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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

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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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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

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

800-1300 hp No. 2 Oil, Gas, Combination Oil/Gas 800-1500 hp Gas 800-1000 hp No. 6 Oil, Gas, Combination Oil/Gas

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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

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 CB780 Infrared

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 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

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 & 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

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

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

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

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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:

FEATURES AND BENEFITS


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.

Figure A2-1. Model CB Steam Boiler Dimensions and Weights (15 and 150 psig Design Pressure 15 to 100 hp) Sheet 2 of 2

A2-11
07-02

Model CB Boilers

Firetube Boilers

NOTE: ALLOW 3 FEET FOR DOOR SWING PER NEC

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

Figure A2-2. Model CB Steam Boiler Dimensions and Weights (15 and 150 psig Design Pressure 125 to 800 hp) Sheet 1 of 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)

Figure A2-2. Model CB Steam Boiler Dimensions and Weights (15 and 150 psig Design Pressure 125 to 800 hp) Sheet 2 of 2

A2-13
07-02

Model CB Boilers

Firetube Boilers

LWCO

NOTE: ALLOW 3 FEET FOR DOOR SWING PER NEC

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

NOTE: ALLOW 3 FEET FOR DOOR SWING PER NEC

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
BOILER HP 50 60 70 80 100 125 150 200 250 300 350 400 500 600 700 750 800 FIRING RATE (%) 25 86.8 86.7 88.4 88.5 88.2 87.2 88.4 88.9 88.8 89.1 89.1 88.4 89.4 89.5 89.6 89.7 89.7 50 87.0 86.9 88.6 88.7 88.5 87.4 88.5 89.2 88.5 89.2 89.5 88.5 89.5 89.9 90.0 90.0 90.0 75 86.6 86.5 88.2 88.3 88.3 87.2 88.3 88.9 87.8 88.4 89.0 88.4 89.3 89.7 89.8 89.8 89.8 100 86.1 86.0 87.7 87.8 88.0 87.0 88.1 88.7 87.1 87.7 88.4 88.1 89.2 88.4 89.6 89.5 89.5

Table A2-8. Predicted Fuel-to-Steam Efciencies (%), Model CB Boilers - 125 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 80.2 80.1 81.7 81.8 81.5 80.4 81.5 82.2 82.0 82.6 82.6 81.8 82.8 82.9 83.0 83.1 83.1 50 80.5 80.4 82.0 82.1 82.4 80.9 82.0 82.7 82.0 82.7 83.2 82.2 83.2 83.5 83.6 83.6 83.6 75 80.4 80.3 81.9 82.0 82.3 81.0 82.0 82.7 81.6 82.2 82.8 82.4 83.3 83.6 83.6 83.7 83.7 100 80.1 80.1 81.7 81.8 82.2 81.0 82.1 82.7 81.3 81.9 82.5 82.2 83.1 83.5 83.6 83.5 83.5

Table A2-10. Predicted Fuel-to-Steam Efciencies (%), Model CB Boilers - 125 psig, No 6 Oil
BOILER HP 50 60 70 80 100 125 150 200 250 300 350 400 500 600 700 750 800 FIRING RATE (%) 25 83.9 83.8 85.5 85.6 84.6 84.1 85.3 86.0 85.8 86.3 86.4 85.5 86.5 86.7 86.8 86.9 86.9 50 84.2 84.1 85.8 85.9 85.8 84.6 85.8 86.5 85.7 86.4 87.0 85.9 86.9 87.3 87.3 87.4 87.4 75 84.0 83.9 85.6 85.7 85.9 84.7 85.8 86.4 85.3 86.0 86.6 86.0 87.0 87.4 87.4 87.5 87.5 100 83.8 83.8 85.4 85.6 85.8 84.8 85.8 86.5 85.0 85.6 86.2 85.9 86.9 87.2 87.4 87.3 87.3

A2-22
07-02

Firetube Boilers
Table A2-11. Predicted Fuel-to-Steam Efciencies (%), Model CB Boilers - 10 psig, No. 2 Oil
BOILER HP 50 60 70 80 100 125 150 200 250 300 350 400 500 600 700 750 800 FIRING RATE (%) 25 86.5 86.3 87.9 88.1 87.8 86.7 87.8 88.4 88.3 88.6 88.6 87.9 88.9 89.0 89.1 89.2 89.2 50 86.7 86.6 88.2 88.3 88.4 86.9 88.0 88.7 88.1 88.7 89.0 88.1 89.0 89.4 89.5 89.5 89.5 75 86.3 86.2 87.8 87.9 88.1 86.7 87.8 88.4 87.4 88.0 88.5 87.9 88.9 89.2 89.3 89.3 89.3 100 85.8 85.7 87.3 87.4 87.7 86.6 87.6 88.2 86.7 87.3 87.8 87.6 88.6 89.0 89.1 89.0 89.0

Model CB Boilers
Table A2-12. Predicted Fuel-to-Steam Efciencies (%), Model CB Boilers - 125 psig, No. 2 Oil
BOILER HP 50 60 70 80 100 125 150 200 250 300 350 400 500 600 700 750 800 FIRING RATE (%) 25 83.6 83.5 85.1 85.2 84.8 83.7 84.8 85.6 85.3 85.9 85.9 85.1 86.1 86.2 86.3 86.4 86.4 50 84.0 83.8 85.4 85.6 85.7 84.2 85.3 86.0 85.3 86.0 86.6 85.5 86.5 86.8 86.9 86.9 86.9 75 83.8 83.7 85.3 85.4 85.6 84.3 85.3 86.0 84.9 85.5 86.1 85.6 86.6 86.9 87.0 87.0 87.0 100 83.5 83.5 85.1 85.3 85.5 84.3 85.4 86.0 84.7 85.2 85.8 85.5 86.4 86.8 86.9 86.8 86.8

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
Table A2-23. Model CB Boiler Sound Pressure Level Details (125 - 200 hp)
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.

Table A2-24. Model CB Boiler Sound Pressure Level Details (250 - 350 hp)

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
Table A2-25. Model CB Boiler Sound Pressure Level Details (400 - 800 hp)
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

Figure A2-19. No. 6 Oil Piping, Single Boiler Installation, Remote Oil Pump

A2-40
07-02

Firetube Boilers

Model CB Boilers

Figure A2-20. No. 6 Oil Piping, Multiple Boiler Installation, Remote Oil Pumps
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

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. OIL HEATER BOILER BASE FRAME F.O.S. F.O.R.

BOILER FRONT

Figure A2-21. No. 6 Oil Piping, Multiple Boiler Installation

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

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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.

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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)

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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
07-02

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.

A2-54
07-02

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.

FEATURES AND BENEFITS


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.

DIMENSIONS AND RATINGS


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

Figure A3-1. Model CB-LE Steam Boiler Dimensions, 60 (15 - 150 psig Design Pressure) - Sheet 2 of 2

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

Figure A3-2. Model CB-LE Steam Boiler Dimensions, 78 (15 - 150 psig Design Pressure) - Sheet 1 of 2

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

Figure A3-2. Model CB-LE Steam Boiler Dimensions, 78 (15 - 150 psig Design Pressure) - Sheet 2 of 2

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

Figure A3-3. Model CB-LE Steam Boiler Dimensions, 96 (15 - 150 psig Design Pressure) - Sheet 1 of 2

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.

Figure A3-3. Model CB-LE Steam Boiler Dimensions, 96 (15 - 150 psig Design Pressure) - Sheet 2 of 2

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

Figure A3-4. Model CB-LE Hot Water Boiler Dimensions, 60 (30 and 125 psig Design Pressure) - Sheet 2 of 2

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

Figure A3-5. Model CB-LE Hot Water Boiler Dimensions, 78 (30 and 125 psig Design Pressure) - Sheet 1 of 2

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

Figure A3-5. Model CB-LE Hot Water Boiler Dimensions, 78 (30 and 125 psig Design Pressure) - Sheet 2 of 2

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

Figure A3-6. Model CB-LE Hot Water Boiler Dimensions, 96 (30 and 125 psig Design Pressure) - Sheet 1 of 2

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.

Figure A3-6. Model CB-LE Hot Water Boiler Dimensions, 96 (30 and 125 psig Design Pressure) - Sheet 2 of 2

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

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 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

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 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

A3-26
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.

A3-27
02-02

Model CB-LE Boilers

Firetube Boilers

Table A3-15. 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 -

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

A3-28
02-02

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

A3-29
02-02

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

A3-30
02-02

Firetube Boilers

Model CB-LE Boilers

Figure A3-16. No. 2 Oil Piping, Single Boiler Installation, Remote Oil Pump

Figure A3-17. No. 2 Oil Piping, Multiple Boiler Installation, Remote Oil Pumps

A3-31
02-02

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

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 F.O.S. F.O.R.

Figure A3-18. No. 2 Oil Piping, Multiple Boiler Installation

BOILER FRONT CONTACTOR CONNECTIONS AT THIS POINT

Figure A3-19. No. 2 Oil Transfer Tank Detail

A3-32
02-02

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.

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).

Boiler Room Information


Figure A3-21 shows typical boiler room length requirements. Figure A3-22 shows typical boiler room width requirements. Figure A3-23 shows typical breeching arrangements.

Stack Support Capabilities


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.

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-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

NOTE: Quantity of water removed from boiler by lowering normal water line 4".

A3-34
02-02

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

Table A3-21. 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) 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.

A3-35
02-02

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)

BOILER HP Dimension A Dimension B

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)

A3-36
02-02

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.

MULTIPLE BOILERS WITH INDIVIDUAL STACKS

Figure A3-23. Breeching Arrangement

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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
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. 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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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
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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

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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
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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.

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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.

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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

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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.

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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.

FEATURES AND BENEFITS


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


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

NOTE: Valve manufacturers are Kunkle, Consolidated or Conbraco, depending on availability.

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

NOTE: ALLOW 3 FEET FOR DOOR SWING PER NEC

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

NOTE: ALLOW 3 FEET FOR DOOR SWING PER NEC

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

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 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.

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 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

Table A4-10. 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.

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


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.

A4-19
10-02

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

A4-20
10-02

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
10-02

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.

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 A4-7. Typical Gas Piping Layout

A4-22
10-02

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

A4-23
10-02

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

A4-24
10-02

Firetube Boilers

Model CBW Boilers

Figure A4-11. No. 2 Oil Piping, Single Boiler Installation, Remote Oil Pump

Figure A4-12. No. 2 Oil Piping, Multiple Boiler Installation, Remote Oil Pumps

A4-25
10-02

Model CBW Boilers

Firetube Boilers

Figure A4-13. No. 2 Oil Piping, Multiple Boiler Installation

Figure A4-14. No. 6 Oil Piping, Single Boiler Installation, Remote Oil Pumps

A4-26
10-02

Firetube Boilers

Model CBW Boilers

Figure A4-15. No. 6 Oil Piping, Multiple Boiler Installation, Remote Oil Pumps

Figure A4-16. No. 6 Oil Piping, Multiple Boiler Installation

A4-27
10-02

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 A4-17. No. 2 Oil Transfer Tank Detail

Figure A4-18. Typical Arrangement

A4-28
10-02

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

A4-29
10-02

Model CBW Boilers


Boiler Room Information
Figure A4-21 shows typical boiler room length requirements. Figure A4-22 shows typical boiler room width requirements. Figure A4-23 shows typical breeching arrangements.

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).

Stack Support Capabilities


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.

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

NOTICE
Consult local codes which may supersede these requirements.

A4-30
10-02

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
10-02

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.

MULTIPLE BOILERS WITH INDIVIDUAL STACKS

Figure A4-23. Breeching Arrangement

A4-32
10-02

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
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, fuel, electrical, vent, and blowdown connections.

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10-02

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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10-02

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:

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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

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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.

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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

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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

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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.

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10-02

Model CBW Boilers


7.0 Execution 7.1 Shop Tests

Firetube 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.

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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

Ohio Special 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.

FEATURES AND BENEFITS


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

Ohio Special Boilers


Special pilot. Alternate fuel ring. Special oil pumps.

Firetube Boilers

DIMENSIONS AND RATINGS


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

Ohio Special Boilers

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

Ohio Special Boilers

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)


NOTE: ALLOW 3 FEET FOR DOOR SWING PER NEC

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

Ohio Special 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

A6-7
02-02

Ohio Special Boilers

Firetube Boilers

NOTE: ALLOW 3 FEET FOR DOOR SWING PER NEC

Figure A6-2. Model CBW Ohio Special Steam Boiler Dimensions - Sheet 1of 2

A6-8
02-02

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

Ohio Special Boilers


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

A6-9
02-02

Ohio Special Boilers

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

NOTE: A, B and C Dimensions may vary by 1/2 inch.

BOILER HP (CBW) 125S-150S 175S-225S

ALL DIMENSIONS IN INCHES A 80 80 B 19 19 C 109 148 D 3 3

NOTE: A, B and C Dimensions may vary by 1/2 inch.

Figure A6-4. Model CB and CBW Ohio Special Boilers Lifting Lug Location

A6-10
02-02

Firetube Boilers

Ohio Special 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

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 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.

A6-11
02-02

Ohio Special Boilers

Firetube Boilers

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

NOTE: Valve manufacturers are Kunkle, Consolidated or Conbraco, depending on availability.

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.

A6-12
02-02

Firetube Boilers

Ohio Special 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

Note: Valve sizes (300 psig flanges) given in inches.

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
02-02

Ohio Special Boilers

Firetube Boilers

Figure A6-7. Complete Linkage Assembly, Combination Gas and Oil

A6-14
02-02

Firetube Boilers

Ohio Special 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.

A6-15
02-02

Ohio Special Boilers

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,
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 -

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.

A6-16
02-02

Firetube Boilers

Ohio Special Boilers

Table A6-13. Minimum Required Gas Pressure Altitude Conversion


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.

A6-17
02-02

Ohio Special 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 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

A6-18
02-02

Firetube Boilers

Ohio Special 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

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 A6-10. Typical Gas Piping Layout

A6-19
02-02

Ohio Special Boilers

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

A6-20
02-02

Firetube Boilers

Ohio Special Boilers

USE LAYOUT FOR: MODEL CB . . . . . . 100S - 225S MODEL CBW . . . . 125 S- 200S

Figure A6-13. No. 2 Oil Piping, Single Boiler Installation, Remote Oil Pump

USE LAYOUT FOR: MODEL CB . . 100S - 225S MODEL CBW . . . 125S - 200S

Figure A6-14. No. 2 Oil Piping, Multiple Boiler Installation, Remote Oil Pumps

A6-21
02-02

Ohio Special Boilers

Firetube Boilers

USE LAYOUT FOR: MODEL CB . . . . . . . 100S - 225S MODEL CBW . . . . . 125S - 200S

Figure A6-15. No. 2 Oil Piping, Multiple Boiler Installation

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.

Figure A6-16. No. 2 Oil Transfer Tank Detail

A6-22
02-02

Firetube Boilers
Boiler Room Information
Figure A6-17 shows typical boiler room length requirements. Figure A6-18 shows typical boiler room width requirements.

Ohio Special Boilers


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).

Stack Support Capabilities


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.

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 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.

A6-23
02-02

Ohio Special Boilers

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

BOILER HP Dimension A Dimension B

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

A6-24
02-02

Firetube Boilers

Ohio Special Boilers

SAMPLE SPECIFICATIONS
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
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.

A6-25
02-02

Ohio Special Boilers

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

Ohio Special Boilers

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

Ohio Special Boilers

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

Ohio Special 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

Ohio Special Boilers


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

Ohio Special 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

Ohio Special Boilers

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

Ohio Special Boilers

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

Ohio Special Boilers

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

Ohio Special 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

Ohio Special Boilers


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.

FEATURES AND BENEFITS


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


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

**

**

**

**

**

**

**

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.

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

NOTE: A, B and C Dimensions may vary by 1/2 inch.

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

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 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.

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. 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

Table A7-13. Minimum Required Gas Pressure Altitude Conversion


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
Boiler Room Information
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.

Stack Support Capabilities


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
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 (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

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 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

SAMPLE SPECIFICATION
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

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.

A7-30
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.

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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.

FEATURES AND BENEFITS


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.

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Model CEW

Firetube Boilers

DIMENSIONS AND RATINGS


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

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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)

* Integral oil pump. **No air compressor required (pressure atomized)


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

* Integral oil pump. **No air compressor required (pressure atomized)


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)

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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)

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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)

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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

DIMENSION (INCHES) A 33 42 51 B 42 53 64 C 54 61 73 D 77 92 109 E 36 46 54

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.

A8-11
10-02

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/Control Information
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.

Boiler Room Information


Figure A8-7 shows typical boiler room length requirements. Figure A8-8 shows typical boiler room width requirements.

Stack Support Capabilities


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.

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

A8-12
10-02

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
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 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.

A8-13
10-02

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.

A8-14
10-02

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

NOTES: Hot water relief valves are Kunkle #537.

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.

A8-15
10-02

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

Note: Valve sizes (300 psig Flanges) given in inches.

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.

A8-16
10-02

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 -

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.

A8-17
10-02

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.

Figure A8-6. Typical Fuel Oil Supply Arrangement

A8-18
10-02

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

BOILER HP Dimension A (inches) Dimension B (inches)

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
10-02

Model CEW

Firetube Boilers

Notes

A8-20
10-02

Firetube Boilers

Model CEW

SAMPLE SPECIFICATION
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

A8-21
10-02

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.

A8-22
10-02

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

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.

A8-30
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

FEATURES AND BENEFITS


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


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

DIMENSION (INCHES) A 33 42 51 B 42 53 64 C 54 61 73 D 77 92 109 E 36 46 54

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.

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 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/Control Information
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-

Boiler Room Information


Figure A9-7 shows typical boiler room length requirements. Figure A9-8 shows typical boiler room width requirements.

A9-12
10-02

Firetube Boilers
Stack Support Capabilities
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
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 (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.

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-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

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 A9-4. Model CEW-LN 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.

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

NOTES: Hot water relief valves are Kunkle #537.

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

Note: Valve sizes (300 psig Flanges) given in inches.

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

NOTE: Quantity of water removed from boiler by lowering normal water line 4". Optional level controls can alter water quantities.

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.

Table A9-11. 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 -

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.

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)

Note: For undersized or oversized gas trains or altitudes above 1,000 feet, contact your local Cleaver-Brooks representative.

Figure A9-6. Typical Fuel Oil Supply Arrangement

A9-18
10-02

Firetube Boilers

Model CEW-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 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 A9-7. Boiler Room Length (Typical Layouts) - Model CEW-LN

BOILER HP Dimension A (inches) Dimension B (inches)

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

SAMPLE SPECIFICATION
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

Model CEW Ohio Special


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.

FEATURES AND BENEFITS


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

Model CEW Ohio Special

Firetube Boilers

DIMENSIONS AND RATINGS


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

Model CEW Ohio Special

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

Model CEW Ohio Special

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

Model CEW Ohio Special

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

Model CEW Ohio Special

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

Model CEW Ohio Special

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/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. 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.

Boiler Room Information


Figure A10-6 shows typical boiler room length requirements. Figure A10-7 shows typical boiler room width requirements.

Stack Support Capabilities


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.

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

A10-10
02-02

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
Consult local codes, which may supersede these requirements.

A10-11
02-02

Model CEW Ohio Special

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

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 A10-3. Model CEW Ohio Special 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.)

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

NOTE: Valve manufacturers are Kunkle, Consolidated or Conbraco, depending on availability. Valve requirements can vary with special pressure settings.

A10-12
02-02

Firetube Boilers

Model CEW Ohio Special

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

Note: Valve sizes (300 psig flanges) given in inches.

A10-13
02-02

Model CEW Ohio Special

Firetube Boilers

Table A10-6. Model CEW Ohio Special Blowdown Tank Sizing Information
BOILER HP 100S-150S 175S-225S WATER (GAL) 110 120

NOTE: Quantity of water removed from boiler by lowering normal water line 4". Optional level controls can alter water quantities.

Table A10-7. 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 -

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.

A10-14
02-02

Firetube Boilers

Model CEW Ohio Special

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

Note: For undersized or oversized gas trains or altitudes above 1,000 feet, contact your local Cleaver-Brooks representative.

Figure A10-5. Typical Fuel Oil Supply Arrangement

A10-15
02-02

Model CEW Ohio Special

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.

Figure A10-6. Boiler Room Length (Typical Layouts)

BOILER HP Dimension A (inches) Dimension B (inches)

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

Model CEW Ohio Special

SAMPLE SPECIFICATION
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

Model CEW Ohio Special


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).

A10-18
02-02

Firetube Boilers
4.4.1 Fuel Series 700 - Gas Fired

Model CEW Ohio Special

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.

A10-19
02-02

Model CEW Ohio Special


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.

A10-20
02-02

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.

FEATURES AND BENEFITS


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


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.

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 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).

Boiler Room Information


Figure A11-7 shows typical boiler room length requirements. Figure A11-8 shows typical boiler room width requirements.

Stack Support Capabilities


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

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 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
BOILER HP FIRING RATE (%) 25 50 75 100

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
BOILER HP FIRING RATE (%) 25 50 75 100

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
BOILER HP FIRING RATE (%) 25 50 75 100

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
BOILER HP FIRING RATE (%) 25 50 75 100

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
BOILER HP FIRING RATE (%) 25 50 75 100

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
BOILER SQUARE FOOT OF HEATING SURFACE
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


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 WATER (GAL)

Table A11-14. 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 -

356 400 418 460 500 500 538 575

NOTE: Quantity of water removed from boiler by lowering normal water line 4". Optional level controls can alter water quantities.

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

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 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.

FEATURES AND BENEFITS


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


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

* = 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.

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

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 A12-4. 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

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

* = 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.

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"

NOTE: Accompanying dimensions, while sufciently accurate for layout purposes, must be conrmed for actual option requirements.

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

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 A12-6 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.

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

NOTE: Valve manufacturers are Kunkle, Consolidated or Conbraco, depending on availability.

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

NOTE: Quantity of water removed from boiler by lowering normal water line 4".

Table A12-13. 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 1.3 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.

Figure A12-6. Typical Fuel Oil Supply Arrangement

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

SAMPLE SPECIFICATION
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.

FEATURES AND BENEFITS


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


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

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 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

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 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

NOTE: All fractional hp motors will be single phase voltage except oil metering pump motor (3-phase); integral motors will be 3-phase voltage.

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

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 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 A13-4. 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

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 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

NOTE: All fractional hp motors will be single phase voltage except oil metering pump motor (3-phase); integral motors will be 3-phase voltage.

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"

NOTE: Accompanying dimensions, while sufciently accurate for layout purposes, must be conrmed for actual option requirements.

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&quo