hydrogen ion concentration in grams per liter. For instance a pH of 7 represent 10-7 grams per liter. PILOT - (See also Ignitor.) A ame which is utilized to ignite the fuel at the main burner or burners. PITOT TUBE - An instrument which will register total pressure and static pressure in a gas stream, used to determine its velocity. PITTING - A concentrated attack by oxygen or other corrosive chemicals in a boiler, producing a localized depression in the metal surface. PORT - An opening through which uid passes. POST PURGE - A method of scavenging the furnace and boiler passes to remove all combustible gases after ame failure controls have sensed pilot and main burner shutdown and safety shut-off valves are closed. ppm - Abbreviation for parts per million. Used in chemical determinations as one part per million parts by weight. PRECIPITATE - To separate materials from a solution by the formation of insoluble matter by chemical reaction. The material which is removed. PRECIPITATION - The removal of solid or liquid particles from a uid. PREHEATED AIR - Air at a temperature exceeding that of the ambient air. PRESSURE - Force per unit of area. PRESSURE DROP - The difference in pressure between two points in a system, caused by resistance to ow. PRESSURE VESSEL - A closed vessel or container designed to conne a uid at a pressure above atmospheric. PRIMARY AIR - Air introduced with the fuel at the burner. PRIMING - The discharge of steam containing excessive quantities of water in suspension from a boiler, due to violent ebullition. PROCESS STEAM - Steam used for industrial purposes other than for producing power. PRODUCTS OF COMBUSTION - The gases, vapors, and solids resulting form the combustion of fuel. PULSATION - Rapid uctuations in pressure. PURGE - To introduce air into the furnace and the boiler ue passages in such volume and manner as to completely replace the air or gas-air mixture contained therein.
O
OIL BURNER - A burner for ring oil. OIL HEATING AND PUMPING SET - A group of apparatus consisting of a heater for raising the temperature of the oil to produce the desired viscosity, and a pump for delivering the oil at the desired pressure. OPERATING CONTROL - A control to start and stop the burner - must be in addition to the high limit control. OPERATING PRESSURE - The pressure at which a boiler is operated. ORGANIC MATTER - Compounds containing carbon often derived from living organisms. ORIFICE - (1) The opening from the whirling chamber of a mechanical atomizer or the mixing chamber of a steam atomizer through which the liquid fuel is discharged. (2) A calibrated opening in a plate, inserted in a gas stream for measure velocity of ow. ORSAT - a gas-analysis apparatus in which certain gaseous constituents are measured by absorption in separate chemical solution. OVERPRESSURE - Minimum operating pressure of a hot water boiler sufcient to prevent the water from steaming. OXIDATION - chemical combination with oxygen. OXIDIZING ATMOSPHERE - An atmosphere which tends to promote the oxidation of immersed materials. OXYGEN ATTACK - Corrosion or pitting in a boiler caused by oxygen.
P
PACKAGED BOILER - A boiler supplied with all of its components burner, controls and auxiliary equipment, designed as a single engineered package, and ready for on-site installation. PACKAGED STEAM GENERATOR - See Packaged Boiler. PARTICLE SIZE - A measure of dust size, expressed in microns or per cent passing through a standard mesh screen. PASS - A conned passageway, containing heating surface, through which a uid ows in essentially one direction. PERFECT COMBUSTION - The complete oxidation of all the combustible constituents of a fuel, utilizing all the oxygen supplied. PETROLEUM - Naturally occurring mineral oil consisting predominately of hydrocarbons.
R
RADIATION LOSS - A comprehensive term used in a boiler-unit heat balance to account for the conduction, radiation, and convection heat losses from the boiler to the ambient air. RATED CAPACITY - The manufacturers stated capacity rating for mechanical equipment; for instance, the maximum continuous capacity in pounds of steam per hour for which a boiler is designed. RATE OF BLOWDOWN - A rate normally expressed as a percentage of the water fed. RATING - See Load.
J-7
Glossary
RAW WATER - Water supplied to the plant before any treatment. REACTION - A chemical transformation or change brought about by the interaction of two substances. REASSOCIATION - The recombination of the products of dissociation. RECIRCULATION - The reintroduction of part of the owing uid to repeat the cycle of circulation. REDUCING ATMOSPHERE - An atmosphere which tends to 1) promote the removal of oxygen from a chemical compound; 2) promote the reduction of immersed materials. REDUCTION - Removal of oxygen from a chemical compound. REFRACTORY - Brickwork or castable used in boilers to protect metal surfaces and for boiler bafes. RELATIVE HUMIDITY - The ratio of the mass of water vapor present in a unit volume of gas to the maximum possible mass of water vapor in unit volume of the same gas at the same temperature and pressure. RELIEF VALVE (Safety Relief Valve) - An automatic pressure relieving device actuated by the pressure upstream of the valve and characterized by opening pop action with further increase in lift with an increase in pressure over popping pressure. RESIDUAL FUELS - Products remaining from crude petroleum by removal of some of the water and an appreciable percentage of the more volatile hydrocarbons. RESIN - A bead-like material used in chemical exchange for softeners and dealkalizers. RESISTANCE - Impediment to gas ow, such as pressure drop or draft loss through a dust collector. Usually measured in inches water column (wc). RETURN FLOW OIL BURNER - A mechanical atomizing oil burner in which part of the oil supplied to the atomizer is withdrawn and returned to storage or to the oil line supplying the atomizer. RINGELMANN CHART - A series of four rectangular grids of black lines of varying widths printed on a white background, and used as a criterion of blackness for determining smoke density in stack gas streams. ROTARY OIL BURNER - A burner in which atomization is accomplished by feeding oil to the inside of a rapidly rotating cup. SATURATED TEMPERATURE - The temperature at which evaporation occurs at a particular pressure. SATURATED WATER - Water at its boiling point. SCALE - A hard coating or layer of materials on surfaces of boiler pressure parts. SECONDARY AIR - Air for combustion supplied to the furnace to supplement the primary air. SECONDARY TREATMENT - Treatment of boiler feed water or internal treatment of boiler-water after primary treatment. SEDIMENT - (1) Matter in water which can be removed from suspension by gravity or mechanical means. (2) A non-combustible solid matter which settles out at bottom of a liquid; a small percentage is present in residual fuel oils. SEGREGATION - The tendency of refuse of varying compositions to deposit selectively in difference parts of the unit. SELF-SUPPORTING STEEL STACK - A steel stack of sufcient strength to require no lateral support. SERVICE WATER - General purpose water which may or may not have been treated for a special purpose. SHELL - The cylindrical portion of a pressure vessel. SLUDGE - A soft water-formed sedimentary deposit which normally can be removed by blowing down. SLUG - A large dose of chemical treatment applied internally to a steam boiler intermittently. Also used sometimes instead of priming to denote a discharge of water out through a boiler steam outlet in relatively large intermittent amounts. SMOKE - Small gas borne particles of carbon or soot, less than 1 micron in size, resulting from incomplete combustion of carbonaceous materials and of sufcient number to be observable. SOFTENING - The act of reducing scale forming calcium and magnesium impurities from water. SOFT WATER - Water which contains little or no calcium or magnesium salts, or water from which scale forming impurities have been removed or reduced. SOLUTION - A liquid, such as boiler water, containing dissolved substances. SOOT - Unburned particles of carbon derived from hydrocarbons. SOOT BLOWER - A mechanical device for discharging steam or air to clean heat absorbing surfaces. SPALLING - The breaking off of the surface of refractory material as a result of internal stresses. SPECIFIC HEAT - The quantity of heat, expressed in Btu, required to raise the temperature of 1 lb of a substance 1oF. SPECIFIC HUMIDITY - The weight of water vapor in a gas water-vapor mixture per unit weight of dry gas. SPRAY ANGLE - The angle included between the sides of the cone formed by liquid fuel discharged from mechanical, rotary atomizers and by some forms of steam or air atomizers. SPRAY NOZZLE - A nozzle from which a liquid fuel is discharged in the form of a spray.
S
SADDLE - A casting, fabricated chair, or member used for the purpose of support. SAFE WORKING PRESSURE - See Design Pressure. SAFETY VALVE - A spring loaded valve that automatically opens when pressure attains the valve setting. Used to prevent excessive pressure from building up in a boiler. SAFETY SHUT-OFF VALVE - A manually opened, electrically latched, electrically operated safety shut-off valve designed to automatically shut off fuel when de-energized. SAMPLING - The removal of a portion of a material for examination or analysis. SATURATED AIR - Air which contains the maximum amount of water vapor that it can hold at its temperature and pressure. SATURATED STEAM - Steam at the temperature and pressure at which evaporation occurs.
J-8
Glossary
STACK - A vertical conduit, which due to the difference in density between internal and external gases, creates a draft at its base. STACK DRAFT - The magnitude of the draft measured at the inlet to the stack. STACK EFFECT - That portion of a pressure differential resulting from difference in elevation of the points of measurement. STACK EFFLUENT - Gas and solid products discharged from stacks. STAGNATION - The condition of being free from movement or lacking circulation. STANDARD AIR - Dry air weighing 0.075 lb per cu ft at sea level (29.92" Barometric Pressure) and 70 oF. STANDARD FLUE GAS - Gas weighing 0.078 lb per cu ft at sea level (29.92" Barometric Pressure) and 70 oF. STATIC PRESSURE - The measure of potential energy of a uid. STEAM - The vapor phase of water, unmixed with other gases. STEAM ATOMIZING OIL BURNER - A burner for ring oil which is atomized by steam. It may be of the inside or outside mixing type. STEAM BINDING - A restriction in circulation due to a steam pocket or a rapid steam formation. STEAM GAUGE - A gauge for indicating the pressure of steam. STEAM GENERATING UNIT - A unit to which water, fuel, and air are supplied and in which steam is generated. It consists of a boiler furnace, and fuel burning equipment, and may include as component parts water walls, superheater, reheater, economizer, air heater, or any combination thereof. STEAM PURITY- The degree of contamination. Contamination is expressed in ppm. STEAM QUALITY - The percent by weight of vapor in a steam and water mixture. STEAM SEPARATOR - A device for removing the entrained water from steam. STRAINER - A device, such as a lter, to retain solid particles allowing a liquid to pass. STRATIFICATION - Non-homogeneity existing transversely in a gas stream. STUD - A projecting pin serving as a support or means of attachment. SUPERHEATED STEAM - Steam with its temperature raised above that of saturation. The temperature in excess of its saturation temperature is referred to as superheat. SURFACE BLOWOFF - Removal of water, foam, etc. from the surface at the water level in a boiler. The equipment for such removal. SURGE - The sudden displacement or movement of water in a closed vessel or drum. SUSPENDED SOLIDS - Undissolved solids in boiler water. SWINGING LOAD - A load that changes at relatively short intervals. THEORETICAL AIR - The quantity of air required for perfect combustion. THEORETICAL DRAFT - The draft which would be available at the base of a stack if there were no friction or acceleration losses in the stack. THEORETICAL FLAME TEMPERATURE - See Adiabatic Flame Temperature. THERM - A unit of heat applied especially to gas. One therm = 100,000 Btu. THERMAL EFFICIENCY - The efciency of a boiler, based on the ratio of heat absorbed to total heat input. This does not include heat loss from the boiler shell. THERMAL SHOCK - A cycle of temperature swings that result in failure of metal due to expansion and contraction. THERMOCOUPLE - A temperature measuring instrument. TILE - A preformed refractory, usually applied to shapes other than standard brick. TOTAL AIR - The total quantity of air supplied to the fuel and products of combustion. Percent total air is the ratio of total air to theoretical air, expressed as percent. TOTAL PRESSURE - The sum of the static and velocity pressures. TOTAL SOLIDS CONCENTRATION - The weight of dissolved and suspended impurities in a unit weight of boiler water, usually expressed in ppm. TRAP - A receptacle for the collection of undesirable material. TREATED WATER - Water which has been chemically treated to make it suitable for boiler feed. TRIM - Ancillary boiler components, like water level controls, pressure controls, and temperature controls. TUBE - A hollow cylinder for conveying uids. TUBE HOLE - A hole in a drum, heater, or tube sheet to accommodate a tube. TURBULENT BURNER - A burner in which fuel and air are mixed and discharged into the furnace in such a manner as to produce turbulent ow from the burner. TURNDOWN RATIO - Ratio of maximum to minimum fuel or steam input or boiler output.
U
ULTIMATE ANALYSIS - See Analysis Ultimate. UL LISTED - Product certication that indicates the product meets safety standards determined by Underwriters Laboratories. (ULC and cUL indicate Canadian requirements.) UNACCOUNTED-FOR LOSS - That portion of a boiler heat balance which represents the difference between 100 per cent and the sum of the heat absorbed by the unit and all the classied losses expressed as per cent. UNBURNED COMBUSTIBLE - The combustible portion of the fuel which is not completely oxidized. UNFIRED PRESSURE VESSEL - A vessel designed to withstand internal pressure, neither subjected to heat from products of combustion nor an integral part of a red pressure vessel system.
T
TERTIARY AIR - Air for combustion supplied to the furnace to supplement the primary and secondary air.
J-9
Glossary
USE FACTOR - The ratio of hours in operation to the total hours in that period. WET STEAM - Steam containing moisture. WINDBOX - A chamber below the grate or surrounding a burner, through which air under pressure is supplied for combustion of the fuel. WINDBOX PRESSURE - The static pressure in the windbox of a burner or stoker.
V
VA - Volt amperes. VAPOR - The gaseous product of evaporation. VAPORIZATION - The change from liquid or solid phase to the vapor phase. VELOCITY PRESSURE - The measure of the kinetic energy of a uid. VENT - An opening in a vessel or other enclosed space for the removal of gas or vapor. VERTICAL FIRING - An arrangement of a burner such that air and fuel are discharged into the furnace in practically a vertical direction. VISCOSITY - Measure of the internal friction of a uid or its resistance to ow. VOLATILE MATTER Those products given off by a material as gas or vapor, determined by denite prescribed methods. VOLUME OF AIR - The number of cu ft of air per min expressed at fan outlet conditions.
W
WASTE HEAT - Sensible heat in non-combustible gases discharged to the environment. WATER - A liquid composed of two parts of hydrogen and sixteen parts oxygen by weight. WATER COLUMN - A vertical tubular member connected at its top and bottom to the steam and water space respectively of a boiler, to which the water gauge, water level controls, and fuel cutoff may be connected. WATER GAUGE - The gauge glass and its ttings for attachment. WATER HAMMER - A sudden increase in pressure of water due to an instantaneous conversion of momentum to pressure. WATER LEVEL - The elevation of the surface of the water in a boiler. WATER SOFTENER - Removes hardness (CaCO3) from water through an ion exchange of sodium with calcium and magnesium. WATER TUBE - A tube in a boiler having the water and steam on the inside and heat applied to the outside. WATER VAPOR - A synonym for steam, usually used to denote steam of low absolute pressure. WEEP - A term usually applied to a minute leak in a boiler joint which forms droplets (or tears) of water very slowly. WETBACK BOILER - Firetube boiler design wherein the back portion of the boiler has a water jacket. WET-BULB TEMPERATURE - The lowest temperature which a water wetted body will attain when exposed to an air current. This is the temperature of adiabatic saturation, and can be used to measure humidity. WETNESS - A term used to designate the percentage of water in steam. Also used to describe the presence of a water lm on heating surface interiors.
J-10
Index
INDEX
-AAccumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-7 Activated Carbon Media Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H7-6 H7-10 Air Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-3
Application and Energy Use Audit, See Steam Systems Section Application/Load, See Boiler Selection Consideration Section, also see Steam Systems Section
ASCII Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-21

ASME Code, see Boiler Selection Consideration Section, also see specic boiler product section
Associations, List of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-43 I4-44 Assured Low Fire Cut Off Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-30 Automatic Fuel Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-32
also see specic boiler products section
-BBent Tube Boiler, see Commercial Boilers, then see Flexible Watertube Boiler Section
BLOWDOWN HEAT RECOVERY SYSTEMS (Section H-11) Dimensions

Model BHR-M (Multiple Boiler) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-10 Model BHR-S (Single Boiler) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-8
Dimensions and Ratings

Model BHR-LPS (Low Pressure) (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-12
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-3 Product Offering

Models BHR-S and BHR-M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-3 H11-4 Model BHR-LPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-4
Ratings/Capacities
Model BHR-M (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-11 Model BHR-S (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-9
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-13 H11-14 Selection, Model BHR-LPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-4 Selection and Payback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-5 H11-7 BLOWDOWN SEPARATOR (Section H-10) Dimensions
5D Model Aftercooler (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Drain Water (18DF) Aftercooler (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Drain Water (20AO) Aftercooler (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blowdown Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Floor Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sizing Boiler Blowdown Separators (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling Water Line and Valve (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wall Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-7 H10-5 H10-6 H10-4 H10-8 H10-4 H10-6 H10-9
Engineering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-5
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-3 Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-3 Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-2 Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-10 Blowdown Systems, discussed, See Steam Systems Section Blowdown, Types of I3-16 Blowdown Water Requirements, see specific boiler product section under Engineering Data BOILER FEED SYSTEMS (Section H5), See also Steam Systems Section Dimensions and Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-5 H5-8
Dual System Selection (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-7 Internal Steam Heater Assemblies High Pressure Systems (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-9 Low Pressure Systems (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-10
J-11
Index
Simplex and Duplex System Selection (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-6 Triplex System Selection (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-8 Vent Capacity Chart (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-5
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H5-3 Package Concept

Intermittent (On-Off) Pump Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-10 Makeup Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-11 Optional Steam Preheater Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-11 Preheater Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-11 Pump Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-10 Pump Material of Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-10 H5-11 Pump Total Dynamic Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-10 Receiver Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-11 Receiver Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-11
Product Offering
Capacities, Tank (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Duplex Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selection Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Units (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Simplex and Duplex Units (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Triplex Units (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Simplex Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Triplex Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-3 H5-4 H5-3 H5-4 H5-7 H5-6 H5-8 H5-3 H5-4
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H5-12 BOILER SELECTION CONSIDERATIONS (Section I1) Common Boiler Types (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-3
Cast Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4 Commercial Watertube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4 Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4 Firebox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4 Firetube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-3 Flexible (Bent Tube). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4 Industrial Watertube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4 Membrane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4 Scotch Marine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Common Boiler Types, chart of. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3 Payback Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10 I1-20
Annual Fuel Oil Cost (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-16 I1-17 Annual Gas Cost (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-14 I1-15 Annual Savings (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-19 I1-20 Efciency Improvements, System (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-18 Firetube Boiler Fuel Consumption Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-1 I1-2 Natural Gas (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-11 No.2 Oil (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-12 No. 6 Oil (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-12
Performance Considerations
Efciency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9 I1-10 Boiler Efciency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9 Combustion Efciency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9 Flue Gas Passes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10 Fuel-to-Steam Efciency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9 Heating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10 Integral Boiler/Burner Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10 Radiation and Convection Losses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10 Stack Temperature and Losses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9 Thermal Efciency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9 Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9 Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9
Selection Considerations (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-5

Codes and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6 Downtime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-8 Load
J-12
Index
Combination Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-7 Dening Load Variations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-7 Heating Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-6 Load Demand Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-7 Process Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-6 I1-7 System Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-6 System Load Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-7 Tracking Load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-7 I1-8 Number of Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-8 Back Up Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-8 Steam or Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-6 Turndown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-8 I1-9 Type of Load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-8
Special Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10

Replacement Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10
Boilers, Cast Iron, see Boiler Selection Considerations Section under Common Boiler Types BOILERS, COMMERCIAL ELECTRIC BOILERS (Section B4) Dimensions
Hot Water Boilers Models HW & CWB (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-7 Hot Water Storage Heaters Models TWH & TWV (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-11 Vessel Sizes (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-22 Instantaneous Water Heaters Model IWH (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-12 Steam Boilers Model S (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-8 Model CR (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-9 Model CSB (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-10
Engineering Data
Power Supply Wire Lug Sizing Guide (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-3 Performance Data

Efciency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5 Emissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5
Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-3 B4-5

Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4 Selection Chart (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4 Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4
Ratings
Hot Water Boilers Model HW (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B413 B4-14 Model CWB (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-15 B4-17 Hot Water Storage Heaters Model TWH & TWV (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-22 Instantaneous Water Heaters Model IWH (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-24 Steam Boilers Models S & CR (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-18 B4-19 Model CSB (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-20 B4-21
Sample Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-25 BOILERS, COMMERCIAL, (Continued) FLEXIBLE WATERTUBE BOILER (Section B1) Dimensions
Hot Water (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-7 Steam (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-8
Efficiency (See Performance Data) Emissions (See Performance Data) Engineering Data
Breeching Arrangements (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-15
J-13
Index
Breechings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-13 Burner Characteristics (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-10 Circulating Rates, Hot Water (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-10 Clearance Requirements (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-14 Combustion Air Requirements (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-15 Flow Rates and Pressure Drop (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-9 B1-10 Fuel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-11 B1-12 Heat Release (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-10 Heating Surface (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-9 Oil Burner Supply Pump Installation (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-13 Outdoor Reset Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-13 Over Pressure Requirements (Minimum) (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-10 Pressure Drops and Flow Rates (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-9 B1-10 Pressure, Minimum Gas Required (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-12 Sound Levels (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-14 Tube Attachment (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-11
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-3 Performance Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-9 B1-10

Efciency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-9 Emissions (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-9
Product Offering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-3 B1-5

Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-4 B1-5 Sizes (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-4 Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-4
Ratings
Hot Water (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-6 Steam (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-6
Sample Specifications
Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-16 Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-20
BOILERS, COMMERCIAL (Continued) MODEL 4 (Section B2) Dimensions

Hot Water (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-8 B2-9 Steam (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-10 B2-11
Efficiency (see Performance Data) Emissions (see Performance Data) Fuels (see Performance Data) Engineering Data
Flow Rates Fuel, Air, Flue Gas (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-14 Hot Water (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-15 Gas Fuel Requirements (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-13 Gas Train, Standard (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-7 Over Pressure Requirements (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-16 Pressure Drop, Hot Water (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-15 Pressure Vessel Thickness, Minimum (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-14 Sound Levels (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-16 Stack Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-12 Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-12 Steam Nozzle Size, Recommended at Reduced Pressure (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-16
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-3 Fuel Requirements, Gas (see Engineering Data) Performance Data
Efciency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-12 Emissions Natural Gas (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-12 No. 2 Oil (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-12
Product Offering
Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4 B2-5 Sizes (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-3
J-14
Index
Special Insurance Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5 Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-3 B2-4
Ratings
Hot Water (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6 Steam (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6
Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-23 B2-28 Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-17 B2-22
BOILERS, COMMERCIAL (Continued) MODEL 5 (Section B3) Dimensions

Hot Water (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-10 B3-11 Steam (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-8 B3-9
Efficiency (See Performance Data) Emissions (See Performance Data) Engineering Data
Boiler Reference Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-13 Circulating Rates and Temperature Drop (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-13 Flow Rates (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-13 Fuel Requirements Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-13 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-12 Fuels Gas (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-13 Oil (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-12 Gas Train, Standard (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-7 Over Pressure Requirements (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-15 Pressure Drop (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-14 Sound Levels (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-15 Steam Nozzle Size at Reduced Pressure (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-14 Temperature Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-14
Features and Benefits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-2 Performance Data

Efciency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-12 Emissions Natural Gas (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-12 Oil (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-12
Product Offering
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-4 B3-5 Sizes (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3 Special Insurance Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-5 Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-4
Ratings
Hot Water (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6 Steam (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6
Hot Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-21 Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-16
Boilers, Firebox, see Boiler Selection Considerations, under Common Boiler Types BOILERS, FIRETUBE (Section A) General
Comparison (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-3 A-14 Features and Benets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-2 Model Designation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-3 Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-2 A1-3
MODEL CB (Section A-1) Dimensions and Weights, General

Lifting Lug Locations (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-18 A2-19 Mounting Piers (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-20 Space Required to Open Rear Head (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-18
J-15
Index
Dimensions and Weights, Hot Water, 30 psig Design Pressure
(15-100 Hp) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2-14 A2-15 (125-800 Hp) Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2-16 A2-17
Dimensions and Weights, Steam, 15-150 psig Design Pressure

(15-100 Hp) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2-10 A2-11 (125-800 Hp) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2-12 A2-13
Engineering Data
Blowdown Water Requirements Tank Sizing Information (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-27 Boiler Room Information Breeching (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-46 Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-44 Room Length, Typical Layout (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-45 Room Width, Typical Layout (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-45 Burners, Gas Fired Gas Consumption, Maximum, (CFH), for Natural Gas and Propane Vapor (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-34 Gas Pressure Altitude, Minimum Required, Conversions (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-33 Gas Pressure, Minimum Required at Entrance to Gas Trains Equipped With IRI Requirements (Table) . . . . . . . . . . . . . . . A2-33 Gas Pressure, Minimum Required at Entrance to Standard and FM Gas Trains (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-31 Gas Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2-31 A2-32 Gas Trains Components (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-36 Standard Connection Size and Location (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-34 Under and Oversized Standard and FM (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-32 IRI (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-33 Piping Layout, Typical (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-35 Burners, Oil-Fired No 2 Oil Connection Size, Location, and Recommended Line Size (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-37 Piping Multiple Boiler Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-40 Multiple Boiler Installation, Oil Pump Integral With Boiler (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-39 Multiple Boiler Installation, Remote Oil Pumps (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-39 Single Boiler Installation, Oil Pump Integral With Boiler (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-38 Single Boiler Installation, Remote Oil Pump (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-38 Transfer Tank Detail (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-42 No 6 Oil Connection Size, Location, and Recommended Line Sizes (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-37 Piping Bundled Lines, Typical Cross Section (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-43 Fuel Storage Tank Arrangement (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-42 Multiple Boiler Installation (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-41 Multiple Boiler Installation, Remote Oil Pumps (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-41 Preheating System, Standard Alstrom Hot Water Safety Type (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-43 Single Boiler Installation, Remote Oil Pump (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-40 Heating Surface (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-24 Non-Return Valve Size, Recommended (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-26 Relief Valve Openings (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-8 Safety Valve Openings (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-7 Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2-27 A2-30 Sound Pressure Level Details 40 Hp (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-27 50-125 Hp (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-28 125-200 Hp (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-29 250-350 Hp (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-29 400-800 Hp (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-30 Sound Pressure Level Summary (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-27 Steam Nozzle Size, Recommended (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-26 Steam Volume and Disengaging Area (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-25 Stack Breeching Arrangement (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-46 Breeching Size Criteria. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-44 Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-44 Water Circulation Rate and Temperature Drop for Hot Water Boilers (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-25
J-16
Index
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-3 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-21 Efficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-21
Fuel-to-Steam (Tables) Natural Gas, 10 psig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-22 Natural Gas, 125 psig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-22 No. 2 Oil, 10 psig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-23 No. 2 Oil, 125 psig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-23 No. 6 Oil, 10 psig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-22 No. 6 Oil, 125 psig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-22 Stack Temperature Increase for Pressures Greater than 125 psig (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-23
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-21
Levels, Uncontrolled (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-24
Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-3 A2-4 Ratings, Hot Water

(15-100 Hp) Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-6 (125-800 Hp) Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-6
Ratings, Steam
(15-100 Hp) Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-5 (125-800 Hp) Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-5
Sample Specifications, Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-57 A2-65 Sample Specifications, Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-47 A2-56 BOILERS, FIRETUBE (Continued) MODEL CBE (Section A7) Dimensions, General
Lifting Lug Locations (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-10 Mounting Piers (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-11 Space Required to Open Rear Head (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-10
Dimensions and Weights, (20-350 Hp)

Hot Water (30 and 125 psig Design Pressure) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-6 A7-7 Steam (30 and 125 psig Design Pressure (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-8 A7-9
Engineering Data
Blowdown Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12 Tank Sizing Information (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-15 Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12 Heating Surfaces (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-13 Non-Return Valve Sizes (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-15 Relief Valve Openings (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-14 Safety Valve Openings (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-14 Steam Nozzle Size (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-15 Steam Volume and Disengaging Area (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-13 Boiler Room Information Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-18 Room Length (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-19 Room Width (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-19 Stack Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-18 Burner/Controls Information Gas Consumption (CFH), Maximum for Natural Gas and Propane Vapor (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-16 Gas Pressure Altitude Conversion, Minimum Required, (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-16 Gas Pressure, Minimum Required at Entrance to Standard, FM, and IRI Gas Trains (Table) . . . . . . . . . . . . . . . . . . . . . . . A7-13 Selection (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-16 Fuel Connection Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12 A7-13 Typical Supply Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-17 Sound Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12 Stack Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-18
Features and Benefits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-3 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12 Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-3 Ratings, Hot Water (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-5 Ratings, Steam (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-5 J-17
Index
Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-25 A2-29 Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-20 A2-24
BOILERS, FIRETUBE (Continued) MODEL CBH (Section A-5) Dimensions, General

Lifting Lug Locations (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-11 Mounting Piers (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-12 Space Required to Open Rear Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-10
Dimensions and Weights (25-100 Hp)

Hot Water (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-8 A5-9 Steam (15 and 150 psig Design Pressure) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-6 A5-7
Engineering Data
Burners, Gas Fired . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-12 A5-14 Gas Consumption (CFH), Maximum for Natural Gas and Propane Vapor (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-13 Gas Pressure Altitude Conversion (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-13 Gas Pressure, Minimum Required at Entrance to Gas Trains Equipped With IRI Requirements (Table) . . . . . . . . . . . . . . . A5-12 Gas Pressure, Minimum Required at Entrance to Standard and FM Gas Trains (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-13 Gas Trains Components (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-13 Fuel Requirements (see Dimensions and Ratings) Relief Valve Openings (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-10 Safety Valve Openings (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-10
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5-3 Performance Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5-4 Product Offering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5-3 A5-4 Ratings, Hot Water
(25-100 Hp), (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5
Ratings, Steam
(25-100 Hp), (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOILERS, FIRETUBE (continued) MODEL CB-LE (Section A3) Dimensions, General

Lifting Lug Locations (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-22 Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 and 78 (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-20 96 (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-21 Space Required to Open Rear Head (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-20 Weights (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6
Dimensions, Hot Water, 125-800 Hp, 30 and 125 psig Design Pressure)
60 (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14 A3-15 78 (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-16 A3-17 96 (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-18 A3-19
Dimensions, Steam, 125-800 Hp, 15-150 psig Design Pressure)

60 (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8 A3-9 78 (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10 A3-11 96 (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-12 A3-13
Engineering Data
Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-33 Blowdown Tank Sizing Information (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-34 Heating Surface (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-34 Non-Return Valve Sizes (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-35 Steam Nozzle Sizes (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-35 Steam Volume and Disengaging Area (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-35 Boiler Room Information Breeching Arrangements (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-37 Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-33 A3-34 Room Length (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-36 Room Width (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-36
J-18
Index
Burners, Gas Fired . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-26 Gas Consumption, (CFH), Maximum for Natural Gas and Propane Vapor (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-28 Gas Pressure Altitude Conversion (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-28 Gas Pressure, Minimum Required at Entrance to Standard, FM and IRI Gas Trains (Table) . . . . . . . . . . . . . . . . . . . . . . . . A3-27 Gas Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-26 A3-27 Gas Trains Components (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-30 Connection Size and Location (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-28 Under and Oversized, Standard, FM, and IRI (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-30 Piping, Typical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-29 Burners, Oil Fired, No. 2 Connection, Size, Location and Recommended Line Sizes (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-30 Piping Multiple Boiler Installation (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-32 Multiple Boiler Installation, Remote Oil Pumps (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-32 Single Boiler Installation, Remote Oil Pumps (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-31 Transfer Tank Detail (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-32 Typical Arrangement (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-33 Relief Valve Openings (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7 Safety Valve Openings (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7 Sound Levels 30 ppm NOx System, Predicted (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-26 Stack Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-33 Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-33
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3 Performance Data

Efciency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel-to-Steam, Predicted, Natural Gas (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2 Oil, Predicted (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stack Temperature Increase, Predicted, for Pressures Greater Than 125 psig (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . Emissions, Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Natural Gas (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-23 A3-24 A3-25 A3-23 A3-24 A3-23 A3-25 A3-25
Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3 Ratings, Hot Water (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4

Combustion Air Fan, Motor Hp Requirements, 125 psig and Less (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
Ratings, Steam (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4

Combustion Air Fan, Motor Hp Requirements, 125 psig and Greater, Steam (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
Weights, See Dimensions, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6 Sample Specifications

Hot Water (125-800 Hp, 30 psig, 125 psig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-45 A3-51 Steam (125-800 Hp, 15-150 psig). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-38 A3-44
BOILERS, FIRETUBE (Continued) MODEL CBW (Section A-4) Dimensions, General

Lifting Lug Locations (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-13 Mounting Piers (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-13 Space Required to Open Rear Door (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-12
Dimensions, Hot Water (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-10 A4-11 Dimensions, Steam (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-8 A4-9 Engineering Data
Blowdown Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank Sizing Information (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boiler Room Information Breeching Arrangements (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Room Length (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Room Width (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Burners, Gas Fired . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Consumption (CFH), Maximum for Natural Gas and Propane Vapor (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-15 A4-17 A4-32 A4-30 A4-31 A4-31 A4-18 A4-20
J-19
Index
Gas Pressure Altitude Conversion, Minimum Required at 700 ft (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-19 Gas Pressure Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-18 Gas Pressure, Minimum Required at Entrance to Gas Trains Equipped with IRI Requirements (Table) . . . . . . . . . . . . . . . A4-19 Gas Pressure, Minimum Required at Entrance to Standard and FM Gas Trains (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-19 Gas Trains Components (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-23 Connection, Size, and Location IRI (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-21 Over and Undersized, Standard, FM, IRI (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-20 Piping, Typical Layout (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-22 Burners, Oil Fired No. 2 Oil Connection, Size, Location and Recommended Line Sizes (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-24 Piping Multiple Boiler Installation, Remote Oil Pumps (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-25 Single Boiler Installation, Remote Oil Pump (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-25 No. 6 Oil Bundled Lines, Typical Cross Section (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-29 Connection Size, Location and Recommended Line Sizes (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-24 Multiple Boiler Installation (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-27 Multiple Boiler Installation, Remote Oil Pump (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-27 Oil Transfer Tank Detail (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-28 Preheating System, Schematic of Standard Alstrom Hot Water System (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-29 Typical Arrangement (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-28 Heating Surface (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-15 Non-Return Valve Size, Recommended (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-17 Relief Valve Openings (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-5 Safety Valve Openings (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-5 Sound Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-17 A4-18 Sound Pressure Level Summary (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-18 Stack Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-30 Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-30 Steam Nozzle Size (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-16 Steam Volume and Disengaging Area (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-15 Water Circulation Rates and Temperature Drop for Hot Water Boilers (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-16
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4-3 Performance Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4-14

Efciency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-14 Emission Levels, Uncontrolled (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-14
Product Offering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4-3 Ratings, Hot Water (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4-5 Ratings, Steam (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4-5 Sample Specifications
BOILERS, FIRETUBE (continued) OHIO SPECIAL (Section A-6) Dimensions, General

Lifting Lug Locations (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-10 Mounting Piers (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-11 Space Required to Open Rear Head (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-10
Dimensions, Steam
CB Model Ohio Special, (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6-6 A-6-7 CBW Model Ohio Special, (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6-8 A6-9
Engineering Data
Blowdown Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank Sizing Information (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boiler Information Heating Surface (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non-Return Valve Size, Recommended (Table) A6-13 Safety Valve Openings (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-11 A6-13 A6-11 A6-12 A6-23
J-20
Index
Steam Nozzle Size, Recommended (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-12 Steam Volume and Disengaging Area (Table) A6-12 Boiler Room Information Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-23 Room Length (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-24 Room Width (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-24 Burners Linkage Assembly, Combination Gas and Oil (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-14 Secondary Air Flow Diagram (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-13 Burners, Gas Fired Gas Modulating Cam (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-15 Gas Piping Layout (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-19 Gas Pressure Altitude Conversion, Minimum Required (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-16 Gas Pressure, Maximum Consumption (CFH) for Natural Gas and Propane Vapor (Table). . . . . . . . . . . . . . . . . . . . . . . . . A6-17 Gas Pressure, Minimum at Entrance to Gas Train Equipped With IRI Requirements (Table). . . . . . . . . . . . . . . . . . . . . . . . A6-15 Gas Pressure, Minimum Requirements at Entrance to Standard and FM Gas Trains (Table) . . . . . . . . . . . . . . . . . . . . . . . A6-15 Gas Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-16 A6-17 Gas Trains, Components, Special (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-18 Connection Size and Location (Figure) A6-20 Over and Undersized for IRI Gas Trains (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-16 Over and Undersized for Standard and FM (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-16 Burners, Oil Fired Connection Size, Locations and Recommended Line Size (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-20 Fuel Oil Consumption (See Boiler Ratings) Multiple Boiler Installation (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-22 Multiple Boiler Installation, Remote Oil Pumps (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-21 Single Boiler Installation, Remote Oil Pump (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-21 Transfer Tank Detail (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-22
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-3 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-4 Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-3 A6-4 Ratings, Steam
CB Model Ohio Special (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-5 CBW Model Ohio Special (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-5
CB Model Ohio Special, Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-25 A6-30 CBW Model Ohio Special, Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-31 A6-36
BOILERS, INDUSTRIAL WATERTUBE (Section C)

Industrial Watertube Boilers (Section C)
Dimensions (Burner, see under Engineering Data)

Hot Water Model DW (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model DLW (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steam Model D (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model DL & DLD (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model DLDH (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C20 C21 C22 C23 C14 C15 C16 C17 C18 C19
Emissions Data
Heavy Oils Models A, BR, CN Burners (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model CT Burner (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Natural Gas Models A, BR, CN Burners (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model CT Burner (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2 Oil Models A, BR, CN Burners (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model CT Burner (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-28 C-29 C-28 C-29 C-28 C-29
Engineering Data
Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-43 Breeching Arrangement, Boiler Right Hand and Left Hand (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-44
J-21
Index
with Common Stack (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-45 with Separate Stacks (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-45 Arrangement, Pier, Recommended (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-44 Arrangement, Two Boilers with Separate Stacks (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-46 Stack Size Selection (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-50 Transition Gas Outlet, Connection to Horizontal Breeching (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-49 Gas Outlet, Direct to Stack (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-48 Top Outlet (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-47 Burner Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-37/C38 C42 Data Models A, BR, CN (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-38 Model CT (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-41 Dimensions Model A (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-24 Model BR (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-25 Model CN (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-26 Model CT (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-27 Offering Models A, BR, CN (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-39 Model CT (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-42 Casing, Setting, and Insulation Arrangement of Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-34 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-34 Enclosure Construction, D Series Boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-35 Furnace Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-35 Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-37/C-42 C43 FGR Systems Models A, BR, CN (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-40 Model CT (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-43 Drums Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-31 Internals and Steam Puriers for 1,3, and 7 ppm Solids (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-32 Internals and Separator for 99.5% Dry Steam (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-32 Lower (Mud) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C30 C31 Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-30 Flame Safeguard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-37/C-42 C-43 Burner Models A, BR, CN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-37 Burner Model CT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-42 C-43 Frame, Structural . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-35 C-36 Skid Assembly (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-36 Support Drum in Skid (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-36 Furnace, Heat Output, Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C31 C33 (Hot Water) (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-31 (Steam) (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-31 Heating Surface (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-30 Steam Capacity in lbs/hr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13 Trim, Standard Model D (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7 Model DL and DLD (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8 Model DLDH (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9 Trim, Steel 300 psig Model D (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10 Model DL and DLD (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-11 Model DLDH (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12 Tubes, Convection, Model D, DL, DLD, DLDH (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-34 Arrangement Bafing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-33 Denition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-33 Figure of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-34 Model D Series Enclosure Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-35 Model D Series Tube Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-33 Internal Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-34 Removal of Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-34 Soot Blowers
J-22
Index
Features and Benefits
Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-3 Burners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3 C4 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4
Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Models (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C6 Standard Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5 C6
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-13
Steam (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-13
FGR (Models A, BR, CN Burners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-69 FGR (Model CT Burner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-70 Hot Water Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C61 C68 Steam Boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C51 C59
Boiler Room Length, see specific boiler product section under Boiler Room Information Boiler Room Width, see specific boiler product section under Boiler Room Information Breeching, see Stacks; also see specific boiler product section under Engineering Data Brine Maker Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-11 Burners, Gas Fired, see specific boiler product section Burners, Oil Fired, see specific boiler product section By-Pass Feeders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-4 -CCB-HAWK Control, see Controls Section CB-HAWK Enhancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D16 D22 CB70 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D9 CB100 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D7 CB110 Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-8 CB780 Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D5-D6 Carbon Monoxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E8-E9 Cast Iron Boiler, see Boiler Selection Considerations, under Common Boiler Types CHEMICAL FEED SYSTEMS AND METERING PUMPS (Section H6) Dimensions
Automatic System (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-5 By-Pass Feeders (Manual System) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-4 Shot Feeders (Manual System) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-4
Engineering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-3 Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-3 Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-3 Manual System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-3
Ratings
Automatic Chemical Feed System Pump (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-3
Sample Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-6 Circulating Rates, Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-5 see also specific boiler product section Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4 I2-5 Codes and Standards, see Boiler Selection Consideration Section, also see specific boiler product section, Hot Water Systems Section, Steam Systems Section Combustion Air Requirements, see specific boiler product section, under Engineering Data, also see Steam Systems Section Communications Module, see Controls Section Condensate Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-5 Condensate Receiver Tanks, See Surge Tank Section, also see Steam Systems Section CONTROLS (Section D) Assured Low Fire Cutoff
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-30
J-23
Index
Features and Benets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-30 Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-30 Sample Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-30
Automatic Fuel Changeover

Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Features and Benets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sample Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-32 D-32 D-32 D-32
Availability, Product/Flame Safeguard (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4 CB70

Features and Benets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engineering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sample Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-9 D-9 D-9 D-9 D-7 D-7 D-7 D-7 D-8 D-8 D-8 D-8 D-5 D-6 D-5 D-6
CB100E
Features and Benets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engineering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sample Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CB110
CB780
CB-HAWK Boiler Management Control System

Features and Benets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10 Engineering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-11 Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10 D-11 Sample Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-11 D-13
CB-HAWK ASCII Interface

CB-HAWK Enhancer Base Unit

Auxiliary Input Monitor Features and Benets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-18 Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-18 Sample Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-18 Base Unit Engineering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-16 Features and Benets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-16 Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-16 Sample Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-16 Efciency Monitor Features and Benets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-17 Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-17 Sample Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-17 Lead/Lag Control (See Also Lead/Lag Systems) Features and Benets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-22 Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-22 Sample Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-22 Outdoor Reset Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Features and Benets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-20 Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-20 Sample Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-20 Time-of-Day Scheduling Control (Day/Night) Features and Benets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-19 Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-19
J-24
Index
Sample Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-19
CB-HAWK Lead/Lag Systems (Two Boiler)

CB-Link Communication Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engineering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-14 D-15 Features and Benets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-14 Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-14 Sample Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-15
Communication Module (See CB-Link) Flame Safeguard

Availability (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4 Comparison (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
Lead/Lag Systems (Two Boiler Lead Lag)

Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-25 Features and Benets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-24 Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-24 Sample Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-24 D-25
Lead/Lag Systems (Two Boiler through Four Boiler Lead/Lag)

Low Fire Hold Control

Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Features and Benets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sample Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-28 D-28 D-28 D-28 D-29 D-29 D-29 D-29
Minimum Temperature, Low Fire Hold Control

Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Features and Benets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sample Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oxygen Trim
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-35 Engineering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-34 Features and Benets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-33 Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-33 D-34 Sample Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-34 D-35
Product/Flame Safeguard
Availability (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4 Comparison (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
Remote Modulation
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Features and Benets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sample Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-31 D-31 D-31 D-31
Conversion of Units, see under Engineering Data, General -DDeaerators, see specific deaerator product section, also see Steam Systems Section, DEAERATORS, BOILERMATE (Section H3) Dimensions and Ratings (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-6 H3-7
Tank Supports and Saddles (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-8
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-3 Product Offering

Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-4 Selection Guide (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-5 Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-4
Return on Investment
Chemical Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-9
J-25
Index
Exhaust Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flash Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intangibles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Makeup Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Surface Blowdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-9 H3-9 H3-9 H3-9 H3-9 H3-9
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H3-10 H3-13 DEAERATORS, SPRAYMASTER, DUO TANK (Section H2) Dimensions and Ratings (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-5 H2-7
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-3 Product Offering (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-3 Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-8 H2-13 DEAERATORS, SPRAYMASTER, SINGLE TANK (Section H1) Dimensions and Ratings (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H1-6 H1-7
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H1-3 Product Offering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H1-3 H1-5

Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-4 Offering (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-4 Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-4 H1-5 Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-4
Return on Investment
Chemical Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flash Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intangibles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Makeup Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Surface Blowdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-8 H1-8 H1-8 H1-8 H1-8 H1-8 H1-8
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H1-9 H-12 DEALKALIZERS (Section H9), See also Steam Systems Section Dimensions and Ratings (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H9-5 Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H9-3 Product Offering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H9-3
Selection and Data Chart (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-1 Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-3 H9-4 Sizing Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-4
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H9-7 H9-10 Dimensions, see specific product section -EECONOMIZERS (Section G) See Also Steam Systems Section Dimensions and Weights
Cylindrical Economizers for Firetube Boiler (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4 Rectangular Economizers for Industrial Watertube Boiler (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4
Efficiencies (See Performance Data) Engineering Data

Installation Firetube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6 G-7 Industrial Watertube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7 Piping Above Industrial Boiler (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8 Feedwater Piping (See Engineering Data) Mounting to Firetube Boiler (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7 On Side of Industrial Watertube Boiler (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8 Typical Feedwater Piping (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-9 G-11
Performance Data
Efciencies Cylindrical Economizer for Firetube Boiler (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6 Rectangular Economizer for Industrial Watertube Boiler (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6
J-26
Index
Performance Cylindrical Economizer for Firetube Boiler (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5 Rectangular Economizer for Industrial Watertube Boiler (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6
Product Offering
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3 Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G12 G-13 Efficiency, see Boiler Selection Considerations under Performance, see specific boiler product section under Performance Data, see also Economizers Section Electric Boilers, see under Boilers, Commercial EMISSIONS (Section E) See also Boiler Selection Consideration Section and specific product section Carbon Monoxide (CO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8
Emission Conversion Curve (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9
Emissions Conversion Curves

CO (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9 NOx (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-10 SOx (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-10 VOC (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-11
Industrial Boilers, Calculating Annual Emissions (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-11 E-13 Nitrogen Compounds (NOx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
Choosing the Best NOx Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6 Combustion Control Techniques Burner Modication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5 Flue Gas Recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5 E-6 Low Excess Air Firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5 Low Nitrogen Fuel Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5 Water/Steam Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5 Control Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4 Correcting Emissions to 3% Oxygen (15% Excess Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9 Converting NOx Emissions Between PPM & LB/MMBTU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9 Effects of Fuel-Bound Nitrogen on NOx Emissions for Fuel Oils (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3 Emission Conversion Curves, 3% Oxygen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-10 New Source Performance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-13 Summary of Federal EPA Rules (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-14 Post Combustion Control Methods for NOx, Selective Reduction Catalytic (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4 E-5 Non-Catalytic (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4
Particulate Matter (PM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8 Pollutants and Control Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3 Sulfur Compounds (SOx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7
Emission Conversion Curve, 3% Oxygen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-10 Sulfur Content, Effects of on SOx Emissions (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7
Units of Emission Levels, Volume or Mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8 E-9 Volatile Organic Compounds (VOCs) /Hydrocarbons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8
Emission Conversion Curve, 3% Oxygen (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-11
ENGINEERING DATA, GENERAL (Section I4) Associations, Standard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-43 I4-44 Conversion of Units (See Unit Conversions) Equivalent Lengths, Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-10
Table of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-10
Factors of Evaporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-12

Table of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-13
Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-3 I4-10

Equivalent Lengths (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-10 Fuel Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-3 Pressure Drop (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-8 I4-9 Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-3 Line Capacities (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-7 Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-3 Pressure Drop (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-4
J-27
Index
Steam Velocity (Figure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-5 Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . !4-3 Pressure Drop (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-6
Stacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-10 I4-12

Breeching and Stack, Common, Multiple Boilers (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-12 Construction, Typical (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-11 Diameter, Vent or Stack, Single Boiler (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-12 Locations, Typical (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-11 Rain Cap Details (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-12
Thermodynamic Properties
Fuel Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-12 I4-17 Grade of Fuel Oil (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-17 Properties of Fuel Oil (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-16 Fuel Oil Specication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-12 I4-14 Temperature and Viscosity Curves (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-15 Units for Fuel, Typical (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-13 Viscosity and Temperature Curves (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-15 Steam, Saturated Properties Pressure (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-26 I4-30 Temperature (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-19 I4-25 Water Thermal Properties of (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-18
Unit Conversions
Conversion Factors (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-32 I4-40 Conversion Tables (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-41 Conversions Accurate to Parts Per Million (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-42 Equivalents, Common, Approximate (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-42 pH Values (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-40 Salinity Indicating Readings (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-40 Temperature Conversion (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-31 Useful Physical Constants (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-40
Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4 I2-5 -FFeedwater Systems, see under specific product section
Blowdown Heat Recovery Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11 Blowdown Separators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10 Boiler Feed Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5 Chemical Feed Systems and Metering Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6 Deaerators, Boilermate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3 Deaerators, Duo Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2 Deaerators, Single Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1 Dealkalizers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9 Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7 Flash Tank Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12 Sample Coolers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H13 Softeners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8 Surge Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4
FILTERS (Section H7) Chlorine, Organics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H7-5 Dimensions

Filters without Regenerant Tanks (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-4
Engineering Data (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-9/H7-10

Activated Carbon Media Filter (Model CF) (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-6/ H7-10 Iron Filter (Model IF) (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-8/H7-10 Multi-Layered Filter (Model MF) (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-7/H7-9 Sand Filter (Model SF) (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-8/H7-9
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H7-3 Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H7-5 Particles Down to 10-Micron Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H7-5 Product Offering
Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-3 Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-3
J-28
Index
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-11 H7-12 Sand, Heavy Sediment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-5 Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-5 Firebox Boilers, see Boiler Selection Considerations Section, under Common Boiler Types Flame Safeguard, see Controls Section; also see specific boiler product sections FLASH TANK HEAT EXCHANGERS (Section H-12) Dimensions
Model AHR (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-5 Model FTE (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-4
Engineering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-3 Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-3 Product Offering

Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-3 Standard Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-3
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-10 H12-11 Selection and Payback (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-6 H12-9 Flexible Watertube Boilers, see under Commercial Boilers Flow Rates, see under specific boiler product Flue Gas Recirculation, see Emissions Sections, see also specific boiler products section Fuel Connections, see specific boiler products section Fuel Oil, see General Engineering Data and specific boiler product sections -GGas Consumption (Maximum CFH), see specific boiler product section under Engineering Data Gas Pressure Altitude Conversion, see specific boiler product section under Engineering Data Gas Pressure, Minimum Required at Gas Train Entrance, see specific boiler product section under Engineering Data Gas Pressure Regulator, see specific boiler product under Engineering Data Gas Train, see specific boiler product section under Engineering Data General Engineering Data, see under Engineering Data, General Generator, Hot Water, see Boilers, Industrial Watertube Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J1 J10 -HHeat Release, see specific Boiler Product Section Heat Users, see Hot Water Systems Section Heating Surface, see specific boiler product section Hot Water Boilers, see specific boiler product section HOT WATER SYSTEMS (Section 12) Control Considerations
Heat Users Common Heat Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-10 Control of water ow through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-10 Pumps Primary-Secondary Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-12 I2-13 Continuous Pump Operation with two-position valve (valve closed) (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-13 Continuous Secondary Pump Operation with two position valve (valve open) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . I2-13 Intermittent Secondary Pump Operation (On-Off) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-12 Water Temperature Constant through Zone Bypass (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-12 Valves Plug Cock or Gate (Manual Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-10 Three Way Diverting (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-12 Three Way Mixing (By Pass Arrangement) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-11 I2-12 Throttling or Modulating (Electric or Pneumatic) (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-11 Two Position (Electric or Pneumatic) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-10 Lead/Lag Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-9 I2-10 Temperature Control Boiler Water Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-8 System Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-9
J-29
Index
Temperature Setbacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-10
Mechanical Considerations
Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-7 Air Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-3 Boiler Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-3 Circulation Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4 I2-5 Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4 Circulation Rates, (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-5 Typical Pump Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-2 Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-3 Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4 Piping Arrangements (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-5 Heating/Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-7 Pressure Drop Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-6 Pressure/Temperature for Firetube Boilers (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-6 Pumping Equipment Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4 Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4 Typical Pump Curve (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-8
System Diagrams
Four Way Valve System (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-20 Individual Zone Circuits (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-18 Multiple Boiler Lead/Lag (Primary/Secondary Pumping) (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-21 Primary Loop Circuit, Constant Speed Pump (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-16 Primary Loop Circuit with Secondary Pumping (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-17 Primary Loop Circuit with Three Way Valve (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-19
Water Considerations Chemical Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-13 Ethylene Glycol as a Heat Transfer Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-14 Makeup Water
Introducing Makeup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-13 Metering Makeup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-14
Water Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14 -I-J-K-L Iron Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-8/H7-10 Lead/Lag Systems, see Controls Section, see Hot Water Systems Section, and see under specific boiler products section Lifting Lug Locations, see specific boiler product section under Dimensions Low Fire Hold Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-28 Low Fire Hold Control, Minimum Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-29 -M-N-O Makeup Water, see under specific product section, see Hot Water System section, see Steam System section Models, see under specific product section Model 4 Commercial Boiler Model 5 Commercial Boiler Model 5D Blowdown Separator Model 18 DF Blowdown Separator Model 20AO Blowdown Separator Model 34 Blowdown Separator Model 56 Blowdown Separator Model ACC-CFB Activated Carbon Filter Model ACC-DAB Dealkalizer Model ACC-IFB Iron Filter
J-30
Index
Model ACC-MFB Multi-layered Filter Model ACC-SAB Softener Model ACC-SFB Sand Filter Model ACC-TAB Softener Model AHR Flash Tank Heat Exchanger Model BHR-M Blowdown Heat Recovery Model BHR-S Blowdown Heat Recovery Model BHR-LPS Blowdown Heat Recovery Model BM Deaerator Model BMP Deaerator Model CB Firetube Boiler Model CB70 Control Model CB100E Control Model CB110 Control Model CB780 Control Model CB-HAWK Control Model CB-HAWK Enhancer Control Model CB-Link Control Model CBE Firetube Boiler Model CBH Firetube Boiler Model CB-LE Firetube Boiler Model CBS-I Stack Model CBS-II Stack Model CBS-III Stack Model CBW Firetube Boiler Model CR Electric Boiler Model CSB Electric Boiler Model CWB Electric Boiler Model D Industrial Watertube Boiler Model DL Industrial Watertube Boiler Model DLD Industrial Watertube Boiler Model DLDH Industrial Watertube Boiler Model DLW Industrial Watertube Boiler Model DW Industrial Watertube Boiler Model EC Economizer Model FLE Commercial Boiler Model FLX Commercial Boiler Model FTE Flash Tank Heat Exchanger Model HW Electric Boiler Model ICBS Stack Model IWH Instantaneous Water Heater Model O2 Trim System Model S Electric Boiler Model SAB Softener Model SC22 Sample Cooler Model SC42 Sample Cooler Model SM Deaerator Model SMD Deaerator Model SMP Deaerator Model SRG Surge Tank Model TWH Electric Storage Heater Model TWV Electric Storage Heater
J-31
Index
Model V5 Chemical Feed System Mounting Piers, see specific boiler product section under Engineering Data Multi-Layered Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-7/H-9 -NNon-Return Valve Size, see specific boiler product section under Engineering Data NOx, see Emissions Section -OOhio Special Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6-1 A6-36 Oxygen Trim Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-33 D-35 -P-Q Particulate Matter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8 Payback Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 I1-20 Performance, see under Boiler Selection Considerations Performance Data, see specific product section Product Offering, see specific product section Piping, see specific boiler product section, also see Economizers Section, General Engineering Data Section, Hot Water Section, Steam Systems Section Pollutants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3 Preheater, see under specific product section Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-6 see also specific product section Pumping Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-2 I2-4 Pumps, See specific product section, also see Hot Water Systems Section and Steam Systems Section -RRatings, see specific product section Rear Head, Space Required to Open, see specific boiler product section under Dimensions, General Relief Valve Openings, see specific boiler product section under Engineering Data Remote Modulation Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-31 Resin Tank Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8 H10 Return on Investment, see Deaerator product sections -SSafety Valve Openings, see specific boiler product section under Engineering Data SAMPLE COOLERS (Section H13) Dimensions
Model SC22 (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H13-4 Model SC42 (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H13-5
Engineering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H13-3 Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H13-3 Performance Curves

Model SC22 (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H13-4 Model SC42 (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H13-5
Product Offering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H13-3 Ratings

Models SC22 and SC42 (Temperature) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H13-3
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H13-6 Sand Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H7-8 H7-9 Shot Feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H6-4 SOFTENERS (Section H8) See also Steam Systems Section Dimensions
Model SAB (Size 30-900) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-6 Model SAB (Size 1050 - 2100) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-7 Model TAB (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-5
J-32
Index
Engineering Data
Brine Maker Data (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-11 Flow Rates and Resin Tank Data (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-10 Resin Tank and Brine Maker Data (Tank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-10 H8-12 Softener Pressure Drop Charts (Figure) Size 30-120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-14 Size 150-450 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-15 Size 600-900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-16
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-3 Product Offering

Operating Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-4 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-4 Sizing Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-8 Charts (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-13 Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-4
Ratings (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-8 H8-9 Sample Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-17 H8-20 Sound Levels, see specific product section Specifications, see specific product section STACKS (Section F) see also under specific boiler product section and under General Engineering Data Section Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3 Engineering Data
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5 Special Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5 Component Names and Part Numbers (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5 Arrangements, Typical Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-12/F-14 Clearance to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5/F-11 F-12 Construction and Joint Details Model CBS-II (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-13 Model CBS-III (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-13 Model ICBS (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-14 (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-13 Clearances for Non-Combustible Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-11 System Extension Above Boiler Room (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7 Connecting to the Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5 Weights (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-14 Expansion and Installation Concerns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7 F-11 Calculating Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8 Graphs (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8 Expansion Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7 Thermal Expansion Between Two Fixed Points (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7 Guide Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8 Cable Guying Specication for Room Level Guide (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-10 Guide and Support Assemblies, Maximum for Vertical, Horizontal, and Sloping Stack Runs (Figure) . . . . . . . . . . . . . . F-10 Support Assemblies Stack Height, Maximum Supported (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-9 Support and Guide Assembly, Maximum for Vertical, Horizontal, and Sloping Stack Runs (Figure) F-1 Unsupported Distance, Maximum, Between Elbows, Tees, or Wyes (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8 Roof Cable Guying Installation Details (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-12 Framing and Curb Details (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-12 Opening Size for Penetration of Roof Support Assemblies (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-11 Safety Specications and Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5 Use of Non-Combustible Enclosure or Chase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-12 (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-14
Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3

Application Information (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4 Selection Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3 Special Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5
J-33
Index
System Components and Part Numbers (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-15 Steam Boilers, see specific boiler product section Steam Nozzle Size, see specific boiler product section under Engineering Data STEAM SYSTEMS (Section I3) Equipment considerations and hardware design
Blowdown Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-15 I3-16 Boiler Feed Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-10 I3-13 Boiler Piping and Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-8 3-10 Safety Valve Discharge Piping, Recommended (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-9 Economizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-15 Steam Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-6 I3-8 Water Treatment Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-13 I3-15 Makeup Water Impurities, Limits and Treatment Methods (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-14 Removal of Harmful Elements with Various Types of Equipment (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-14
Example
Application/Energy Use Audit Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-17 I3-18 Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-19 Boiler Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-18 I3-19 Condensate Return and Feedwater System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-19 System Schematic (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-20 Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-19 Water Test Results and Limits (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-19
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-3 Steam-Generating Facility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-3 I3-6

Application/Energy use Audit Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-6 Summary of (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-6 Application Load, Type of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-3 Codes and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-5 Federal, State, Local, and Provincial Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-6 Operating Conditions, Requirements, and Constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-3 I3-5 Schematic Diagram of a Generic Steam -Generating Facility (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-4 Typical Steam System (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-4
System Integration and Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-16 I3-17 Steam Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I419 I4-30 Steam Volume and Disengaging Area, see specific boiler product section under Engineering Data Sulfur Compounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7/ E-10 Surface Blowdown, see specific product section SURGE TANKS (Section H4) See Also Steam Systems Section Dimensions and Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H4-4 H4-5
Tank Supports and Saddles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-6
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H4-3 Product Offering

Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-3 H4-4 Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-3
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H4-7 H4-10 System Diagrams, Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I216 I2-20 SYSTEM FUNDAMENTALS See Boiler Selection Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1 See Hot Water Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2 See Steam Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3 See Engineering Data, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4 -T-U Tank Capacity, see under specific product section Tank Support and Saddles, see specific deaerator product section
J-34
Index
Temperature Control, see Hot Water Systems Section Temperature Drop, see specific boiler products section Temperature Setbacks, see Hot Water Systems Section Thermodynamic Properties, see General Engineering Data Section -VValves, see Hot Water Systems under Control Considerations Vent Capacities, see under specific product section VOCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-8 -W-X-Y-Z Water Considerations, Hot Water Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-12 I2-14 Water Heaters, Instantaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4 Water Treatment Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-13 also see specific water treatment product sections
J-35

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The Boiler Book

Produced by the Employees of

Performance Proven Worldwide

Cleaver-Brooks Division, Aqua-Chem, Inc. 2002

Cleaver-Brooks P.O. Box 421 Milwaukee, WI 53201

(414) 359-0600 email: Iinfo@Cleaver-Brooks.com www.cleaver-brooks.com Printed in the U.S.A.

Commercial Boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B

System Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section I

FEATURES AND BENEFITS

MODEL NUMBER, FUEL SERIES NUMBER, HORSEPOWER, AND DESIGN PRESSURE

MODEL Rated Capacity Design PressureA

CBL 800-1500 HP (SECTION A11) 800-1500 hp Steam 150-250 psig

Boiler Type Shell Size

Passes VaryC 48" 100 hp 60"125-225 hp

3-Pass Dry Back 48" 60-100 hp 60" 125-200 hp 78" 250-350 hp

3 Pass Wet Back 60" 100-225 hp

3 or 4-Pass Wet Back 114" or 126"E

No. 2 Oil, Gas, Combination Oil/Gas

No. 2 Oil, Gas, Combination Oil/Gas

No. 2 Oil, Gas, Combination Oil/Gas

No. 2 Oil, Gas, Combination Oil/Gas

No. 2 Oil, Gas, Combination Oil/Gas

15-20 hp On-off 30-40 hp Low-High-Low-Off 50-800 hp Full Modulation

Air Damper Type

Rotary & Louvers

Paint Color Approvals

McD&M 157 Warrick 3C-2 N/A

McD&M 157 Warrick 3C-2 N/A

N/A Yes N/A Davit

Rear Door Insulation Standard Voltage Requirements 12-02 Fuse Protection

Hinge 100 hp Davit 125-225 hp 2 inch 3 Phase

Davit 2 Inch 3 Phase

Davit 2 Inch 3 Phase

Davit 2 Inch 3 Phase

Davit 2 Inch 3 Phase

Davit 2 inch 3 Phase

Davit 2 inch 3 Phase

Control Circuit Transformer Flame Safeguard Control Scanner Type

Control Panel Location Indicating Lights Type of Pilot

Burner without Key Lock LD, FV, LW, FF

Burner without Key Lock LD, FV, LW, FF

Burner without Key Lock LD, FV, LW, FF

On Burner without Key Lock LD, FV, LW, FF

Remote-Right Side without Key Lock LD, FV, LW, FF

Spark Ignited Oil Pilot No. 2 Oil

No. 2 Oil Direct Spark Ignition 60-100 hp Gas Pilot 125-350 hp

MODEL Gas Burner Type

CBE 60-350 HP (SECTION A7) High Radiant Multi-Port

CEW 125-800 HP (SECTION A8) High Radiant Multi-Port

CEW-LN 125-800 HP (SECTION A9) High Radiant Multi-Port

CEW OHIO SPECIAL 100-225 HP (SECTION A10) High Radiant Multi-Port

CBL 800-1500 HP (SECTION A11) High Radiant Multi-Port

ICB 100-800 HP (SECTION A12) High Radiant Multi-Port

ICB-LN 100-800 HP (SECTION A13) High Radiant Multi-Port

Motorized Buttery Valve Required, Not Included Yes Yes

Motorized Buttery Valve Included Yes Yes

Solenoid Metering Valve Included No. 2 Oil 125-800 hp Remote

Solenoid Metering Valve Included No. 2 Oil 100-800 hp Remote

Solenoid Metering System Included No. 2 Oil 100-225 hp Remote

Motorized Metering System Included No. 2 Oil Remote

Solenoid Metering System Included No. 2 Oil 100-800 hp Remote

Induced FGR 30 ppm (Natural Gas)

Maximum Stack Pressure Variation Start-Up Included

15-40 hp + or-0.25" W.C. 50-800 hp + or-0.50" W.C. Yes