Boiler Book - Cleaver Brooks

TABLE OF CONTENTS
Firetube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A

A1 Promethean Boilers Model CB-LE (Dry-Back) 125-800 HP Low NOx
A2 Promethean Boilers Model 4WI (Wet-Back) 100-800 HP Low NOx
A3 Criterion Boilers Model 4WG (Wet-Back) 100-800 HP Low NOx
A4 Criterion Boilers Model ICB (Intercooled Back) 100-800 HP Low NOx
A5 Model CBL (Wet-Back) 900-1500 HP Low NOx
A6 Model CB (Dry-Back) 15-100 HP
A7 Model CBE (Dry-Back) 60-80 HP
A8 Model CB Ohio Special (Dry-Back) 100-225 HP
A9 Model CEW Ohio Special Boilers (Wet-Back) 100-225 HP
A10 Model CBR Boilers 125-800 HP
A11 Optimized Boiler Package
Commercial Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
B1 Model FLX Boilers
B2 Model 4 Boilers
B3 Model 5 Boilers
B4 Electric Boilers
B5 ClearFire Model CFC Condensing Hot Water Boilers
B6 ClearFire Model CFH Steam Boilers
B7 ClearFire Model CFV Steam 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 Traymaster Deaerators
H4 Boilermate Deaerators
H5 Surge Tanks
H6 Boiler Feed Systems
H7 Chemical Feed Systems and Metering Pumps
H9 Softeners
H10 Dealkalizers
H11 Blowdown Separators
H12 Blowdown Heat Recovery Systems
H13 Flash Tank Heat Exchangers
H14 Sample Coolers
System Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section I
I1 Boiler Selection Considerations
I2 Hot Water Systems
I3 Steam Systems
I4 General Engineering Data
I5 Alternative Fuels
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section J
Notes
A1-1
03-08
Tiny Tots for you
WAR NING! R ick Marino is hazardous to your health But, he has managed to hire exceptional employees. Unfortunately, they continue to write crazy unnecessary comments on drawings.
A lot of little words for a very little space R eggie the dog was here
69 69 69 69 6 9 6 9 6 9 69 69 69 69 69 6 96 96 9 69 69 69
BLAH, BLAH, BLAH, BLAH, BLAH, BLAH, BLAH, BLAH, BLAH, BLAH, BLAH, BLAH,
WAR NING!!!
THIS TAG IS NOT TO BE R E MOVE D
UNLE S S A PS YCHOLOGIS T HAS
FIR S T BE CONS ULTE D. THIS IS
TO E NS UR E ME NTAL S TABILITY.
This text is to small to read. If you are able to read this, you must be an insect.
CB-LE
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-4
True Boiler/Burner/Low NOx Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-4
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-4
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-4
Available Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-4
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-4
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-24
Specifying Boiler Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-24
Efficiency Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-24
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-25
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-28
Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-28
Gas-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-29
Oil-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-33
General Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-33
Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-33
Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-33
Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-33
Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-33
Sample Specifications (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-43
Sample Specifications (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-55
Section A1
Promethean Series Model CB-LE Boilers
A1-2
Promethean Series Model CB-LE Firetube Boilers
03-08
ILLUSTRATIONS
Figure A1-1. CB-LE Steam - 125-200 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-6
Figure A1-4. CB-LE Hot Water - 125-200 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-12
Figure A1-5. CB-LE Hot Water 250-350 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-14
Figure A1-6. CB-LE Hot Water 400-800 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-16
Figure A1-7. Space Required to Open Rear Head on Model CB-LE Boilers Equipped with Davits . . A1-21
Figure A1-8. Model CB-LE Boiler Mounting Piers (60 and 78) . . . . . . . . . . . . . . . . . . . . . . . . . A1-21
Figure A1-9. Model CB-LE Boiler Mounting Piers (96) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-22
Figure A1-10. Lifting Lug Location, Model CB-LE Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-23
Figure A1-11. Predicted Stack Temperature Increase for Pressure Greater Than 125 psig . . . . . . . A1-26
Figure A1-12. Standard Gas Train Connection Size and Location . . . . . . . . . . . . . . . . . . . . . . . . A1-32
Figure A1-13. Typical Gas Piping Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-35
Figure A1-14. Model CB-LE Gas Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-36
Figure A1-15. No.2 Oil Connection Size, Location, and Recommended Line Sizes . . . . . . . . . . . . A1-36
Figure A1-16. No. 2 Oil Piping, Single Boiler Installation, Remote Oil Pump . . . . . . . . . . . . . . . . A1-37
Figure A1-17. No. 2 Oil Piping, Multiple Boiler Installation, Remote Oil Pumps . . . . . . . . . . . . . . A1-37
Figure A1-18. No. 2 Oil Piping, Multiple Boiler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-38
Figure A1-19. No. 2 Oil Transfer Tank Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-38
Figure A1-20. Typical Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-39
Figure A1-21. Boiler Room Length (Typical Layouts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-41
Figure A1-22. Boiler Room Width (Typical Layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-41
Figure A1-23. Breeching Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-42
TABLES
Table A1-1. Model CB-LE Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-5
Table A1-2. Model CB-LE Hot Water Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-5
Table A1-3. Model CB-LE Steam Boiler Dimensions,
60 (15 - 150 psig Design Pressure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-6
Table A1-6. Model CB-LE Hot Water Boiler Dimensions,
60 (30 and 125 psig Design Pressure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-12
Table A1-9. Fan Motor Horsepower Requirements - Steam Boilers O 150 psig, all HW boilers . . . . A1-18
Table A1-10. Fan Motor Horsepower Requirements - Steam Boilers >150 psig . . . . . . . . . . . . . . A1-18
Table A1-11. Model CB-LE Boiler Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-19
Table A1-12. Steam Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-20
Table A1-13. Hot Water Boiler Relief Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-20
Table A1-14. Predicted Fuel-to-Steam Efficiencies - Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . A1-26
Table A1-15. Predicted Fuel-to-Steam Efficiencies - No. 2 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . A1-27
Firetube Boilers Promethean Series Model CB-LE
A1-3
03-08
Table A1-16. CB-LE Boilers - Natural Gas, Emission Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-27
Table A1-17. CB-LE Boilers - No. 2 Oil, Emission Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-27
Table A1-18. Model CB-LE Predicted Sound Levels 30 ppm NOx Systems . . . . . . . . . . . . . . . . . . A1-28
Table A1-19. Standard, Undersize, and Oversize Gas Trains, Model CB-LE Boilers . . . . . . . . . . . . A1-30
Table A1-20. Recommended NTI Gas Train Sizes & Pressure Ranges . . . . . . . . . . . . . . . . . . . . . . A1-31
Table A1-21. Minimum Required Regulated Gas Pressure Altitude Conversion . . . . . . . . . . . . . . . A1-32
Table A1-22. Maximum Gas Consumption (CFH) for Natural Gas and Propane Vapor. . . . . . . . . . . A1-32
Table A1-23. Model CB-LE Blowdown Tank Sizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-39
Table A1-24. Heating Surface, Model CB-LE Boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-39
Table A1-25. Steam Volume & Disengaging Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-40
Table A1-26. Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-40
Table A1-27. Recommended Non-Return Valve Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-40
Table A1-28. Blower Motor Selection CB-LE NTI Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-40
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 efficiency. The Low Emission Option combines the packaging of
induced flue gas recirculation with the Cleaver-Brooks integral front head. The front head routes the flue 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 firing 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% O
2
):
NOx performance for 60 ppm (natural gas corrected to 3% O
2
) uses a standard size combustion air fan for
induced flue gas recirculation.
NOx performance for 30, 25, or 20 ppm (natural gas corrected to 3% O
2
) 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 guar-
anteed emission performance levels.
A1-4
03-08
FEATURES AND BENEFITS
The Cleaver-Brooks Model CB Boiler - the premium firetube on the market today -
includes the four-pass dryback design, five square feet of heating surface per boiler
horsepower, and maximum boiler efficiency. 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 flame 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 efficiency.
Eliminates the need for field installation of burner, controls, or NOx equipment.
Single point positioning of fuel and air ensures ease of startup and provides
reliable operation.
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 fired.
Retrofit 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.
Full line of Model CB Firetube options.
Additional NOx reduction packages.
DIMENSIONS AND RATINGS
The Model CB-LE dimensions and ratings are provided inTable A1-1 through Table
A1-8, and in Figure A1-1 through Figure A1-6.
A1-5
03-08
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
36.4 43.7 58.3 72.9 87.5 102.1 116.6 145.8 175.0 204.1 218.7 233.3
Natural Gas (cfh) MBtu 5103 6124 8165 10206 12247 14288 16329 20415 24494 28576 30618 32659
Gas (Therm/hr) 51.0 61.2 81.7 102.1 122.5 142.9 163.3 204.2 245.0 285.8 306.2 326.6
Blower Motor hp Refer to Tables A1-9 and A1-10
Oil Pump Motor, hp No. 2 Oil 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4 1 1 1
Air Compressor Motor hp (Oil firing Only) 3 3 3 5 5 5 7-1/2 7-1/2 7-1/2 7-1/2 7-1/2 7-1/2
NOTES:
A. Based on 140,000 Btu/gal.
Table A1-2. Model CB-LE Hot Water 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)
4313 5175 6900 8625 10350 12075 13800 17250 20700 24150 25875 27600
Btu Output (1000 Btu/hr) 4184 5021 6695 8369 10043 11716 13390 16738 20085 23432 25106 26779
APPROXIMATE FUEL CONSUMPTION AT RATED CAPACITY
Light Oil (gph)
A
36.4 43.7 58.3 72.9 87.5 102.1 116.6 145.8 175.0 204.1 218.7 233.3
Natural Gas (cfh) MBtu 5103 6124 8165 10206 12247 14288 16329 20412 24494 28576 30618 32659
Gas (Therm/hr) 51.0 61.2 81.7 102.1 122.5 142.8 163.3 204.2 245.0 285.8 306.2 326.6
Blower Motor hp Refer to Tables A1-9 and A1-10
Oil Pump Motor, hp No. 2 Oil 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4 1 1 1
Air Compressor Motor hp (Oil
firing Only)
3 3 3 5 5 5 7-1/2 7-1/2 7-1/2 7-1/2 7-1/2 7-1/2
NOTES:
Table A1-1. Model CB-LE Steam Boiler Ratings
A1-6
03-08
GG
RR/ RF/ RD
EE
FF
DD
P V
D
A
B
H
E T
U/Y
W
G C
X
J
II
F
W
Q
I
LL
L K
OO
O
KK
M
N
60 (15 - 150 psig Design Pressure) - Sheet 1 of 2
BOILER HP DIM 125 150 200
LENGTHS
Overall (60 ppm System) A 171-1/2 196-1/2 228-1/2
Overall (30 ppm System) A
Overall (15-<9 ppm System) A
Shell B 125 149 180
Base Frame C 112 136 167
Front Head Extension (60 ppm System) D 27 28 29
Rear Head Extension E 19-1/2 19-1/2 19-1/2
Front Ring Flange to Nozzle - 15 lb H 88 90 96
Front Ring Flange to Nozzle -150 lb H 84 84 96
Ring Flange to Base F 1/2 1/2 1/2
Over Tubesheets V 113 137 168
Shell Extension P 12 12 12
Rear Flange Ring to Base G 12-1/2 12-1/2 12-1/2
Figure A1-1. CB-LE Steam - 125-200 HP
A1-7
03-08
WIDTHS
Overall I 90 90 90
Center to Panel II 50 50 50
I.D. Boiler J 60 60 60
Center to Water Column K 45 45 45
Center to Outside Hinge KK 35 35 35
Center to Lagging L 33 33 33
Center to Auxiliary LWCO LL 40 40 40
Base, Outside M 52-1/2 52-1/2 52-1/2
Base, Inside N 44-1/2 44-1/2 44-1/2
HEIGHTS
Base to Steam Outlet X 82-3/8 82-3/8 82-3/8
Overall OO 86 86 86
Base to Vent Outlet O 85 85 85
Height of Base Q 12 12 12
Base to Bottom of Boiler R 16 16 16
BOILER CONNECTIONS
Feedwater, Right and Left S 1-1/2 1-1/2 2
Chemical Feed Z 1 1 1
Low Pressure (15 lb only)
Steam Nozzle

Drain, Front and Rear
U
W
8
A
1-1/2
8
A
1-1/2
10
A
2
High Pressure (150 lb only)
Surface Blowoff, Top C
L
Steam Nozzle

Blowdown, Front and Rear
T
Y
W
1
4
B
1-1/2
1
4
B
1-1/2
1
4
B
1-1/2
VENT STACK
Diameter (flgd. connection) BB 16 16 16
MINIMUM CLEARANCES
Rear Door Swing (Davit Equipped) DD 32 32 32
Front Door Swing EE 67 67 67
Tube Removal, Rear FF 115 139 170
Tube Removal, Front GG 103 127 158
MINIMUM BOILER ROOM LENGTH ALLOWING FOR DOOR SWING AND TUBE REMOVAL FROM:
Rear of Boiler RR 307 355 417
Front of Boiler RF 260 308 370
Thru Window or Doorway RD 224 248 279
WEIGHT IN LBS
Normal Water Capacity 5750 7250 8625
Approx. Ship Wgt - 15 psig 11300 12600 14600
NOTES: All connections are threaded unless indicated.
A. ANSI 150 psig flange.
B. ANSI 300 psig flange.
A1-8
03-08
GG
RR/ RF/ RD
EE
FF
DD
P V
D
A
B
H
E T
U/Y
W
G C
X
J
N
M
KK
I
II
K
OO
O
Q
L
LL
F
W
LENGTHS
Overall (60 ppm System) A 191-1/2 220 252
Overall (15 - <9 ppm System) A
Shell B 144 171 201
Front Head Extension (60 ppm System) D 23-1/2 25 28
Rear Head Extension E 24 24 24
A1-9
03-08
WIDTHS
Overall I 108 108 108
Center to Panel II 59 59 59
Center to Water Column K 54 54 54
Center to Auxiliary LWCO LL 49 49 49
Base, Outside M 64 64 64
Base, Inside N 56 56 56
HEIGHTS
Base to Steam Outlet X 101-1/2 101-1/2 101-1/2
Overall OO 115 115 115
BOILER CONNECTIONS
Feedwater, Right and Left S 2 2 2-1/2
Chemical Feed Z 1 1 1
Low Pressure (15 lb only)
Steam Nozzle

U
W
10
A
2
12
A
2
12
A
2
High Pressure (150 lb only)
L
Steam Nozzle

T
Y
W
1
6
B
1-1/2
1
6
B
1-1/2
1
6
B
1-1/2
VENT STACK
MINIMUM CLEARANCES
Rear Door Swing DD 43 43 43
Tube Removal, Front GG 116 142 172
WEIGHT IN LBS
Normal Water Capacity 10670 13000 15465
A1-10
03-08
GG
RR/ RF/ RD
EE
FF
DD
P V
D
A
B
H
E T
U/Y
W
G C
X
J
N
M
KK
I
II
K
OO
O
Q
L
LL
F
W
BOILER HP DIM 400 500 600 700 750 800
LENGTHS
Overall (60 ppm System) A 206 228 262 299 300 300
Overall (15-<9 ppm System) A
Shell B 147 168 200 233 233 233
Base Frame C 134 155 187 220 220 220
Front Head Extension (60 ppm System) D 27 28 30 34 35 35
Rear Head Extension E 32 32 32 32 32 32
Shell Ring Flange to Base F 1/2 1/2 1/2 1/2 1/2 1/2
Rear Ring Flange to Base G 12-1/2 12-1/2 12-1/2 12-1/2 12-1/2 12-1/2
Shell Flange to Nozzle 15 lb H 98 101 96 112 112 112
Shell Flange to Nozzle 150 lb H 96 100 96 112 112 112
Over Tubesheets V 130 151 183 216 216 216
A1-11
03-08
WIDTHS
Overall I 127 127 127 127 127 127
Center to Panel II 68 68 68 68 68 68
I.D. Boiler J 96 96 96 96 96 96
Center to Water Column K 64 64 64 64 64 64
Center to Outside Hinge KK 62 62 62 62 62 62
Center to Lagging L 51 51 51 51 51 51
Center to Auxiliary LWCO LL 59 59 59 59 59 59
Base, Outside M 72 72 72 72 72 72
Base, Inside N 58-7/8 58-7/8 58-7/8 58-78 58-7/8 58-7/8
HEIGHTS
Overall OO 134 134 134 134 134 134
Base to Vent Outlet O 126 126 126 126 126 126
Height of Base Q 12 12 12 12 12 12
Base to Steam Outlet X 121-1/2 121-1/2 121-1/2 121-1/2 121-1/2 121-1/2
Base to Bottom of Boiler R 19 19 19 19 19 19
BOILER CONNECTIONS
Feedwater, Right and Left S 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2
Chemical Feed Z 1 1 1 1 1 1
L (150 lb only)
T 1 1 1 1 1 1
Blowdown, Front and Rear W 2 2 2 2 2 2
Low Pressure (15 psig Only) U 12
A
12
A
12
A
12
A
12
A
12
A

High Pressure (150 psig Only) Y 6
B
8
B
8
B
8
B
8
B
8
B

VENT STACK
Diameter (Flanged Connection) BB 24 24 24 24 24 24
MINIMUM CLEARANCES
Rear Door Swing DD 53 53 53 53 53 53
Front Door Swing EE 108 108 108 108 108 108
Tube Removal, Rear FF 131 152 184 217 217 217
Tube Removal, Front GG 114 135 167 200 200 200
Rear of Boiler RR 386 428 492 558 558 558
Front of Boiler RF 314 356 420 486 486 486
Thru Window or Doorway RD 308 329 361 394 394 394
WEIGHT IN LBS
Normal Water Capacity 14810 15950 19270 23000 23000 23000
Approx. Ship. Wgt. 15 psig 33500 37110 42300 49500 49600 49600
Approx. Ship. Wgt. - 150 psig 36570 39970 45025 52050 52150 52150
Approx. Ship. Wgt. - 200 psig 39680 43580 49400 57315 57415 57415
NOTES: All connections are threaded unless indicated:
BOILER HP DIM 400 500 600 700 750 800
Table A1-5 Model CB-LE Steam Boiler Dimensions,
A1-12
03-08
LENGTHS
Overall (60 ppm System) A 171-1/2 196-1/2 228-1/2
Overall (30 ppm System)
Overall (15 - <9 ppm System)
Shell B 125 149 180
Front Head Extension (60 ppm System) D 27 28 29
Front Ring Flange to Outlet HH 114 136 167
Front Ring Flange to Return H 89 102 131
60 (30 and 125 psig Design Pressure) - Sheet 1 of 2
Figure A1-4. CB-LE Hot Water - 125-200 HP
A1-13
03-08
WIDTHS
Overall I 75-1/2 75-1/2 75-1/2
Center to Entrance Box K 42-1/2 42-1/2 42-1/2
Base, Outside M 52-1/2 52-1/2 52-1/2
Base, Inside N 44-1/2 44-1/2 44-1/2
HEIGHTS
Overall OO 86 86 86
Base to Return and Outlet X 82-3/8 82-3/8 82-3/8
BOILER CONNECTION
Waterfill Conn. Right & Left S 1-1/2 1-1/2 2
Auxiliary Connection Z 1 1 1
Water Return Flange T 6
A
6
A
6
A
Water Outlet Flange (2" Dip Tube Included) U 6
A
6
A
6
A
Drain, Front and Rear W 1-1/2 1-1/2 2
Air Vent Y 1-1/2 1-1/2 1-1/2
VENT STACK
MINIMUM CLEARANCES
Tube, Removal, Front GG 103 127 158
WEIGHT IN LBS
Water Capacity Flooded 7670 9295 11130
Approx. Ship. Wgt. 30 psig
11400
11800
12500
12900
14500
14900
A1-14
03-08
LENGTHS
Overall (60 ppm System) A 191-1/2 220 252
Overall (15-<9 ppm System)
Shell B 144 171 201
Front Head Extension (60 ppm System) D 23-1/2 25 27
Rear Head Extension E 24 24 24
Front Ring Flange to Return H 103-1/2 130 160
Front Ring Flange to Outlet HH 131 158 188
Figure A1-5. CB-LE Hot Water 250-350 HP
A1-15
03-08
WIDTHS
Overall I 93 93 93
Center to Entrance Box K 51 51 51
Base, Outside M 64 64 64
Base, Inside N 52 52 52
HEIGHTS
Overall OO 115 115 115
Base to Return and Outlet X 101-1/2 101-1/2 101-1/2
BOILER CONNECTION
Waterfill Conn. Right & Left S 2 2 2-1/2
Auxiliary Connection Z 1-1/4 1-1/4 1-1/4
Water Return Flange (2" Dip Tube included) T 8
A
8
A
8
A
Water Outlet Flange (2" Dip Tube Included) U 8
A
8
A
8
A
Air Vent Y 1-1/2 1-1/2 1-1/2
Drain, Front and Rear W 2 2 2
VENT STACK
MINIMUM CLEARANCES
Tube, Removal, Front GG 116 142 172
WEIGHT IN LBS
Water Capacity Flooded 13880 16840 20090
21400
22200
23500
24300
26700
27500

NOTES: All connections are threaded unless indicted.
A1-16
03-08
BOILER HP DIM 400 500 600 700 750 800
LENGTHS
Overall (60 ppm System) A 206 228 262 299 300 300
Overall (15-<9 ppm System)
Shell B 147 168 200 233 233 233
Base Frame C 134 155 187 220 220 220
Front Head Extension (60 ppm System) D 27 28 30 34 35 35
Rear Head Extension E 32 32 32 32 32 32
Shell Ring Flange to Base F 1/2 1/2 1/2 1/2 1/2 1/2
Rear Ring Flange to Base G 12-1/2 12-1/2 12-1/2 12-1/2 12-1/2 12-1/2
Shell Flange to Outlet HH 139-1/2 156-1/2 182-1/2 216-1/2 216-1/2 216-1/2
Shell Flange to Return H 107 125 151-1/2 185 185 185
Over Tubesheets V 130 151 183 216 216 216
Shell Extension P 17 17 17 17 17 17
Figure A1-6. CB-LE Hot Water 400-800 HP
A1-17
03-08
WIDTHS
Overall I 113 113 113 113 115 115
I.D. Boiler J 96 96 96 96 96 96
Center to Entrance Box K 62 62 62 62 64 64
Base, Outside M 72 72 72 72 72 72
Base, Inside N 56 56 56 56 56 56
HEIGHTS
Overall OO 134 134 134 134 134 134
Height of Base Q 12 12 12 12 12 12
Base to Bottom of Boiler R 19 19 19 19 19 19
Base to Return and Outlet X 121-9/16 121-9/16 121-9/16 121-9/16 121-9/16 121-9/16
BOILER CONNECTIONS
Waterfill Connection, Right and Left S 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2
Auxiliary Connection Z 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4
Drain, Front and Rear W 2 2 2 2 2 2
Water Return T 10
A
10
A
12
A
12
A
12
A
12
A

Water Outlet (2Dip Tube Included) U 10
A
10
A
12
A
12
A
12
A
12
A

Air Vent Y 2 2 2 2 2 2
VENT STACK
Diameter (Flanged Connection) BB 24 24 24 24 24 24
MINIMUM CLEARANCES
Rear of Boiler RR 386 428 492 558 558 558
Front of Boiler RF 314 356 420 486 486 486
Thru Window or Doorway RD 308 329 361 394 394 394
WEIGHT IN LBS
33300
37270
36900
40780
42150
46005
49650
53300
49750
53400
49750
53400
NOTES: All connections are threaded unless indicated:
BOILER HP DIM 400 500 600 700 750 800
A1-18
03-08
BOILER HP
MOTOR HP
60
PPM
30
PPM
25
PPM
20
PPM
125 5 10 5 10
150 7.5 10 10 10
200 15 15 20 NA
250 7.5 10 15 15
300 10 15 20 25
350 15 25 40 40
400 10 15 20 20
500 15 20 25 30
600 25 30 50 60
700 30 50 75 75
750 50 60 75 NA
800 50 75 NA NA
NOTES: For elevations above 700 - contact your local
Cleaver-Brooks authorized representative.
Table A1-9. Model CB-LE Combustion Air Fan Motor
Horsepower Requirements - Operating Pressures 150
psig and Less, and All Hot Water Boilers
BOILER HP
MOTOR HP
60
PPM
30
PPM
25
PPM
20
PPM
125 5 10 10 10
150 10 10 10 15
200 15 20 20 NA
250 7.5 10 15 20
300 10 20 30 40
350 20 30 40 50
400 10 15 20 25
500 20 25 30 40
600 25 40 60 60
700 40 60 75
B
75
C
750 50 75 NA NA
800 60 75
A
NA NA
NOTES: For elevation above 700 - contact your local
A. Downrate to 770 hp.
B. Downrate to 675 hp.
C. Downrate to 660 hp.
Table A1-10. Model CB-LE Combustion Air Fan
Motor Horsepower Requirements - Operating
Pressures Greater than 150 psig (Steam Boilers)
06-11-07
A1-19
03-08
BOILER HP
FUEL
SERIES
HOT WATER STEAM
30 PSIG 125 PSIG 15 PSIG 150 PSIG 200 PSIG
125
100 11200 11600 11300 12000 12600
200 11400 11800 11500 12400 13000
700 11300 11700 11400 12300 12900
150
100 12300 12700 12400 13200 13900
200 12500 12900 12600 13500 14200
700 12300 12700 12400 13300 14000
200
100 14400 14800 14500 15500 16300
200 14500 14900 14600 15600 16400
700 14500 14900 14600 15600 16400
250
100 20700 21500 20800 22000 23800
200 21400 22200 21500 22800 24600
700 20900 21700 21000 22500 24300
300
100 23100 23900 23200 24800 26800
200 23500 24300 23600 25200 27200
700 23400 24200 23500 25000 27000
350
100 26200 27000 26300 27600 29100
200 26700 27500 26800 27800 29300
700 26400 27200 26500 27700 29200
400
100 33000 36970 33200 36270 39380
200 33300 37270 33500 36570 39680
700 33200 37170 33400 36470 39580
500
100 36600 40470 36810 39670 43480
200 36900 40780 37110 39970 43580
700 36800 40680 37010 39870 43280
600
100 41850 45905 42000 44725 49100
200 42150 46005 42300 45025 49400
700 42050 45915 42200 44925 49300
700
800
100 49450 53000 49300 51850 57015
200 49750 53300 49600 52150 57315
700 49650 53200 49500 52050 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.
Table A1-11. Model CB-LE Boiler Weights
A1-20
03-08
VALVE
SETTING
15 PSIG STEAM 100 PSIG STEAM 125 PSIG STEAM 150 PSIG STEAM 200 PSIG STEAM 250 PSIG STEAM
BOILER HP
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
125 1 3 2 1-1/2 2
(1) 1-1/2
(1) 1-1/4
2
(1) 1-1/2
(1) 1-1/4
2
(1) 1-1/4
(1) 1
2 1
150 1 3 2
(1) 2
(1) 1-1/2
2 1-1/2 2
(1) 1-1/2
(1) 1-1/4
2 1-1/4 2
(1) 1
(1) 1-1/4
200 2 2-1/2 2 2 2
(1) 2
(1) 1-1/2
2 1-1/2 2
(1) 1-1/2
(1) 1-1/4
2 1-1/4
250 2
(1) 2-1/2
(1) 3
2
(1) 2-1/2
(1) 2
2 2 2
(1) 2
(1) 1-1/2
2 1-1/2 2
(1) 1-1/2
(1) 1-1/4
300 2 3 2
(1) 2-1/2
(1) 2
2
(1) 2-1/2
(1) 2
2 (2) 2 2
(1) 2
(1) 1-1/2
2 1-1/2
350 3
(1) 2
(2) 3
3
(1) 2-1/2
(2) 2
2 2-1/2 2
(1) 2-1/2
(1) 2
2 2 2
(1) 1-1/2
(1) 2
400 3
(2) 3
(1) 2-1/2
3
(1) 2
(2) 2-1/2
2 2-1/2 2
(1) 2-1/2
(1) 2
2 2 2
(1) 2
(1) 1-1/2
500 3 (3) 3 3 2-1/2 3
(2) 2-1/2
(1) 2
2 (2) 2-1/2 2
(1) 2-1/2
(1) 2
2 (2) 2
600 4 3 4
(3) 2-1/2
(1) 2
3 2-1/2 3
(2) 2-1/2
(1) 2
2 2-1/2 2
(1) 2
(1) 2-1/2
700, 750 &
800
5
(3) 3
(2) 2-1/2
5
(3) 2-1/2
(2) 2
4
(3) 2-1/2
(1) 2
3
(2) 2-1/2
(1) 2
2 2-1/2 2 2-1/2
NOTES: Valve manufacturers are Kunkle, Consolidated or Conbraco, depending on availability.
Table A1-12. Steam Boiler Safety Valve Openings
VALVE
SETTING
30 PSIG HW 60 PSIG HW 100 PSIG HW 125 PSIG HW
BOILER HP
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
125 1 2-1/2 1 2 1 2 1 1-1/4
150 1 2-1/2 1 2-1/2 1 2 1 2
200 2
(1) 2-1/2
(1) 1-1/4
1 2-1/2 1 2 1 2
250 2
(1) 2
(1) 2-1/2
1 2-1/2 1 2-1/2 1 2
300 2 2-1/2 2
(1) 1
(1) 2-1/2
1 2-1/2 1 2-1/2
350 3
(2) 2-1/2
(1) 1
2
(1) 2-1/2
(1) 2
1 2-1/2 1 2-1/2
400 3
(1) 2
(2) 2-1/2
2
(1) 2
(2) 2-1/2
2
(1) 1
(1) 2-1/2
1 2-1/2
500 4
(1) 1
(3) 2-1/2
2 2-1/2 2
(1) 2-1/2
(1) 1-1/4
2
(1) 1
(1) 2-1/2
600 4
(3) 2-1/2
(1) 2
3
(1) 1-1
(2) 2-1/2
2
(1) 2
1) 2-1/2
2
(1) 2-1/2
(1) 1-1/4
700, 750 &
800
5
(1) 1
(4) 2-1/2
3
(1) 2
(2) 2-1/2
2 2-1/2 2
(1) 2-1/2
(1) 2
NOTES: Hot water relief valves are Kunkle #537.
Table A1-13. Hot Water Boiler Relief Valve Openings
A1-21
03-08
BOILER HP A B C D E F G X1 X2 X3
125 6 9 112 39-1/2 57-1/2 4 44-1/2 10 9-3/4 22-1/2
150 6 9 136 39-1/2 57-1/2 4 44-1/2 10 9-3/4 22-1/2
200 6 9 167 39-1/2 57-1/2 4 44-1/2 10 9-3/4 22-1/2
250 6 12 131 46 70 4 56 10 22 22-1/2
300 6 12 158 46 70 4 56 10 22 22-1/2
350 6 12 188 46 70 4 56 10 22 22-1/2
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 A1-7. Space Required to Open Rear Head on Model CB-LE Boilers Equipped with Davits
BOILER HP
DIMENSIONS (INCHES)
A B C D E
CB-125 THRU CB-200 33 55 45 68 32
CB-250 THRU CB-350 42 69 58 86 43
CB-400 THRU CB-800 51 88 71 10
9
53
Figure A1-8. Model CB-LE Boiler Mounting Piers (60 and 78)
A1-22
03-08
BOILER HP A B C D E F G
400 6 14 134 50 78 6-1/2 58-7/8
500 6 14 155 50 78 6-1/2 58-7/8
600 6 14 187 50 78 6-1/2 58-7/8
700-750-800 6 14 220 50 78 6-1/2 58-7/8
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 in-
creased inspection accessibility to the piping beneath the boiler and added height for washing down the area beneath
the boiler.
Figure A1-9. Model CB-LE Boiler Mounting Piers (96)
A1-23
03-08
NEAR
SIDE
VIEW B
FAR
SIDE
FRONT
FLANGE
VIEWA
E DIA. HOLE
A
C
L
B
D
D
C
BOILER
HP
VIE
W
ALL DIMENSIONS IN INCHES
A B C D E
125 All B 80-1/4 29-3/4 70-1/2 10 3
150 All B 80-1/4 29-3/4 83-1/2 10 3
200 All B 80-1/4 29-3/4 114-1/2 10 3
250
Steam B 99 36 72 10 3
Hot Water B 99 36 81 10 3
300
Steam B 99 36 99 10 3
Hot Water B 99 36 108 10 3
350
Steam B 99 36 129 10 3
Hot Water B 99 36 138 10 3
400
Steam B 119 35-3/4 78 11 3
Hot Water B 119 35-3/4 78 11 3
500
Steam B 119 35-3/4 99 11 3
Hot Water B 119 35-3/4 99 11 3
600
Steam B 119 35-3/4 131 11 3
Hot Water B 119 35-3/4 131 11 3
700, 750 &
800
Steam B 119 35-3/4 164 11 3
Hot Water B 119 35-3/4 164 11 3
NOTE: A, B and C dimensions may vary by 1/2 inch.
Figure A1-10. Lifting Lug Location, Model CB-LE Boilers
A1-24
03-08
PERFORMANCE DATA
The Low Emission Option provides NOx reduction at current published and
predicted fuel-to-steam efficiencies.
Specifying Boiler
Efficiency
Cleaver-Brooks offers an industry leading fuel-to-steam boiler efficiency guarantee
for Model CB-LE Firetube Boilers. The guarantee is based on the fuel-to-steam
efficiencies shown in the efficiency tables and the following conditions. The
efficiency percent number is only meaningful if the specific conditions of the
efficiency calculations are clearly stated in the specification (see Cleaver-Brooks
publication CB-7768 for a detailed description of efficiency calculations).
When specifying the efficiencies in the tables, be sure to include the specific
guarantee conditions to maximize the effectiveness of your efficiency specification. If
you have any questions regarding the efficiency specifications, 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 efficiency (as shown in Table A1-14 and Table A1-15) at
100% firing rate (add efficiency guarantees at 25%, 50%, and 75% of rating, if
required). If the boiler(s) fail to achieve the corresponding guaranteed efficiency as
published, the boiler manufacturer will rebate, to the ultimate boiler owner, five
thousand dollars ($5,000) for every full efficiency point (1.0%) that the actual
efficiency is below the guaranteed level.
The specified boiler efficiency is based on the following conditions.
1. Fuel specification used to determine boiler efficiency:
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
Sulfur,% (wt) = 0.2
No. 6 Oil
Sulfur,% (wt) = 2.09
2. Efficiencies are based on ambient air temperature of 80 F, relative humidity of
30%, and 15% excess air in the exhaust flue gas.
3. Efficiencies are based on manufacturers published radiation and convection
losses. (For Cleaver-Brooks radiation and convection losses, see Boiler
Efficiency Facts Guide, publication number CB-7767).
4. Any efficiency verification testing will be based on the stack loss method.
For efficiencies and stack temperatures at operating pressures not listed, follow
these procedures:
A1-25
03-08
When the operating steam pressure is between 10 psig and 125 psig, interpolate
the values from the efficiency tables.
When the operating steam pressure is above 125 psig, estimated efficiency can be
calculated as follows:
Example:
Boiler: 350 hp.
Fuel: natural gas.
Operating steam pressure: 200 psig.
Find the fuel-to-steam efficiency at 100% firing rate. FromTable A1-14 for a 350 hp
boiler operating at 100% firing rate and an operating steam pressure of 125 psig,
the efficiency is 82.5%.
Using Figure A1-11, note that the stack temperature increases 36 F at the higher
operating pressure. To estimate boiler efficiency, use this rule of thumb: For every
40 F increase in stack temperature, efficiency decreases by 1%. Since the stack
temperature rise is 36 F, the decrease in the boiler efficiency at 200 psig operating
pressure is calculated as follows: 36/40 =.9%. Therefore, the boiler efficiency 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 firing
natural gas and No. 2 oil.
Notice
The data in Table A1-16 and Table A1-17 represent typical emission levels only.
Guaranteed emission levels are available from your local Cleaver-Brooks authorized
representative.
A1-26
03-08
BOILER
HP
OPERATING PRESSURE = 10 psig OPERATING PRESSURE = 125 psig
% OF LOAD % OF LOAD
25% 50% 75% 100% 25% 50% 75% 100%
125 83.3 83.6 83.4 83.2 80.4 80.9 81.0 81.0
150 84.4 84.6 84.5 84.3 81.5 82.0 82.0 82.1
200 85.0 85.3 85.1 84.9 82.2 82.7 82.7 82.7
250 85.0 84.7 84.0 83.3 82.0 82.0 81.6 81.3
300 85.3 85.3 84.6 83.9 82.6 82.7 82.2 81.9
350 85.3 85.7 85.2 84.5 82.6 83.2 82.8 82.5
400 84.5 84.7 84.6 84.4 81.8 82.2 82.4 82.2
500 85.5 85.7 85.5 85.2 82.8 83.2 83.3 83.1
600 85.7 86.0 85.8 85.6 82.9 83.5 83.6 83.5
700 85.7 86.2 86.0 85.7 83.0 83.6 83.6 83.6
750, 800 85.8 86.1 85.9 85.6 83.1 83.6 83.7 83.5
Table A1-14. Predicted Fuel-to-Steam Efficiencies - Natural Gas
Figure A1-11. Predicted Stack Temperature Increase for Pressure Greater Than 125 psig
A1-27
03-08
Table A1-16. CB-LE Boilers - Natural Gas, Emission Levels
POLLUTANT
ESTIMATED LEVEL
60 ppm 30 ppm 25 ppm 20 ppm 15 ppm 9 ppm
CO
ppm
A
lb./MMBtu
50/150
B
0.04/0.11
50/150
B
0.04/0.11
50/150
B
0.04/0.11
50/150
B
0.04/0.11
50
0.04
50
0.04
NOx
ppm
A
lb/MMBtu
60
0.07
30
0.035
25
0.03
20
0.024
15
0.018
9
0.011
SOx
ppm
A
lb/MMBtu
1
0.001
1
0.001
1
0.001
1
0.001
1
0.001
1
0.001
HC/VOC
5
ppm
A
lb/MMBtu
10
0.004
10
0.004
10
0.004
10
0.004
10
0.004
10
0.004
PM
ppm
A
lb/MMBtu
-
0.01
-
0.01
-
0.01
-
0.01
-
0.01
-
0.01
A. ppm levels are given on a dry volume basis and corrected to 3% oxygen (15% excess air).
B. CO emission for 60, 30, 25 & 20 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 A1-15. Predicted Fuel-to-Steam Efficiencies - No. 2 Oil
BOILER
HP
% OF LOAD % OF LOAD
25% 50% 75% 100% 25% 50% 75% 100%
125 86.7 86.9 86.7 86.6 83.7 84.2 84.3 84.3
150 87.8 88.0 87.8 87.6 84.8 85.3 85.3 85.4
200 88.4 88.7 88.4 88.2 85.6 86.0 86.0 86.0
250 88.3 88.1 87.4 86.7 85.3 85.3 84.9 84.7
300 88.6 88.7 88.0 87.3 85.9 86.0 85.5 85.2
350 88.6 89.0 88.5 87.8 85.9 86.6 86.1 85.8
400 87.9 88.1 87.9 87.6 85.1 85.5 85.6 85.5
500 88.9 89.0 88.9 88.6 86.1 86.5 86.6 86.4
600 89.0 89.4 89.2 89.0 86.2 86.8 86.9 86.8
700 89.1 89.5 89.3 89.1 86.3 86.9 87.0 86.9
750, 800 89.2 89.5 89.3 89.0 86.4 86.9 87.0 86.8
Table A1-17. CB-LE Boilers - No. 2 Oil, Emission Levels
POLLUTANT
ESTIMATED LEVEL
60 ppm LE Option 30, 25, 20 ppm LE Option 15 ppm 9 ppm
CO
ppm
A
lb/MMBtu
50
0.039
50
0.039
50
0.039
50
0.039
NOx
ppm
A
lb/MMBtu
140
0.186
90
0.120
85
0.113
70
0.093
SOx
ppm
A
lb/MMBtu
278
0.52
278
0.52
278
0.52
278
0.52
HC/VOCs
ppm
A
lb/MMBtu
4
0.002
4
0.002
4
0.002
4
0.002
PM
ppm
A
lb/MMBtu
-
0.025
-
0.025
-
0.025
-
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 =0.015% by weight.
Sulfur content =0.5% by weight.
Ash content =0.01% by weight.
BBA1_02-08
A1-28
03-08
ENGINEERING DATA
Sound Level Table A1-18 gives a summary of predicted 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
Packaged 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.
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 finally, 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).
BOILER HP 125 150 200 250 300 350 400 500 600 700 750 800
HFO, dbA 84 84 84 83 84 85 84 85 85 88 89 90
LFO, dbA 82 82 83 81 82 83 82 83 83 84 87 89
HFG, dbA 82 82 83 82 83 84 83 83 85 87 89 90
LFG, dbA 81 81 82 81 82 83 81 81 82 84 86 88
NOTES
1. Sound pressure levels measured on boilers operating in various locations and ex-
pressed 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
Table A1-18. Model CBLE Predicted Sound Levels 30 ppm NOx Systemss
A1-29
03-08
Gas-Fired Burners Table A1-19 shows gas pressure with standard, over- and undersized gas trains.
Table A1-20 shows recommended NTI gas train sizes and pressure ranges.
Table A1-21 shows minimum required gas pressure altitude conversion.
Figure A1-12 shows standard gas train sizes and locations for Model CB Firetube
Boilers.
Figure A1-13 shows typical gas train piping layouts for multiple boiler applications.
Figure A1-14 shows standard gas train components.
A1-30
03-08
Table A1-19. Standard, Undersize, and Oversize Gas Trains
CBLE 20 PPM CBLE 30 PPM CBLE 60 PPM
Boiler HP
Gas Train Pressure Gas Train Pressure Gas Train Pressure
Size, in PSI Size, in PSI Size, in PSI
125 1.5 0.8 - 3.0 1.5 0.7 - 3.0 1.5 0.7 - 3.0
150 1.5 1.0 -3.0 1.5 0.9 - 3.0 1.5 0.9 - 3.0
200 NA NA
1.5 1.5 - 4.0 1.5 1.5 - 4.0
2 1.0 - 1.5 2 1.0 - 1.5
250
1.5 2.4 - 5.0 1.5 2.4 - 5.0 1.5 2.3 - 5.0
2 1.6 - 2.4 2 1.5 - 2.4 2 1.5 - 2.3
300
1.5-2 3.0 - 5.0 1.5-2 3.0 - 5.0 1.5-2 3.0 - 5.0
2 2.0 - 3.0 2 2.0 - 3.0 2 1.9 - 3.0
3 1.3 - 2.0 3 1.3 - 2.0 3 1.2 - 1.9
350
1.5-2 4.2 - 6.5 1.5-2 4.2 - 6.5 1.5-2 3.8 - 5.0
2 3.2 - 4.2 2 3.1 - 4.2 2 2.8 - 3.8
2.5 2.5-3.2 2.5 2.5-3.1 2.5 2.1 - 2.8
3 1.8 - 2.5 3 1.7 - 2.5 3 1.4 - 2.1
400
1.5-2 4.6 - 7.0 1.5-2 4.6 - 7.0 1.5-2 4.6 - 7.0
2 3.1 - 4.6 2 3.1 - 4.6 2 3.1 - 4.6
2.5 2.5 - 3.1 2.5 2.5 - 3.1 2.5 2.3 - 3.1
3 1.4 - 2.3 3 1.4 - 2.3 3 1.4 - 2.3
500
1.5-2.5 6.9 - 10.0 1.5-2.5 6.9 - 10.0 1.5-2.5 6.8 - 10.0
2-2.5 5.0 - 6.9 2-2.5 5.0 - 6.9 2-2.5 4.9 - 6.8
2.5 3.6 - 5.0 2.5 3.5 - 5.0 2.5 3.5 - 4.9
3 2.2 - 3.6 3 2.2 - 3.5 3 2.2 - 3.5
600
1.5-2.5 9.7 - 10.0 1.5-2.5 9.6 - 10.0 1.5-2.5 9.5 - 10.0
2-2.5 7.0 - 9.7 2-2.5 6.9 - 9.6 2-2.5 6.8 - 9.5
2.5 5.0 - 7.0 2.5 4.9 - 6.9 2.5 4.9 - 6.8
2.5-3 4.3 - 5.0 2.5-3 4.2 - 4.9 2.5-3 4.2 - 4.9
3 2.9 - 4.3 3 2.9 - 4.2 3 2.8 - 4.2
700
2-3 8.7 - 10.0 2-3 8.6 - 10.0 2-3 8.6 - 10.0
2.5-3 5.6 - 8.7 2.5-3 5.5 - 8.6 2.5-3 5.5 - 8.69
3 3.8 - 5.6 3 3.7 - 5.5 3 3.7 - 5.5
4 2.9 - 3.8 4 2.8 - 3.7 4 2.8 - 3.7
750
2.5-3 6.9 - 10.0 2.5-3 6.9 - 10.0
NA NA 3 4.6 - 6.9 3 4.6 - 6.9
4 3.2 - 4.6 4 3.2 - 4.6
800
2.5-3 7.2 - 10.0 2.5-3 7.1 - 10.0
NA NA 3 5.0 - 7.2 3 4.9 - 7.1
4 3.7 - 5.0 4 3.6 - 4.9
Note: Some units list two diameters because the gas train
increases in size after the regulating valve. The first number is
the customer connection size.
UNDERSIZE
STANDARD
OVERSIZE
Table is based on Siemens gas train, which includes a
regulating actuator.
A1-31
03-08
Table A1-20. Recommended NTI Gas Train Sizes and Pressure Ranges
LE 15 PPM LE 9 PPM
Boiler HP
Gas Train Pressure Range Gas Train Pressure Range
Size, in PSI Size, in PSI
125 1.5 3.3 - 6.0 1.5 3.3 - 6.0
150 1.5 3.9 - 6.0 1.5 4.1 - 6.0
200 1.5 4.5 - 7.0 1.5 4.5 - 7.0
250 1.5 - 2 4.4 - 7.0 1.5 - 2 4.1 - 7.0
300 1.5 - 2 6.1 - 9.0 1.5 - 2 5.9 - 9.0
2 4.8 - 6.1 2 4.6 - 5.9
350 1.5 - 2 5.1 - 7.5 1.5 - 2 6.2 - 9.0
2 4.1 - 5.1 2 5.2 - 6.2
2.5 3.4 - 4.1 2.5 4.5 - 5.2
400 1.5 - 2 7.3 - 10.0 1.5 - 2 7.2 - 10.0
2 5.8 - 7.3 2 5.7 - 7.2
2.5 5.0 - 5.8 2.5 4.9 - 5.7
3 4.1 - 5.0 3 4.0 - 4.9
500 1.5 - 2 8.1 - 10.0 1.5 - 2 8.1 - 10.0
2 6.1 - 8.1 2 6.1 - 8.1
2.5 4.7 - 6.1 2.5 4.7 - 6.1
3 3.4 - 4.7 3 3.4 - 4.7
600 2 - 2.5 7.8 - 10.0 2 - 2.5 7.8 - 10.0
2.5 5.8 - 7.8 2.5 5.8- 7.8
3 4.4 - 5.8 3 4.4 - 5.8
700 2.5 - 3 7.7 - 10.0 2.5 - 3 8.0 - 10.0
3 5.9 - 7.7 3 6.2 - 8.0
720 2.5 - 3 8.2 - 10.0
3 6.3 - 8.2
750 2.5 - 3 8.6 - 10.0
3 6.7 - 8.6
Note: Some units list two diameters because the gas train increases in size
after the regulating valve. The first number is the customer connection size.
UNDERSIZE
STANDARD
OVERSIZE
Table is based on Siemens gas train, which includes a regulating actuator.
A1-32
03-08
A
PLAN VIEW
BOILER
FRONT
ALTITUDE
(FT)
CORRECTION
FACTOR
ALTITUDE
(FT)
CORRECTION
FACTOR
1000 1.04 6000 1.25
2000 1.07 7000 1.30
3000 1.11 8000 1.35
4000 1.16 9000 1.40
5000 1.21 - -
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.
Table A1-21. Minimum Required Regulated Gas Pressure
Altitude Conversion
BOILER
HP
TYPE OF GAS AND HEAT CONTENT
NATURAL GAS
1000 (Btu/cu-ft)
PROPANE GAS
2550 (Btu/cu-ft)
125 5103 2000
150 6124 2402
200 8165 3202
250 10206 4002
300 12247 4802
350 14280 5600
400 16329 6404
500 20415 8006
600 24494 9605
700 28576 11206
750 30618 12007
800 32659 12807
Table A1-22. Maximum Gas Consumption (CFH)
for Natural Gas and Propane Vapor
BOILER
HP
MODEL CB
CONNECTION
SIZE
(IN. NPT)
LOCATION
DIMENSION
A (IN.)
125-200 1-1/2 52
250-350 2 56
400 2 58
500 2-1/2 60
600 2-1/2 - 3 71
700-800 3 65
Figure A1-12. Standard Gas Train Connection Size and Location
A1-33
03-08
Oil-Fired Burners Fuel oil consumption information is shown on the boiler rating sheets in the
Dimensions and Rating Section.
Figure A1-15 shows the oil connection sizes and locations for Model CB Boilers
firing No. 2 oil.
Figure A1-16 through Figure A1-18 show typical oil systems and layouts.
Figure A1-19 and Figure A1-20 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.
General Boiler
Information
Table A1-23 shows blowdown tank sizing information.
Table A1-24 provides heating surface information.
Table A1-25 provides steam volume and disengaging area information
Table A1-26 provides recommended steam nozzle sizes.
Table A1-27 provides recommended non-return valve sizes.
Boiler Room
Information
Figure A1-21 shows typical boiler room length requirements.
Figure A1-22 shows typical boiler room width requirements.
Figure A1-23 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
flue gas outlet. Proper draft is critical to burner performance.
Although constant pressure at the flue gas outlet of the Model CB-LE is not required,
it is necessary to size the stack/breeching to limit flue 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.
Boiler Room
Combustion Air
When determining boiler room air requirements, the size of the room, air flow, 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 fine mesh wire, as this type of covering has poor air flow
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.
A1-34
03-08
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 floor 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 floor 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).
Notice
Consult local codes, which may supersede these requirements.
A1-35
03-08
MODEL
CB-LE
BOILERS
PLUG
COCK
A
B
C
D CONTRACTOR
CONNECTION
POINT
GAS TRAIN
ON BOILER
STREET GAS MAIN
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 con-
struction.
A. Utilities service valve.
B. Utilities service regulator.
C. Gas meter.
D. Piping from meter to boiler.
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 A1-13. Typical Gas Piping Layout
A1-36
03-08
5
6
S
1
3
4
2
PILOT GAS LINE
S
S
MAIN GAS LINE
M M
To
Burner
Gas
Supply
11
10
9
7
12
13
8
14
15
FLOW
FLOW
BOILER BASE FRAME
RIGHT HAND SIDE VIEW
BOILER
FRONT
A
CONTRACTOR
CONNECTIONS
Figure A1-14. Model CB-LE Gas Train Components
BOILER
HP
MODEL CB
SUPPLY
AND
RE-
TURN
CONN
SIZES
(IN.)
(NPT)
A
(IN.)
RECOMMENDED OIL LINE
A
SIZES
(STANDARD PIPE)
(IN. - IPS)
STOR-
AGE
TANK TO
BOILER
OR PUMP
CONNECT
PUMP
TO
BOILER
RE-
TURN
LINE TO
TANK
125
150
200
3/4 12-1/2 1 1 1
250
300
350
3/4 34 1 1 1
400
500
600
3/4 11-3/4 1 1 1
700
750
800
1 11-3/4 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 A1-15. No.2 Oil Connection Size, Location, and Recommended Line Sizes
CSD-1 NFPA-85
125 hp -
300 hp
350 hp -
800 hp
125 hp -
300 hp
350 hp -
800 hp
125 hp -
300 hp
350 hp -
800 hp
1 Pilot Shut Off Cock X X X X X X
2 Pilot Pressure Regulator X X X X X X
3 Pilot Pressure Gauge X X X X X X
4 Gas Pilot Valve X X X X X X
5 Pilot Vent Valve X
6 Gas Pilot Valve X
7 Manual Shut Off Valve X X X X X X
8 Low Gas Pressure Switch X X X X X X
9 Main Gas Valve w/o POC X X X X
10 Main Gas Valve w/ POC X X
11 Vent Valve or Valve Proving Switch X X X
12 Regulating Gas Valve w/ POC X X X X X X
13 High Gas Pressure Switch X X X X X X
15 Butterfly Valve X X X X X X
UL FM
ITEM DESCRIPTION
A1-37
03-08
BOILER
BASE FRAME
BOILER
FRONT
F.O.S.
F.O.R.
CONTRACTOR
CONNECTIONS
AT THIS POINT
GATE VALVE
OIL PUMP
CHECK
VALVE
VACUUM
GAUGE
STRAINER
GATE VALVE
RELIEF VALVE
UNION
GATE VALVE
CHECK VALVE
F.O.R.
F.O.S.
BOILER
BASE FRAME
BOILER
FRONT
F.O.S.
F.O.R.
CONTRACTOR
CONNECTIONS
AT THIS POINT
GATE VALVE
OIL PUMP NO. 1
OIL
PUMP
NO. 2
VACUUM GAUGE STRAINER
GATE VALVE
GATE VALVE
CHECK VALVE
RELIEF
VALVE
(100 PSIG)
UNION
GATE VALVE
CHECK VALVE
F.O.S.
F.O.R.
Figure A1-16. No. 2 Oil Piping, Single Boiler
Installation, Remote Oil Pump
Figure A1-17. No. 2 Oil Piping, Multiple Boiler
Installation, Remote Oil Pumps
A1-38
03-08
ITEM SIZE DESCRIPTION
A 1/2" NT Connection to oil
level switch
B See Note Return line to tank
C See Note Oil supply connec-
tion from transfer
pump
D 1/2" NPT Tank drain connec-
tion
E See Note FOS connection
F 1/8" NPT Oil level test valve
connection
G See Note FOR connection
H No.80 Oil level switch
McD
NOTE: Connections should be
sized using recommended sizes in
oil line sizing instructions.
F.O.R.
OIL LEVEL
TEST VALVE
OIL TRANSFER PUMP
NEAR STORAGE TANK
SUPPLY TO BOILER
TERMINAL BLOCK OR
TO BOILER OIL PUMP
GATE
VALVE
GATE
VALVE
OIL TRANSFER TANK
AT LOCATION NEAR
BOILER
VENT
H
F.O.S.
F.O.R.
F.O.S.
CHECK
VALVE STRAINER
VACUUM
GAUGE
UNION
RELIEF VALVE
(100 PSIG)
3/8" MTL
D
4" OR 6"
STD
BLACK
PIPE
F
E
22"
33"
3"
2"
60"
G
A
B
C
5"
3"
Installation
Figure A1-19. No. 2 Oil Piping
(For elevated boiler room locations
using an oil transfer pump and tank)
Relief valve on the boiler
must be set at 100 psig so
that adjustable pressure
relief valve in the loop
system is in control.
STANDBY
OIL PUMP
UNION
GATE VALVE
CHECK
GATE
RELIEF
VACUUM GAUGE
STRAINER
GATE VALVE
F.O.S.
F.O.R.
PRESSURE

USE LAYOUT FOR: MODEL CB. . . . . . . 50 THRU 800 HP
BOILER
CONTRACTOR
BOILER
F.O.S.
F.O.R.
VALVE
VALVE
VALVE
(100 PSIG)
GAUGE
FRONT
CONNECTIONS
AT THIS POINT
BASE FRAME
CHECK
GATE
VALVE
VALVE
ADJUSTABLE
PRESSURE
RELIEF VALVE
(75 PSIG)
A1-39
03-08
CONDENSATE OR HOT WATER
OIL STORAGE
TANK
MANHOLE
OIL RETURN
OIL SUCTION
STEAM OR HOT WATER
NOTE: OBSERVE ALL LOCAL AND NATIONAL
(EG. FIRE UNDERWRITERS) CODE RE-
QUIREMENTS GOVERNING THE INSTAL-
LATION OF FUEL OIL STORAGE TANKS
AND SUPPLY SYSTEMS.
Figure A1-20. Typical Arrangement
Table A1-23. Model CB-LE Blowdown
Tank Sizing
BOILER HP WATER (GAL)
125 97
150 118
200 145
250 146
300 176
350 210
400 177
500 209
600 250
700, 750, 800 296
NOTE: Quantity of water removed from boiler by lowering
normal water line 4".
BOILER
HP
HEATING SURFACE (SQ-FT)
FIRESIDE WATERSIDE
125 625 679
150 750 820
200 1000 1092
250 1250 1346
300 1500 1623
350 1750 1932
400 2000 2151
500 2500 2691
600 3000 3262
700, 750, 800 3500 3810
Table A1-24. Heating Surface, Model CB-LE
A1-40
03-08
Altitude: 700 ft and less - Design Pressure: 150 psi and less
* 800 HP - to be de-rated to 720 HP for 9 ppm and to 750 HP for 15 ppm.
m p p 9 m p p 5 1 Nominal
Boiler Size
Blower Motor HP Blower Motor HP
BOILER HP
STEAM VOLUME CU-FT
STEAM DISENGAGING AREA
SQ-IN
HIGH PRESSURE
A
LOW PRESSURE
B
HIGH PRESSURE
A
LOW PRESSURE
B
125 25.4 36.6 5371 5887
150 30.7 44.3 6511 7138
200 37.7 54.4 7985 8752
250 49.2 70.6 7980 8695
300 59.5 85.3 9651 10516
350 70.9 101.7 11507 12538
400 72.1 97.9 9793 10593
500 83.7 113.7 11376 12303
600 101.5 137.8 13787 14911
700-800 119.8 162.7 16273 17600
NOTE: Based on normal water level.
A. Based on 150 psig design pressure.
B. Based on 15 psig design pressure.
Table A1-25. Steam Volume and Disengaging Area
BOILER
HP
BOILER
CAPACITY
(LBS/HR)
OPERATING PRESSURES (PSIG)
50 75 100 125 150 175 200 250
100 3450
2-1/2 2-1/2 NA NA NA NA NA NA
125 4313
3 2-1/2 2-1/2 2-1/2 NA NA NA NA
150 5175
3 3 2-1/2 2-1/2 2-1/2 2-1/2 NA NA
200 6900
3* 3 3 3 3 2-1/2 2-1/2 2-1/2
250 8625
4 3* 3 3 3 3 3 3
300 10350
4 4 4 3* 3 3 3 3
350 12025
4 4 4 4 4 3* 3 3
400 13800
5 4 4 4 4 4 4 3*
500 17210
6 5 5 4 4 4 4 4
600 20700
6 6 5 5 5 4 4 4
700 24150
6 6 6 5 5 5 5 4
800 27600
6 6 6 6 6 5 5 5
NOTE: Valve sizes (300 # Flanges) given in inches.
Standard Non-Return valve selections limited to a maximum 2 to 1 turndown
(50% of full load); selections based on typical non-return valve sizing recommen-
dations. For final valve selection contact your C-B authorized representative. For
high turndown applications see Boiler Book Section I3, Table I3-3.
* Indicates pressure drop of less than 7.5 psig. All other selections are less than
6 psig pressure drop.
Boiler HP
OPERATING
PRESSURE
PSIG
125 150 200 250 300 350 400 500 600 700 750 800
15 8 8 10 10 12 12 12 12 12 12 12 12
30 6 6 8 8 8 10 10 10 12 12 12 12
40 6 6 6 8 8 8 10 10 10 12 12 12
50 6 6 6 6 8 8 8 10 10 10 12 12
75 4 4 6 6 6 8 8 8 8 10 10 10
100 4 4 6 6 6 6 6 8 8 8 8 10
125 4 4 4 6 6 6 6 8 8 8 8 8
150 3 3 4 4 6 6 6 6 6 8 8 8
200 2.5 3 4 4 4 4 6 6 6 6 6 6
250 2.5 3 3 4 4 4 4 6 6 6 6 6
NOTES:
1. Steam nozzle sizes given in inches.
2. Recommended steam nozzle sizes based on 4000 to 5000 fpm steam velocity.
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.
4. Shaded area denotes special surge load baffles must be installed to avoid possible
water carry-over.
5. For incremental operating pressures, see Table I3-1 Steam Systems Fundamentals.
Table A1-26. Recommended Steam Nozzle Size (for
4000 to 5000 fpm nozzle velocity)
Table A1-27. Recommended Non-Return Valve Size
Table A1-28. Blower Motor Selection CB-LE NTI Boilers
A1-41
03-08
FRONT
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
A B
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
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.
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 A1-21. Boiler Room Length (Typical Layouts)
BOILER HP 125-200 250-350 400-800
Dimension A 82" 93" 102"
Dimension B 115" 141" 171"
NOTES:
1. Recommended Minimum Distance Between Boiler and Wall. Dimen-
sion A allows for a clear 42" aisle between the water col-
umn 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 A1-22. Boiler Room Width (Typical Layout)
DWG A
DWG B
DWG C
A1-42
03-08
STACK
DRAIN
CONNECTION
CLEAN-
OUT
MANUAL
DAMPER
LOCK (OPEN)
TIGHT SEAL
CLEANOUT
STACK
DRAIN
CONNECTION
CLEAN-
OUT
MANUAL
DAMPER
LOCK (OPEN)
TIGHT SEAL
CLEANOUT
STACK
DRAIN
CONNECTION
CLEAN-
OUT
MANUAL
DAMPER
LOCK (OPEN)
TIGHT SEAL
CLEANOUT
MAXIMUM 10
CONE ANGLE
MAXIMUM 10 CONE ANGLE
EVEN WITH LIMITED SPACE
DETAIL OF TRANSITION PIECES
Figure A1-23. Breeching Arrangement
NOTE: These stack breeching arrangements for multiple
boilers are generic and not intended for your specific
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 specific criteria. Your
local Cleaver-Brooks authorized representative is capa-
ble of assisting in your evaluation of stack and breeching
design.
MULTIPLE BOILERS WITH A COMMON STACK
MULTIPLE BOILERS WITH INDIVIDUAL STACKS
A1-43
5-08
Section A1
Model CB-LE Steam Boiler Specifications
(125-800 hp, Steam 15-300 psig)
Table Of Contents
Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-44
General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-44
Boiler Shell (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-44
Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-45
Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-46
Boiler Flame Safeguard Controller and Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-49
Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-51
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-52
Performance Criteria: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-52
Shop Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-53
Start-up Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-53
Model CB-LE Steam Boiler Specifications Section A1
A1-44
5-08
Model CB-LE Steam Boiler Specifications
(125-800 hp, Steam 15-300 psig)
PART 1 GENERAL
The LE Option specification includes information on the base low emissions package for 60 or 30
ppm NOx (dry volume basis and corrected to 3% O
2
) when firing 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)
1.1 Boiler Characteristics (Steam)
A. 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.
B. The boiler shall have a maximum output of _____ Btu/hr, or _____ horsepower when
fired with CS 12-48 _____ oil and/or natural gas, _____ Btu/cu-ft. Electrical power
available will be _____ Volt _____ Phase _____ Cycle.
1.2 General Boiler Design
A. The boiler shall be a four pass horizontal firetube updraft boiler with five (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.
1. The boiler shall be completely preassembled and fire tested at the factory. The
unit shall be ready for immediate mounting on floor or simple foundation and
ready for attachment of water, steam, fuel, electrical, vent and blowdown
connections.
2. The boiler shall be built to comply with the following insurance and codes
__________________(Factory Mutual, GE-GAP Insurance, ASME CSD-1).
PART 2 PRODUCTS
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 Boiler Shell (Steam)
A. 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.
B. Two lifting eyes shall be located on top of the boiler.
C. Front and rear doors on the boiler shall be hinged or davited. Doors are to be sealed
with fiberglass tadpole gaskets and fastened tightly using heavy capscrews that
thread into replaceable brass nuts.
D. Rear refractory and insulation shall be contained in the formed door, which must
swing open for inspection of brick work.
E. The boiler tubes shall not include turbulators, swirlers or other add-on
appurtenances.
Section A1 Model CB-LE Steam Boiler Specifications
A1-45
5-08
F. Front and rear tube sheets and all flues 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.
G. For boilers 125 horsepower and over, a manhole shall be provided.
H. The exhaust gas vent shall be located near the front of the boiler on the top center
line and shall be capable of supporting:
1. 15-100 hp. 1000 lbs and shall contain a stack thermometer
2. 125-800 hp. 2000 lbs and shall contain a stack thermometer
I. The boiler shell shall contain a chemical feed connection.
J. Observation ports for the inspection of flame conditions shall be provided at each end
of the boiler.
K. 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.
L. The entire boiler base frame and other components shall be factory painted before
shipment using a hard finish enamel coating.
2.2 Steam Boiler Trim
A. 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.
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.
2. WATER COLUMN/LOW WATER CUTOFF AND WATER LEVEL CONTROL
SYSTEM
(150-250 psig design): Shall be a CB LEVEL MASTER Water level control
system and shall be comprised of a microprocessor-based electronic controller, a
non-contact, non-wearing, continuously reading absolute level sensor and
pressure chamber. The control system shall be designed as follows: The
electronic controller shall be mounted in the common control panel (see 2.4
below) and operate in ambient temperatures from 32 degrees F to 125 degrees
F. The pressure chamber shall be boiler mounted and operate to pressures of
250 PSIG and the level sensor shall operate to pressures of 250 PSIG and
temperatures to 400 degrees F. The pressure-containing components shall be
constructed in accordance with ASME Code. A shielded, four conductor cable
with ground shall be run in metal conduit between the level sensor and the
controller. Supply power shall be 115VAC-1 phase- 60 Hz. All wiring shall be in
compliance with the National Electrical Code.
The pressure chamber shall have a sight glass mounted on the side. The level
sensor shall have an accuracy of .01" or greater. The electronic controller shall
have level and error indicating lights, alphanumeric display for messaging, reset/
menu switch and the following features:
a. Continuous Level Indication
b. Low Water Cutoff & Alarm
c. High Water Alarm
d. Low & High Water Warning
A1-46
5-08
e. Full Modulating Control of Modulating Feedwater Control Valve
f. Continuous Monitoring of Float Operation
g. Column Blowdown Detection and Reminder
h. Auto or Manual Reset
i. Real Time Clock
j. Alarm Annunciation
k. Alarm History Files with Time Stamp
l. Water Column Blowdown Record
m. Auxiliary Low Water Cutoff Check
n. RS 232 Interface
o. Maximum Contacts Rating 15 amps Resistive Load
3. Low Water Cutoff (15 psig design)
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.
B. 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.
C. Steam Pressure Gauge
The steam pressure gauge shall be located at the front of the boiler and include cock
and test connection.
D. Safety Valves
Safety valves of a type and size to comply with ASME Code requirements shall be
shipped loose.
E. 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 firing rate control (30-800 hp).
2.3 Burner and Controls
A. Mode of Operation
Burner operation shall be full modulation principle. The burner shall always return to
low fire position for ignition.
B. Blower
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.
2. Maximum sound level of the boiler/burner package shall not exceed _____ dbA
(when measured in accordance with ABMA Sound Test Standards).
3. The impeller shall be cast aluminum, radial blade, carefully balanced, and
directly connected to the blower motor shaft.
C. Combustion Air Control
Combustion air damper and cam operated fuel metering valves shall be operated by a
single damper control motor that regulates the fire 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 flame safeguard is
used).
A1-47
5-08
D. Fuel Specification and Piping
Select one of the following fuel types:
Fuel series 700 - Gas fired (4.4.1).
Fuel series 100 - Light oil (No. 2) fired (4.4.2).
Fuel series 200 - Light oil or gas fired (4.4.3).
1. Fuel Series 700 - Gas Fired
a. 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.
b. 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 flame has been established. The pilot
train shall include two manual shut-off valves, solenoid valve, pressure
regulator and pressure gauge.
c. Gas Burner Piping - Gas burner piping on all units shall include pressure
regulating 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, flame failure, low water
or any safety shutdown condition. A lubricating plug cock or butterfly
shutoff valve shall be provided as a means for a tightness check of the
primary shut off valve. An additional plug cock on butterfly valve shall be
furnished at entrance to gas train. Select one of the following:
1) 125-300 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.
leakage test connection shall be provided. A valve proving switch
shall be located between the safety shutoff valves.
d. Burner Turndown - Select one of the following:
1) 125-200 hp. Turndown range of burner shall be 4:1 when firing
natural gas.
2) 250-800 hp. Turndown range of the burner shall be 10:1 when firing
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.)
2. Fuel Series 100 - Light Oil Fired
a. 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.
b. Gas Pilot - The gas pilot shall be premix type with automatic electric
fuel valve cannot open until flame has been established. The pilot train
shall include two manual shut-off valves, solenoid valve, pressure regulator
and pressure gauge.
c. 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.
A1-48
5-08
d. 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.
e. Low Pressure Air Atomizing
Separate air compressor module mounted on boiler base rail with low
atomizing air pressure switch.
f. Burner Turndown.
Select one of the following:
1) A. 125 hp through 200 hp. Turndown range shall be 4:1 when firing
No. 2 oil.
2) B. 250 hp through 800 hp Turndown range shall be 8:1 when firing
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 firing natural
gas.)
3. Fuel Series 200 - Light Oil or Gas Fired
a. 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.
and pressure gauge.
c. Oil Burner
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.
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.
3) Low pressure air atomizing - Separate air compressor module
mounted on boiler base rail with low atomizing air pressure switch.
A1-49
5-08
d. Gas Burner
Gas Burner Piping - gas burner piping on all units shall include pressure
regulatinggas shutoff valve, motor operated with proof of closure switch
primary shut off valve. An additional plug cock or butterfly valve shall be
A second motorized safety shutoff valve, plus and additional plugged
e. Burner Turndown - Select one of the following:
1) 125-200 hp. Turndown range of the burner shall be 4:1.
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
firing natural gas.)
2.4 Boiler Controls and Control Panel
A. Control/Entrance Panel
A common enclosure shall house the control panel and the entrance panel. Enclosure
shall be NEMA 4 rated and shall be mounted at the side of the boiler in a location
convenient to the operator. Enclosure shall consist of upper and lower sections
divided by a partition with a separate hinged door for each section. Upper section
(low voltage) will house boiler controls including flame safeguard, water level system
controller, and Hawk ICS if so equipped. Lower panel section (high voltage) will
house entrance panel.
B. CB780E Flame Safeguard
1. Boilers with CB780E Control - Each boiler shall be factory equipped with flame
safeguard controller providing technology and functions equal to the Cleaver-
Brooks Model CB780E.
Controller shall be computerized solid state having sequence and flame-on lights
and digital first out fault code indications of flame safeguard trip functions. It
shall include dynamic self-check logic. The controller shall have a fixed
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 flame failure, high and low fire proving switch faults, running interlocks
open, false flame 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
A1-50
5-08
sequence just after pre-purge, during pilot ignition trial and run cycles for
adjustments to firing rate motor, damper linkages and pilot flame for minimum
turndown tests.
2. Lights
White - load demanded.
White - fuel valve open.
Red - low water.
Red - flame failure.
3. Control Switches
Burner On-Off.
Manual-Automatic.
Manual Firing Rate Control.
4. Oil, heat and moisture resistant wire shall be used and identified with circuit
numbers corresponding to the electrical wiring diagram.
5. All electrical equipment and wiring shall be in conformance with Underwriters
Laboratories requirements.
6. Boiler to be supplied with a control circuit transformer and fuse protection for
the control circuit.
C. CB-HAWK ICS Integrated Boiler Control and Management System:
Boiler Control System combining a Digital Burner Management System for flame
safety and a Programmable Logic Controller for boiler modulation and operator
interface functions.
The factory pre-configured Boiler Control System shall integrate the Burner
Management functions and the PLC based modulation and operator interface
functions. The logic of the Burner Management System and the modulating controls
will not be run in the same processor or powered by the same DC supply. The PLC
and Operator Interface Hardware shall be as manufactured by Allen Bradley.
Major system components shall include:
Programmable Logic Controller
Touch Screen HMI
One Burner Management Controller with Wiring Sub-Base
One Flame Scanner and amplifier
Various Temperature and Pressure Sensors
Major functions provided by the Boiler Control System shall be:
Automatic sequencing of the boiler through standby, pre-purge, pilot
flame establishing period, main flame establishing period, run, flame
proving and lockout and post-purge
Full modulating control of fuel and air
Utilize solid state controls and sensors to provide various control
functions, such as:
Modulating control (algorithm shall be Proportional-lntegral-Derivative (PID) type)
Thermal shock protection
High and Low limit alarms and shutdowns
Touch Screen graphical operator interface and monitoring
Manual control of the boiler firing rate using control screens on the HMI to increment
or decrement the firing rate
A1-51
5-08
On screen indication of burner management controller status and diagnostics
On screen display of system alarms and faults
On screen history of alarms and faults
On screen recommendations for troubleshooting of fault conditions
On screen water level indication and alarm(s)
Stack Flue Gas, Combustion Air and Shell (water) temperature indication
Boiler efficiency calculation
Low Fire Hold with Minimum Temperature Control
Assured Low Fire Cut-Off (ALFCO)
The Boiler Control System shall incorporate the following safety provisions:
Examine all load terminals to assure it is capable of recognizing the true status
of the external controls, limits and interlocks. If any input fails this test, the
Burner Management System shall lockout on safety shutdown.
Closed-loop logic test of critical loads (ignition, pilot and main fuel valves) and
must be able to lockout on safety.
Pre-ignition interlocks (fuel valve proof of closure, etc.) and flame signal
checked during Standby and Pre-Purge.
Dynamic checking of the flame signal amplifier.
Safe start check and expand check to include monitoring flame signal during
standby.
High and Low fire switches checked for proper sequencing.
The Boiler Control System shall provide the ability to communicate with external digital
devices via Ethernet as standard. OPC compliant Internet communications shall be
supported, with the Boiler Control System supplied with its own IP address.
2.5 Efficiency Guarantee
A. The boiler manufacturer shall guarantee that, at the time of startup, the boiler will
achieve ________ fuel-to-steam efficiency at 100% firing rate when burning natural
gas and ________ fuel-to-steam efficiency at 100% firing rate when burning oil (add
efficiency guarantees at 25%, 50%, and 75% of rating, if required). If the boiler(s)
fail to achieve the corresponding guaranteed efficiency as published, the boiler
manufacturer will rebate, to the ultimate boiler owner, five thousand dollars ($5,000)
for every full efficiency point (1.0%) that the actual efficiency is below the guaranteed
level.
B. Fuel specification used to determine boiler efficiency:
Natural Gas
Carbon,% (wt) = 69.98
Sulfur,% (wt) = 0.0
No. 2 Oil
Sulfur,% (wt) = 0.2
No. 6 Oil
A1-52
5-08
C. Efficiencies are based on ambient air temperature of 80 F, relative humidity of 30%,
and 15% excess air in the exhaust flue gas.
D. Efficiencies are based on manufacturers published radiation and convection losses.
(For Cleaver-Brooks radiation and convection losses, see Boiler Efficiency Facts
Guide, publication number CB-7767).
E. Any efficiency verification testing will be based on the stack loss method.
2.6 Warranty
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 first.
2.7 Performance Criteria:
Performance Criteria
Manufacturer: CLEAVER-BROOKS
Model: Promethean Line
Horsepower: ________HP
Output: ________#/hr (from and at 212F)
Gas Input: ________MBH
Oil Input: ________GPH
Design Pressure: ________PSIG
Operating Pressure ________PSIG
Steam Disengaging Area (minimum) ________Sq. Inches
Steam storage area (minimum) ________Cu. Ft.
Heating Surface (minimum): ________Sq. Ft. Fireside
Heating Release (maximum): ________BTU/Cu. Ft.
Burner Turndown Ratio Natural Gas:
Overall Efficiency (Fuel to Steam)
Natural Gas (%):
No. 2 Oil (%):
________% at High Fire
NOX Emission (maximum)
Gas (Natural):
Oil (No. 2):
________PPM (corrected to 3%O2)
CO Emissions (maximum)
Gas (Natural):
Oil (No. 2):
A1-53
5-08
PART 3 EXECUTION
3.1 Shop Tests
A. 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.
3.2 Start-up Service
A. After boiler installation is completed, the manufacturer shall provide the services of a
field representative for starting the unit and training the operator at no additional
costs.
1. A factory approved and authorized start-up report shall be submitted to the
customer/user at the time of start-up.
Electrical:
Fan Motor:
Air Compressor Motor:
Oil Pump Motor:
Noise Level (3' from burner):
____ V / ____ H / ____ P
____HP
____HP
____HP
____dBA
Available Gas Supply Pressure: ____PSIG
Weight
Dry:
Flooded:
____
____
Seismic Zone: ____
Altitude: ____ ASL
Code Requirements: ASME / NATIONAL BOARD
CSD-1 NFPA 8501
Underwriters Lab (UL)
State Of _______
Factory Mutual (FM)
Industrial Risk Insurers (IRI)
Model CB-LE Steam Boiler Specifications Firetube Boilers
A1-54
Notes
A1-55
5-08
Section A1
Model CB-LE Hot Water Specifications
(125-800 hp, 30 psig, 125 psig)
Table Of Contents
Hot Water Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-57
Performance Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-64
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-65
Shop Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-65
Section A1
A1-56
5-08
PART 1 GENERAL
1.1 Boiler Characteristics (Hot Water)
A. 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.
B. The boiler shall have a maximum output of _____ Btu/hr, or _____ horsepower when
available shall be _____Volt _____ Phase _____ Cycle.
PART 2 PRODUCTS
A. The boiler shall be a four pass horizontal firetube updraft boiler with five (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.
connections.
____________________ (Factory Mutual, Industrial Risk Insurance, ASME CSD-
1).
B. Boiler Shell (Hot Water)
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. 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.
3. A dip tube shall be included as an integral part of the water outlet.
4. Two lifting eyes shall be located on top of the boiler.
5. Front and rear doors on the boiler shall be hinged or davited. Doors are to be
sealed with fiberglass tadpole gaskets and fastened tightly using heavy
capscrews that thread into replaceable brass nuts.
6. Rear refractory and insulation shall be contained in the formed door, which must
7. The boiler tubes shall not include turbulators, swirlers or other add-on
appurtenances.
8. Front and rear tube sheets and all flues 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.
9. A manhole shall be provided.
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.
Section A1
A1-57
5-08
C. Observation ports for the inspection of flame conditions shall be provided at each end
of the boiler.
D. The boiler insulation shall consist of a 2 inch blanket under a sectional preformed
E. The entire boiler based frame and other components shall be factory painted before
shipment using a hand finish enamel coating.
F. Emission Controls
1. Boiler shall be equipped with a low emission (LE) option for guaranteed NOx
performance at ________ ppm, dry volume basis and corrected to 3% O
2
when
firing natural gas.
2. The low emission option shall include an integral front head, burner, and boiler
package, providing NOx reduction through an internal flue 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
efficiency and rated boiler capacity shall be guaranteed while the boiler is
operating at the low NOx performance levels.
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
field assembly of the burner or low NOx equipment shall be required.
2.2 Hot Water Boiler Trim
A. 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.
B. 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.
C. Relief Valves
Water relief valves of a type and size to comply with ASME Code requirements shall
be shipped loose.
D. 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 firing rate control.
B. Blower
Section A1
A1-58
5-08
used).
Fuel series 700 - Gas fired.
Fuel series 100 - Light oil (No. 2) fired.
Fuel series 200 - Light oil or gas fired.
natural gas.
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.)
Section A1
A1-59
5-08
and pressure gauge.
shall be provided.
e. Low Pressure Air Atomizing - Separate air compressor module mounted on
boiler base rail with low atomizing air pressure switch.
f. Burner Turndown - Select one of the following:
1) 125 hp through 200 hp. Turndown range shall be 4:1 when firing
No. 2 oil.
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 firing natural
gas.)
and pressure gauge.
c. Oil Burner
Section A1
A1-60
5-08
d. Gas Burner
1) Gas Burner Piping - Gas burner piping on all units shall include
pressure regulating 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, flame failure, low water or any safety shutdown condition. A
lubricating plug cock or butterfly shutoff valve shall be provided as a
means for a tightness check of the primary shut off valve. An
additional plug cock or butterfly valve shall be furnished at entrance
to gas train. Select one of the following:
125-300 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.
safety shutoff valve, plus and additional plugged leakage test connection shall be provided. A
valve proving switch shall be located between the safety shutoff valves.
125-200 hp. Turndown range of the burner shall be 4:1.
250-800 hp. Turndown range of the burner shall be 10:1 when firing 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 firing natural gas.)
E. Boiler Controls and Control Panel
1. CB780E Flame Safeguard
a. Boilers with CB780E Control - Each boiler shall be factory equipped with
flame safeguard controller providing technology and functions equal to the
Cleaver-Brooks Model CB780E.
Controller shall be computerized solid state having sequence and flame-on
lights and digital first out fault code indications of flame safeguard trip
functions. It shall include dynamic self-check logic. The controller shall
have a fixed 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 flame failure, high and low fire proving switch
faults, running interlocks open, false flame signal and fuel valve open
(when proof of closure switch is furnished).
Section A1
A1-61
5-08
adjustments to firing rate motor, damper linkages and pilot flame for
minimum turndown tests.
b. 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 flame safeguard controller, blower motor
starter, indicating lights and selector switches.
The panel shall have a removable sub-base for mounting the flame
safeguard controller, blower motor starter, and terminal blocks. For
combination gas-oil fired boilers the panel shall contain the fuel selector
switch.
The panel shall contain the following lights and switches:
c. Lights
Red - low water.
d. Control Switches
Burner On-Off.
Manual-Automatic.
e. Oil, heat and moisture resistant wire shall be used and identified with
circuit numbers corresponding to the electrical wiring diagram.
f. All electrical equipment and wiring shall be in conformance with
Underwriters Laboratories requirements.
g. Boiler to be supplied with a control circuit transformer and fuse protection
for the control circuit.
2. CB-HAWK ICS Integrated Boiler Control and Management System:
Boiler Control System combining a Digital Burner Management System for flame
safety, and a Programmable Logic Controller for boiler modulation and operator
interface functions.
The factory pre-configured Boiler Control System shall integrate the Burner
Management functions and the PLC based modulation and operator interface
functions. The logic of the Burner Management System and the modulating controls
will not be run in the same processor or powered by the same DC supply. The PLC
and Operator Interface Hardware shall be as manufactured by Allen Bradley.
Touch Screen HMI
Automatic sequencing of the boiler through standby, pre-purge, pilot
Section A1
A1-62
5-08
flame establishing period, main flame establishing period, run, flame
proving and lockout and post-purge
Utilize solid state controls and sensors to provide various control
functions, such as:
Manual control of the boiler firing rate using control screens on the HMI to increment
Examine all load terminals to assure it is capable of recognizing the true status
of the external controls, limits and interlocks. If any input fails this test, the
Burner Management System shall lockout on safety shutdown.
Closed-loop logic test of critical loads (ignition, pilot and main fuel valves) and
must be able to lockout on safety.
Pre-ignition interlocks (fuel valve proof of closure, etc.) and flame signal
checked during Standby and Pre-Purge.
Safe start check and expand check to include monitoring flame signal during
standby.
The Boiler Control System shall provide the ability to communicate with external digital via Ethernet
as a standard. OPC compliant Internet communications shall be supported, with the Boiler Control
System supplied with its own IP address.Efficiency Guarantee
F. The boiler manufacturer shall guarantee that, at the time of startup, the boiler will
level.
G. Fuel specification used to determine boiler efficiency:
Natural Gas
Carbon, % (wt) = 69.98
Hydrogen, % (wt) = 22.31
Section A1
A1-63
5-08
Sulfur, % (wt) = 0.0
Heating value, Btu/lb = 21,830
No. 2 Oil
Carbon, % (wt) = 85.8
No. 6 Oil
Carbon, % (wt) = 86.6
Sulfur, % (wt) = 2.09
H. Efficiencies are based on ambient air temperature of 80 F, relative humidity of 30%,
I. Efficiencies are based on manufacturers published radiation and convection losses.
J. Any efficiency verification testing will be based on the stack loss method.
2.4 Performance Criteria
Operating Temperature ________degrees F
Natural Gas (%):
No. 2 Oil (%):
Gas (Natural):
Oil (No. 2):
Section A1
A1-64
5-08
PART 3 EXECUTION
3.1 Warranty
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 first.
3.2 Shop Tests
B. Start-up Service
1. After boiler installation is completed, the manufacturer shall provide the services
of a field representative for starting the unit and training the operator at no
additional costs.
a. A factory approved and authorized start-up report shall be submitted to the
Gas (Natural):
Oil (No. 2):
Electrical:
Fan Motor:
Oil Pump Motor:
____ V / ____ H / ____ P
____HP
____HP
____HP
____dBA
Weight
Dry:
Flooded:
____
____
Seismic Zone: ____
Altitude: ____ ASL
CSD-1 NFPA 85 (optional)
State Of _______
Factory Mutual (FM) (optional)
GE-GAP (optional)
Section A1
A1-65
5-08
Firetube Boilers
A1-66
Notes
A2-1
05-08
TABLE OF CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-4
Promethean Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-4
Specifying Boiler Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-13
Efficiency Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-13
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-14
Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-19
Gas-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-19
Oil-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-20
General Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-26
Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-26
100 - 800 HP
4 pass Wet-Back Integral Burner (4WI)
Section A2
Promethean Series Model 4WI
Promethean Series - 4WI Firetube Boilers
A2-2
05-08
Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-26
Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-26
Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-26
Sample Specifications - Steam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-33
Sample Specifications - Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-45
LIST OF FIGURES
Figure A2-1. Model 4WI Steam Boiler 100-800 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-6
Figure A2-2. Model 4WI Hot Water Boiler 100-800HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-8
Figure A2-3. Predicted stack temp. increase for pressure greater than 125 psig - Model 4WI . . . . A2-15
Figure A2-4. Typical Gas Piping Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-22
Figure A2-5. No. 2 Oil Piping, Single Boiler Installation, Remote Oil Pump . . . . . . . . . . . . . . . . . A2-24
Figure A2-6. No. 2 Oil Piping, Multiple Boiler Installation, Remote Oil Pumps . . . . . . . . . . . . . . . A2-24
Figure A2-7. No. 2 Oil Piping, Multiple Boiler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-25
Figure A2-8. No. 2 Oil Transfer Tank Detail (for consideration with elevated boiler rooms) . . . . . . . A2-25
Figure A2-9. Typical Fuel Storage Tank Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-26
Figure A2-10. Boiler Room Length (Typical Layouts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-30
Figure A2-11. Boiler Room Width (Typical Layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-30
Figure A2-12. Breeching Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-31
LIST OF TABLES
Table A2-1. Horsepower -vs- Shell Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-3
Table A2-2. Model 4WI Steam Boiler Ratings 100 to 800 HP . . . . . . . . . . . . . . . . . . . . . . . . . . A2-6
Table A2-3. Model 4WI Steam Boiler Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-7
Table A2-4. Model 4WI Hot Water Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-8
Table A2-5. 4WI Hot Water Boiler Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-9
Table A2-6. Steam Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-10
Table A2-7. Hot Water Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-10
Table A2-8. Space required to open rear head on boilers equipped with davits (4WI) . . . . . . . . . . A2-11
Table A2-9. Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-11
Table A2-10. Lifting Lug Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-12
Table A2-11. Firing Rates 4WI Boilers with Integral Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-14
Table A2-12. Predicted Fuel-to-Steam Efficiencies - Natural Gas - Model 4WI . . . . . . . . . . . . . . . A2-15
Table A2-13. Predicted Fuel-to-Steam Efficiencies - No. 2 Oil - Model 4WI . . . . . . . . . . . . . . . . . A2-16
Table A2-14. Promethean Boilers - Natural Gas, Emission Levels - Model 4WI . . . . . . . . . . . . . . A2-16
Table A2-15. Promethean Boilers - No. 2 Oil, Emission Levels - Model 4WI 17 . . . . . . . . . . . . . . A2-16
Table A2-16. Standard, undersized, and oversized gas trains - sizes and pressure ranges . . . . . . . . A2-17
Table A2-17. Recommended NTI Gas Train Sizes and Pressure Ranges . . . . . . . . . . . . . . . . . . . . A2-18
Table A2-18. Predicted Sound Levels (30 ppm NOx system) at High Fire - Model 4WI . . . . . . . . . A2-18
Table A2-19. Minimum Required Gas Pressure Altitude Conversion. . . . . . . . . . . . . . . . . . . . . . . A2-21
Table A2-20. Maximum Gas Consumption (CFH) for Natural Gas and Propane Vapor . . . . . . . . . . A2-21
Table A2-21. Standard Gas Train Connection Size and Location . . . . . . . . . . . . . . . . . . . . . . . . . A2-21
Table A2-22. Gas Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-23
Table A2-23. N0. 2 Oil Connection Size, Location and Recommended Line Sizes . . . . . . . . . . . . . A2-23
Firetube Boilers Promethean Series - 4WI
A2-3
05-08
Table A2-24. Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-27
Table A2-25. Heating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-28
Table A2-26. Steam Volume Disengaging Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-28
Table A2-27. Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity . A2-29
Table A2-28. Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-29
Table A2-29. Blower Motor Selection 4WI NTI Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-29
Table A2-1. Horsepower vs Shell Diameter
Wet-Back Boilers
HP Dia. (IN)
4WI 100-125 60
4WI 150-200 67
4WI 250-300 78
4WI 350-400 85
4WI 500-600 96
4WI 700-800 106
A2-4
05-08
GENERAL
The Promethean Boiler Model 4WI (100 - 800 hp), provides NOx control, top
performance, and reliable Cleaver-Brooks efficiency. The Low Emission capabilities
combines the packaging of induced flue gas recirculation with the Cleaver-Brooks
integral front head and the Nat-Com burner internal components to gain the ultra-
low NOx of 15 to < 9 ppm levels on natural gas demanded by the environmental
concerns of today. The burner head combines advanced burner technology to
match the geometric and aerodynamic parameters to meet the stringent NOx and
CO standards for all applications. The front head routes a portion of the flue 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
firing rates while maintaining top of the line boiler performance.
Low Emission Options include packages from 60 ppm to ultra-low < 9 ppm.(all
NOx emission levels are given for natural gas and on a dry volume basis and
corrected to 3% O
2
):
Fan diameters and motor horsepower will vary in size depending on NOx
reduction requirements with the lower NOx levels requiring larger fans and
more horsepower.
Cleaver-Brooks' commitment to lowering emissions is based on more than 2000
low NOx installations - all passing guaranteed emission performance levels.
The Cleaver-Brooks Promethean Firetube Boiler model 4WI, is a 4 pass wet-back
design including five square feet of heating surface per boiler horsepower, and
maximum guaranteed efficiencies. The shell sizes can be found in Table A2-1.
The Promethean model 4WI includes a complete package; pressure vessel, integral
burner and controls including the revolutionary Level Master water level control on
High pressure steam units. Additionally, options can be added to further enhance
the package...
One such option is the CB Hawk ICS, integrated control system providing boiler
control, monitoring, communication and system integration in a single PLC based
package. To this system you may also add a VSD (variable speed drive) for
controlling combustion air, parallel positioning for independent control of fuel and
air, modulating feed water valve, and Oxygen trim for additional energy savings in
an integrated package.
The Promethean model 4WI is offered with;
Promethean Boilers 4-pass wetback design
100-800 boiler horsepower, steam or hot water
Compact footprint; optimized shell and furnace geometry
Lower furnace heat release
Integral burner
Low emissions on natural gas; selections from 60 to Ultra-low NOx reduction
(ULNOx(tm)) of 15 - <9 PPM
Low emissions on #2 oil; 70 PPM with 0.015% fuel bound nitrogen.
A2-5
05-08
Level Master water level control on high pressure steam units
Multiple fuel firing
CB 780E burner management control
UL/ULC approved package.
Single point positioning of fuel and air ensures ease of startup and reliable
operation.
The 4 pass Wet-Back boiler ratings for the steam boiler are on Table A2-2 and the
4 pass Wet-Back hot water boilers ratings are on Table A2-4. Dimensions and
weights for the 4 pass Wet-Back steam boiler is on Table A2-3. The 4 pass Wet-
Back hot water boiler dimension and weights are on Table A2-5.
Notes:
A2-6
05-08
Table A2-2. Model 4WI Steam Boiler Ratings 100 to 800 HP
NOTE:
A. Blower motor size for boiler operating pressures 125 psig and less, contact your local Cleaver-Brooks authorized representative for higher pressures and altitude.
B. 800 hp boilers are available w/3500 or 4000 sq. ft. of heating surface
BOILER H.P. 100 125 150 200 250 300 350 400 500 600 700 800
RATINGS - SEA LEVEL TO 700 FT.
Rated Capacity
(lbs-steam/hr from and at 212F)
3450 4313 5175 6900 8625 10350 12075 13800 17250 20700 24150 27600
Btu Output (1000 Btu/hr) 3347 4184 5021 6694 8368 10042 11715 13389 16736 20083 23430 26778
APPROXIMATE FUEL CONSUMPTION AT RATED CAPACITY BASED ON NOMINAL 82% EFFICIENCY
Light Oil gph (140,000 Btu/gal) 29.2 36.4 43.7 58.3 72.9 87.5 102.0 116.6 145.8 174.9 204.1 233.3
Gas CFH (1000 Btu) 4082 5102 6123 8164 10205 12246 14287 16328 20410 24492 28574 32656
Gas (Therm/hr) 40.8 51.0 61.2 81.6 102.0 122.5 142.9 163.3 204.1 244.9 285.7 326.6
POWER REQUIREMENTS - SEA LEVEL TO 700 FT. (60 HZ)
Blower Motor hp (60 ppm)
(See Note A )
2 5 5 10 10 15 15 20 15 25 30 50
(See Note A )
3 7-1/2 7-1/2 15 15 20 20 25 25 40 50 75
Oil Pump Motor, No. 2 Oil 1/2 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4 1 1
Air Compressor Motor hp
(No. 2 Oil firing Only)
3 3 3 3 5 5 5 5 7-1/2 7-1/2 7-1/2 7-1/2
BOILER DATA
Heating Surface sq-ft. (Fireside) 500 625 750 1000 1250 1500 1750 2000 2500 3000 3500 See Note
"B"
R
F G
W
W
S
Z
E
BB
U
D 4"
F F
Q
A
B
60" D IA. (100/ 125 H P) U SES HI NG ED
F RON T D OOR ( NOT DAV IT AS SH OW N) .
X
KK
H
P
I
L
O O
O
M
N
E E
J
C
K
LL
D D
R F/ R D
s
k
o
o r B
r e v
a
e l
C
II
Figure A2-1. Model 4WI Steam Boiler 100-800 HP
A2-7
05-08
Table A2-3. Model 4WI Steam Boiler Dimensions
BBA2_02-08
BOILER H.P. DIM 100 125 150 200 250 300 350 400 500 600 700/800 *800
LENGTHS See Note "C"
Overall Length (60 PPM system) A 162 186 175 209 200 225.5 221.75 238.75 245.75 282.75 270.75 297.75
Overall Length (30 PPM system) A 162 186 175 209 200 225.5 221.75 247 253.5 287.25 276.75 303.75
Shell B 131 155 143 177 172.5 196.5 189.75 207.75 213.75 248.75 232.75 259.75
Base Frame C 110 124 122 156 150.125 174.125 167.25 185.25 188.25 223.25 207.25 234.25
Front Head Extension (60 PPM system) D 27 27 28 28 23.5 25 28 27 28 30 34 34
Front Head Extension (30 PPM system) D 27 27 28 28 23.5 25 28 35.25 35.75 34.5 40 40
Shell Extension E 12 12 12 12 14.5 14.5 16.75 16.75 16.25 16.25 16.75 16.75
Shell Ring Flange to Base F 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Rear Ring Flange to Base G 20.5 20.5 20.5 20.5 22 22 22 22 25 25 25 25
Shell Flange to Steam Nozzle 15 psi H 78.38 88.38 87.38 93.38 84.38 98.38 94.5 104.5 101.5 124.5 110.5 128.5
Shell Flange to Steam Nozzle 150 psi H 70.38 90.38 73.38 87.38 92.38 98.38 95.5 104.5 106.5 124.5 115.5 128.5
WIDTHS
Overall Width I 90 90 97.25 97.25 108 108 115 115 127 127 137 137
Center to Panel II 50 50 53.75 53.75 59 59 62.5 62.5 68 68 73 73
I.D. Boiler J 60 60 67 67 78 78 85 85 96 96 106 106
Center to Water Column K 45 45 48.5 48.5 54 54 57.5 57.5 64 64 69 69
Center to Outside Davit/Hinge KK 35 35 41.5 41.5 51 51 56.5 56.5 62 62 67 67
Center to Lagging L 33 33 36.75 36.75 42 42 45.5 45.5 51 51 56 56
Center to Auxiliary LWCO LL 40 40 43.5 43.5 49 49 52.5 52.5 59 59 64 64
Base Outside M 52.5 52.5 51 51 64 64 60 60 71.88 71.88 74.75 74.75
Base Inside N 44.5 44.5 43 43 56 56 47 47 58.88 58.88 61.75 61.75
HEIGHTS
Overall Height OO 86 86 101.75 101.75 115 115 123.5 123.5 134 134 145.5 145.5
Base to Vent Outlet O 85 85 92.63 92.63 106 106 115 115 126 126 135.63 135.63
Base to Boiler Centerline P 46 46 50 50 56 56 61 61 67 67 71 71
Height of Base Frame Q 12 12 12 12 12 12 12 12 12 12 12 12
Base to Bottom of Boiler R 15.63 15.63 16.13 16.13 16.5 16.5 18 18 18.5 18.5 17.5 17.5
Base to Steam Outlet X 82.38 82.38 89.88 89.88 101.5 101.5 110 110 121.5 121.5 130.5 130.5
BOILER CONNECTIONS
Feedwater Inlet (Both Sides) S 1.25 1.5 1.5 2 2 2 2.5 2.5 2.5 2.5 2.5 2.5
Surface Blowoff (150 lb only) T 1 1 1 1 1 1 1 1 1 1 1 1
Steam Nozzle 15 lb (See Note "A") U 8 8 8 10 10 12 12 12 12 12 12 12
Steam Nozzle 150 lb (See Note "B") U 4 4 4 4 6 6 6 6 8 8 8 8
Blowdown-Front & Rear (15 lb) W 1.5 1.5 1.5 2 2 2 2 2 2 2 2 2
Blowdown-Front & Rear (150 lb) W 1.25 1.5 1.5 1.5 1.5 1.5 1.5 2 2 2 2 2
Chemical Feed Z 1 1 1 1 1 1 1 1 1 1 1 1
VENT STACK
Vent Stack Diameter (Flanged) BB 16 16 16 16 20 20 24 24 24 24 24 24
MINIMUM CLEARANCES
Rear Door Swing DD 36 36 40 40 46 46 50 50 55 55 60 60
Front Door Swing EE 67 67 78 78 89 89 97 97 108 108 118 118
Tube Removal - Front Only FF 96 120 108 142 132.5 156.5 148 166 169 204 188 215
Thru Window or Door RD 234 258 261 295 308 332 337 355 377 412 411 438
Front of Boiler RF
263 311 291 359 351 399 388 424
438 508 481 535
WEIGHTS IN LBS
Normal Water Weight - 5,867 7,310 7,625 9,996 12,587 14,848 16,025 17,953 21,053 25,352 28,700 32,770
Approx. Shipping Weight - (15psig) - 11,760 12,980 14,200 16,260 20,130 22,080 25,810 27,950 33,810 38,170 41,980 46,300
NOTES:
Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension diagram/drawing.
All Connections are Threaded Unless Otherwise Indicated:
NOTE "A": ANSI 150 psig Flange
NOTE "B": ANSI 300 psig Flange
NOTE "C": *800 hp w/ 4000 sq. ft. of heating surface
A2-8
05-08
Figure A2-2. Model 4WI Hot Water Boiler 100-800HP
R
F G
W
W S
E
BB
U
D 4"
FF
Q
A
B
60" DIA. (100/125 HP) USES HINGED
FRONT DOOR (NOT DAVIT AS SHOWN).
X
KK
EE
LWCO
I
L K
T
Y
J
P
OO
O
M
N
HH
H
C
DD
RF/RD
s
k
o
o r
B
r e
v
a
e
l
C
Table A2-4. Model 4WI Hot Water Boiler Ratings
BOILER H.P. 100 125 150 200 250 300 350 400 500 600 700 800
Btu Output (1000 Btu/hr) 3347 4184 5021 6694 8368 10042 11715 13389 16736 20083 23430 26778
Gas CFH (1000 Btu) 4082 5102 6123 8164 10205 12246 14287 16328 20410 24492 28574 32656
Gas (Therm/hr) 40.8 51.0 61.2 81.6 102.0 122.5 142.9 163.3 204.1 244.9 285.7 326.6
Blower Motor hp (60 ppm) 2 5 5 10 10 15 15 20 15 25 30 50
Blower Motor hp (30 ppm) 3 7-1/2 7-1/2 15 15 20 20 25 25 40 50 75
Oil Pump Motor, No. 2 Oil 1/2 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4 1 1
Air Compressor Motor hp (No. 2
Oil firing Only)
3 3 3 3 5 5 5 5 7-1/2 7-1/2 7-1/2 7-1/2
Heating Surface sq-ft. (Fireside) 500 625 750 1000 1250 1500 1750 2000 2500 3000 3500 See Note "A"
NOTE 'A': 800 hp boilers are available w/ 3500 or 4000 sq. ft. of heating surface
BOILER DATA
A2-9
05-08
Table A2-5. 4WI Hot Water Boiler Dimensions
05-08
BOILER H.P. DIM 100 125 150 200 250 300 350 400 500 600 700/800 *800
Overall Length (60 PPM system) A 162 186 175 209 200 225.5 221.75 238.75 245.75 282.75 270.75 297.75
Overall Length (30 PPM system) A 162 186 175 209 200 225.5 221.75 247 253.5 287.25 276.75 303.75
Shell B 131 155 143 177 172.5 196.5 189.75 207.75 213.75 248.75 232.75 259.75
Base Frame C 110 124 122 156 150.12 174.12 167.25 185.25 188.25 223.25 207.25 207.25
Front Head Extension (60 PPM
D 27 27 28 28 23.5 25 28 27 28 30 34 34
Front Head Extension (30 PPM
D 27 27 28 28 23.5 25 28 35.25 35.75 34.5 40 40
Shell Extension E 12 12 12 12 14.5 14.5 16.75 16.75 16.25 16.25 16.75 16.75
Shell Ring Flange to Base F 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Shell Flange to Return H 78 99 87 121 113.5 137.5 130.75 148.75 143 151.75 146.75 173.75
Shell Flange to Outlet HH 103 124 112 146 139.5 163.5 156.75 174.75 179 187.75 182.75 209.75
WIDTHS
Overall Width I 75.5 75.5 82.75 82.75 93 93 102 102 113 113 123 123
I.D. Boiler J 60 60 67 67 78 78 85 85 96 96 106 106
Center to Entrance Box K 42.5 42.5 46 46 51 51 56.5 56.5 62 62 67 67
Center to Outside Davit/Hinge KK 35 35 41.5 41.5 51 51 56.5 56.5 62 62 67 67
Base Outside M 52.5 52.5 51 51 64 64 60 60 71.88 71.88 74.75 74.75
Base Inside N 44.5 44.5 43 43 56 56 47 47 58.88 58.88 61.75 61.75
HEIGHTS
Overall Height OO 86 86 101.75 101.75 115 115 123.5 123.5 134 134 145.5 145.5
Base to Return & Outlet X 82.38 82.38 89.88 89.88 101.5 101.5 110 110 121.5 121.5 130.5 130.5
BOILER CONNECTIONS
Waterfill Connection (Both Sides) S 1.25 1.5 1.5 2 2 2 2.5 2.5 2.5 2.5 2.5 2.5
Water Return (See Note "A") T 4 6 6 6 8 8 8 10 10 12 12 12
Water Outlet (See Notes "A & B") U 4 6 6 6 8 8 8 10 10 12 12 12
Drain-Front & Rear W 1.5 1.5 1.5 2 2 2 2 2 2 2 2 2
Air Vent Y 1.5 1.5 1.5 1.5 1.5 1.5 1.5 2 2 2 2 2
VENT STACK
MINIMUM CLEARANCES
Front Door Swing EE 67 67 78 78 89 89 97 97 108 108 118 118
MINIMUM BOILER ROOM LENGTH
Thru Window or Door RD 234 258 261 295 308 332 337 355 377 412 411 438
Front of Boiler RF
263 311 291 359 351 399 388 424
438 508 481 535
WEIGHTS IN LBS
NOTES:
NOTE "B": Water Outlet includes 2" Dip Tube
NOTE C: 800 HP w/ 4000 sq. ft. of heating surface
A2-10
05-08
Table A2-7. Hot Water Boiler Safety Valve Openings
VALVE SETTING 30 PSIG HW 125 PSIG HW 150 PSIG HTHW
BOILER HP
NO. OF
VALVES
REQ'D
OUTLET
SIZE (IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE (IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE (IN.)
100 1 2-1/2 1 1-1/4 1 2
125 1 2-1/2 1 1-1/4 2
(1) 1-1/2
(1) 2
150 1 2-1/2 1 2 2
(1) 1-1/2
(1) 2
200 2
(1) 2-1/2
(1) 1-1/4
1 2 2 2
250 2
(1) 2
(1) 2-1/2
1 2 2
(1) 2
(1) 2-1/2
300 2 2-1/2 1 2-1/2 2 2-1/2
350 3
(2) 2-1/2
(1) 1
1 2-1/2 2
(1) 2-1/2
(1) 3
400 3
(1) 2
(2) 2-1/2
1 2-1/2 2
(1) 2-1/2
(1) 3
500 4
(1) 1
(3) 2-1/2
2
(1) 1
(1) 2-1/2
2 3
600 4
(3) 2-1/2
(1) 2
2
(1) 1-1/4
(1) 2-1/2
3
(2) 3
(1) 2-1/2
700, 800 5
(1) 1
(4) 2-1/2
2
(1) 2-1/2
(1) 2
3 3
NOTE: Relief valve is Kunkle #537 for 30#& 125#(Section IV) boiler and
is Kunkle #927 for 150#HTHW(Section I) boiler.
VALVE SETTING 15 PSIG STEAM 150 PSIG STEAM 200 PSIG STEAM 250 PSIG STEAM
BOILER HP
NO. OF
VALVES
REQ'D
OUTLET
SIZE (IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE (IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE (IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE (IN.)
100 1 2-1/2 1 1-1/2 1 1-1/2 1 1-1/4
125 1 3 2
(1) 1-1/2
(1) 1-1/4
2
(1) 1-1/4
(1) 1
2 1
150 1 3 2
(1) 1-1/2
(1) 1-1/4
2 1-1/4 2
(1) 1
(1) 1-1/4
200 2 2-1/2 2 1-1/2 2
(1) 1-1/2
(1) 1-1/4
2 1-1/4
250 2
(1) 2-1/2
(1) 3
2
(1) 2
(1) 1-1/2
2 1-1/2 2
(1) 1-1/2
(1) 1-1/4
300 2 3 2 2 2
(1) 2
(1) 1-1/2
2 1-1/2
350 3
(1) 2
(2) 3
2
(1) 2-1/2
(1) 2
2 2 2
(1) 1-1/2
(1) 2
400 3
(2) 3
(1) 2-1/2
2
(1) 2-1/2
(1) 2
2 2 2
(1) 1-1/2
(1) 2
500 3 3 2 2-1/2 2
(1) 2-1/2
(1) 2
2 2
600 4
(3) 3
(1) 2-1/2
3
(2) 2-1/2
(1) 2
2 2-1/2 2
(1) 2
(1) 2-1/2
700, 800 5
(3) 3
(2) 2-1/2
3
(2) 2-1/2
(1) 2
2 2-1/2 2 2-1/2
NOTE: Valve manufacturers are Kunkle, Consolidated or Conbraco, depending on availability.
A2-11
05-08
Table A2-8. Space Required to Open Rear Head on Promethean Boilers Equipped with Davits (4WI)
Table A2-9. Boiler Mounting Piers
BOILER ALL DIMENSIONS IN INCHES
HP A B C D E
100-125 33 47 52 80 36
150-200 36.5 49 56 83 40
250-300 42 56 61 92 46
350-400 45.5 58 68 99 50
500-600 51 66 75 111 55
700-800 56 74 80 121 60
05-08
HP A B C D E F G X1 X2
100 6 9 110 39.5 57.5 4 44.5 12 8
125 6 9 124 39.5 57.5 4 44.5 12 8
150 6 9 122 38 56 4 43 12 8
200 6 9 156 38 56 4 43 12 8
250 6 9 150.125 51 69 4 56 16.125 11.5
300 6 9 174.125 51 69 4 56 16.125 11.5
350 6 12 167.25 41.5 65.5 6.5 47 17.75 11.5
400 6 12 185.25 41.5 65.5 6.5 47 17.75 11.5
500 6 12 188.25 53.375 77.375 6.5 58.875 18.75 10.5
600 6 12 223.25 53.375 77.375 6.5 58.875 18.75 10.5
700-800 6 12 207.25 56.25 80.25 6.5 61.75 18.75 10.5
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.
A2-12
05-08
HP A B C D E
100 79.5 21.375 84.75 10 3
125 79.5 21.375 108.75 10 3
150 87.125 21.375 96.75 10 3
200 87.125 21.375 130.75 10 3
250 99 28.75 104.25 10 3
300 99 28.75 128.25 10 3
350 107.625 33.25 126 10 3
400 107.625 33.25 144 10 3
500 125.375 34.5 145 10 3
600 125.375 34.5 180 10 3
700-800 134.5 34.5 164 10 3
NOTE: A, B, and C dimensions may vary by 1 inch.
NEAR
SIDE
VIEW B
FAR
SIDE
FRONT
FLANGE
VIEWA
E DIA. HOLE
A
C
L
B
D
D
C
Table A2-10. Lifting Lug Locations
A2-13
05-08
PERFORMANCE DATA
The Low Emission Option provides NOx reduction at current published and
predicted fuel-to-steam efficiencies. Refer to Table A2-12 and Table A2-13.
Specifying Boiler
Efficiency
for Promethean 4WI Firetube Boilers. The guarantee is based on the fuel-to-steam
guarantee conditions to maximize the effectiveness of your efficiency specification.
If you have any questions regarding the efficiency specifications, please contact
your local Cleaver-Brooks authorized representative.
Efficiency
Specification
achieve fuel-to-steam/water efficiency (as shown in Table A2-12 and Table A2-13)
at 100% firing rate (Reference efficiency guarantees at 25%, 50%, and 75% of
rating, if required). If the boiler(s) fail to achieve the corresponding guaranteed
efficiency as published, the boiler manufacturer will rebate, to the ultimate boiler
owner, ten thousand dollars ($10,000) for every full efficiency point (1.0%) that
the actual efficiency is below the guaranteed level.
Natural Gas
Carbon,% (wt) = 69.98
Sulfur,% (wt) = 0.0
No. 2 Oil
Sulfur,% (wt) = 0.2
No. 6 Oil
losses. (For Cleaver-Brooks radiation and convection losses, see Boiler Efficiency
Facts Guide, publication number CB-7767).
For efficiencies and stack temperatures at operating pressures not listed, follow
these procedures:
A2-14
05-08
Example:
Boiler: 350 hp.
Fuel: natural gas.
Find the fuel-to-steam efficiency at 100% firing rate. From Table A2-12 a boiler
operating at 100% firing rate and an operating steam pressure of 125 psig, the
efficiency is 82.1%.
pressure is calculated as follows: 36/40 =.9%. Therefore, the boiler efficiency at
200 psig operating pressure is 82.1 -.9 = 81.2%
Emissions
The emission data included in this section consists of typical emission levels for the
4WI boiler equipped with 60 & 30 ppm reduction with natural gas or No. 2 oil.
Table A2-11. Firing Rates 4WI Boilers with Integral Burner
BHP Low High Low High
100 1021 4082 7.3 29.2
125 1276 5103 9.1 36.4
150 1531 6124 10.9 43.7
200 2041 8165 14.6 58.3
250 1021 10206 9.1 72.9
300 1225 12247 10.9 87.5
350 1428 14280 12.8 102.1
400 1633 16329 14.6 116.6
500 2042 20415 18.2 145.8
600 2449 24494 21.9 175
700 2858 28576 25.5 204.1
750 3062 30617 27.3 218.7
800 3266 32659 29.2 233.3
Notes:
Fuel input rates are based on nominal 82% efficiency.
No. 2 Oil =140,000 Btu/Gal
Natural Gas, 1000 Btu/hr No. 2 Oil, GPH
A2-15
05-08
25% 50% 75% 100% 25% 50% 75% 100%
100 84.4 84.6 84.1 83.6 81.6 82.0 81.7 81.3
125 84.6 85.0 84.7 84.3 81.8 82.3 82.2 82.0
150 84.5 84.8 84.4 83.9 81.6 82.0 81.7 81.3
200 84.7 85.2 85.1 84.8 81.8 82.4 82.3 82.2
250 84.7 85.1 84.9 84.5 81.8 82.4 82.3 82.1
300 84.8 85.3 85.2 85.0 81.9 82.6 82.6 82.5
350 84.7 85.2 85.1 84.8 81.8 82.4 82.3 82.1
400 85.4 85.6 85.5 85.2 82.6 82.9 82.8 82.6
500 85.4 85.6 85.5 85.3 82.6 83.0 82.9 82.8
600 85.5 85.8 85.7 85.6 82.7 83.2 83.2 83.1
700 85.5 85.7 85.7 85.6 82.7 83.1 83.1 83.0
800 85.5 85.8 85.7 85.6 82.7 83.1 83.1 83.0
BHP
OPERATING PRESSURE =10 psig
% OF LOAD
% OF LOAD
Table A2-12. Predicted Fuel-to-Steam Efficiencies - Natural Gas - Model 4WI
Figure A2-3. Predicted Stack Temperature Increase for Pressure Greater Than 125 psig - Model 4WI
Note: Using the ultra low NOx burner (15-<9ppm) will result in a slight reduction of fuel-to-steam efficiency.
A2-16
05-08
25% 50% 75% 100% 25% 50% 75% 100%
100 87.9 88.1 87.6 87.0 85.1 85.4 85.1 84.7
125 88.0 88.5 88.2 87.8 85.2 85.7 85.7 85.5
150 88.0 88.3 87.9 87.4 85.1 85.4 85.1 84.8
200 88.2 88.7 88.5 88.2 85.3 85.8 85.7 85.6
250 88.1 88.6 88.3 88.0 85.3 85.8 85.7 85.6
300 88.2 88.8 88.6 88.4 85.4 86.0 86.0 86.0
350 88.2 88.7 88.5 88.2 85.3 85.8 85.7 85.6
400 88.8 89.0 88.9 88.7 86.0 86.3 86.2 86.0
500 88.8 89.0 88.9 88.7 86.1 86.4 86.4 86.2
600 88.9 89.2 89.2 89.1 86.2 86.6 86.6 86.6
700 88.9 89.2 89.1 89.0 86.1 86.5 86.5 86.4
800 88.9 89.2 89.2 89.1 86.1 86.5 86.5 86.4
BHP
% OF LOAD
% OF LOAD
Table A2-13. Predicted Fuel-to-Steam Efficiencies - No. 2 Oil - Model 4WI
Note: Using the ultra low NOx burner (15-<9ppm) will result in a slight reduction of fuel-to-steam efficiency.
05-08
POLLUTANT UNITS 60 PPM SYSTEM 30 PPM SYSTEM
CO ppm* 50/150** 50/150**
lb/MMbtu 0.04/0.11 0.04/0.11
NOx ppm* 60 30
lb/MMbtu 0.07 0.035
SOx ppm* 1 1
lb/MMbtu 0.001 0.001
HC/VOC
5
ppm* 10 10
lb/MMbtu 0.004 0.004
PM ppm* - -
lb/MMbtu 0.01 0.01
* ppm levels are given on a dry volume basis and are corrected to 3% oxygen (15% excess air)
** CO emission is 50 ppm when boiler is operating above 50% of rated capacity. CO emission is
150 ppm when boiler is operating below 50% of rated capacity.
Table A2-14. Promethean Boilers - Natural Gas, Emission Levels - Model 4WI
POLLUTANT UNITS 60 PPM SYSTEM 30 PPM SYSTEM
CO ppm* 50 50
lb/MMbtu 0.04 0.04
NOx ppm* 140 90
lb/MMbtu 0.186 0.12
SOx ppm* 278 278
lb/MMbtu 0.52 0.52
HC/VOC
5
ppm* 4 4
lb/MMbtu 0.002 0.002
PM ppm* - -
lb/MMbtu 0.025 0.025
* ppm levels are given on a dry volume basis and are corrected to 3% oxygen (15% excess air)
BASED ON THE FOLLOWING CONSTITUENT LEVELS:
Fuel-bound Nitrogen content = 0.015% by weight
Sulfur content = 0.5% by weight
Ash content = 0.01% by weght
Table A2-15. Promethean Boilers - No. 2 Oil, Emission Levels - Model 4WI
A2-17
05-08 05-08
Table A2-16. 4WI Gas Pressure at Entrance to Standard, Undersized, and Oversized Gas Trains
30 PPM 60 PPM
Boiler HP Pipe Size Pressure
Range PSI
Pressure
Range PSI
100 1.5 0.6 - 2.0 0.5 - 2.0
125 1.5 0.8 - 3.0 0.8 - 3.0
150 1.5 1.0 - 3.0 0.9 - 3.0
200 1.5 1.7 - 4.0 1.6 - 4.0
2 1.1 - 1.7 1.1 - 1.6
250 1.5 2.4 - 5.0 2.5 - 5.0
2 1.5 - 2.4 1.6 - 2.5
300 1.5 - 2 2.9 - 5.0 3.1 - 5.0
2 1.9 - 2.9 2.1 - 3.1
3 1.2 - 1.9 1.4 - 3.1
350 1.5 - 2 3.8 - 5.0 3.8 - 5.0
2 2.8 - 3.8 2.8 - 3.8
2.5 2.1 - 2.8 2.1 - 2.8
3 1.4 - 2.1 1.4 - 2.1
400 1.5 - 2 5.0 - 7.0 5.0 - 7.0
2 3.5 - 5.0 3.5 - 5.0
2.5 2.7 - 3.5 2.7 - 3.5
3 1.8 - 2.7 1.9 - 2.7
500 1.5 - 2.5 6.6 - 10.0 6.6 - 10.0
2 - 2.5 4.7 - 6.6 4.7 - 6.6
2.5 3.3 - 4.7 3.3 - 4.7
3 1.9 - 3.3 1.9 - 3.3
600 1.5 - 2.5 9.5 - 10.0 9.5 - 10.0
2 - 2.5 6.8 - 9.5 6.8 - 9.5
2.5 4.8 - 6.8 4.8 - 6.8
2.5 - 3 4.1 - 4.8 4.1 - 4.8
3 2.8 - 4.1 2.7 - 4.1
700 2 - 3 8.5 - 10.0 8.4 - 10.0
2.5 - 3 5.4 - 8.5 5.3 - 8.4
3 3.6 - 5.4 3.5 - 5.3
4 2.7 - 3.6 2.6 - 3.5
750 2.5 - 3 6.4 - 10.0 6.4 - 10.0
3 4.6 - 6.4 4.6 - 6.4
4 3.1 - 4.6 3.1 - 4.6
800 2.5 - 3 6.8 10.0 7.0 - 10.0
3 4.6 - 6.8 4.8 - 7.0
4 3.3 - 4.6 3.5 - 4.8
Note: Some units list two diameters because the
gas train increases in size after the regulating
valve. The first number is the customer connec-
tion size.
UNDERSIZE
STANDARD
OVERSIZE
Table is based on Siemens gas train, which includes a regulating
actuator.
A2-18
05-08
Table A2-17. Recommended NTI Gas Train Sizes and Pressure Ranges
4WI 15 PPM 4WI 9 PPM
Boiler HP
100 1.5 2.3 - 5.0 1.5 2.3 - 5.0
125 1.5 3.3 - 6.0 1.5 3.3 - 6.0
150 1.5 3.9 - 6.0 1.5 4.1 - 6.0
200 1.5 4.5 - 7.0 1.5 4.5 - 7.0
250 1.5 - 2 4.5 - 7.0 1.5 - 2 4.2 - 7.0
300 1.5 - 2 6.1 - 9.0 1.5 - 2 5.9 - 9.0
2 4.8 - 6.1 2 4.6 - 5.9
350 1.5 - 2 5.1 - 7.5 1.5 - 2 6.2 - 9.0
2 4.0 - 5.1 2 5.2 - 6.2
2.5 4.5 - 5.2
400 1.5 - 2 7.3 - 10.0 1.5 - 2 7.2 - 10.0
2 5.8 - 7.3 2 5.7 - 7.2
2.5 5.0 - 5.8 2.5 4.9 - 5.7
3 4.1 - 5.0
500 1.5 - 2 8.1 - 10.0 1.5 - 2 8.1 - 10.0
2 6.1 - 8.1 2 6.1 - 8.1
2.5 4.7 - 6.1 2.5 4.7 - 6.1
3 3.4 - 4.7 3 3.4 - 4.7
600 2 - 3 7.8 - 10.0 2 - 3 7.8 - 10.0
2.5 -3 5.8 - 7.8 2.5 -3 5.8 - 7.8
3 4.4 - 5.8 3 4.4 - 5.8
700 2.5 - 3 7.7 - 10.0 2.5 - 3 7.9 - 10.0
3 5.9 - 7.7 3 6.1 - 7.9
720 2.5 - 3 8.1 - 10.0
3 6.3 - 8.1
750 2.5 - 3 8.6 - 10.0
3 6.7 - 8.6
increases in size after the regulating valve. The first number is the
customer connection size.
UNDERSIZE
STANDARD
OVERSIZE
BHP Sound Level-dbA
100 79
125 83
150 83
200 84
250 83
300 84
350 84
400 85
500 85
600 87
700 88
800 90
Table A2-18. Predicted Sound Levels (30
ppm NOx system) at High Fire - Model 4WI
A2-19
05-08
ENGINEERING DATA
Sound Level Table A2-18 gives a summary of predicted sound pressure levels for the CB boilers
with 30 ppm LE Options. Contact your local Cleaver-Brooks authorized representative
for sound levels for 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
With larger sized 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
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 finally, 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).
Gas-Fired Burners Table A2-16 shows gas pressure ranges for standard, oversized, and undersized gas
trains.
C-B O
2
Trim Systems: If a C-B O
2
Trim system will be utilized, contact your local
Cleaver-Brooks authorized representative to be sure that a compatible regulator is
selected.
Table A2-20 shows maximum gas consumption for natural gas and propane vapor.
Table A2-21 shows standard gas train sizes and locations for Model CB Firetube
Boilers.
A2-20
05-08
Table A2-23 shows the oil connection sizes and locations for Model CB Boilers firing
No. 2 oil.
Figures Figure A2-5 through Figure A2-8 show typical oil systems and layouts.
Figure A2-8 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.
A2-21
05-08
A
PLAN VIEW
BOILER
FRONT
BOILER
HP
NATURAL GAS
1000 (Btu/cu-ft)
PROPANE GAS
2550 (Btu/cu-ft)
125 5103 2000
150 6124 2402
200 8165 3202
250 10206 4002
300 12247 4802
350 14280 5600
400 16329 6404
500 20415 8006
600 24494 9605
700 28576 11206
750 30618 12007
800 32659 12807
BOILER
HP
MODEL 4WI
CONNECTION
SIZE
(IN.) (NPT)
LOCATION
DIMENSION
A (IN.)
100-125 1-1/2 52
150-200 1-1/2 47-1/2
250-400 2 50
500 2-1/2 60
600 2-1/23 71
700-800 3 65
ALTITUDE
(FT)
CORRECTION
FACTOR
ALTITUDE
(FT)
CORRECTION
FACTOR
1000 1.04 6000 1.25
2000 1.07 7000 1.30
3000 1.11 8000 1.35
4000 1.16 9000 1.40
5000 1.21 - -
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.
Table A2-19. Minimum Required Gas Pressure
Altitude Conversion
Table A2-20. Maximum Gas Consumption (CFH) for Natural
Gas and Propane Vapor
Table A2-21. Standard Gas Train Connection Size and Location
A2-22
05-08
This figure illustrates the basic gas valve arrangement on Cleaver-Brooks
Model 4WI 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.
C. Gas meter.
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 siz-
ing is dependent on:
The local gas utility will advise the pressure that is available at the outlet of
their meter.
MODEL
4WI
BOILERS
PLUG
COCK
A
B
C
D CONTRACTOR
CONNECTION
POINT
GAS TRAIN
ON BOILER
STREET GAS MAIN
MODEL
4WI
BOILERS
A2-23
05-08
5
6
S
1
3
4
2
PILOT GAS LINE
S
S
MAIN GAS LINE
M M
To
Burner
Gas
Supply
11
10
9
7
12
13
8
14
15
FLOW
FLOW
CSD-1 NFPA-85
125 hp -
300 hp
350 hp -
800 hp
125 hp -
300 hp
350 hp -
800 hp
125 hp -
300 hp
350 hp -
800 hp
5 Pilot Vent Valve X
6 Gas Pilot Valve X
9 Main Gas Valve w/o POC X X X X
10 Main Gas Valve w/ POC X X
11 Vent Valve or Valve Proving Switch X X X
UL FM
ITEM DESCRIPTION
BOILER BASE FRAME
BOILER
FRONT
A
CONTRACTOR
CONNECTIONS
BOILER
HP
MODEL 4WI
SUPPLY
AND
RE-
TURN
CONN
SIZES
(IN.)
(NPT)
A
(IN.)
A
SIZES
(STANDARD PIPE)
(IN. - IPS)
STOR-
AGE
TANK TO
BOILER
OR PUMP
CONNECT
PUMP
TO
BOILER
RE-
TURN
LINE TO
TANK
100
150
200
3/4 12-1/2 1 1 1
250
300
350
3/4 34 1 1 1
400
500
600
3/4 11-3/4 1 1 1
700
750
800
1 11-3/4 1 1 1
NOTE: See No. 2 Oil Line Sizing Instruction for systems with other
conditions.
total of 100 feet of suction line.
Table A2-22. Gas Train Components
Table A2-23. N0. 2 Oil Connection Size, Location and Recommended Line Sizes
A2-24
05-08
BOILER
BASE FRAME
BOILER
FRONT
F.O.S.
F.O.R.
CONTRACTOR
CONNECTIONS
AT THIS POINT
GATE VALVE
OIL PUMP NO. 1
OIL
PUMP
NO. 2
GATE VALVE
GATE VALVE
CHECK VALVE
RELIEF
VALVE
(100 PSIG)
UNION
GATE VALVE
CHECK VALVE
F.O.S.
F.O.R.
BOILER
BASE FRAME
BOILER
FRONT
F.O.S.
F.O.R.
CONTRACTOR
CONNECTIONS
AT THIS POINT
GATE VALVE
OIL PUMP
CHECK
VALVE
VACUUM
GAUGE
STRAINER
GATE VALVE
RELIEF VALVE
UNION
GATE VALVE
CHECK VALVE
F.O.R.
F.O.S.
Figure A2-5. No. 2 Oil Piping, Single
Boiler Installation, Remote Oil Pump
Figure A2-6. No. 2 Oil Piping, Multiple
Boiler Installation, Remote Oil Pumps
A2-25
05-08
level switch
tion from transfer
pump
tion
connection
McD
F.O.R.
OIL LEVEL
TEST VALVE
OIL TRANSFER PUMP
NEAR STORAGE TANK
SUPPLY TO BOILER
TERMINAL BLOCK OR
TO BOILER OIL PUMP
GATE
VALVE
GATE
VALVE
OIL TRANSFER TANK
AT LOCATION NEAR
BOILER
VENT
H
F.O.S.
F.O.R.
F.O.S.
CHECK
VALVE STRAINER
VACUUM
GAUGE
UNION
RELIEF VALVE
(100 PSIG)
3/8" MTL
D
4" OR 6"
STD
BLACK
PIPE
F
E
22"
33"
3"
2"
60"
G
A
B
C
5"
3"
that adjustable pressure relief
valve in the loop system is in
control.
STANDBY
OIL PUMP
UNION
GATE VALVE
CHECK
GATE
RELIEF
VACUUM GAUGE
STRAINER
GATE VALVE
F.O.S.
F.O.R.
PRESSURE
USE LAYOUT FOR: MODEL 4WI 100 THRU 800 HP
BOILER
CONTRACTOR
BOILER
F.O.S.
F.O.R.
VALVE
VALVE
VALVE
(100 PSIG)
GAUGE
FRONT
CONNECTIONS
AT THIS POINT
BASE FRAME
CHECK
GATE
VALVE
VALVE
ADJUSTABLE
PRESSURE
RELIEF VALVE
(75 PSIG)
Figure A2-7. No. 2 Oil Piping, Multiple
Boiler Installation
Figure A2-8. No. 2 Oil Transfer Tank
Detail (For consideration with elevated
boiler rooms)
A2-26
05-08
OIL STORAGE
TANK
MANHOLE
OIL RETURN
OIL SUCTION
STEAM OR HOT WATER
AND SUPPLY SYSTEMS.
General Boiler
Information
Table A2-24 shows blowdown tank sizing information.
Table A2-25 provides heating surface information.
Table A2-26 provides steam volume and disengaging area information
Table A2-27 provides recommended steam nozzle sizes.
Table A2-28 provides recommended non-return valve sizes.
Boiler Room
Information
Stack Support
Capabilities
All standard Cleaver-Brooks Firetube Boilers can support up to 2,000 lbs without
additional support.
Boilers 250 hp through 800 hp can be reinforced to support 3,000 lbs.
Stack/Breeching
Size Criteria
Although constant pressure at the flue gas outlet is not required, it is necessary to
size the stack/breeching to limit flue gas pressure variation. The allowable pressure
range is 0.25" W.C. to +0.25" W.C.
Boiler Room
Combustion Air
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.
qualities and is subject to clogging by dust or dirt. A vent fan in the boiler room
is not recommended, as it could create a slight vacuum under certain
Figure A2-9. Typical Fuel Storage Tank Arrangement
A2-27
05-08
conditions and cause variations in the quantity of combustion air. This can
result in unsatisfactory burner performance.
C. Under no condition should the total area of the air supply openings be less
than (1) square foot.
D. Size the openings by using the formula:
C. Total recommended air = 10 cfm/bhp - up to 1000 feet elevation. Add 3
percent more per 1000 feet of added elevation.
A. From floor to (7) foot height - 250 fpm
B. Above (7) foot height - 500 fpm
Area Required: Area = cfm = 3000/250 = 12 sq-ft total.
Notice
100 85
125 104
150 102
200 131
250 145
300 169
350 178
400 198
500 233
600 278
700 286
800 286
Table A2-24. Blowdown Tank Sizing Information
A2-28
05-08
HIGH PRESSURE LOW PRESSURE HIGH PRESSURE LOW PRESSURE
(A) (B) (A) (B)
100 16.5 22.3 4565 4954
125 20.3 27.4 5587 6077
150 19.9 26.8 5443 5918
200 25.7 34.6 7013 7632
250 34.8 49.5 7790 8597
300 40.6 57.9 9115 10051
350 51.3 69.6 9734 10570
400 57.2 77.5 10843 11779
500 83.6 107.6 12874 13781
600 100 128.6 15394 16474
700 115.6 144.9 15826 16819
800 115.6 144.9 15826 16819
NOTE:
1. Based on normal water level.
STEAM VOLUME CU-FT STEAM RELIEVING AREA SQ-IN
BOILER HP
BOILER
HP
FIRESIDE WATERSIDE
100 500
125 625 679
150 750 820
200 1000 1092
250 1250 1346
300 1500 1623
350 1750 1932
400 2000 2151
500 2500 2691
600 3000 3262
700 & 800 3500 3810
Table A2-25. Heating Surface
Table A2-26. Steam Volume Disengaging Area
A2-29
05-08
Altitude: 700 ft and less Design Pressure: 150 psi and less
* 800 HP - to be de-rated to 720 HP for 9 ppm and to 750 HP for 15 ppm.
m p p 9
m p p 5 1
-
Blower Motor HP Blower Motor HP
Nominal
Boiler Size
Table A2-27. Recommended Steam Nozzle Size (To Maintain 4000 to
5000 fpm Nozzle Velocity
Model 4WI Recommended Steam Nozzle Size
OPERATING PRESSURE
PSIG 100 125 150 200 250 300 350 400 500 600 700 800
15 8 8 8 10 10 12 12 12 12 12 12 12
30 6 6 6 8 8 8 10 10 10 12 12 12
40 6 6 6 6 8 8 8 10 10 10 12 12
50 4 6 6 6 6 8 8 8 10 10 10 12
75 4 4 4 6 6 6 8 8 8 8 10 10
100 4 4 4 6 6 6 6 6 8 8 8 10
125 4 4 4 4 6 6 6 6 8 8 8 8
150 2.5 3 3 4 4 6 6 6 6 6 8 8
200 2.5 2.5 3 4 4 4 4 6 6 6 6 6
250 2 2.5 3 3 4 4 4 4 6 6 6 6
NOTES:
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
4. Shaded area denotes special surge load baffles must be installed to avoid possible water carryover.
5. For incremental operating pressure, see Table I3-1 Steam System Fundamentals.
BOILER HP
Table A2-29. Blower Motor Selection 4WI NTI Boilers
BOILER
HP
BOILER CAPACITY
(LBS/HR)
50 75 100 125 150 175 200 250
100 3450
2-1/2 2-1/2 NA NA NA NA NA NA
125 4313
3 2-1/2 2-1/2 2-1/2 NA NA NA NA
150 5175
3 3 2-1/2 2-1/2 2-1/2 2-1/2 NA NA
200 6900
3* 3 3 3 3 2-1/2 2-1/2 2-1/2
250 8625
4 3* 3 3 3 3 3 3
300 10350
4 4 4 3* 3 3 3 3
350 12025
4 4 4 4 4 3* 3 3
400 13800
5 4 4 4 4 4 4 3*
500 17210
6 5 5 4 4 4 4 4
600 20700
6 6 5 5 5 4 4 4
700 24150
6 6 6 5 5 5 5 4
800 27600
6 6 6 6 6 5 5 5
Standard Non-Return valve selections limited to a maximum 2 to 1 turndown (50% of full load); selections based on typical non-return valve sizing recommen-
dations. For final valve selection contact your C-B authorized representative. For high turndown applications see Boiler Book Section I3, Table I3-3.
* Indicates pressure drop of less than 7.5 psig. All other selections are less than 6 psig pressure drop.
A2-30
05-08
FRONT
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
A B
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
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.
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.
DWG A
DWG B
DWG C
BOILER HP 100
125
150
200
250
300
350
400
500
600
700
800
Dimension A 87 91" 96" 100" 105 110
Dimension B 120 127" 144" 151" 174 184
NOTES:
1. Recommended Minimum Distance Between Boiler and Wall. Di-
mension A allows for a clear 42" aisle between the wa-
ter column on the boiler and the wall. If space permits,
this aisle should be widened.
42" - 125 -200 hp
48" - 250-350 hp
60" - 400-800 hp
A2-31
05-08
STACK
DRAIN
CONNECTION
CLEAN-
OUT
MANUAL
DAMPER
LOCK (OPEN)
TIGHT SEAL
CLEANOUT
STACK
DRAIN
CONNECTION
CLEAN-
OUT
MANUAL
DAMPER
LOCK (OPEN)
TIGHT SEAL
CLEANOUT
STACK
DRAIN
CONNECTION
CLEAN-
OUT
MANUAL
DAMPER
LOCK (OPEN)
TIGHT SEAL
CLEANOUT
MAXIMUM 10
CONE ANGLE
NOTE: These stack breeching arrangements for multiple
boilers are typical and not intended for your specific
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 specific criteria. Your
local Cleaver-Brooks authorized representative is capable
of assisting in your evaluation of stack and breeching
design.
A2-32
05-08
Notes
Section A2 Promethean Series - Model 4WI
A2-33
03-08
SAMPLE SPECIFICATIONS - Model 4WI STEAM BOILERS
PART 1 GENERAL
1.1 SCOPE
A. The work to be performed consists of providing all labor, equipment, materials, etc. to furnish
and install new factory assembled steam boiler(s) as described in the specifications herein.
1.2 REFERENCES
A. Product Data: Include rated capacities; shipping, installed, and operating weights; furnished
specialties; and accessories for each model indicated.
B. Shop Drawings: Detail equipment assemblies and indicate dimensions, required clearances, and
method of field assembly, components, and location and size of each field connection.
C. Wiring Diagrams: Detail wiring for power, signal, and control systems and differentiate between
manufacturer-installed and field-installed wiring.
D. Source Quality Control Tests and Inspection Reports: Indicate and interpret test results for
compliance with performance requirements before shipping.
E. Field Test Reports: Indicate and interpret test results for compliance with performance
requirements.
F. Maintenance Data: Include parts list, maintenance guide, and wiring diagrams for each boiler.
G. ASME Section I or IV (Power boilers or Heating Boilers)
H. ANSI Z21.13 (Gas Fired Low Pressure Boilers)
I. NFPA 54 (ANSI Z221.3) National Fuel Gas Code
J. Factory Mutual
K. ASME CSD-1 (Controls and Safety Devices)
L. XL-GAP (formerly GE-GAP GE Global Asset Protection)
M. UBC (Uniform Building Code)
N. UMC (Uniform Mechanical Code)
O. NEC (National Electrical Code)
P. UL (Underwriters Laboratories)
Q. NFPA 85
1.3 QUALITY ASSURANCE
A. The equipment shall, as a minimum, be in strict compliance with the requirements of this
specification and shall be the manufacturer's standard commercial product unless specified
otherwise. Additional equipment features, details, accessories, appurtenances, etc. which are not
specifically identified but which are a part of the manufacturer's standard commercial product,
shall be included in the equipment being furnished.
B. The equipment shall be of the type, design, and size that the manufacturer currently offered for
sale and appears in the manufacturer's current catalogue. The equipment shall be new and
fabricated from new materials and shall be free from defects in materials and workmanship
C. The equipment must fit within the allocated space, leaving ample allowance for maintenance and
cleaning, and must leave suitable space for easy removal of all equipment appurtenances. Tube
pull clearance space from either the front or rear of boiler must be maintained.
D. All units of the same classification shall be identical to the extent necessary to insure
interchangeability of parts, assemblies, accessories, and spare parts wherever possible.
Promethean Series - Model 4WI Section A2
A2-34
03-08
E. In order to provide unit responsibility for the specified capacities, efficiencies, and performance,
the boiler manufacturer shall certify in writing that the equipment being submitted shall perform
as specified. The boiler manufacturer shall be responsible for guarantying that the boiler provides
the performance as specified herein.
1.4 SUBMITTALS
A. The contractor shall submit, in a timely manner, all submittals for approval by the engineer.
Under no circumstances shall the contractor install any materials until the engineer has made
final approval on the submittals.
B. The engineer shall review and stamp submittals. Work may proceed and equipment released for
fabrication after contractor receives returned submittals stamped with "NO EXCEPTIONS TAKEN"
or "MAKE CORRECTIONS NOTED".
C. The bidder must submit in writing to the engineer any request for a proposed deviation, omission,
modification, or substitution to this specification for evaluation no later than ten (10) days prior
to the bid date. A request for any substitution shall be accompanied by technical data, drawings,
product samples, and complete data substantiating compliance of proposed substitution with
these specifications. No materials shall be deemed acceptable if not in strict and full compliance
with these specifications. All bidders must bid solely on the specified materials unless
acceptance by the engineer of a deviation, omission, modification, or substitution is granted in
writing to all bidders prior to the bid date.
D. Shop Drawings - Shop drawings shall be submitted to the engineer for approval and shall consist
of:
E. General assembly drawing of the boiler including product description, model number,
dimensions, clearances, weights, service sizes, etc.
F. Schematic flow diagram of gas valve trains.
G. Schematic wiring diagram of boiler control system of the ladder-type showing all components, all
interlocks, etc. Schematic wiring diagram shall clearly identify factory wiring and field wiring.
H. Installation Instructions: Manufacturer's printed instructions for installation shall be submitted to
the engineer for approval.
I. Manufacturer's Warranties: Manufacturer's printed warranties, as specified hereinafter, shall be
submitted prior to final acceptance by the engineer.
J. Manufacturer's Field Service: Manufacturer's printed field service procedures and reports, as
specified hereinafter, shall be submitted prior to final acceptance by the engineer. Report forms
shall contain all information as required to do start-up and testing as specified in the products
section.
1.5 CERTIFICATIONS
A. Manufacturer's Certification: The boiler manufacturer shall certify the following:
1. The products and systems furnished are in strict compliance with the specifications.
2. The boiler, burner and other associated mechanical and electrical equipment have all been
properly coordinated and integrated to provide a complete and operable boiler.
3. ASME certification.
4. UL and CSD-1 certification.
5. The equipment furnished has been installed in accordance with the manufacturer's
installation instructions.
6. The specified factory tests have been satisfactorily performed.
7. The specified field tests have been satisfactorily performed.
A2-35
03-08
B. Contractor's Certification: The contractor shall certify the following:
1. The products and systems installed are in strict compliance with the specifications.
C. Boiler Inspectors' Certification: All boiler inspections during hydrostatic testing shall be performed
by an authorized boiler inspector who is certified by the National Board of Boiler and Pressure
Vessel Inspectors and shall be submitted in writing prior to final acceptance by the engineer.
D. Test Reports: Factory and field test reports as described above and as specified hereinafter, shall
be submitted prior to final acceptance by the engineer.
E. Operation and Maintenance Manuals: Manufacturer's printed operation and maintenance
manuals shall be submitted prior to final acceptance by the engineer. Operation and maintenance
manuals shall contain shop drawings, product data, operating instructions, cleaning procedures,
replacement parts list, maintenance and repair data, complete parts list, etc.
1.6 DELIVERY, STORAGE, AND HANDLING
A. The contractor shall be responsible for the timely delivery of the equipment to the job site. The
contractor shall be responsible for unloading and rigging of the equipment. The contractor shall
be responsible for protecting the equipment from the weather, humidity and temperature
conditions, dirt, dust, other contaminants, as well as job site conditions during construction.
B. Equipment shall be unloaded, handled, and stored in accordance with the manufacturer's
handling and storage instructions.
C. The work to be performed consists of providing all labor, equipment, materials, etc. to furnish
and install new factory assembled, low pressure hot water boilers as described in the
specifications herein.
PART 2 PRODUCTS
2.1 MANUFACTURERS
A. Contractor shall furnish and install Cleaver Brooks Model 4WI natural gas (combination Gas/Oil
fired) steam boiler(s) with design pressure as scheduled on the drawings.
B. Alternate manufacturers complying with plans and specifications must be submitted and
approved by the consulting engineer within 10 days prior to bid date.
2.2 GENERAL DESCRIPTION
Factory packaged unit shall include boiler, burner, heavy duty skids, painted steel jacket with two inches of
fiberglass insulation, controls and accessories all piped and wired for single point field connections. Units shall
carry packaged label of Underwriters Laboratory (UL) and be in accordance with ASME/CSD-1, all codes
required by the local governing authorities and as indicated on the design performance data sheet. A certified
factory fire-test shall be provided on all fuels with data sheets furnished to Engineer and Owner. ASME certified,
labeled, stamped and designed for ____PSIG steam in accordance with Section (I or IV) of ASME Code. Unit
shall be designed to Seismic Zone requirements and be provided with tie down clips and calculations showing
bolt diameter requirements. Manufacturer's Representative to provide services for field testing and adjusting of
boiler and controls to meet design requirements.
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03-08
2.3 PERFORMANCE: BOILER SIZE AND RATINGS
A. The capacity of each unit shall be indicated on the drawing schedule.
B. Performance Criteria:
Natural Gas (%):
No. 2 Oil (%):
Gas (Natural):
Oil (No. 2):
Gas (Natural):
Oil (No. 2):
Electrical:
Fan Motor:
Oil Pump Motor:
____ V / ____ H / ____ P
____HP
____HP
____HP
____dBA
Weight
Dry:
Flooded:
____
____
Seismic Zone: ____
Altitude: ____ ASL
CSD-1 NFPA 8501
State Of _______
Factory Mutual (FM)
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03-08
A. Noise Sound Levels: Based on ABMA test code for packaged boilers measured 41/2 feet
vertically above the bottom of the base rail and 3'0" horizontally in front of the end of the blower
motor or front surface of control cabinet. Sound levels dBA on the scale in reference to 0.0002
microbars.
2.4 BOILER DESIGN
A. Four pass steel scotch marine firetube boiler for positive pressurized firing with forced draft
burner. Wet back design with a minimum five (5) square feet of heating surface per boiler
horsepower. Front and rear doors shall be davited and sealed with tad-pole gaskets using heavy
duty cap screws threaded into replaceable brass nuts. When opened, doors shall expose all
tubes, tubesheets and furnace for ease of inspection and maintenance. Lifting loops shall be
provided. Rear door shall be refractory lined with air cooled observation port. Tubes shall be
rolled, beaded and/or welded into tube sheets and tubes shall be cleanable and removable from
either front or back. Tubes shall be a minimum 2.5" O.D., with a tube wall thickness of not less
than.095".
B. The boiler pressure vessel shall be completely insulated with a minimum of 2" of insulation and
shall be encased in an 18 gauge metal cabinet with primer and finish coat of paint.
2.5 BURNER DESIGN
A. GENERAL: Forced draft burner mounted in and integral with boiler hinged front boiler door so
when door is opened burner head, furnace, tubesheet and tubes are exposed; reversed curve cast
aluminum blower fan; motor(s); ACCU-LINK single point positioning system consisting of rotary
air damper located on fan discharge, straight line linkage and characterized cams; air flow
switch; fuel trains and control panels. To conform to UL and other insurance requirements as
indicated.
B. GAS BURNER: Shall be of the high radiant multi-port type for natural gas. Minimum pilot safety
burner shall consist of gas-electric spark ignition with 100% safety shut-off pilot, solenoid gas
valve, pressure regulator and shut-off cock. Minimum main gas train shall include manual shut-
off valve, pressure regulating valve, dual safety gas valves, manual test valve high-low pressure
switches, manifold pressure gauge and butterfly gas valve with (14) point characterized cam
assembly. Gas train shall be factory packaged to meet insurance requirements as indicated. Gas
turn down shall be minimum______. 4:1 up to 200 HP, 10:1 from 250 HP and above.
High Fire#2 #2 oil ____dBA
Low Fire #2 oil ____dBA
High Fire Nat Gas ____dBA
Low Fire Nat Gas ____dBA
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03-08
C. OIL BURNER Oil burner shall be of the low pressure air atomizing type for No. 2 oil. Minimum
pilot safety burner shall consist of gas-electric spark ignition with 100% safety shut-off pilot,
solenoid gas valve, pressure regulator and shut-off cock. Oil train shall consist of retractable
nozzle with flexible hoses; gauges, manifold block; air purge valve; fuel-oil controller with (14)
point characterized cam assembly; dual oil solenoids; temperature switch, air compressor
assembly and oil pump assembly. (For heavy oil, an oil preheat system shall be provided to
include a water to water to oil safety type preheater and thermostatically controlled electric
preheater.) Oil train shall be factory packaged to meet insurance requirements as indicated. Oil
turn down shall be minimum 8:1(250 hp-800 hp), 4:1 (up to 200 hp).
D. COMBINATION BURNER: Provide gas-oil fuel selector switch to provide fuel switch over without
any required adjustments to burner linkage.
E. FUEL-AIR CONTROL: Modulating fire with proven low fire start. Provide manual potentiometer
with manual-auto switch on boiler control panel in addition to automatic fuel-air controller.
Linkage system shall be Cleaver-Brooks ACCU-LINK single point positioning with rotary air
damper, linkage and (14) point characterized cam assembly for all fuels. Provide automatic
operating control and manual reset high limit.
F. FORCED DRAFT BLOWER: All air for combustion shall be supplied by a blower mounted in the
front boiler door above the burner. The Backward curved cast aluminum radial impeller shall be
directly connected to a flanged type ODP motor. This rigid mounting with the blower wheel inside
the head shall eliminate vibration and reduce noise level. The balanced blower wheel shall be
cast aluminum with radial blades. The combustion air damper shall be an integral rotating
damper and shall be automatically adjusted for proper air quantity by a mod motor to maintain
proper fuel-air ratios.
G. EMISSION CONTROL: Boiler NOx shall be furnished with guaranteed internal induced NOx
control for 60 PPM (30, 15 & <9 PPM NOx systems are optional) corrected to3% 02 over the
entire turndown range. Boiler capacity, turndown, flame stability and efficiency shall not be
affected by the internal NOx control. External FGR piping shall not be allowed. Low NOx system
shall be part of the Boiler/Burner UL package label and manufacture shall have Twelve (12) years
of emission control experience in the state of_____.
2.6 BOILER TRIM
A. To include the following:
1. ______" diameter pressure gauge.
2. ASME safety relief valve(s).
3. Auxiliary Low Water Cutoff, Warrick 3C-2.
4. Primary low water cut-off.
5. Operating control.
6. Limit control with manual reset.
7. ______" stack thermometer.
8. Feedwater regulating valve with 3 valve bypass
9. Low fire hold controller (optional).
10. 1 Slow Opening Blowdown Valve, Size______", Class 200#
11. 2 Quick Opening Blowdown Valves, Size______", Class 490#
12. Feedwater Globe Valve, Size______", Class 240#
13. 1 Feedwater Check Valve, Size______", Class 240#
14. 1 ASME Spool Piece, Inlet Size______", Outlet Size______", Length______"
15. 1 Stop Valve (Steam Header Valve), Size______ , Flanged, Cast Iron, Class 250
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03-08
16. 1 Stop Check Valve (Non-Return Valve), Size______", Flanged, Cast Iron, Class 250",
Straight Pattern, with Free Blow Drain Valve
17. Factory mounted, installed, tested, and certified piping (by A, S, or PP ASME stamp holder)
and valves per ASME Code, including:
Water Column piping
Bottom Blowdown (from boiler to last code valve)
Feedwater assembly (shipped loose)
Surface Blowdown piping with stop valve and metering valve.
18. Modulating Feedwater Control Valve, including 3-Valve Bypass
19. Oil Pump, Mounted and Wired
20. Air Atomizing Compressor, Mounted and Wired
21. Platforms and ladder to access steam header and safety relief valves. Built to OSHA
requirements.
B. WATER COLUMN/LOW WATER CUTOFF AND WATER LEVEL CONTROL SYSTEM (150-250
psig design): Shall be a CB LEVEL MASTER Water level control system and shall be comprised of
a microprocessor-based electronic controller, a non-contact, non-wearing, continuously reading
absolute level sensor and pressure chamber. The control system shall be designed as follows: The
electronic controller shall be mounted in the common control panel and operate in ambient
temperatures from 32 degrees F to 125 degrees F, the pressure chamber shall be boiler mounted
and operate to pressures of 250 psig and the level sensor shall operate to pressures of 250 psig
and temperatures to 400 degrees F. The pressure containing components shall be constructed in
accordance with ASME Code. A shielded, four conductor cable with ground shall be run in metal
conduit between the level sensor and the controller. Supply power shall be 115VAC-1 phase- 60
Hz. All wiring shall be in compliance with the National Electrical Code.
The pressure chamber shall have a sight glass mounted on the side. The level sensor shall have
an accuracy of.01" or greater. The electronic controller shall have level and error indicating lights,
alphanumeric display for messaging, reset/menu switch and the following features:
1. Continuous Level Indication
2. Low Water Cutoff & Alarm
3. High Water Alarm
4. Low & High Water Warning
5. Full Modulating Control of Modulating Feedwater Control Valve
6. Continuous Monitoring of Float Operation
7. Column Blowdown Detection and Reminder
8. Auto or Manual Reset
9. Real Time Clock
10. Alarm Annunciation
11. Alarm History Files with Time Stamp
12. Water Column Blowdown Record
13. Auxiliary Low Water Cutoff Check
14. RS 232 Interface
15. Maximum Contacts Rating 15 amps Resistive Load
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03-08
2.7 BOILER CONTROLS
A. A common enclosure shall house the control panel and the entrance panel. Enclosure shall be
NEMA 4 rated and shall be mounted at the side of the boiler in a location convenient to the
operator. Enclosure shall consist of upper and lower sections divided by a partition with a
separate hinged door for each section. Upper section (low voltage) will house boiler controls
including flame safeguard, water level system controller, and Hawk ICS if so equipped. Lower
panel section (high voltage) will house entrance panel.
B. (OPTION 1) BURNER MANAGEMENT SYSTEM (CB 780E Standard): Mounted at side of boiler
in control panel enclosure. 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 flame failure. Dynamic self checking. System to provide pre-post purge
status, fault history, and diagnostic information by means of a two-line alpha-numeric display
with alarm/status LEDS.
C. (OPTION 2) CB-HAWK ICS Boiler Control System (Optional upgrade): Integrated Boiler Control
and Management System:
Boiler shall be factory equipped with a Boiler Control System combining a Digital Burner
Management System for flame safety, and a Programmable Logic Controller for boiler modulation
and operator interface functions.
The factory pre-configured Boiler Control System shall integrate the Burner Management
functions and the PLC based modulation and operator interface functions. The logic of the Burner
Management System and the modulating controls will not be run in the same processor or
powered by the same DC supply. The PLC and Operator Interface Hardware shall be as
manufactured by Allen Bradley.
Touch Screen HMI
Automatic sequencing of the boiler through standby, pre-purge, pilot flame
establishing period, main flame establishing period, run, flame proving and lockout
and post-purge
Utilize solid state controls and sensors to provide various control functions, such as:
Manual control of the boiler firing rate using control screens on the HMI to increment or decrement
the firing rate
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03-08
Examine all load terminals to assure it is capable of recognizing the true status of the
external controls, limits and interlocks. If any input fails this test, the Burner Management
System shall lockout on safety shutdown.
Closed-loop logic test of critical loads (ignition, pilot and main fuel valves) and must be
able to lockout on safety.
Pre-ignition interlocks (fuel valve proof of closure, etc.) and flame signal checked during
Standby and Pre-Purge.
Safe start check and expand check to include monitoring flame signal during standby.
The Boiler Control System shall provide the ability to communicate with external digital via Ethernet
as a standard. OPC compliant Internet communications shall be supported, with the Boiler Control
System supplied with its own IP address.
2.8 SHOP TEST
A. Shop test: The complete packaged boiler shall receive factory tests to check construction and
function of all controls. All shop tests may be witnessed by the purchaser at his own c upon
sufficient notice to the company.
2.9 ACCESSORIES - BOILER FLUE VENT
2.10 ACCESSORIES - FEEDWATER SYSTEM (BOILER FEEDSET OR DEAERATOR)
2.11 ACCESSORIES - FEEDWATER HEATER OR ECONOMIZER
2.12 ACCESSORIES - BLOWDOWN SEPARATOR AND/OR BLOWDOWN HEAT RECOVERY
2.13 ACCESSORIES - 02 TRIM SYSTEM
2.14 ACCESSORIES - CHEMICAL FEED SYSTEM AND/OR WATER TREATMENT
2.15 MANUFACTURER FIELD SERVICES
A. General: The boiler and accessories supplier shall be responsible for performance of inspections, start up and testing
of the package boiler and accessory equipment and materials furnished under this section. A detailed written record
of the start up performance, including burner setting data entire load range shall be furnished to the test engineer
before test personnel leave the site. Equipment and test apparatus shall be furnished by the supplier. All equipment
defects discovered by the tests shall be rectified. The minimum time for two (2) boilers is five (5) days.
B. Equipment inspection: Boiler representative to provide ______hours of job site assistance to inspect boilers and other
equipment upon arrival, verifying completeness of equipment supplied ar damages. Responsibility of making freight
claims to be performed by contractor or owner personnel.
C. Pre start-up walk through: Boiler representative shall spend _____hours at job site reviewing with mechanical
contractor to be conducted approximately 1 week prior to startup.
D. Start-up shall be conducted by experienced and factory authorized technician in the regular employment of the boiler
supplier, and shall include:
1. Demonstrate that boiler, burner, controls and accessories comply with requirement Section as proposed by the
boiler and accessories supplier. Pre-test all items prior to scheduling the final testing that will be witnessed by the
test engineer.
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03-08
2. Readings at different firing rates (25, 50, 75 and 100%) of load for the modulating burner shall be taken with a
written report of the tests submitted to the test engineer. The reports shall include readings for each firing rate
tested and include stack temperatures, O2, CO, Nox and overall boiler efficiency.
3. Auxiliary Equipment and Accessories: Observe and check all valves, draft fans, electric motors and other acces-
sories and appurtenant equipment during the operational and capacity tests for leakage, malfunctioning, defects,
and non compliance with referenced standards or overloading as applicable.
4. Commissioning Requirements:
a).Fireside inspection
b).Waterside inspection
c).Closing and resealing of doors, manways and hand holes
d).Set up fuel train and combustion air system
e).Set up operating set points
f).Check all safeties, including: Flame safeguard, LWCO, ALWCO, Air flow, Fuel pressures, High limits
g).Set up and verify efficiencies at 25%, 50%, 75%, and 100%
h).Set up and verify burner turndown.
i).Set up and verify feedwater/level controls
j).Set up and verify Emissions Compliance
E. Training to include all safety procedures, maintenance procedures, control operations, and diagnostic procedures.
Training to be provided in a single _hour continuous session to accommodate operator's availability on site.
2.16 OPERATING & MAINTENANCE MANUALS
A. Provide two (2) Operating and Maintenance manuals including cut-away views of boiler and burner, schematics
including fuel trains, general instructions for maintenance and inspections, complete spare parts lists and trouble
shooting procedures.
B. A wiring diagram corresponding to the boiler shall be affixed to the boiler near the electrical panel.
2.17 WARRANTY DATA
A. The entire boiler/burner package shall be guaranteed and warranted by the boiler manufacturer. Warranty shall include
all parts for a period of (12) months from the date of start-up or beneficial use or 18 months from shipment, whichever
comes first.
PART 3 EXECUTION
3.1 GENERAL
A. Installation shall be provided by the contractor in accordance with the requirements of the codes specified
hereinbefore. All of the contractor's work shall be performed by experienced workman previously engaged in boiler
plant construction and shall be under the supervision of a qualified installation supervisor.
3.2 INSTALLATION
A. Install equipment in strict compliance with manufacturer's installation instructions.
B. Install equipment in strict compliance with state and local codes and applicable NFPA standards.
C. Maintain manufacturer's recommended clearances around sides and over top of equipment.
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03-08
D. Install components that were removed from equipment for shipping purposes.
E. Install components that were furnished loose with equipment for field installation.
F. Provide all interconnecting electrical control and power wiring.
G. Provide all fuel gas vent and service piping.
H. Provide all piping for boiler pipe connections.
3.3 FIELD TESTING
A. The manufacturer's representative shall test all boiler and burner interlocks, actuators, valves, controllers, gauges,
thermometers, pilot lights, switches, etc. Any malfunctioning component shall be replaced.
B. All adjustments to boiler, burner, and boiler control system shall be performed by the manufacturer's representative.
3.4 START-UP, INSTRUCTION AND WARRANTY SERVICE
The manufacturer's representative shall provide start-up and instruction of each new boiler, including burner and boiler con-
trol system as specified herein. Start-up and instruction shall cover all components assembled and furnished by the manu-
facturer whether or not of his own manufacture.
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03-08
NOTES
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03-08
SAMPLE SPECIFICATIONS - Model 4WI HOT WATER BOILERS
PART 1 GENERAL
1.1 SCOPE
The work to be performed consists of providing all labor, equipment, materials, etc. to furnish and
install new factory assembled steam boiler(s) as described in the specifications herein.
1.2 REFERENCES
A. ASME Section IV (Heating Boilers)
B. ANSI Z21.13 (Gas Fired Low Pressure Boilers)
C. NFPA 54 (ANSI Z221.3)
D. National Fuel Gas Code
E. FACTORY MUTUAL
F. ASME CSD-1 (Controls and Safety Devices)
G. GE-GAP (GE Global Asset Protection)
H. UBC (Uniform Building Code)
I. UMC (Uniform Mechanical Code)
J. NEC (National Electrical Code)
K. UL (Underwriters Laboratories)
otherwise. Additional equipment features, details, accessories, appurtenances, etc. which are
not specifically identified but which are a part of the manufacturer's standard commercial
product, shall be included in the equipment being furnished.
cleaning, and must leave suitable space for easy removal of all equipment appurtenances.
as specified. The boiler manufacturer shall be responsible for guarantying that the boiler
provides the performance as specified herein.
1.4 SUBMITTALS
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03-08
of:
1. General assembly drawing of the boiler including product description, model number,
2. Schematic flow diagram of gas valve trains.
3. Schematic wiring diagram of boiler control system of the ladder-type showing all
components, all interlocks, etc. Schematic wiring diagram shall clearly identify factory
wiring and field wiring.
E. Manufacturer's Warranties: Manufacturer's printed warranties, as specified hereinafter, shall be
F. Manufacturer's Field Service: Manufacturer's printed field service procedures and reports, as
section.
1.5 CERTIFICATIONS
1. The products and systems furnished are in compliance with the specifications, except as
clarified in the bid package.
2. The boiler and burner have all been properly coordinated and integrated to provide a
complete and operable boiler.
4. UL and CSD-1 (if applicable) certification.
C. Boiler Inspectors' Certification: All boiler inspections during hydrostatic testing shall be
performed by an authorized boiler inspector who is certified by the National Board of Boiler and
Pressure Vessel Inspectors and shall be submitted in writing prior to final acceptance by the
engineer.
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03-08
manuals shall be submitted prior to final acceptance by the engineer. Operation and
maintenance manuals shall contain, product data, operating instructions, cleaning procedures,
replacement parts list, maintenance and repair data, etc.
1.6 SHIPMENT, STORAGE, AND HANDLING
A. The contractor shall be responsible for the timely shipment of the equipment to the job site. The
and new factory assembled, low pressure hot water boilers as described in the specifications
herein.
PART 2 PRODUCTS
2.1 MANUFACTURERS
A. Contractor shall furnish and install Cleaver Brooks Model 4WI___________natural gas
(combination Gas/Oil fired) hot water boiler(s) with design pressure as scheduled on the
drawings.
A. Factory packaged unit shall include boiler, burner, heavy duty skids, painted steel jacket with two
inches of fiberglass insulation, controls and accessories all piped and wired for single point field
connections. Units shall carry packaged label of Underwriters Laboratory (UL) and be in
accordance with ASME, all codes required by the local governing authorities and as indicated on
the design performance data sheet. A certified factory fire-test shall be provided on all fuels with
data sheets furnished to Engineer and Owner. ASME certified, labeled, stamped and designed for
_____PSIG water in accordance with Section IV of ASME Code. Unit shall be designed to
Seismic Zone __requirements applicable to boiler location. Manufacturer's Representative to
provide services for field testing and adjusting of boiler and controls to meet design requirements.
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03-08
Operating Temperature ________degrees F
Overall Efficiency
Natural Gas (%):
No. 2 Oil (%):
Gas (Natural):
Oil (No. 2):
Gas (Natural):
Oil (No. 2):
Electrical:
Fan Motor:
Oil Pump Motor:
____ V / ____ H / ____ P
____HP
____HP
____HP
____dBA
Weight
Dry:
Flooded:
____
____
Seismic Zone: ____
Altitude: ____ ASL
CSD-1 NFPA 85 (optional)
State Of _______
Factory Mutual (FM) (optional)
GE-GAP (optional)
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03-08
C. Noise Sound Levels: Based on ABMA test code for packaged boilers measured 41/2 feet
vertically above the bottom of the base rail and 3'0" horizontally in front of the end of the blower
motor or front surface of control cabinet. Sound levels dBA on the scale in reference to 0.0002
microbars.
2.4 EFFICIENCY GUARANTEE
The boiler manufacturer shall guarantee that, at the time of startup, the boiler will achieve ________
fuel-to- steam efficiency at 100% firing rate when burning natural gas and ________fuel-to-steam
efficiency at 100% firing rate when burning oil (add efficiency guarantees at 25%, 50%, and 75% of
rating, if required). If the boiler(s) fail to achieve the corresponding guaranteed efficiency as published,
the boiler manufacturer will rebate, to the ultimate boiler owner, ten thousand dollars ($10,000) for
every full efficiency point (1.0%) that the actual efficiency is below the guaranteed level.
Natural Gas
Carbon, % (wt) = 69.98
No. 2 Oil
Carbon, % (wt) = 85.8
No. 6 Oil
Carbon, % (wt) = 86.6
Sulfur, % (wt) = 2.09
Efficiencies are based on ambient air temperature of 80 F, relative humidity of 30%, and 15% excess
air in the exhaust flue gas.
Efficiencies are based on manufacturers published radiation and convection losses. (For Cleaver-
Brooks radiation and convection losses, see Boiler Efficiency Facts Guide, publication number CB-
7767).
Any efficiency verification testing will be based on the stack loss method.
Warranty
High Fire#2 #2 oil ____dBA
Low Fire #2 oil ____dBA
High Fire Nat Gas ____dBA
Low Fire Nat Gas ____dBA
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03-08
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.
Start-up Service
After boiler installation is completed, the manufacturer shall provide the services of a field
representative for starting the unit and training the operator at no additional costs.
A factory approved and authorized start-up report shall be submitted to the customer/user at the time
of start-up.
2.5 GENERAL BOILER DESIGN
A. The boiler shall be a four pass horizontal firetube updraft boiler with five (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.
B. 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.
C. The boiler shall be completely pre assembled and fire tested at the factory. The unit shall be
ready for immediate mounting on floor or simple foundation and ready for attachment of water,
steam, fuel, electrical, vent and blowdown connections.
D. The boiler shall be built to comply with the following insurance and codes
____________________(Factory Mutual, ASME CSD-1).
2.6 BOILER SHELL (HOT WATER)
A. 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.
B. 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.
C. A dip tube shall be included as an integral part of the water outlet.
D. Two lifting eyes shall be located on top of the boiler.
E. Front and rear doors on the boiler shall be hinged or davited. Doors are to be sealed with
fiberglass tadpole gaskets and fastened tightly using heavy capscrews that thread into
replaceable brass nuts.
F. Rear refractory and insulation shall be contained in the formed door, which must swing open for
inspection of brick work.
G. The boiler tubes shall not include turbulators, swirlers or other add-on appurtenances.
H. Front and rear tube sheets and all flues 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.
I. The exhaust gas vent shall be located near the front of the boiler on the top center line and shall
be capable of supporting 1000 lbs and shall contain a stack thermometer
2.7 EMISSION CONTROLS
A. Boiler shall be equipped with a low emission (LE) option for guaranteed NOx performance at
________ppm, dry volume basis and corrected to 3% O
2
when firing natural gas.
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03-08
B. The low emission option shall include an integral front head, burner, and boiler package,
providing NOx reduction through an internal flue 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 efficiency and rated boiler capacity shall be guaranteed while the boiler is operating
at the low NOx performance
levels.
C. 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 field assembly of the burner or low NOx equipment
shall be required.
2.8 HOT WATER BOILER TRIM
A. 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.
Pressure and temperature gauges shall be mounted on the boiler with temperature sensing element located
adjacent to the hot water outlet.
C. Relief Valves
Water relief valves of a type and size to comply with ASME Code requirements shall be shipped loose.
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 firing rate control (30-100 hp).
2.9 BURNER AND CONTROLS
B. Burner operation shall be full modulation principle. The burner shall always return to low fire
position for ignition.
2.10 BLOWER
A. 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.
B. Maximum sound level of the boiler/burner package shall not exceed _____dbA (when measured
in accordance with ABMA Sound Test Standards).
C. The impeller shall be cast aluminum, radial blade, carefully balanced, and directly connected to
the blower motor shaft.
2.11 COMBUSTION AIR CONTROL
Combustion air damper and cam operated fuel metering valves shall be operated by a single damper
control motor that regulates the fire 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 flame safeguard is used).
2.12 FUEL SPECIFICATION AND PIPING
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03-08
1. Fuel series 700 - Gas fired (4.4.1).
2. Fuel series 100 - Light oil (No. 2) fired (4.4.2).
3. Fuel series 200 - Light oil or gas fired (4.4.3).
2.13 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.
2.14 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 flame has been established.
The pilot train shall include two manual shut-off valves, solenoid valve, pressure regulator and
pressure gauge.
2.15 GAS BURNER PIPING
A. Gas burner piping on all units shall include pressure regulating 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, flame failure, low water or any safety
shutdown condition. A lubricating plug cock or butterfly shutoff valve shall be provided as a
means for a tightness check of the primary shut off valve. An additional plug cock on butterfly
valve shall be furnished at entrance to gas train. Select one of the following:
B. 125-300 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. 350-800 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 valve
proving switch shall be located between the safety shutoff valves.
2.16 BURNER TURNDOWN
1. 125-200 hp. Turndown range of burner shall be 4:1 when firing natural gas.
2. 250-800 hp. Turndown range of the burner shall be 10:1 when firing 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 15 and 9 ppm LE options.)
2.17 FUEL SERIES 100
Light Oil Fired
2.18 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.
2.19 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 flame has been established.
The pilot train shall include two manual shut-off valves, solenoid valve, pressure regulator and
pressure gauge.
A2-53
03-08
2.20 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.
2.21 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.
2.22 LOW PRESSURE AIR ATOMIZING
Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch.
2.23 BURNER TURNDOWN Fuel Series 200 Light Oil or Gas Fired
125 hp through 200 hp. Turndown range shall be 4:1 when firing No. 2 oil. When Firing natural gas
refer to section 2.23
2.24 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.
2.25 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 flame has been established. The pilot train
shall include two manual shut-off valves, solenoid valve, pressure regulator and pressure gauge.
2.26 OIL BURNER
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
2.27 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.
2.28 LOW PRESSURE AIR ATOMIZING
Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch.
A2-54
03-08
2.29 GAS BURNER PIPING
Gas burner piping on all units shall include pressure regulating 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, flame failure, low water or any safety shutdown
condition. A lubricating plug cock or butterfly shutoff valve shall be provided as a means for a
tightness check of the primary shut off valve. An additional plug cock or butterfly valve shall be
2.30 BURNER
A. Boiler Flame Safeguard Controller and Control Panel
B. CB780E Flame Safeguard
C. Boilers with CB780E Control - Each boiler shall be factory equipped with flame safeguard
controller providing technology and functions equal to the Cleaver-Brooks Model CB780.
D. Controller shall be computerized solid state having sequence and flame-on lights and digital first
out fault code indications of flame safeguard trip functions. It shall include dynamic self-check
logic. The controller shall have a fixed operating sequence incapable of being manually altered.
The sequence shall include start, pre-purge, pilot and main fuel ignition run and post-purge
cycles.
E. 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 flame failure, high and low fire
proving switch faults, running interlocks open, false flame signal and fuel valve open (when proof
of closure switch is furnished).
F. 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 firing rate motor, damper
linkages and pilot flame for minimum turndown tests.
2.31 CONTROL PANEL
A. 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 flame safeguard controller, blower motor starter, indicating
lights and selector switches.
B. The panel shall have a removable sub-base for mounting the flame safeguard controller, blower
motor starter, and terminal blocks. For combination gas-oil fired boilers the panel shall contain
the fuel selector switch.
C. The panel shall contain the following lights and switches:
D. Lights
E. White - load demanded.
F. White - fuel valve open.
G. Red - low water.
H. Red - flame failure.
I. Control Switches
J. Burner On-Off.
K. Manual-Automatic.
L. Manual Firing Rate Control.
A2-55
03-08
M. Oil, heat and moisture resistant wire shall be used and identified with circuit numbers
corresponding to the electrical wiring diagram.
N. All electrical equipment and wiring shall be in conformance with Underwriters Laboratories
requirements.
O. Boiler to be supplied with a control circuit transformer and fuse protection for the control circuit.
2.32 BOILER CONTROLS
A. BOILER MANAGEMENT CONTROL SYSTEM CONTROL PANEL: Boiler mounted NEMA 1
enclosure(s) with key lock; fusing, magnetic starters; step-down control transformer; flame
safeguard and burner management system as indicated; annunciator lights for load demand, fuel
on , low water and flame failure; selector switches, required by dry contacts, relays and terminal
strips. Oil, heat and moisture resistant wire with circuit number corresponding to electrical
wiring diagrams. In accordance with UL and National Electric Code.
B. (OPTION 1) BURNER MANAGEMENT SYSTEM (CB 780E Standard): Boiler mounted in control
panel enclosure. 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 flame failure. Dynamic self checking. System to provide pre-post purge
C. (OPTION 2) CB-HAWK ICS Boiler Control System (Optional upgrade): Integrated Boiler Control
And Management System
functions and the PLC based modulation and operator interface functions. The logic of the
Burner Management System and the modulating controls will not be run in the same processor or
a. Programmable Logic Controller
b. Touch Screen HMI
c. One Burner Management Controller with Wiring Sub-Base
d. One Flame Scanner and amplifier
e. Various Temperature and Pressure Sensors
Automatic sequencing of the boiler through standby, pre-purge, pilot flame establishing period, main
flame establishing period, run, flame proving and lockout and post-purge
1. Full modulating control of fuel and air
2. Utilize solid state controls and sensors to provide various control functions, such as:
a. Modulating control (algorithm shall be Proportional-Integral-Derivative (PID) type)
b. Thermal shock protection
c. High and Low limit alarms and shutdowns
3. Touch Screen graphical operator interface and monitoring
a. Manual control of the boiler firing rate using control screens on the HMI to increment
A2-56
03-08
b. On screen indication of burner management controller status and diagnostics
c. On screen display of system alarms and faults
d. On screen history of alarms and faults
e. On screen recommendations for troubleshooting of fault conditions
f. On screen water level indication and alarm(s)
g. Stack Flue Gas, Combustion Air and Shell (water) temperature indication
4. Boiler efficiency calculation
5. Low Fire Hold with Minimum Temperature Control
6. Assured Low Fire Cut-Off (ALFCO)
7. The Boiler Control System shall incorporate the following safety provisions:
a. Examine all load terminals to assure it is capable of recognizing the true status of the
external controls, limits and interlocks. If any input fails this test, the Burner
Management System shall lockout on safety shutdown.
b. Closed-loop logic test of critical loads (ignition, pilot and main fuel valves) and must be
c. Pre-ignition interlocks (fuel valve proof of closure, etc.) and flame signal checked
during Standby and Pre-Purge.
d. Dynamic checking of the flame signal amplifier.
e. Safe start check and expand check to include monitoring flame signal during standby.
f. High and Low fire switches checked for proper sequencing.
The Boiler Control System shall provide the ability to communicate with external digital devices via
Ethernet as a standard. It shall be possible to communicate with any OPC compliant device. Internet
communications shall be supported, with the Boiler Control System supplied with its own IP address.
2.34 MANUFACTURER FIELD SERVICES
A. General: The boiler and accessories supplier shall be responsible for performance of inspections,
start up and testing of the package boiler and accessory equipment and materials furnished
under this Section. A detailed written record of the start up performance, including burner
setting data over the entire load range shall be furnished to the test engineer before test
personnel leave the site. All labor, equipment and test apparatus shall be furnished by the
supplier. All equipment defects discovered by the tests shall be rectified. The minimum time for
two (2) boilers is five (5) days.
B. Equipment inspection: Boiler representative to provide ___hours of jobsite assistance to inspect
boilers and other equipment upon arrival, verifying completeness of equipment supplied and
potential damages. Responsibility of making freight claims to be performed by contractor or
owner personnel.
C. Pre start-up walk through: Boiler representative shall spend ___hours at jobsite reviewing
installation with mechanical contractor to be conducted approximately 1 week prior to startup.
D. Start-up shall be conducted by experienced and factory authorized technician in the regular
employment of the boiler supplier, and shall include:
1. Demonstrate that boiler, burner, controls and accessories comply with requirements of this
Section as proposed by the boiler and accessories supplier. Pre-test all items prior to
scheduling the final testing that will be witnessed by the test engineer.
A2-57
03-08
2. Readings at different firing rates (25, 50, 75 and 100%) of load for the modulating burner
shall be taken with a written report of the tests submitted to the test engineer. The reports
shall include readings for each firing rate tested and include stack temperatures, O2, CO,
NOx, and overall boiler efficiency.
3. Auxiliary Equipment and Accessories: Observe and check all valves, draft fans, electric
motors and other accessories and appurtenant equipment during the operational and
capacity tests for leakage, malfunctioning, defects, non compliance with referenced
standards or overloading as applicable.
a. Fireside inspection
b. Waterside inspection
c. Closing and resealing of doors, manways and hand holes
d. Set up fuel train and combustion air system
e. Set up operating set points
f. Check all safeties, including: Flame safeguard, LWCO, ALWCO, Air flow, Fuel
pressures, High limits
g. Set up and verify efficiencies at 25%, 50%, 75%, and 100%
h. Set up and verify burner turndown.
i. Set up and verify feedwater/level controls
E. Training to include all safety procedures, maintenance procedures, control operations, and
diagnostic procedures. Training to be provided in a single ____hour continuous session to
accommodate operator's availability on site.
A. Provide two (2) Operating and Maintenance manuals including cut-away views of boiler and
burner, schematics including fuel trains, general instructions for maintenance and inspections,
complete spare parts lists and trouble shooting procedures.
B. A wiring diagram corresponding to the boiler shall be affixed to the boiler near the electrical
panel.
2.36 WARRANTY DATA
The entire boiler/burner package shall be guaranteed and warranted by the boiler manufacturer.
Warranty shall include all parts for a period of (12) months from the date of start-up or beneficial use
or 18 months from shipment, whichever comes first.
PART 3 EXECUTION
3.1 GENERAL
Installation shall be provided by the contractor in accordance with the requirements of the codes
specified hereinbefore. All of the contractor's work shall be performed by experienced workman
previously engaged in boiler plant construction and shall be under the supervision of a qualified
installation supervisor.
3.2 INSTALLATION
A. Install equipment in strict compliance with state and local codes and applicable NFPA standards.
B. Install components that were removed from equipment for shipping purposes.
A2-58
03-08
C. Install components that were furnished loose with equipment for field installation.
D. Provide all interconnecting electrical control and power wiring.
E. Provide all fuel gas vent and service piping.
F. Provide all piping for boiler pipe connections.
3.3 FIELD TESTING
A. The manufacturer's representative shall test all boiler and burner interlocks, actuators, valves,
controllers, gauges, thermometers, pilot lights, switches, etc. Any malfunctioning component
shall be replaced.
B. All adjustments to boiler, burner, and boiler control system shall be performed by the
manufacturers representative.
The manufacturer's representative shall provide start-up and instruction of each new boiler, including
burner and boiler control system as specified herein. Start-up and instruction shall cover all
components assembled and furnished by the manufacturer whether or not of his own manufacture.
A3-1
02-08
Section A3
Criterion Series - Model 4WG
Steam and Hot Water
Table Of Contents
Criterion Model 4WG
Four-Pass Wetback Design: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Hinged Burner, Front and Rear Doors: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Natural Gas, No. 2 Oil, or Combination Burners Available: . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Burner/Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-15
Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-17
Sample Specifications - Steam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-25
Criterion Series - Model 4WG Section A3
A3-2
02-08
List of Figures
4WG Dimensions - Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
4WG Dimensions - Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
4WG Low NOx Steam 100-800 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-9
4WG Low NOX Hot Water 100-800 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-11
Space Required to Open Rear Head on Criterion Model 4WG . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-13
Model 4WG Lift Lug Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-13
Model 4WG Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14
Typical Fuel Oil Supply Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-23
Boiler Room Length (Typical Layouts) - Model 4WG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-24
Boiler Room Width (Typical Layout) - Model 4WG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-24
List of Tables
4WG Ratings Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
4WG Dimensions - Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6
4WG Ratings - Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
4WG Dimensions - Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8
4WG Low NOx Ratings Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-9
4WH Low NOx Dimensions Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10
4WH Ratings Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-11
4WG Low NOx Dimensions Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-12
4WG Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-18
4WG Boilers: Predicted Sound Levels (30 ppm NOx systems) @ High Fire . . . . . . . . . . . . . . . . . A3-18
Steam Volume and Disengaging Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-19
Model 4WG Steam Boiler Safety Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-19
Model 4WG Hot Water Relief Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-20
4WG Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-20
4WG Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-21
Altitude Correction for Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-21
Model 4WG, Standard and Low NOx, Mini. Req. Gas Pressure Standard, FM and IRI Gas Trains . . A3-22
Section A3 Criterion Series - Model 4WG
A3-3
02-08
FEATURES AND
BENEFITS
The Cleaver-Brooks Criterion Model 4WG Boiler provides an integrated boiler
burner package with optimized pressure vessel and furnace working in
conjunction with a matching Profire gun burner. Additionally, the boiler/
burner package is fully UL and cUL approved and available from 100 - 800
hp. The following features apply:
Four-Pass Wetback Design:
Four-pass design provides high flue gas velocities and low stack
temperatures to maximize efficiency.
Five square feet of heating surface per boiler horsepower (except for the
750 and 800 hp unless otherwise specified) provides guaranteed
efficiency performance and long boiler life.
Hinged Burner, Front and Rear Doors:
Hinged burner assembly provides ease of access to the furnace.
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.
PRODUCT
OFFERING
Cleaver-Brooks Criterion Model 4WG Boilers are available in low pressure
steam, high pressure steam, and hot water designs. Burners are available to
fire 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 - 250 psig steam.
Full modulation, all sizes.
Available options include the following (contact your local Cleaver-Brooks
authorized representative for option details).
Boiler Options:
Low NOx emission levels from 75, 30, 15 - <9PPM when burning
natural gas and 70 PPM on # 2 oil when the fuel bound nitrogen is at
0.02% or less.
Drain valves.
Additional screwed or flanged trappings.
Blowdown valves.
Non-return valves.
Feedwater valves and regulators.
Surface blowdown systems.
Blend pump.
Surge load baffles.
Seismic design.
A3-4
02-08
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 efficiency).
Special indicating lights.
Main disconnect.
Elapsed time meter.
Voltmeter/micro-ammeter.
NEMA enclosures.
Low-fire 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.
DIMENSIONS AND
RATINGS
Dimensions and ratings for the Criterion Model 4WG Boilers are shown in the
following tables and illustrations. The information is subject to change
without notice.
Table A3-1 Model 4WG Steam Boiler Ratings
Table A3-3 Model 4WG Hot Water Boiler Ratings
Figure A3-1 Model 4WG Steam Boiler Dimensions
Figure A3-2 Model 4WG Hot Water Boiler Dimensions
Figure A3-5 Model 4WG Boiler Space Requirements to Open Rear
Door
Figure A3-6 Lifting Lug Location, Model 4WG Boilers
Figure A3-7 Model 4WG Boiler Mounting Piers
A3-5
02-08
Table A3-1. 4WG Ratings - Steam
Figure A3-1. 4WG - Steam 100-800 HP
J
FRONT VIEW RIGHT SIDE VIEW
U T
W W
S
(BOTH SIDES)
(NEARSIDE)
Z
M
N
P
O
LL
L
I
BB
Q
OO
K
FF
A
C
R
X
RF/RD
H
B
G
4
DD
F
D
BOILER H.P. 100 125 150 200 250 300 350 400 500 600 700 800
BURNER MODEL FP-3 FP-3 FP-3 FP-4 FP-4 FP-4 D145P D175P D210P D252P D300P D378P
Rated Capacity (lbs-steam/hr
from and at 212
0
F)
3450 4313 5175 6900 8625 10350 12075 13800 17250 20700 24150 27600
Btu Output (1000 Btu/hr) 3347 4184 5021 6694 8368 10042 11715 13389 16736 20083 23430 26778
Gas CFH (1000 Btu) 4082 5102 6123 8164 10205 12246 14287 16328 20410 24492 28574 32656
Gas (Therm/hr) 40.8 51.0 61.2 81.6 102.0 122.5 142.9 163.3 204.1 244.9 285.7 326.6
Blower Motor hp 2 3 5 5 5 7-1/2 15 20 25 30 40 75
Circulating Oil Pump Motor hp
(Oil only)
* * * 1/2 1/2 3/4 3/4 3/4 3/4 3/4 1 1
Oil Metering Pump Motor hp
(Oil only)
- - - - - - - 1/2 3/4 3/4 3/4 1
Integral Oil/Air Motor hp (Oil only) - - - - - - 2 - - - - -
only)
** ** ** 3 3 3 - 5 5 7-1/2 7-1/2 15
Heating Surface sq-ft. (Fireside) 500 625 750 1000 1250 1500 1750 2000 2500 3000 3500 See Note "B"
* Integral oil pump
** No air compressor required (pressure atomized)
NOTES:
A. All fractional hp motors will be single phase voltage except oil metering pump motor(3-phase); integral hp motors will be 3-phase voltage.
B. 800 hp boilers are available w/ 3500 or 4000 sq. ft. of heating surface
BOILER DATA
A3-6
02-08
Table A3-2. 4WG Dimensions - Steam
02-08
BOILER H.P. DIM 100 125 150 200 250 300 350 400 500 600 700 800 *800
LENGTHS See Note "C
Overall Length A 174 198 186 227.5 220.3 244.3 245.3 263.3 276.8 311.8 296.5 304 331
Shell B 131 155 143 177 172.5 196.5 189.8 207.8 213.8 248.8 232.8 232.8 259.8
Base Frame C 110 124 122 156 150.12 174.13 167.25 185.25 188.25 223.75 207.25 207.25 234.75
Burner Extension D 39 39 39 46.5 43.75 43.75 51.5 51.5 59 59 59.75 67.25 67.25
Smokebox to Base F 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Rear Ring Flange to Base G 20.5 20.5 20.5 20.5 22 22 22 22 25 25 25 25 25
Smokebox to Steam Nozzle H 50.88 74.88 63.88 97.88 86.25 110.3 95.63 113.6 106 141 115.6 115.6 142.6
WIDTHS
Overall Width I 85 85 92 92 103 103 110 110 123 123 133 133 133
I.D. Boiler J 60 60 67 67 78 78 85 85 96 96 106 106 106
Center to Water Column K 45 45 48.5 48.5 54 54 57.5 57.5 64 64 69 69 69
Center to Lagging L 33 33 36.75 36.75 42 42 45.5 45.5 51 51 56 56 56
Center to Auxiliary LWCO LL 40 40 43.5 43.5 49 49 52.5 52.5 59 59 64 64 64
Base Outside M 52.5 52.5 51 51 64 64 60 60 71.88 71.88 74.75 74.75 74.75
Base Inside N 44.5 44.5 43 43 56 56 47 47 58.88 58.88 61.75 61.75 61.75
HEIGHTS
Base to Rear Davit OO 86.12 86.12 92.75 92.75 98.88 98.88 112.8 112.8 125.1 125.1 134.3 134.3 134.3
Base to Vent Outlet O 85 85 92.63 92.63 106 106 115 115 126 126 135.6 135.6 135.6
Base to Boiler Centerline P 46 46 50 50 56 56 61 61 67 67 71 71 71
Height of Base Frame Q 12 12 12 12 12 12 12 12 12 12 12 12 12
Base to Bottom of Boiler R 15.63 15.63 16.13 16.13 16.5 16.5 18 18 18.5 18.5 17.5 17.5 17.5
Base to Steam Outlet X 82.38 82.38 89.88 89.88 101.5 101.5 110 110 121.5 121.5 130.5 130.5 130.5
BOILER CONNECTIONS
Feedwater Inlet (Both Sides) S 1.25 1.5 1.5 2 2 2 2.5 2.5 2.5 2.5 2.5 2.5 2.5
Surface Blowoff (150 lb only) T 1 1 1 1 1 1 1 1 1 1 1 1 1
Steam Nozzle 15 lb (See Note "A") U 8 8 8 10 10 12 12 12 12 12 12 12 12
Steam Nozzle 150 lb (See Note "B") U 4 4 4 4 6 6 6 6 8 8 8 8 8
Blowdown-Front & Rear (15 lb) W 1.5 1.5 1.5 2 2 2 2 2 2 2 2 2 2
Blowdown-Front & Rear (150 lb) W 1.25 1.5 1.5 1.5 1.5 1.5 1.5 2 2 2 2 2 2
Chemical Feed Z 1 1 1 1 1 1 1 1 1 1 1 1 1
VENT STACK
Vent Stack Diameter (Flanged) BB 16 16 16 16 20 20 24 24 24 24 24 24 24
MINIMUM CLEARANCES
Rear Door Swing DD 36 36 40 40 46 46 50 50 55 55 60 60 60
Tube Removal - Front Only FF 96 120 108 142 132.5 156.5 148 166 169 204 188 188 215
Thru Window or Door RD 234 258 261 295 307.5 331.5 337 355 377 412 411 411 438
Front of Boiler RF 263 311 291 359 351 399 388 424 438 508 481 481 535
WEIGHTS IN LBS
Normal Water Weight - 5,870 7,310 7,625 9,995 12,590 14,850 16,025 17,950 21,050 25,350 28,700 28,700 32,770
Approx. Shipping Weight - (15psig) - 10,860 12,080 13,090 15,260 19,110 21,050 24,760 27,640 33,295 38,150 42,320 42,320 46,300
NOTES:
A3-7
02-08
Table A3-3. 4WG Ratings - Hot Water
Figure A3-2. 4WG - Hot Water 100-800 HP
J
LWCO
W
(BOTH SIDES)
S
Y
LWCO
W
T U
N
M
P
O
L
I
BB
Q
OO
K
FF
A
C
R
RF/RD
H
HH
B
G
X
DD
4
D
F
BOILER H.P. 100 125 150 200 250 300 350 400 500 600 700 800
BURNER MODEL FP-3 FP-3 FP-3 FP-4 FP-4 FP-4 D145P D175P D210P D252P D300P D378P
Btu Output (1000 Btu/hr) 3347 4184 5021 6694 8368 10042 11715 13389 16736 20083 23430 26778
Light Oil gph (140,000 Btu/gal 29.2 36.4 43.7 58.3 72.9 87.5 102.0 116.6 145.8 174.9 204.1 233.3
Gas CFH (1000 Btu) 4082 5102 6123 8164 10205 12246 14287 16328 20410 24492 28574 32656
Gas (Therm/hr) 40.8 51.0 61.2 81.6 102.0 122.5 142.9 163.3 204.1 244.9 285.7 326.6
Blower Motor hp 2 3 5 5 5 7-1/2 15 20 25 30 40 75
Circulating Oil Pump Motor
hp (Oil only)
* * * 1/2 1/2 3/4 3/4 3/4 3/4 3/4 1 1
(Oil only)
- - - - - - - 1/2 3/4 3/4 3/4 1
Integral Oil/Air Motor hp (Oil
only)
- - - - - - 2 - - - - -
only)
** ** ** 3 3 3 - 5 5 7-1/2 7-1/2 15
Heating Surface sq-ft. (Firesid 500 625 750 1000 1250 1500 1750 2000 2500 3000 3500
See Note "B"
* Integral oil pump
** No air compressor required (pressure atomized)
NOTES:
BOILER DATA
A3-8
02-08
Table A3-4. 4WG Dimensions - Hot Water
02-08
BOILER H.P. DIM 100 125 150 200 250 300 350 400 500 600 700 800 *800
LENGTHS See Note "C
Overall Length A 174 198 186 227.5 220.25 244.25 245.25 263.25 276.75 311.75 296.5 304 331
Shell B 131 155 143 177 172.5 196.5 189.75 207.75 213.75 248.75 232.75 232.75 259.75
Base Frame C 110 124 122 156 150.125 174.125 167.25 185.25 188.25 223.25 207.25 207.25 234.25
Burner Extension D 39 39 39 46.5 43.75 43.75 51.5 51.5 59 59 59.75 67.25 67.25
Smokebox to Base F 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Rear Ring Flange to Base G 20.5 20.5 20.5 20.5 22 22 22 22 25 25 25 25 25
Smokebox to Return H 78 99 87 121 113.5 137.5 130.75 148.75 143 151.75 146.25 146.75 173.75
Smokebox to Outlet HH 103 124 112 146 139.5 163.5 156.75 174.75 179 187.75 182.25 182.75 209.75
WIDTHS
Overall Width I 70 70 77.5 77.5 88 88 95 95 106 106 116 116 116
I.D. Boiler J 60 60 67 67 78 78 85 85 96 96 106 106 106
Center to LWCO Controller K 37 37 40.75 40.75 46 46 49.5 49.5 55 55 60 60 60
Center to Lagging L 33 33 36.75 36.75 42 42 45.5 45.5 51 51 56 56 56
Base Outside M 52.5 52.5 51 51 64 64 60 60 71.88 71.88 74.75 74.75 74.75
Base Inside N 44.5 44.5 43 43 56 56 47 47 58.88 58.88 61.75 61.75 61.75
HEIGHTS
Base to Rear Davit OO 86.12 86.12 92.75 92.75 98.88 98.88 112.75 112.75 125.12 125.12 134.25 134.25 134.25
Base to Vent Outlet O 85 85 92.63 92.63 106 106 115 115 126 126 135.63 135.63 135.63
Base to Boiler Centerline P 46 46 50 50 56 56 61 61 67 67 71 71 71
Height of Base Frame Q 12 12 12 12 12 12 12 12 12 12 12 12 12
Base to Bottom of Boiler R 15.63 15.63 16.13 16.13 16.5 16.5 18 18 18.5 18.5 17.5 17.5 17.5
Base to Return & Outlet X 82.38 82.38 89.88 89.88 101.5 101.5 110 110 121.5 121.5 130.5 130.5 130.5
BOILER CONNECTIONS
Waterfill Connection (Both Sides) S 1.25 1.5 1.5 2 2 2 2.5 2.5 2.5 2.5 2.5 2.5 2.5
Water Return (See Note "A") T 4 6 6 6 8 8 8 10 10 12 12 12 12
Water Outlet (See Notes "A & B") U 4 6 6 6 8 8 8 10 10 12 12 12 12
Drain-Front & Rear W 1.5 1.5 1.5 2 2 2 2 2 2 2 2 2 2
Air Vent Y 1.5 1.5 1.5 1.5 1.5 1.5 1.5 2 2 2 2 2 2
VENT STACK
Vent Stack Diameter (Flanged) BB 16 16 16 16 20 20 24 24 24 24 24 24 24
MINIMUM CLEARANCES
Rear Door Swing DD 36 36 40 40 46 46 50 50 55 55 60 60 60
Tube Removal - Front Only FF 96 120 108 142 132.5 156.5 148 166 169 204 188 188 215
Thru Window or Door RD 234 258 261 295 307.5 331.5 337 355 377 412 411 411 438
Front of Boiler RF 263 311 291 359 351 399 388 424 438 508 481 481 535
WEIGHTS IN LBS
Normal Water Weight - 6,890 8,580 8,870 11,600 14,760 17,380 19,220 21,520 26,260 31,580 35,900 35,900 40,930
NOTES:
A3-9
02-08
Figure A3-3. 4WG Low NOx - Steam 100-800 HP
Table A3-5. 4WG Low NOx Ratings - Steam
BOILER H.P. 100 125 150 200 250 300 350 400 500 600 700 800
BURNER MODEL LND54S LND63P LND84P LND105P LND145S LND145P LND175P LND210P LND252P LND300P LND378P LND420P
Rated Capacity (lbs-steam/hr from
and at 212
0
F)
3450 4313 5175 6900 8625 10350 12075 13800 17250 20700 24150 27600
Btu Output (1000 Btu/hr) 3347 4184 5021 6694 8368 10042 11715 13389 16736 20083 23430 26778
Gas CFH (1000 Btu) 4082 5102 6123 8164 10205 12246 14287 16328 20410 24492 28574 32656
Gas (Therm/hr) 40.8 51.0 61.2 81.6 102.0 122.5 142.9 163.3 204.1 244.9 285.7 326.6
Blower Motor hp 3 5 7-1/2 10 15 15 20 25 30 40 75 75
Circulating Oil Pump Motor hp (Oil
only)
1/2 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4 1 1
Oil Metering Pump Motor hp (Oil
only)
- - - - - - 1/2 1/2 3/4 3/4 1 1
Integral Oil/Air Motor hp (Oil only) 1 1 1 1 2 2 - - - - - -
Air Compressor Motor hp (Oil only) - - - - - - 5 5 5 7-1/2 15 15
NOTES:
BOILER DATA
A3-10
02-08
Table A3-6. 4WG Low NOx Dimensions - Steam
02-08
BOILER H.P. DIM 100 125 150 200 250 300 350 400 500 600 700/800 *800
LENGTHS
See Note "C"
Overall Length A 176 200 189.6 223.6 229.6 253.6 250 270.6 276.6 311.6 304 331
Shell B 131 155 143 177 172.5 196.5 189.8 207.8 213.8 248.8 232.8 259.8
Base Frame C 110 124 122 156 150.13 174.13 167.25 185.25 188.25 223.25 207.25 234.25
Burner Extension D 41 41 42.62 42.62 53.12 53.12 56.25 58.88 58.88 58.88 67.25 67.25
Smokebox to Base F 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Smokebox to Steam Nozzle H 50.88 74.88 63.88 97.88 86.25 110.3 95.63 113.6 106 141 115.6 142.6
WIDTHS
Overall Width I 90.5 85 92 92 103 103 110 110 125 126 133 133
I.D. Boiler J 60 60 67 67 78 78 85 85 96 96 106 106
Center to Water Column K 45 45 48.5 48.5 54 54 57.5 57.5 64 64 69 69
Center to Auxiliary LWCO LL 40 40 43.5 43.5 49 49 52.5 52.5 59 59 64 64
Base Outside M 52.5 52.5 51 51 64 64 60 60 71.88 71.88 74.75 74.75
Base Inside N 44.5 44.5 43 43 56 56 47 47 58.88 58.88 61.75 61.75
Center to Outside of FGR Duct NN 45.5 39.5 39.5 39.5 43.5 43.5 49.75 49.75 61 62 62.5 62.5
FGR Duct Size V 6 6 6 6 6 8 8 8 8 10 10 10
HEIGHTS
Base to Rear Davit OO 86.12 86.12 92.75 92.75 98.88 98.88 112.8 112.8 125.1 125.1 134.3 134.3
Base to Steam Outlet X 82.38 82.38 89.88 89.88 101.5 101.5 110 110 121.5 121.5 130.5 130.5
BOILER CONNECTIONS
Feedwater Inlet (Both Sides) S 1.25 1.5 1.5 2 2 2 2.5 2.5 2.5 2.5 2.5 2.5
Surface Blowoff (150 lb only) T 1 1 1 1 1 1 1 1 1 1 1 1
Steam Nozzle 15 lb (See Note "A") U 8 8 8 10 10 12 12 12 12 12 12 12
Steam Nozzle 150 lb (See Note "B") U 4 4 4 4 6 6 6 6 8 8 8 8
Blowdown-Front & Rear (15 lb) W 1.5 1.5 1.5 2 2 2 2 2 2 2 2 2
Blowdown-Front & Rear (150 lb) W 1.25 1.5 1.5 1.5 1.5 1.5 1.5 2 2 2 2 2
Chemical Feed Z 1 1 1 1 1 1 1 1 1 1 1 1
VENT STACK
MINIMUM CLEARANCES
Thru Window or Door RD 234 258 261 295 307.5 331.5 337 355 377 412 411 438
Front of Boiler RF 263 311 291 359 351 399 388 424 438 508 481 535
WEIGHTS IN LBS
NOTES:
A3-11
02-08
Figure A3-4. 4WG Low NOX - Hot Water 100-800 HP
Table A3-7. 4WG Low NOx Ratings - Hot Water
BOILER H.P. 100 125 150 200 250 300 350 400 500 600 700 800
BURNER MODEL LND54S LND63P LND84P LND105P LND145S LND145P LND175P LND210P LND252P LND300P LND378P LND420P
Btu Output (1000 Btu/hr) 3347 4184 5021 6694 8368 10042 11715 13389 16736 20083 23430 26778
Gas CFH (1000 Btu) 4082 5102 6123 8164 10205 12246 14287 16328 20410 24492 28574 32656
Gas (Therm/hr) 40.8 51.0 61.2 81.6 102.0 122.5 142.9 163.3 204.1 244.9 285.7 326.6
Blower Motor hp 3 5 7-1/2 10 15 15 20 25 30 40 75 75
Circulating Oil Pump Motor hp (Oil
only)
1/2 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4 1 1
Oil Metering Pump Motor hp (Oil
only)
- - - - - - 1/2 1/2 3/4 3/4 1 1
Integral Oil/Air Motor hp (Oil only) 1 1 1 1 2 2 - - - - - -
Air Compressor Motor hp (Oil only) - - - - - - 5 5 5 7-1/2 15 15
NOTES:
BOILER DATA
A3-12
02-08
Table A3-8. 4WG Low NOx Dimensions - Hot Water
02-08
BOILER H.P. DIM 100 125 150 200 250 300 350 400 500 600 700/800 *800
Overall Length A 176 200 189.62 223.62 229.62 253.62 250 270.63 276.63 311.63 304 331
Shell B 131 155 143 177 172.5 196.5 189.75 207.75 213.75 248.75 232.75 259.75
Base Frame C 110 124 122 156 150.13 174.13 167.25 185.25 188.25 223.25 207.25 234.25
Burner Extension D 41 41 42.62 42.62 53.12 53.12 56.25 58.88 58.88 58.88 67.25 67.25
Smokebox to Base F 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Smokebox to Return H 78 99 87 121 113.5 137.5 130.75 148.75 143 151.75 146.75 173.75
Smokebox to Outlet HH 103 124 112 146 139.5 163.5 156.75 174.75 179 187.75 182.75 209.75
WIDTHS
Overall Width I 82.5 76.5 80.25 80.25 89.5 89.5 99.25 99.25 116 117 122.5 122.5
I.D. Boiler J 60 60 67 67 78 78 85 85 96 96 106 106
Center to LWCO Controller K 37 37 40.75 40.75 46 46 49.5 49.5 55 55 60 60
Base Outside M 52.5 52.5 51 51 64 64 60 60 71.88 71.88 74.75 74.75
Base Inside N 44.5 44.5 43 43 56 56 47 47 58.88 58.88 61.75 61.75
Center to Outside of FGR Duct NN 45.5 39.5 39.5 39.5 43.5 43.5 49.75 49.75 61 62 62.5 62.5
FGR Duct Size V 6 6 6 6 6 8 8 8 8 10 10 10
HEIGHTS
Base to Rear Davit OO 86.12 86.12 92.75 92.75 98.88 98.88 112.75 112.75 125.12 125.12 134.25 134.25
Base to Return & Outlet X 82.38 82.38 92.63 92.63 101.5 101.5 110 110 121.5 121.5 130.5 130.5
BOILER CONNECTIONS
Waterfill Connection (Both Sides) S 1.25 1.5 1.5 2 2 2 2.5 2.5 2.5 2.5 2.5 2.5
Water Return (See Note "A") T 4 6 6 6 8 8 8 10 10 12 12 12
Water Outlet (See Notes "A & B") U 4 6 6 6 8 8 8 10 10 12 12 12
Drain-Front & Rear W 1.5 1.5 1.5 2 2 2 2 2 2 2 2 2
Air Vent Y 1.5 1.5 1.5 1.5 1.5 1.5 1.5 2 2 2 2 2
VENT STACK
MINIMUM CLEARANCES
Thru Window or Door RD 234 258 261 295 307.5 331.5 337 355 377 412 411 438
Front of Boiler RF 263 311 291 359 351 399 388 424 438 508 481 535
WEIGHTS IN LBS
NOTES:
A3-13
02-08
Figure A3-5. Space Required to Open Rear Head on Criterion Model 4WG
Figure A3-6. Model 4WG Lift Lug Locations
HP A B C D E
100 79.5 21.375 84.75 10 3
125 79.5 21.375 108.75 10 3
150 87.125 21.375 96.75 10 3
200 87.125 21.375 130.75 10 3
250 99 28.75 104.25 10 3
300 99 28.75 128.25 10 3
350 107.625 33.25 126 10 3
400 107.625 33.25 144 10 3
500 125.375 34.5 145 10 3
600 125.375 34.5 180 10 3
700-800 134.5 34.5 164 10 3
B C
FAIR SIDE
NEAR SIDE
E DIA OF HOLE
A
D
D
02-08
HP A B C D E
100-125 33 47 52 80 36
150-200 36.5 49 56 83 40
250-300 42 56 61 92 46
350-400 45.5 58 68 99 50
500-600 51 66 75 111 55
700-800 56 74 80 121 60
A3-14
02-08
Figure A3-7. Model 4WG Mounting Piers
PERFORMANCE
DATA
Contact your local Cleaver-Brooks authorized representative for efficiencies.
Cleaver-Brooks 4WG boilers are available with the standard burner package,
or optional model Profire LE or Profire NT if NOx reductions of between 75
and <9 PPM on natural gas are required, or 70 PPM on #2 oil with 0.02%
fuel bound nitrogen.
HP A B C D E F G X
100 6 9 110 39.5 57.5 4 44.5 8
125 6 9 124 39.5 57.5 4 44.5 8
150 6 9 122 38 56 4 43 8
200 6 9 156 38 56 4 43 8
250 6 9 150.125 51 69 4 56 11.5
300 6 9 174.125 51 69 4 56 11.5
350 6 12 167.25 41.5 65.5 6.5 47 11.5
400 6 12 185.25 41.5 65.5 6.5 47 11.5
500 6 12 188.25 53.375 77.375 6.5 58.875 10.5
600 6 12 223.25 53.375 77.375 6.5 58.875 10.5
700-800 6 12 207.25 56.25 80.25 6.5 61.75 10.5
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.
A3-15
02-08
ENGINEERING DATA The following engineering information is provided for Model 4WG Boilers.
Additional detail is available from your local Cleaver-Brooks authorized
representative.
Boiler Information
Table A3-11 shows steam volume and disengaging area for model
4WG boilers.
Table A3-12 lists quantity and outlet size for safety valves supplied on
Model 4WG steam boilers.
Table A3-13 lists quantity and outlet size for relief valves supplied on
Model 4WG hot water boilers.
Table A3-14 gives recommended steam nozzle sizes on Model 4WG
Boilers.
Table A3-15 shows recommended non-return valve sizes for Model
4WG 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 Board's recommendations base the size of the blowdown tank
on the removal of at least 4 inches of water from the boiler.
Table A3-9 lists the approximate quantity of water represented by 4 inches of
water at normal operating level for Cleaver-Brooks Model 4WG Boilers.
Burner/Control Information
Burner Characteristics
Maximum altitude for standard burners is shown in Table A3-16. 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 A3-16 shows correction factors for gas pressure at elevations over 700
ft. above sea level.
Table A3-17 shows minimum and maximum gas pressure requirements for
Standard, FM and IRI 4WG Boiler gas trains upstream of the gas pressure
regulator.
For oversized or undersized gas trains or altitude above 2,000 feet, contact
A3-16
02-08
Fuel Connections - Gas
The local gas company should be consulted for requirements and
authorization for installation and inspection of gas supply piping. Installation
of gas supply piping and venting must be in accordance with all applicable
engineering guidelines and regulatory codes. All connections made to the
boiler should be arranged so that all components remain accessible for
inspection, cleaning and maintenance.
A drip leg should be installed in the supply piping before the connection to
the gas pressure regulator. The drip leg should be at least as large as the inlet
fitting supplied with the boiler. Consideration must be given to both volume
and pressure requirements when choosing gas supply piping size. Refer to the
boiler dimension diagram provided by Cleaver-Brooks for the particular
installation. Connections to the burner gas train should be made with a union,
so that gas train components or the burner may be easily disconnected for
inspection or service. Upon completion of the gas piping installation, the
system should be checked for gas leakage and tight shutoff of all valves.
Fuel Connections - Oil
Oil-fired 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 firing 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 A3-8 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.
Boiler Room Information
A3-17
02-08
Stack Support Capabilities
100 - 800 hp Model 4WG Boilers can support up to 2000 lbs without
additional support.
100 - 800 hp Model 4WG 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 flow,
and velocity of air must be reviewed as follows:
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 fine mesh wire, as this type of covering
has poor air flow 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.
Area (sq.-ft.) = CFM/FPM
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.
A. From floor 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 floor level.
Area Required: Area = cfm/fpm = 3000/250 = 12 Sq.-ft. total.
Area/Opening: 12/2 = 6 sq.-ft./opening (2 required).
Notice
A3-18
02-08
Stack/Breeching Size Criteria
The design of the stack and breeching must provide the required draft at each
boiler flue gas outlet. Proper draft is critical to burner performance.
Although constant pressure at the flue gas outlet of the Model 4WG is not
required, it is necessary to size the stack/ breeching to limit flue 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.
Table A3-9. 4WG Blowdown Tank Sizing
Information
Table A3-10. 4WG Boilers: Predicted Sound Levels
(30 ppm NOx systems) @ High Fire
BHP Sound Level-dbA
100 81
125 83.5
150 89.5
200 88.6
250 88.5
300 91
350 94
400 91.5
500 93.5
600 93.5
700 93.7
800 93.5
100 85
125 104
150 102
200 131
250 145
300 169
350 178
400 198
500 233
600 278
700 286
800 286
NOTE: Quantity of water removed from boiler
by lowering normal water line 4".
A3-19
02-08
Table A3-11. Steam Volume and Disengaging Areas
Table A3-12. Model 4WG Steam Boiler Safety Valve Outlet Size
(A) (B) (A) (B)
100 16.5 22.3 4565 4954
125 20.3 27.4 5587 6077
150 19.9 26.8 5443 5918
200 25.7 34.6 7013 7632
250 34.8 49.5 7790 8597
300 40.6 57.9 9115 10051
350 51.3 69.6 9734 10570
400 57.2 77.5 10843 11779
500 83.6 107.6 12874 13781
600 100 128.6 15394 16474
700 115.6 144.9 15826 16819
800 115.6 144.9 15826 16819
NOTE:
BOILER HP
BOILER HP
NO. OF
VALVES
REQ'D
OUTLET
SIZE (IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE (IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE (IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE (IN.)
100 1 2-1/2 1 1-1/2 1 1-1/2 1 1-1/4
125 1 3 2
(1) 1-1/2
(1) 1-1/4
2
(1) 1-1/4
(1) 1
2 1
150 1 3 2
(1) 1-1/2
(1) 1-1/4
2 1-1/4 2
(1) 1
(1) 1-1/4
200 2 2-1/2 2 1-1/2 2
(1) 1-1/2
(1) 1-1/4
2 1-1/4
250 2
(1) 2-1/2
(1) 3
2
(1) 2
(1) 1-1/2
2 1-1/2 2
(1) 1-1/2
(1) 1-1/4
300 2 3 2 2 2
(1) 2
(1) 1-1/2
2 1-1/2
350 3
(1) 2
(2) 3
2
(1) 2-1/2
(1) 2
2 2 2
(1) 1-1/2
(1) 2
400 3
(2) 3
(1) 2-1/2
2
(1) 2-1/2
(1) 2
2 2 2
(1) 1-1/2
(1) 2
500 3 3 2 2-1/2 2
(1) 2-1/2
(1) 2
2 2
600 4
(3) 3
(1) 2-1/2
3
(2) 2-1/2
(1) 2
2 2-1/2 2
(1) 2
(1) 2-1/2
700, 800 5
(3) 3
(2) 2-1/2
3
(2) 2-1/2
(1) 2
2 2-1/2 2 2-1/2
A3-20
02-08
Table A3-13. Model 4WG Hot Water Relief Valve Outlet Size
Table A3-14. 4WG Recommended Steam Nozzle Size
BOILER HP
NO. OF
VALVES
REQ'D
OUTLET
SIZE (IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE (IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE (IN.)
100 1 2-1/2 1 1-1/4 1 2
125 1 2-1/2 1 1-1/4 2
(1) 1-1/2
(1) 2
150 1 2-1/2 1 2 2
(1) 1-1/2
(1) 2
200 2
(1) 2-1/2
(1) 1-1/4
1 2 2 2
250 2
(1) 2
(1) 2-1/2
1 2 2
(1) 2
(1) 2-1/2
300 2 2-1/2 1 2-1/2 2 2-1/2
350 3
(2) 2-1/2
(1) 1
1 2-1/2 2
(1) 2-1/2
(1) 3
400 3
(1) 2
(2) 2-1/2
1 2-1/2 2
(1) 2-1/2
(1) 3
500 4
(1) 1
(3) 2-1/2
2
(1) 1
(1) 2-1/2
2 3
600 4
(3) 2-1/2
(1) 2
2
(1) 1-1/4
(1) 2-1/2
3
(2) 3
(1) 2-1/2
700, 800 5
(1) 1
(4) 2-1/2
2
(1) 2-1/2
(1) 2
3 3
NOTE: Relief valve is Kunkle #537 for 30# & 125#(Section IV) boiler and is Kunkle #927
02-08
OPERATING PRESSURE
PSIG 100 125 150 200 250 300 350 400 500 600 700 800
15 8 8 8 10 10 12 12 12 12 12 12 12
30 6 6 6 8 8 8 10 10 10 12 12 12
40 6 6 6 6 8 8 8 10 10 10 12 12
50 4 6 6 6 6 8 8 8 10 10 10 12
75 4 4 4 6 6 6 8 8 8 8 10 10
100 4 4 4 6 6 6 6 6 8 8 8 10
125 4 4 4 4 6 6 6 6 8 8 8 8
150 2.5 3 3 4 4 6 6 6 6 6 8 8
200 2.5 2.5 3 4 4 4 4 6 6 6 6 6
250 2 2.5 3 3 4 4 4 4 6 6 6 6
NOTES:
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
BOILER HP
A3-21
02-08
Table A3-15. 4WG Recommended Non-Return Valve Size
Table A3-16. Altitude Correction for Gas
ALTITUDE CORRECTION ALTITUDE CORRECTION
(FT) FACTOR (FT) FACTOR
1000 1.04 6000 1.25
2000 1.07 7000 1.3
3000 1.11 8000 1.35
4000 1.16 9000 1.4
5000 1.21 - -
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.
02-08
BOILER HP BOILER CAPACITY
(LBS/HR)
OPERATING PRESSURE (PSIG)
50 75 100 125 150 175 200 250
100 3450 2-1/2 2-1/2 NA NA NA NA NA NA
125 4313 3 2-1/2 2-1/2 2-1/2 NA NA NA NA
150 5175 3 3 2-1/2 2-1/2 2-1/2 2-1/2 NA NA
200 6900 3* 3 3 3 3 2-1/2 2-1/2 2-1/2
250 8625 4 3* 3 3 3 3 3 3
300 10350 4 4 4 3* 3 3 3 3
350 12025 4 4 4 4 4 3* 3 3
400 13800 5 4 4 4 4 4 4 3*
500 17210 6 5 5 4 4 4 4 4
600 20700 6 6 5 5 5 4 4 4
700 24150 6 6 6 5 5 5 5 4
800 27600 6 6 6 6 6 5 5 5
Standard Non-Return valve selections limited to a maximum 2 to 1 turndown (50% of full load); selections based on typical non-
return valve sizing recommendations. For final valve selection contact your C-B authorized representative. For high turndown ap-
plications see Boiler Book Section I3, Table I3-3.
* Indicates pressure drop of less than 7.5 psig. All other selections are less than 6 psig pressure drop.
A3-22
02-08 02-08
Table A3-17. Model 4WG, Standard and Low NOx (30 ppm), Minimum Required Gas Pressure at Entrance to
Standard, FM and IRI Gas Trains (Upstream of Gas Pressure Regulator)
BOILER STD PIPE PRESSURE REQUIRED-STD
("WC)
PRESSURE REQUIRED-30 PPM
("WC) HP SIZE
(Inches) GPR* Minimum Maximum GPR* Minimum Maximum
100 2 RV91 9 27.7 RV91 12.3 27.7
125 2 RV91 16.6 27.7 RV91 21.6 27.7
150 2 RV91 23.2 27.7 RV91 21.9 27.7
200 2.5 210G 20.7 277 210G 28.5 277
250 2.5 210G 29.9 277 210G 29 277
300 2.5 210G 40.8 277 210G 39.5 277
350 3 210G 42.7 277 210G 40.7 277
400
1.5-2 S 130 208 S 130 208
2-2.5 S 89 130 S 89 130
2.5 S 64 89 S 64 89
3 S 39 64 S 39 64
500
1.5-2.5 S 183 277 S 175 277
2-2.5 S 130 183 S 125 175
2.5 S 89 130 S 83 125
3 S 50 89 S 44 83
600
2-1.5-2.5 S 233 277 S 241 277
2-2.5 S 177 233 S 186 241
2.5 S 119 177 S 127 186
2.5-3 S 100 119 S 108 127
3 S 61 100 S 69 108
700
2-3 S 222 277 S 213 277
2.5-3 S 133 222 S 125 213
3 S 83 133 S 75 125
4 S 55 83 S 44 75
800
2-3 S 255 277 S 260 277
2.5-3 S 152 255 S 155 260
3 S 94 152 S 94 155
4 S 53 94 S 55 94
NOTE: Where multiple gas train sizes are shown, the shaded row indicates standard size. For altitudes above 700 feet,
contact your local Cleaver-Brooks authorized representative.
* GPR Gas Pressure Regulator
S-Siemens regulating actuator.
A3-23
02-08
Figure A3-8. Typical Fuel Oil Supply Arrangement
A3-24
02-08
FRONT
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
Figure A3-9. Boiler Room Length (Typical Layouts) - Model 4WG
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.
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.
BOILER HP 100-125 150-200 250-300 350-400 500-600 700-800
DIM. "A" 87 91 96 100 105 110
DIM. "B" 120 127 144 151 174 184
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.
Dimension "B" between boilers allows for a "clear" aisle of:
42" - 100-200 HP
48" - 250-400 HP
60" - 500-800 HP
A B
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
Figure A3-10. Boiler Room Width (Typical Layouts) - Model 4WG
Section A3 Criterion Model 4WG
A3-25
3-08
SAMPLE SPECIFICATIONS Model 4WG STEAM BOILERS
PART 1 GENERAL
STEAM BOILERS
Cleaver Brooks Criterion Line
1.01 SCOPE
B. Related Sections include the following:
1. Division 15 Section "Chemical Water Treatment" for feedwater treatment and connections.
2. Division 15 Section "Breechings, Chimneys, and Stacks" for connections to breechings,
chimneys, and stacks.
3. Division 15 Sections for control wiring for automatic temperature control.
1.02 REFERENCES
requirements.
F. Maintenance Data: Include in the maintenance manuals specified in Division 1. Include parts
list, maintenance guide, and wiring diagrams for each boiler.
1. ASME Section (I or IV) (Power boilers or Heating Boilers)
2. ANSI Z21.13 (Gas Fired Low Pressure Boilers)
3. NFPA 54 (ANSI Z221.3) National Fuel Gas Code
4. FACTORY MUTUAL
5. ASME CSD-1 (Controls and Safety Devices)
6. IRI (Industrial Risks Insurance)
7. UBC (Uniform Building Code)
8. UMC (Uniform Mechanical Code)
9. NEC (National Electrical Code)
10. UL (Underwriters Laboratories)
11. NFPA 85
Criterion Model 4WG Section A3
A3-26
3-08
1.04 SUBMITTALS
of:
E. Installation Instructions: Manufacturer's printed instructions for installation shall be submitted to
F. Manufacturer's Warranties: Manufacturer's printed warranties, as specified hereinafter, shall be
G. Manufacturer's Field Service: Manufacturer's printed field service procedures and reports, as
section.
A3-27
3-08
1.05 CERTIFICATIONS
PART 2 PRODUCTS
2.01 MANUFACTURERS
A. Contractor shall furnish and install Cleaver Brooks Model 4WG natural gas (combination Gas/Oil
A3-28
3-08
labeled, stamped and designed for PSIG steam in accordance with Section (I or IV) of ASME Code. Unit shall
be designed to Seismic Zone _ requirements and be provided with tie down clips and calculations showing bolt
diameter requirements. Manufacturer's Representative to provide services for field testing and adjusting of boiler
and controls to meet design requirements.
Model: Criterion Line
Gas Input: ________MB
No. 2 Oil:
Natural Gas (%):
No. 2 Oil (%):
Gas (Natural):
Oil (No. 2):
Gas (Natural):
Oil (No. 2):
A3-29
3-08
A.Noise Sound Levels: Based on ABMA test code for packaged boilers measured 41/2 feet vertically above
the bottom of the base rail and 3'0" horizontally in front of the end of the blower motor or front surface of
control cabinet. Sound levels dBA on the scale in reference to 0.0002 microbars.
2.04 BOILER DESIGN
burner. Wet-Back design with a minimum five (5) square feet of heating surface per boiler
provided. The rear door shall be insulated with a blanket material and a steel covering to give the
surface a hard durable finish.The boiler tubes shall not include turbulators, swirlers or other add-
on appurtenances. The boiler shall be furnished with a manhole and handholes to facilitate boiler
inspection and cleaning.
shall be encased in an 18 gauge metal cabinet with primer and finish coat of paint. The entire
boiler based frame and other components shall be factory painted before shipment using a hard
finish enamel coating.
Electrical:
Fan Motor:
Oil Pump Motor:
____ V / ____ H / ____ P
____HP
____HP
____HP
____dBA
Weight
Dry:
Flooded:
____
____
Seismic Zone: ____
Altitude: ____ ASL
CSD-1 NFPA 8501
State Of _______
Factory Mutual (FM)
High Fire#2 #2 oil ____ dBA
Low Fire #2 oil ____ dBA
High Fire Nat Gas ____ dBA
Low Fire Nat Gas ____ dBA
A3-30
3-08
2.05 BURNER DESIGN
A. GENERAL: Forced draft burner of the gun design with hinged access for inspection and service.
Reversed curve fabricated aluminum blower fan; motor(s); ACCU-LINK single point positioning
system consisting of rotary air damper located on the combustion air intake, straight line linkage
and characterized cams; air flow switch; fuel trains and control panels. To conform to UL and
other insurance requirements as indicated.
turn down shall be minimum 8:1 up to 800 HP.
turn down shall be minimum 6:1 for #2 Oil and 4:1 for Heavy Oil.
control for 60 PPM (30, 15, <9 PPM NOx systems are optional) corrected to3% 02 over the
2.06 BOILER TRIM
3. Auxiliary Low Water Cutoff, (optional)
A3-31
3-08
10. 1 Slow Opening Blowdown Valve, Size______ ", Class 200#
11. 2 Quick Opening Blowdown Valves, Size______ ", Class 490#
12. Feedwater Globe Valve, Size______ ", Class 240# m.
13. 1 Feedwater Check Valve, Size______ ", Class 240# n.
14. 1 ASME Spool Piece, Inlet Size______ ", Outlet Size______ ", Length______ "
15. 1 Stop Valve (Steam Header Valve), Size______, Flanged, Cast Iron, Class 250
16. 1 Stop Check Valve (Non-Return Valve), Size______ ", Flanged, Cast Iron, Class 250",
Water Column piping
18. JHB Modulating Feedwater Control Valve, including 3-Valve Bypass
requirements.
B. WATER COLUMN/LOW WATER CUTOFF AND WATER LEVEL CONTROL SYSTEM:
(Standard vs. Optional)
Shall be a CB LEVEL MASTER Water level control system and shall be comprised of a
microprocessor-based electronic controller, a non-contact, non-wearing, continuously reading
electronic controller shall be panel mounted and operate in ambient temperatures from 32
degrees F to 125 degrees F, the pressure chamber shall be boiler mounted and operate to
pressures of 250PSIG and the level sensor shall operate to pressures of 250 PSIG and
temperatures to 400 degrees F. The pressure containing components shall be constructed in
The pressure chamber shall have tri-cocks and sight glass mounted on the side. The level sensor
shall have an accuracy of.01" or greater. The electronic controller shall have level and error
indicating lights, alphanumeric display for messaging, reset/menu switch and the following
features:
3. High Water Alarm
A3-32
3-08
9. Real Time Clock
Maximum Contacts Rating 15 amps Resistive Load
on, low water and flame failure; selector switches, required by dry contacts, relays and terminal
strips. Oil, heat and moisture resistant wire with circuit number corresponding to electrical wiring
diagrams. In accordance with UL and National Electric Code.
B. (OPTION 1) BURNER MANAGEMENT SYSTEM (CB 780-Standard): Boiler mounted in control
C. (OPTION 2) CB-HAWK ICS Boiler Control System (Optional upgrade): Burner Management
System (CB HAWK ICS - optional upgrade): Integrated Boiler Control and Management System:
1. Programmable Logic Controller
2. Touch Screen HMI
3. One Burner Management Controller with Wiring Sub-Base
4. One Flame Scanner and amplifier
5. Various Temperature and Pressure Sensors
D. Major functions provided by the Boiler Control System shall be:
1. Automatic sequencing of the boiler through standby, pre-purge, pilot flame establishing
period, main flame establishing period, run, flame proving and lockout and post-purge
a. Modulating control (algorithm shall be Proportional-lntegral-Derivative (PID) type)
A3-33
3-08
d. o On screen history of alarms and faults
5. Stack Flue Gas, Combustion Air and Shell (water) temperature indication
E. The Boiler Control System shall incorporate the following safety provisions:
1. Examine all load terminals to assure it is capable of recognizing the true status of the
2. Closed-loop logic test of critical loads (ignition, pilot and main fuel valves) and must be able
to lockout on safety.
3. Pre-ignition interlocks (fuel valve proof of closure, etc.) and flame signal checked during
4. Dynamic checking of the flame signal amplifier.
5. Safe start check and expand check to include monitoring flame signal during standby.
6. High and Low fire switches checked for proper sequencing.
7. The Boiler Control System shall provide the ability to communicate with external digital via
Ethernet as a standard. It shall be possible to communicate with any OPC compliant
Internet communications shall be supported, with the Boiler Control System supplied with
its own IP address.
2.08 SHOP TEST
2.13 ACCESSORIES - 02 TRIM SYSTEM AND/OR
A3-34
3-08
2.15 MANUFACTURES FIELD SERVICES
A. General: The boiler and accessories supplier shall be responsible for performance of insp up and
testing of the package boiler and accessory equipment and materials furnished under Section. A
detailed written record of the start up performance, including burner setting data entire load
range shall be furnished to the test engineer before test personnel leave the site equipment and
test apparatus shall be furnished by the supplier. All equipment defects discovered by the tests
shall be rectified. The minimum time for two (2) boilers is five (5) days.
B. Equipment inspection: Boiler representative to provide ______hours of job site assistance to i
boilers and other equipment upon arrival, verifying completeness of equipment supplied ar
damages. Responsibility of making freight claims to be performed by contractor or owner
personnel.
C. Pre start-up walk through: Boiler representative shall spend _____ hours at job site reviewing
with mechanical contractor to be conducted approximately 1 week prior to startup.
1. Demonstrate that boiler, burner, controls and accessories comply with requirement Section
as proposed by the boiler and accessories supplier. Pre-test all items prior to scheduling the
final testing that will be witnessed by the test engineer.
Nox and overall boiler efficiency.
capacity tests for leakage, malfunctioning, defects, and non compliance with referenced
j. Set up and verify Emissions Compliance
5. Training to include all safety procedures, maintenance procedures, control operations, and
diagnostic procedures. Training to be provided in a single _ hour continuous session to
6. Special tool / safety equipment:
a. Boiler/burner supplier to include in their proposal safety equipment required to perform
annual inspections and maintenance per OSHA requirements, Section
29CFR,1910.146, date 4115193, Paragraphs 5.6.4.2 through 5.6.6.6 confined
space requirements on rear furnace and flue gas turnaround area. Items to include
respirator, tag out devices, atmospheric tester, acid suit, harness, wrist straps, life
A3-35
3-08
wire, and safety belt
b. Special Safety Training on safety procedures by a qualified trainer to be provided per
OSHA Section 1910.146, Paragraph 5.6.5.2, to all owners and employees who are
operating specified equipment. The cost of training to be included in boiler supplier's
proposal
complete spare parts lists and trouble shooting procedures. Operating and maintenance manuals
shall be provided including cut-away views of boiler and burner schematics including fuel trains,
general instructions for maintenance and inspections, complete spare parts lists and trouble
panel.
2.17 WARRANTY DATA
A. The entire boiler/burner package shall be guaranteed and warranted by the boiler manufacturer.
Warranty shall include all parts for a period of (12) months from the date of start-up or beneficial
use or 18 months from shipment, whichever comes first.
PART 3 EXECUTION
3.01 GENERAL
A. Installation shall be provided by the contractor in accordance with the requirements of the codes
3.02 INSTALLATION
A. Install equipment in strict compliance with manufacturer's installation instructions.ww
3.03 FIELD TESTING
shall be replaced.
manufacturer's representative.
A3-36
3-08
The manufacturer's representative shall provide start-up and instruction of each new boiler, including burner
and boiler control system as specified herein. Start-up and instruction shall cover all components assembled
and furnished by the manufacturer whether or not of his own manufacture.
A3-37
03-08
SAMPLE SPECIFICATIONS Model 4WG HOT WATER BOILERS
PART 1 GENERAL
HOT WATER
Cleaver Brooks Criterion Line
1.01 SCOPE
1. Division 15 Section "Chemical Water Treatment" for feedwater treatment and connections.
2. Division 15 Section "Breechings, Chimneys, and Stacks" for connections to breechings,
chimneys, and stacks.
3. Division 15 Sections for control wiring for automatic temperature control.
1.02 REFERENCES
requirements.
F. Maintenance Data: Include in the maintenance manuals specified in Division 1. Include parts
list, maintenance guide, and wiring diagrams for each boiler.
1. ASME Section (I or IV) (Power boilers or Heating Boilers)
2. ANSI Z21.13 (Gas Fired Low Pressure Boilers)
3. NFPA 54 (ANSI Z221.3) National Fuel Gas Code
4. FACTORY MUTUAL
5. ASME CSD-1 (Controls and Safety Devices)
6. IRI (Industrial Risks Insurance)
7. UBC (Uniform Building Code)
8. UMC (Uniform Mechanical Code)
9. NEC (National Electrical Code)
10. UL (Underwriters Laboratories)
11. NFPA 85
A3-38
03-08
1.04 SUBMITTALS
of:
E. Installation Instructions: Manufacturer's printed instructions for installation shall be submitted to
F. Manufacturer's Warranties: Manufacturer's printed warranties, as specified hereinafter, shall be
G. Manufacturer's Field Service: Manufacturer's printed field service procedures and reports, as
section.
A3-39
03-08
1.05 CERTIFICATIONS
PART 2 PRODUCTS
2.01 MANUFACTURERS
A. Contractor shall furnish and install Cleaver Brooks Model 4WG natural gas (combination Gas/Oil
A3-40
03-08
labeled, stamped and designed for PSIG steam in accordance with Section (I or IV) of ASME Code. Unit shall
be designed to Seismic Zone _ requirements and be provided with tie down clips and calculations showing bolt
diameter requirements. Manufacturer's Representative to provide services for field testing and adjusting of boiler
and controls to meet design requirements.
Model: Criterion Line
Output: ________#/hr (from and at 212F
Gas Input: ________MB
No. 2 Oil:
Natural Gas (%):
No. 2 Oil (%):
Gas (Natural):
Oil (No. 2):
Gas (Natural):
Oil (No. 2):
A3-41
03-08
A.Noise Sound Levels: Based on ABMA test code for packaged boilers measured 41/2 feet vertically above
the bottom of the base rail and 3'0" horizontally in front of the end of the blower motor or front surface of
control cabinet. Sound levels dBA on the scale in reference to 0.0002 microbars.
2.04 BOILER DESIGN
burner. Wet back design with a minimum five (5) square feet of heating surface per boiler
provided. The rear door shall be insulated with a blanket material and a steel covering to give the
surface a hard durable finish.The boiler tubes shall not include turbulators, swirlers or other add-
on appurtenances. The boiler shall be furnished with a manhole and handholes to facilitate boiler
shall be encased in an 18 gauge metal cabinet with primer and finish coat of paint. The entire
boiler based frame and other components shall be factory painted before shipment using a hard
finish enamel coating.
Electrical:
Fan Motor: Air Compressor Motor:
Oil Pump Motor:
____ V / ____ H / ____ P
____HP
____HP
____dBA
Weight
Dry:
Flooded:
____
____
Seismic Zone: ____
Altitude: ____ ASL
CSD-1 NFPA 8501
State Of _______
Factory Mutual (FM)
High Fire#2 #2 oil ____ dBA
Low Fire #2 oil ____ dBA
High Fire Nat Gas ____ dBA
Low Fire Nat Gas ____ dBA
A3-42
03-08
2.05 BURNER DESIGN
A. GENERAL: Forced draft burner of the gun design with hinged access for inspection and service.
Reversed curve fabricated aluminum blower fan; motor(s); ACCU-LINK single point positioning
system consisting of rotary air damper located on the combustion air intake, straight line linkage
and characterized cams; air flow switch; fuel trains and control panels. To conform to UL and
other insurance requirements as indicated.
turn down shall be minimum 8:1 up to 800 HP.
turn down shall be minimum 6:1 for #2 Oil and 4:1 for Heavy Oil.
control for 60 PPM (30, 25, 20 PPM NOx systems are optional) corrected to3% 02 over the
2.06 BOILER TRIM
3. Auxiliary Low Water Cutoff, M/M Model 150 d.
A3-43
03-08
10. 1 Slow Opening Blowdown Valve, Size______ ", Class 200#
11. 2 Quick Opening Blowdown Valves, Size______ ", Class 490#
12. Feedwater Globe Valve, Size______ ", Class 240# m.
13. 1 Feedwater Check Valve, Size______ ", Class 240# n.
14. 1 ASME Spool Piece, Inlet Size______ ", Outlet Size______ ", Length______ "
15. 1 Stop Valve (Steam Header Valve), Size______, Flanged, Cast Iron, Class 250
16. 1 Stop Check Valve (Non-Return Valve), Size______ ", Flanged, Cast Iron, Class 250",
Water Column piping
18. JHB Modulating Feedwater Control Valve, including 3-Valve Bypass
requirements.
B. WATER COLUMN/LOW WATER CUTOFF AND WATER LEVEL CONTROL SYSTEM:
(Standard vs. Optional)
Shall be a CB LEVEL MASTER Water level control system and shall be comprised of a
microprocessor-based electronic controller, a non-contact, non-wearing, continuously reading
electronic controller shall be panel mounted and operate in ambient temperatures from 32
degrees F to 125 degrees F, the pressure chamber shall be boiler mounted and operate to
pressures of 250PSIG and the level sensor shall operate to pressures of 250 PSIG and
temperatures to 400 degrees F. The pressure containing components shall be constructed in
The pressure chamber shall have tri-cocks and sight glass mounted on the side. The level sensor
shall have an accuracy of.01" or greater. The electronic controller shall have level and error
indicating lights, alphanumeric display for messaging, reset/menu switch and the following
features:
3. High Water Alarm
A3-44
03-08
9. Real Time Clock
Maximum Contacts Rating 15 amps Resistive Load
on, low water and flame failure; selector switches, required by dry contacts, relays and terminal
strips. Oil, heat and moisture resistant wire with circuit number corresponding to electrical wiring
diagrams. In accordance with UL and National Electric Code.
B. (OPTION 1) BURNER MANAGEMENT SYSTEM (CB 780-Standard): Boiler mounted in control
C. (OPTION 2) CB-HAWK ICS Boiler Control System (Optional upgrade): Burner Management
System (CB HAWK ICS - optional upgrade): Integrated Boiler Control and Management System:
1. Programmable Logic Controller
2. Touch Screen HMI
3. One Burner Management Controller with Wiring Sub-Base
4. One Flame Scanner and amplifier
5. Various Temperature and Pressure Sensors
D. Major functions provided by the Boiler Control System shall be:
1. Automatic sequencing of the boiler through standby, pre-purge, pilot flame establishing
period, main flame establishing period, run, flame proving and lockout and post-purge
a. Modulating control (algorithm shall be Proportional-lntegral-Derivative (PID) type)
A3-45
03-08
d. o On screen history of alarms and faults
5. Stack Flue Gas, Combustion Air and Shell (water) temperature indication
E. The Boiler Control System shall incorporate the following safety provisions:
1. Examine all load terminals to assure it is capable of recognizing the true status of the
2. Closed-loop logic test of critical loads (ignition, pilot and main fuel valves) and must be able
to lockout on safety.
3. Pre-ignition interlocks (fuel valve proof of closure, etc.) and flame signal checked during
4. Dynamic checking of the flame signal amplifier.
5. Safe start check and expand check to include monitoring flame signal during standby.
6. High and Low fire switches checked for proper sequencing.
7. The Boiler Control System shall provide the ability to communicate with external digital via
Ethernet as a standard. It shall be possible to communicate with any OPC compliant
Internet communications shall be supported, with the Boiler Control System supplied with
its own IP address.
2.08 SHOP TEST
2.13 ACCESSORIES - 02 TRIM SYSTEM AND/OR
A3-46
03-08
2.15 MANUFACTURES FIELD SERVICES
A. General: The boiler and accessories supplier shall be responsible for performance of insp up and
testing of the package boiler and accessory equipment and materials furnished un~ Section. A
detailed written record of the start up performance, including burner setting dat entire load range
shall be furnished to the test engineer before test personnel leave the sit equipment and test
apparatus shall be furnished by the supplier. All equipment defects discovered by the tests shall
be rectified. The minimum time for two (2) boilers is five (5) days.
B. Equipment inspection: Boiler representative to provide ______hours of job site assistance to i
boilers and other equipment upon arrival, verifying completeness of equipment supplied ar
damages. Responsibility of making freight claims to be performed by contractor or owner
personnel.
C. Pre start-up walk through: Boiler representative shall spend _____ hours at job site reviewing
with mechanical contractor to be conducted approximately 1 week prior to startup.
1. Demonstrate that boiler, burner, controls and accessories comply with requirement Section
as proposed by the boiler and accessories supplier. Pre-test all items prior to scheduling the
final testing that will be witnessed by the test engineer.
Nox and overall boiler efficiency.
capacity tests for leakage, malfunctioning, defects, and non compliance with referenced
j. Set up and verify Emissions Compliance
5. Training to include all safety procedures, maintenance procedures, control operations, and
diagnostic procedures. Training to be provided in a single _ hour continuous session to
6. Special tool / safety equipment:
a. Boiler/burner supplier to include in their proposal safety equipment required to perform
annual inspections and maintenance per OSHA requirements, Section
29CFR,1910.146, date 4115193, Paragraphs 5.6.4.2 through 5.6.6.6 confined
space requirements on rear furnace and flue gas turnaround area. Items to include
respirator, tag out devices, atmospheric tester, acid suit, harness, wrist straps, life
A3-47
03-08
wire, and safety belt
b. Special Safety Training on safety procedures by a qualified trainer to be provided per
OSHA Section 1910.146, Paragraph 5.6.5.2, to all owners and employees who are
operating specified equipment. The cost of training to be included in boiler supplier's
proposal
complete spare parts lists and trouble shooting procedures. Operating and maintenance manuals
shall be provided including cut-away views of boiler and burner schematics including fuel trains,
general instructions for maintenance and inspections, complete spare parts lists and trouble
panel.
2.17 WARRANTY DATA
A. The entire boiler/burner package shall be guaranteed and warranted by the boiler manufacturer.
Warranty shall include all parts for a period of (12) months from the date of start-up or beneficial
use or 18 months from shipment, whichever comes first.
PART 3 EXECUTION
3.01 GENERAL
A. Installation shall be provided by the contractor in accordance with the requirements of the codes
3.02 INSTALLATION
A. Install equipment in strict compliance with manufacturer's installation instructions.ww
3.03 FIELD TESTING
A3-48
03-08
shall be replaced.
manufacturer's representative.
The manufacturer's representative shall provide start-up and instruction of each new boiler, including burner
and boiler control system as specified herein. Start-up and instruction shall cover all components assembled
and furnished by the manufacturer whether or not of his own manufacture.
A4-1
02-08
Section A4
Criterion Series Model ICB 100-800 HP
Table of Contents
Four-Pass Intercooled Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-3
Three-Pass Intercooled Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-3
Intercooled Rear Turnaround . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-3
Front and Rear Doors: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-3
Natural Gas, No. 2 Oil, or Combination Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-3
Blowdown Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-19
Fuel Connections Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-19
Fuel Connections Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-19
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-29
Criterion Series Model ICB 100-800 HP Section A4
A4-2
02-08
ILLUSTRATIONS
Figure A4-1. Model ICB Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional) . . . . . . . . . . . . . A4-9
Figure A4-2. Model ICB Hot Water Boiler Dimensions, 4-Pass and 3-Pass (Optional) . . . . . . . . . . A4-11
Figure A4-3. Model ICB-LE Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional) . . . . . . . . . . . A4-13
Figure A4-4. Model ICB-LE Hot Water Boiler Dimensions, 4-Pass and 3-Pass (Optional) . . . . . . . . A4-15
Figure A4-5. Space Required to Open Rear Head on Model ICB Boilers . . . . . . . . . . . . . . . . . . . . A4-17
Figure A4-6. Model ICB Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-17
Figure A4-7. Model ICB Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-18
Figure A4-8. Typical Fuel Oil Supply Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-27
Figure A4-9. Boiler Room Length (Typical Layouts) Model ICB . . . . . . . . . . . . . . . . . . . . . . . . A4-28
Figure A4-10. Boiler Room Width (Typical Layout) Model ICB . . . . . . . . . . . . . . . . . . . . . . . . A4-28
TABLES
Table A4-1. Model ICB Steam Boiler Ratings, 4-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-5
Table A4-2. Model ICB Steam Boiler Ratings, 3-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-5
Table A4-3. Model ICB Hot Water Boiler Ratings, 4-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-6
Table A4-4. Model ICB Hot Water Boiler Ratings, 3-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-6
Table A4-5. Model ICB-LE Steam Boiler Ratings, 4 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-7
Table A4-6. Model ICB-LE Steam Boiler Ratings, 3 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-7
Table A4-7. Model ICB-LE Hot Water Ratings, 4 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-8
Table A4-8. Model ICB-LE Hot Water Ratings, 3 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-8
Table A4-9. Model ICB Steam Boiler Dimensions, 4-Pass and 3-Pass . . . . . . . . . . . . . . . . . . . . . A4-10
Table A4-10. Model ICB Hot Water Boiler Dimensions, 4-Pass and 3-Pass . . . . . . . . . . . . . . . . . A4-12
Table A4-11. Model ICB-LE Steam Boiler Dimensions, 4-Pass and 3-Pass . . . . . . . . . . . . . . . . . . A4-14
Table A4-12. Model ICB-LE Hot Water Boiler Dimensions, 4-Pass and 3-Pass . . . . . . . . . . . . . . . A4-16
Table A4-13. Model ICB Steam Volume and Disengaging Areas . . . . . . . . . . . . . . . . . . . . . . . . . A4-21
Table A4-14. Model ICB Steam Boiler Safety Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . A4-22
Table A4-15. Model ICB Hot Water Boiler Relief Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . A4-22
Table A4-16. Model ICB Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-23
Table A4-17. Model ICB Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . A4-23
Table A4-18. Model ICB Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-24
Table A4-19. Altitude Correction for Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-24
Table A4-20. Sound Levels in dBA for 4-Pass ICB Boilers at High Fire . . . . . . . . . . . . . . . . . . . . A4-24
Table A4-21. Model ICB, Standard, Min. Req. Gas Pressure Standard, FM & IRI Gas Trains . . . . . A4-25
Table A4-22. Model ICB, Low NOx, Min. Req. Gas Pressure Standard, FM & IRI Gas Trains . . . . . . A4-26
The following information applies to the Cleaver-Brooks Model ICB Boiler.
Section A4 Criterion Series Model ICB 100-800 HP
A4-3
02-08
The Cleaver-Brooks Model ICB Boiler line provides a quality product utilizing a
baseline boiler/burner design. Additionally, the boiler/burner package is UL
compliant. The following features apply:
Four-Pass
Intercooled Design:
Four-pass design provides high flue gas velocities and low stack temperatures to
maximize efficiency.
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 fluid cooled and has a davited access opening
for full accessibility to 2nd pass tubes and furnace. It eliminates confined 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.
Natural Gas, No. 2
Oil, or Combination
Burners Available:
adjustment.
Ultra low NOx emissions (<9ppm), consult factory.
PRODUCT OFFERING
Cleaver-Brooks Model ICB Boilers are available in low pressure steam, high pressure
steam, and hot water designs. Burners are available to fire natural gas, No. 2 oil, or
a combination of oil and gas. Standard product offering is:
100 800 hp.
15 300 psig steam.
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 flanged tappings.
Blowdown valves.
Non-return valves.
Blend pump.
Surge load baffles.
Seismic design.
A4-4
02-08
Lead/lag system.
High altitude design.
Elapsed time meter.
NEMA enclosures.
Circuit breakers.
Day/night controls.
Stack thermometer.
Fuel Options
Air atomizing oil burner, 200 800 hp.
Pressure atomizing oil burner, 100 150 hp.
Gas strainer.
Gas pressure gauge.
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 A4-1 Model ICB Steam Boiler Ratings, 4-Pass
Table A4-2 Model ICB Steam Boiler Ratings, 3-Pass (Optional)
Table A4-3 Model ICB Hot Water Boiler Ratings, 4-Pass
Table A4-4 Model ICB Hot Water Boiler Ratings, 3-Pass (Optional)
Figure A4-1 Model ICB Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional)
Table A4-9 Model ICB Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional)
Figure A4-6 Model ICB Hot Water Boiler Dimensions, 4-Pass and 3-Pass
(Optional)
Table A4-10 Model ICB Hot Water Boiler Dimensions, 4-Pass and 3-Pass
(Optional)
Figure A4-5 Space Required to Open Rear Head on Model ICB Boilers
Figure A4-6 Model ICB Boilers Lifting Lug Location
Figure A4-7 Model ICB Boiler Mounting Piers
A4-5
02-08
Table A4-1. Model ICB Steam Boiler Ratings, 4-Pass
* =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 A4-2. Model ICB Steam Boiler Ratings, 3-Pass
BOILER H.P. 100 125 150 200 250 300 350 400 500 600 700 800
BURNER MODEL Model ICB FP-3 FP-3 FP-3 FP-4 FP-4 D145P D175P D210P D252P D300P D336P D378P
RATINGS SEA LEVEL TO 700 FT.
Rated Capacity (lbs-steam/hr. from and at 212F) 3450 4313 5175 6900 8625 10350 12075 13800 17250 20700 24150 27600
Btu Output (1000 Btu/hr.) 3348 4184 5021 6695 8369 10043 11716 13390 16738 20085 23433 26780
Gas CFH (1000 Btu) 4082 5103 6124 8165 10206 12247 14280 16329 20415 24494 28576 32659
Gas (Therm/hr.) 40.8 51.0 61.2 81.7 102.1 122.5 142.8 163.3 204.2 245.0 285.8 326.6
POWER REQUIREMENTS SEA LEVEL TO 700 FT. (60 HZ)
Blower Motor hp 3 5 7-1/2 7-1/2 7-1/2 15 20 25 30 40 60 60
Separate Compressor Motor hp (Oil only) ** ** ** 3 3 7-1/2 7-1/2 7-1/2 7-1/2 7-1/2 15
Integral Oil/Air Motor hp (Oil only) 2
Oil Metering Pump Motor hp (Oil only) 1/2 3/4 3/4 3/4 3/4 1
Circulating Oil Pump Motor hp (Oil only) * * * 1/2 1/2 3/4 3/4 3/4 3/4 3/4 1 1
BOILER DATA
Heating Surface sq.-ft. (Fireside) 353 438 555 729 885 1055 1384 1522 1734 2094 3244 3641
BOILER H.P. 100 125 150 200 250 300 350 400 500 600 700 800
BURNER MODEL Model ICB FP-3 FP-3 FP-3 FP-4 FP-4 FP-4 FP-4 D175P D210P D252P D300P D336P
Rated Capacity (lbs-steam/hr. from and at 212F) 3450 4313 5175 6900 8625 10350 12075 13800 17250 20700 24150 27600
Btu Output (1000 Btu/hr.) 3348 4184 5021 6695 8369 10043 11716 13390 16738 20085 23433 26780
Light Oil gph (140,000 Btu/gal) 29.9 37.5 45.0 60.0 74.5 89.5 104.5 119.5 149.5 179.5 209 239
Gas CFH (1000 Btu) 4184 5230 6280 8370 10460 12555 14650 16750 20925 25100 29300 33500
Gas (Therm/hr.) 41.8 52.3 62.8 83.7 104.6 125.5 146.5 167.5 209.3 251.0 293.0 335.0
Blower Motor hp 2 3 5 7-1/2 7-1/2 10 10 20 25 30 40 60
Separate Compressor Motor hp (Oil only) ** ** ** 3 3 3 3 5 5 7-1/2 7-1/2 7-1/2
Integral Oil/Air Motor hp (Oil only)
Oil Metering Pump Motor hp (Oil only) 1/2 3/4 3/4 3/4 3/4
BOILER DATA
A4-6
02-08
Table A4-3. Model ICB Hot Water Boiler Ratings, 4-Pass
Table A4-4. Model ICB Hot Water Boiler Ratings, 3-Pass
BOILER H.P. 100 125 150 200 250 300 350 400 500 600 700 800
BURNER MODEL Model ICB FP-3 FP-3 FP-3 FP-4 FP-4 D145P D175P D210P D252P D300P D336P D378P
Btu Output (1000 Btu/hr.) 3348 4184 5021 6695 8369 10043 11716 13390 16738 20085 23433 26780
Gas CFH (1000 Btu) 4082 5103 6124 8165 10206 12247 14280 16329 20415 24494 28576 32659
Gas (Therm/hr.) 40.8 51.0 61.2 81.7 102.1 122.5 142.8 163.3 204.2 245.0 285.8 326.6
Blower Motor hp 3 5 7-1/2 7-1/2 7-1/2 15 20 25 30 40 60 60
Separate Compressor Motor hp (Oil only) ** ** ** 3 3 7-1/2 7-1/2 7-1/2 7-1/2 7-1/2 15
Integral Oil/Air Motor hp (Oil only) 2
Oil Metering Pump Motor hp (Oil only) 1/2 3/4 3/4 3/4 3/4 1
BOILER DATA
BOILER H.P. 100 125 150 200 250 300 350 400 500 600 700 800
BURNER MODEL Model ICB FP-3 FP-3 FP-3 FP-4 FP-4 FP-4 FP-4 D175P D210P D252P D300P D336P
Btu Output (1000 Btu/hr.) 3348 4184 5021 6695 8369 10043 11716 13390 16738 20085 23433 26780
Gas CFH (1000 Btu) 4184 5230 6280 8370 10460 12555 14650 16750 20925 25100 29300 33500
Gas (Therm/hr.) 41.8 52.3 62.8 83.7 104.6 125.5 146.5 167.5 209.3 251.0 293.0 335.0
Blower Motor hp 2 3 5 7-1/2 7-1/2 10 10 20 25 30 40 60
Separate Compressor Motor hp (Oil only) ** ** ** 3 3 3 3 5 5 7-1/2 7-1/2 7-1/2
Integral Oil/Air Motor hp (Oil only)
Oil Metering Pump Motor hp (Oil only) 1/2 3/4 3/4 3/4 3/4
BOILER DATA
A4-7
02-08
BOILER H.P. 100 125 150 200 250 300 350 400 500 600 700 800
BURNER MODEL LND54P LND84P LND105P LND125P LND145P LND175P LND210P LND252P LND300P LND315P LND378P LND420P
from and at 212
0
F)
3450 4313 5175 6900 8625 10350 12075 13800 17250 20700 24150 27600
Btu Output (1000 Btu/hr) 3348 4184 5021 6695 8369 10043 11716 13390 16738 20085 23433 26780
Gas CFH (1000 Btu) 4082 5103 6124 8165 10206 12247 14280 16329 20415 24494 28576 32659
Gas (Therm/hr) 40.8 51.0 61.2 81.7 102.1 122.5 142.8 163.3 204.2 245.0 285.8 326.6
Blower Motor hp 5 7 1/2 10 15 15 20 25 30 40 60 60 60
Separate Compressor Motor hp
(Oil only)
- - - - - 5 5 7 1/2 7 1/2 7 1/2 15 15
Integral Oil/Air Motor hp
(Oil only)
1 1 1 1 2 - - - - - - -
(Oil only)
- - - - - 1/2 3/4 3/4 3/4 3/4 1 1
(Oil only)
1/2 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4 1 1
BOILER DATA
Heating Surface sq-ft. (Fireside) 353 438 555 729 885 1055 1384 1522 1734 2094 3244 3641
BOILER H.P. 100 125 150 200 250 300 350 400 500 600 700 800
BURNER MODEL LND54P LND63P LND84P LND105P LND145S LND145P LND175P LND210P LND252P LND300P LND315P LND378P
from and at 212
0
F)
3450 4313 5175 6900 8625 10350 12075 13800 17250 20700 24150 27600
Btu Output (1000 Btu/hr) 3348 4184 5021 6695 8369 10043 11716 13390 16738 20085 23433 26780
Gas CFH (1000 Btu) 4184 5230 6280 8370 10460 12555 14650 16750 20925 25100 29300 33500
Gas (Therm/hr) 41.8 52.3 62.8 83.7 104.6 125.5 146.5 167.5 209.3 251.0 293.0 335.0
Blower Motor hp 5 5 7 1/2 10 15 15 20 25 30 40 60 60
Separate Compressor Motor hp
(Oil only)
- - - - - - 5 5 7 1/2 7 1/2 7 1/2 15
(Oil only)
1 1 1 1 2 2 - - - - - -
(Oil only)
- - - - - - 1/2 3/4 3/4 3/4 3/4 1
(Oil only)
1/2 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4 1 1
BOILER DATA
Heating Surface sq-ft. (Fireside) 353 438 555 729 885 1055 1384 1522 1734 2094 3244 3641
Table A4-5. Model ICB-LE Steam Boiler Ratings, 4 Pass
Table A4-6. Model ICB-LE Steam Boiler Ratings, 3 Pass
A4-8
02-08
BOILER H.P. 100 125 150 200 250 300 350 400 500 600 700 800
BURNER MODEL LND54P LND84P LND105P LND125P LND145P LND175P LND210P LND252P LND300P LND315P LND378P LND420P
Btu Output (1000 Btu/hr) 3348 4184 5021 6695 8369 10043 11716 13390 16738 20085 23433 26780
Light Oil gph (140,000 Btu/g 29.2 36.4 43.7 58.3 72.9 87.5 102.1 116.6 145.8 175.0 204.1 233.3
Gas CFH (1000 Btu) 4082 5103 6124 8165 10206 12247 14280 16329 20415 24494 28576 32659
Gas (Therm/hr) 40.8 51.0 61.2 81.7 102.1 122.5 142.8 163.3 204.2 245.0 285.8 326.6
Blower Motor hp 5 7 1/2 10 15 15 20 25 30 40 60 60 60
Separate Compressor
Motor hp (Oil only)
- - - - - 5 5 7 1/2 7 1/2 7 1/2 15 15
(Oil only)
1 1 1 1 2 - - - - - - -
Oil Metering Pump Motor
hp (Oil only)
- - - - - 1/2 3/4 3/4 3/4 3/4 1 1
hp (Oil only)
1/2 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4 1 1
BOILER DATA
Heating Surface sq-ft. (Fires 353 438 555 729 885 1055 1384 1522 1734 2094 3244 3641
BOILER H.P. 100 125 150 200 250 300 350 400 500 600 700 800
BURNER MODEL LND54P LND63P LND84P LND105P LND145S LND145P LND175P LND210P LND252P LND300P LND315P LND378P
Btu Output (1000 Btu/hr) 3348 4184 5021 6695 8369 10043 11716 13390 16738 20085 23433 26780
Light Oil gph (140,000 Btu/g 29.9 37.5 45.0 60.0 74.5 89.5 104.5 119.5 149.5 179.5 209 239
Gas CFH (1000 Btu) 4184 5230 6280 8370 10460 12555 14650 16750 20925 25100 29300 33500
Gas (Therm/hr) 41.8 52.3 62.8 83.7 104.6 125.5 146.5 167.5 209.3 251.0 293.0 335.0
Blower Motor hp 5 5 7 1/2 10 15 15 20 25 30 40 60 60
Separate Compressor
Motor hp (Oil only)
- - - - - - 5 5 7 1/2 7 1/2 7 1/2 15
(Oil only)
1 1 1 1 2 2 - - - - - -
Oil Metering Pump Motor
hp (Oil only)
- - - - - - 1/2 3/4 3/4 3/4 3/4 1
hp (Oil only)
1/2 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4 1 1
BOILER DATA
Heating Surface sq-ft. (Fire 353 438 555 729 885 1055 1384 1522 1734 2094 3244 3641
Table A4-7. Model ICB-LE Hot Water Ratings, 4 Pass
Table A4-8. Model ICB-LE Hot Water Ratings, 3 Pass
A4-9
02-08
Figure A4-1. Model ICB Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional)
4-PASS ICBSTANDARD STEAM BOILERS
3-PASS ICBSTANDARD STEAM BOILERS
A4-10
02-08
Table A4-9. Model ICB Steam Boiler Dimensions, 4-Pass and 3-Pass
NOTE: Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for actual option require-
ments.
BOILER H.P. DIM 100 125 150 200 250 300 350 400 500 600 700 800
LENGTHS
Overall (3-Pass) A 171" 197" 195" 243-1/2" 208-1/2" 234-1/2" 237-1/2" 263" 255" 290-1/2" 281-1/2" 306-1/2"
Overall (4-Pass) A 171" 197" 195" 243-1/2" 208-1/2" 241" 247" 268" 257-1/2" 290-1/2" 284-1/2" 312"
Shell B 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"
Base Frame C 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"
Base Frame to Rear Flange D 9-1/2" 9-1/2" 9-1/2" 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"
Flange to Steam Nozzle E 55-7/8" 61-7/8" 65-7/8" 77-7/8" 68-7/8" 80-7/8" 78-7/8" 94-7/8" 82-3/4" 106-3/4" 98-7/8" 111-7/8"
WIDTHS
Overall I 80" 80" 85" 85" 97" 97" 103" 103" 117" 117" 131" 131"
I.D. Boiler J 55" 55" 60" 60" 72" 72" 78" 78" 92" 92" 106" 106"
Center to Water Column K 42-1/2" 42-1/2" 45" 45" 51" 51" 54" 54" 61" 61" 68" 68"
Center to Lagging L 30-1/2" 30-1/2" 33" 33" 39" 39" 42" 42" 49" 49" 56" 56"
Center to Auxiliary LWCO LL 37-1/2" 37-1/2" 40" 40" 46" 46" 49" 49" 56" 56" 63" 63"
Base Outside M 47-1/2" 47-1/2" 52-1/2" 52-1/2" 58-1/2" 58-1/2" 64" 64" 68" 68" 74-3/4" 74-3/4"
Base Inside N 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"
HEIGHTS
Base to Boiler Centerline F 44-1/2" 44-1/2" 46" 46" 54" 54" 56" 56" 65-1/2" 65-1/2" 71" 71"
Base to Vent Outlet O 80-3/4" 80-3/4" 85" 85" 101" 101" 106" 106" 122-1/2" 122-1/2" 135-5/8" 135-5/8"
Base to Rear Door Davit OA 82-1/4" 82-1/4" 86-1/2" 86-1/2" 101" 101" 106" 106" 122-1/2" 122-1/2" 135-5/8" 135-5/8"
Base to Steam Outlet P 78-3/8" 78-3/8" 82-3/8" 82-3/8" 96-1/4" 96-1/4" 101-1/2" 101-1/2" 118" 118" 130-5/8" 130-5/8"
Base Frame Q 12" 12" 12" 12" 10" 10" 10" 10" 12" 12" 12" 12"
Base to Bottom Boiler R 16" 16" 16" 16" 17" 17" 17" 17" 19" 19" 17-1/2" 17-1/2"
CONNECTIONS
Chemical Feed G 1" 1" 1" 1" 1" 1" 1" 1" 1" 1" 1" 1"
Feedwater Inlet (Both Sides) S 1-1/4" 1-1/2" 1-1/2" 2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 2-1/2" 2-1/2" 2-1/2"
Steam Nozzle (15 psig) 150 LB. FLG. Y 8" 8" 8" 10" 10" 12" 12" 12" 12" 12" 12" 12"
Steam Nozzle

(150 psig) 300 LB. FLG. Y 4" 4" 4" 4" 6" 6" 6" 6" 8" 8" 8" 8"
Drain Front & Rear (15 psig) W 1-1/2" 1-1/2" 1-1/2" 2" 2" 2" 2" 2" 2" 2" 2" 2"
Blowdown-Front & Rear(150 psig) W 1-1/4" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 2" 2" 2" 2" 2"
Surface Blowoff (150 psig only) T 1" 1" 1" 1" 1" 1" 1" 1" 1" 1" 1" 1"
Vent Stack Diameter (Flanged) BB 16" 16" 16" 16" 20" 20" 20" 20" 24" 24" 24" 24"
Flange to Center Vent CC 9-1/8" 9-1/8" 9-1/8" 9-1/8" 10-5/8" 10-5/8" 10-5/8" 10-5/8" 12-5/8" 12-5/8" 12-5/8" 12-5/8"
MINIMUM CLEARANCES
Rear Door Swing DD 34" 34" 36" 36" 43" 43" 46" 46" 53" 53" 60" 60"
Tube Removal Front GG 95" 121" 119" 160" 122" 148" 149" 165" 146" 179" 170" 192"
Tube Removal Rear HH 96-1/2" 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"
Front of Boiler RF 257" 309" 307" 389" 326" 378" 385" 417" 395" 461" 450" 494"
Rear of Boiler (3-Pass) RR 303-1/2" 355-1/2" 351-1/2" 441" 371" 423" 427" 468-1/2" 441-1/2" 510" 492" 539"
Rear of Boiler (4-Pass) RR 303-1/2" 355-1/2" 351-1/2" 441" 371" 429-1/2" 436-1/2" 473-1/2" 444" 510" 495" 544-1/2"
Thru Window or Door (3-Pass) RD 237" 263" 263" 311-1/2" 283-1/2" 309-1/2" 315-1/2" 341" 340" 375-1/2" 373-1/2" 398-1/2"
Thru Window or Door (4-Pass) RD 237" 263" 263" 311-1/2" 283-1/2" 316" 325" 346" 342-1/2" 375-1/2" 376-1/2" 404"
WEIGHTS
Normal Water Weight (lbs) 5,140 6,515 7,184 9,612 10,175 12,278 13,192 14,593 17,870 21,780 26,638 30,026
Shipping Weight (15psig) (lbs) 10,123 11,303 11,931 14,106 16,958 19,051 22,344 23,918 28,934 33,189 41,179 45,226
A4-11
02-08
Figure A4-2. Model ICB Hot Water Boiler Dimensions, 4-Pass and 3-Pass (Optional)
4-PASS ICB STANDARD HOT WATER BOILERS
3-PASS ICB STANDARD HOT WATER BOILERS
A4-12
02-08
Table A4-10. Model ICB Hot Water Boiler Dimensions, 4-Pass and 3-Pass
NOTE: Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for actual option requirements.
BOILER H.P. DIM 100 125 150 200 250 300 350 400 500 600 700 800
LENGTHS
Overall (3-Pass) A 171" 197" 195" 243-1/2" 208-1/2" 234-1/2" 237-1/2" 263" 255" 290-1/2" 281-1/2" 306-1/2"
Overall (4-Pass) A 171" 197" 195" 243-1/2" 208-1/2" 241" 247" 268" 257-1/2" 290-1/2" 284-1/2" 312"
Shell B 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"
Base Frame C 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"
Flange to Return E 82" 98" 95-5/8" 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"
Flange to Outlet F 97-1/2" 123" 120-5/8" 161-5/8" 127-5/8" 141-5/8" 143-5/8" 158-5/8" 152-1/2" 175" 171" 193"
WIDTHS
Overall I 65" 65" 70" 70" 82" 82" 88" 88" 102" 102" 116" 116"
I.D. Boiler J 55" 55" 60" 60" 72" 72" 78" 78" 92" 92" 106" 106"
Center to LWCO Controller K 34-1/2" 34-1/2" 37 37" 43" 43" 46" 46" 53" 53" 60" 60"
Base Outside M 47-1/2" 47-1/2" 52-1/2" 52-1/2" 58-1/2" 58-1/2" 64" 64" 68" 68" 74-3/4" 74-3/4"
Base Inside N 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"
HEIGHTS
Base to Boiler Centerline H 44-1/2" 44-1/2" 46" 46" 54" 54" 56" 56" 65-1/2" 65-1/2" 71" 71"
Base to Return/Outlet P 78-3/8" 78-3/8" 82-3/8" 82-3/8" 96-1/4" 96-1/4" 101-1/2" 101-1/2" 118" 118" 130-5/8" 130-5/8"
Base Frame Q 12" 12" 12" 12" 10" 10" 10" 10" 12" 12" 12" 12"
CONNECTIONS
Waterfill (Both Sides) S 1-1/2" 1-1/2" 1-1/2" 2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 2-1/2" 2-1/2" 2-1/2"
Water Return U 4" 6" 6" 6" 8" 8" 8" 10" 10" 12" 12" 12"
Water Outlet Y 4" 6" 6" 6" 8" 8" 8" 10" 10" 12" 12" 12"
Drain Front & Rear W 1-1/2" 1-1/2" 1-1/2" 2" 2" 2" 2" 2" 2" 2" 2" 2"
Air Vent T 1-1/4" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 2" 2" 2" 2"
MINIMUM CLEARANCES
Rear of Boiler (3-Pass) RR 303-1/2" 355-1/2" 351-1/2" 441" 371" 423" 427" 468-1/2" 441-1/2" 510" 492" 539"
Rear of Boiler (4-Pass) RR 303-1/2" 355-1/2" 351-1/2" 441" 371" 429-1/2" 436-1/2" 473-1/2" 444" 510" 495" 544-1/2"
Thru Window or Door (3-Pass) RD 237" 263" 263" 311-1/2" 283-1/2" 309-1/2" 315-1/2" 341" 340" 375-1/2" 373-1/2" 398-1/2"
Thru Window or Door (4-Pass) RD 237" 263" 263" 311-1/2" 283-1/2" 316" 325" 346" 342-1/2" 375-1/2" 376-1/2" 404"
WEIGHTS
BBA4_02-08
A4-13
02-08
Figure A4-3. Model ICB-LE Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional)
A4-14
02-08
BOILER H.P. DIM 100 125 150 200 250 300 350 400 500 600 700 800
LENGTHS
Overall (3-Pass) A 173" 199" 199" 240" 215" 241" 247" 268" 257-1/2" 290-1/2" 285-1/2" 312"
Overall (4-Pass) A 173" 201" 199" 240" 215" 244" 252" 270-1/2" 257-1/2" 293-1/2" 290" 312"
Shell B 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"
Base Frame C 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"
Flange to Steam Nozzle E 55-7/8" 61-7/8" 65-7/8" 77-7/8" 68-7/8" 80-7/8" 78-7/8" 94-7/8" 82-3/4" 106-3/4" 98-7/8" 111-7/8"
WIDTHS
Overall (3-Pass) I 87" 87" 92" 92" 104" 106" 112" 112" 126" 128" 142" 142"
Overall (4-Pass) I 82" 82" 87" 87" 100" 100" 109" 109" 122" 122" 133" 133"
I.D. Boiler J 55" 55" 60" 60" 72" 72" 78" 78" 92" 92" 106" 106"
Center to Water Column K 44-1/2" 44-1/2" 47" 47" 53" 53" 56" 56" 63" 63" 70" 70"
Center to Outside FGR Pipe (3-Pass) KK 42-1/2" 42-1/2" 45" 45" 51" 53" 56" 56" 63" 65" 72" 72"
Center to Outside FGR Pipe (4-Pass) KK 37" 37" 37" 37" 47" 47" 53" 53" 59" 59" 59" 59"
FGR Duct Size (3-Pass) V 6" 6" 6" 6" 6" 8" 8" 8" 8" 10" 10" 10"
Center to Auxiliary LWCO LL 37-1/2" 37-1/2" 40" 40" 46" 46" 49" 49" 56" 56" 63" 63"
Base Outside M 47-1/2" 47-1/2" 52-1/2" 52-1/2" 58-1/2" 58-1/2" 64" 64" 68" 68" 74-3/4" 74-3/4"
Base Inside N 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"
HEIGHTS
Base to Boiler Centerline F 44-1/2" 44-1/2" 46" 46" 54" 54" 56" 56" 65-1/2" 65-1/2" 71" 71"
Base to FGR Stack Extension
(3-Pass Only)
FF 94-3/4" 94-3/4" 99" 99" 118" 118" 123" 123" 142-1/2" 142-1/2" 155-5/8" 155-5/8"
Base to Steam Outlet P 78-3/8" 78-3/8" 82-3/8" 82-3/8" 96-1/4" 96-1/4" 101-1/2" 101-1/2" 118" 118" 130-5/8" 130-5/8"
Base Frame Q 12" 12" 12" 12" 10" 10" 10" 10" 12" 12" 12" 12"
CONNECTIONS
Chemical Feed G 1" 1" 1" 1" 1" 1" 1" 1" 1" 1" 1" 1"
Feedwater Inlet (Both Sides) S 1-1/4" 1-1/2" 1-1/2" 2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 2-1/2" 2-1/2" 2-1/2"
Steam Nozzle (15 psig) 150 LB. FLG. Y 8" 8" 8" 10" 10" 12" 12" 12" 12" 12" 12" 12"
Steam Nozzle (150 psig
)
300 LB. FLG. Y 4" 4" 4" 4" 6" 6" 6" 6" 8" 8" 8" 8"
Drain Front & Rear (15 psig) W 1-1/2" 1-1/2" 1-1/2" 2" 2" 2" 2" 2" 2" 2" 2" 2"
Blowdown-Front & Rear(150 psig) W 1-1/4" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 2" 2" 2" 2" 2"
Surface Blowoff (150 psig only) T 1" 1" 1" 1" 1" 1" 1" 1" 1" 1" 1" 1"
MINIMUM CLEARANCES
Rear of Boiler (3-Pass) 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" 444" 510" 496" 544-1/2"
Rear of Boiler (4-Pass) RR 305-1/2" 359-1/2" 355-1/2" 437-1/2" 377-1/2" 432-1/2" 441-1/2" 476" 444" 513" 500-1/2" 544-1/2"
Thru Window or Door (3-Pass) RD 239" 265" 267" 308" 290" 316" 325" 346" 342-1/2" 375-1/2" 376-1/2" 404"
Thru Window or Door (4-Pass) RD 239" 267" 267" 308" 290" 319" 330" 348-1/2" 342-1/2" 378-1/2" 382" 404"
WEIGHTS
Normal Water Weight 5,140 6,515 7,184 9,612 10,175 12,278 13,192 14,593 17,870 21,780 26,638 30,026
Shipping Weight (15psig) 10,123 11,303 11,931 14,106 16,958 19,051 22,344 23,918 28,934 33,189 41,179 45,226
Shipping Weight (150psig) 10,877 12,220 13,112 15,637 17,613 20,404 25,344 27,175 31,990 36,780 45,724 50,244
Table A4-11. Model ICB-LE Steam Boiler Dimensions, 4-Pass and 3-Pass
A4-15
02-08
Figure A4-4. Model ICB-LE Hot Water Boiler Dimensions, 4-Pass and 3-Pass (Optional)
A4-16
02-08
BOILER H.P. DIM 100 125 150 200 250 300 350 400 500 600 700 800
LENGTHS
Overall (3-Pass) A 173" 199" 199" 240" 215" 241" 247" 268" 257-1/2" 290-1/2" 285-1/2" 312"
Overall (4-Pass) A 173" 201" 199" 240" 215" 244" 252" 270-1/2" 257-1/2" 293-1/2" 290" 312"
Shell B 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"
Base Frame C 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"
Flange to Return E 82" 98" 95-5/8" 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"
Flange to Outlet F 97-1/2" 123" 120-5/8" 161-5/8" 127-5/8" 141-5/8" 143-5/8" 158-5/8" 152-1/2" 175" 171" 193"
WIDTHS
Overall (3-Pass) I 87" 87" 92" 92" 104" 106" 112" 112" 126" 128" 142" 142"
Overall (4-Pass) I 81-1/2" 81-1/2" 84" 84" 100" 100" 109" 109" 122" 122" 129" 129"
I.D. Boiler J 55" 55" 60" 60" 72" 72" 78" 78" 92" 92" 106" 106"
Center to Control Panel K 44-1/2" 44-1/2" 47" 47" 53" 53" 56" 56" 63" 63" 70" 70"
Center to Outside FGR Pipe (3-Pass) KK 42-1/2" 42-1/2" 45" 45" 51" 53" 56" 56" 63" 65" 72" 72"
Center to Outside FGR Pipe (4-Pass) KK 37" 37" 37" 37" 47" 47" 53" 53" 59" 59" 59" 59"
Base Outside M 47-1/2" 47-1/2" 52-1/2" 52-1/2" 58-1/2" 58-1/2" 64" 64" 68" 68" 74-3/4" 74-3/4"
Base Inside N 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"
HEIGHTS
Base to Boiler Centerline H 44-1/2" 44-1/2" 46" 46" 54" 54" 56" 56" 65-1/2" 65-1/2" 71" 71"
Base to FGR Stack Extension
(3-Pass Only)
FF 94-3/4" 94-3/4" 99" 99" 118" 118" 123" 123" 142-1/2" 142-1/2" 155-5/8" 155-5/8"
Base to Return/Outlet P 78-3/8" 78-3/8" 82-3/8" 82-3/8" 96-1/4" 96-1/4" 101-1/2" 101-1/2" 118" 118" 130-5/8" 130-5/8"
Base Frame Q 12" 12" 12" 12" 10" 10" 10" 10" 12" 12" 12" 12"
CONNECTIONS
Waterfill (Both Sides) S 1-1/2" 1-1/2" 1-1/2" 2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 2-1/2" 2-1/2" 2-1/2"
Water Return U 4" 6" 6" 6" 8" 8" 8" 10" 10" 12" 12" 12"
Water Outlet Y 4" 6" 6" 6" 8" 8" 8" 10" 10" 12" 12" 12"
Drain Front & Rear W 1-1/2" 1-1/2" 1-1/2" 2" 2" 2" 2" 2" 2" 2" 2" 2"
Air Vent T 1-1/4" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 2" 2" 2" 2"
MINIMUM CLEARANCES
Rear of Boiler (3-Pass) 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" 444" 510" 496" 544-1/2"
Rear of Boiler (4-Pass) RR 305-1/2" 359-1/2" 355-1/2" 437-1/2" 377-1/2" 432-1/2" 441-1/2" 476" 444" 513" 500-1/2" 544-1/2"
Thru Window or Door (3-Pass) RD 239" 265" 267" 308" 290" 316" 325" 346" 342-1/2" 375-1/2" 376-1/2" 404"
Thru Window or Door (4-Pass) RD 239" 267" 267" 308" 290" 319" 330" 348-1/2" 342-1/2" 378-1/2" 382" 404"
WEIGHTS
Table A4-12. Model ICB-LE Hot Water Boiler Dimensions, 4-Pass and 3-Pass
BBA4_02-08
A4-17
02-08

Figure A4-5. Space Required to Open Rear Head on Model ICB Boilers
Figure A4-6. Model ICB Boilers Lifting Lug Location
BOILER HP
A B C D E
100 125 31 45 47 70 34
150 200 33 47 52 80 36
250 300 39 53 58 86 43
350 400 42 56 61 92 46
500 600 49 65 69 106 53
700 800 56 74 80 121 60
BOILER HP
A B C D E
100 75-1/4 21-3/8 81-1/4 10 3
125 75-1/4 21-3/8 107-1/4 10 3
150 79-1/2 25-3/8 96-1/2 10 3
200 79-1/2 25-3/8 137-1/2 10 3
250 94 32 96-1/4 10 3
300 94 32 122-1/4 10 3
350 99 32 123-1/4 10 3
400 99 32 139-1/4 10 3
500 115-1/2 34 125-3/4 11 3
600 115-1/2 34 158-3/4 11 3
700 128-1/4 34 151 11 3
800 128-1/4 34 173 11 3
A4-18
02-08
NOTE: 6-inch high mounting piers recommended for use beneath the boiler
base frame. The use of these piers provides increased inspection accessi-
bility to the boiler and added height for washing down the area beneath the
boiler.
Figure A4-7. Model ICB Boiler Mounting Piers
PERFORMANCE DATA
Contact your local Cleaver-Brooks Authorized Representative for efficiencies or
additional information.
Cleaver-Brooks ICB boilers are available with the standard burner package, or
optional induced flue gas recirculation, refer to the Model ICB-LE for low NOx
information.
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 A4-13 shows steam volume and disengaging area for Model ICB Boilers.
E " "
BOILER HP
A B C D E F G X
100 6 9 127-1/2 34-1/2 52-1/2 4 39-1/2 17-1/2
125 6 9 153-1/2 34-1/2 52-1/2 4 39-1/2 17-1/2
150 6 9 151-1/2 39-1/2 57-1/2 4 44-1/2 17-1/2
200 6 9 192-1/2 39-1/2 57-1/2 4 44-1/2 17-1/2
250 6 9 160-1/2 45-1/2 63-1/2 4 50-1/2 17-1/2
300 6 9 186-1/2 45-1/2 63-1/2 4 50-1/2 17-1/2
350 6 9 187-1/2 51 69 4 56 17-1/2
400 6 9 203-1/2 51 69 4 56 17-1/2
500 6 12 190-1/2 49-1/2 73-1/2 6-1/2 55 20-1/2
600 6 12 223-1/2 49-1/2 73-1/2 6-1/2 55 20-1/2
700 6 12 214-1/2 56-1/4 80-1/4 6-1/2 61-3/4 20-1/2
800 6 12 236-1/2 56-1/4 80-1/4 6-1/2 61-3/4 20-1/2
A4-19
02-08
Table A4-14 lists quantity and outlet size for safety valves supplied on Model ICB
Steam Boilers.
Table A4-15 lists quantity and outlet size for relief valves supplied on Model ICB Hot
Water Boilers.
Table A4-16 gives recommended steam nozzle sizes on Model ICB Boilers.
Table A4-17 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.
water at normal operating level for Cleaver-Brooks Model ICB Boilers.
Burner/Control
Information
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.
Gas-Fired Burners
Table A4-19 lists minimum required gas pressure for altitude correction.
Table A4-21 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
The local gas company should be consulted for requirements and authorization for
installation and inspection of gas supply piping. Installation of gas supply piping and
venting must be in accordance with all applicable engineering guidelines and
regulatory codes. All connections made to the boiler should be arranged so that all
components remain accessible for inspection, cleaning and maintenance.
A drip leg should be installed in the supply piping before the connection to the gas
pressure regulator. The drip leg should be at least as large as the inlet fitting
supplied with the boiler. Consideration must be given to both volume and pressure
requirements when choosing gas supply piping size. Refer to the boiler dimension
diagram provided by Cleaver-Brooks for the particular installation. Connections to
the burner gas train should be made with a union, so that gas train components or
the burner may be easily disconnected for inspection or service. Upon completion of
the gas piping installation, the system should be checked for gas leakage and tight
shutoff of all valves.
Fuel Connections
Oil
Oil-fired 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 firing 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 A4-8 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
A4-20
02-08
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.
Boiler Room
Information
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
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 fine mesh wire, as this type of covering has poor air flow 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. Under no condition should the total
area of the air supply openings be less than one (1) square foot.
D. Size the openings by using the formula:
Area (sq.-ft.) = CFM/FPM
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.
A. From floor to (7) foot height 250 fpm.
A4-21
02-08
B. Above (7) foot height 500 fpm.
Area Required: Area = cfm/fpm = 3000/250 = 12 sq.-ft. total.
Area/Opening: 12/2 = 6 sq.-ft./opening (2 required).
Notice
Stack/Breeching
Size Criteria
Although constant pressure at the flue gas outlet of the Model ICB is not required, it
is necessary to size the stack/breeching to limit flue gas pressure variation. The
on the above criteria. Your local Cleaver-Brooks Authorized Representative is capable
Table A4-13. Model ICB Steam Volume and Disengaging Areas
BOILER
HP
STEAM VOLUME CU-FT.
STEAM RELIEVING
AREA SQ.-IN
HIGH
PRESSURE
(A)
LOW
PRESSURE
(B)
HIGH
PRESSURE
(A)
LOW
PRESSURE
(B)
100 11.2 16.5 3917 4363
125 14 20.5 4882 5443
150 19 26.3 5472 5990
200 25 34.6 7200 7891
250 27.8 41.4 6811 7618
300 33.2 49.4 8122 9072
350 47.9 66.3 9374 10238
400 52.6 72.9 10296 11246
500 74.5 94.9 11405 12168
600 89.6 114.2 13723 14630
700 100.8 127 14602 15538
800 112.7 142 16315 17381
NOTE:
A4-22
02-08
Table A4-14. Model ICB Steam Boiler Safety Valve Outlet Size
Table A4-15. Model ICB Hot Water Boiler Relief Valve Outlet Size
NOTE: Relief valve is Kunkle #537 for 30#& 125#(Section IV) boiler and is Kunkle #927 for 150#HTHW (Section I) boiler.
VALVE
SETTING 15 PSIG STEAM 150 PSIG STEAM 200 PSIG STEAM 250 PSIG STEAM
BOILER HP
NO. OF
VALVES
REQD
OUTLET
SIZE (IN.)
NO. OF
VALVES
REQD
OUTLET
SIZE (IN.)
NO. OF
VALVES
REQD
OUTLET
SIZE (IN.)
NO. OF
VALVES
REQD
OUTLET
SIZE (IN.)
100 1 2-1/2 1 1-1/2 1 1-1/2 1 1-1/4
125 1 2-1/2 1 2 1 (1) 1-1/2 1 1 1/2
150 1 3 2 (1) 1-1/2
(1) 1-1/4
2 1-1/4
(1) 1
2 1
200 2 (1) 2-1/2
(1) 2
2 1-1/2 2 (1) 1-1/2
(1) 1-1/4
2 1-1/4
250 2 (2) 2-1/2 2 (1) 2
(1) 1-1/2
2 1-1/2
(1) 1-1/4
2 (1) 1-1/2
(1) 1-1/4
300 2 3
(1) 2-1/2
2 (1) 2
(1) 1-1/2
2 (2) 1-1/2 2 (1) 1-1/2
(1) 1-1/4
350 2 (2) 3 2 (1) 2-1/2
(1) 2
2 2
(1) 1-1/2
2 (1) 1-1/2
(1) 2
400 2 (2) 3 2 (1) 2-1/2
(1) 2
2 2
(1) 1-1/2
2 (2) 1-1/2
500 3 (2)3
(1) 2-1/2
2 (1) 2-1/2
(1) 2
2 (1) 2-1/2
(1) 2
2 2
(1) 1-1/2
600 3 (3) 3 2 (2) 2-1/2 2 (1) 2-1/2
(1) 2
2 2
700 4 (4) 3 3 (2) 2-1/2
(1) 2
2 2-1/2 2 (1) 2-1/2
(1) 2
800 5 (3) 3
(2) 2-1/2
3 2-1/2 3 (2) 2
(1) 2-1/2
2 2-1/2
VALVE
SETTING 30 PSIG HW 125 PSIG HW 150 PSIG HW
BOILER HP
NO. OF
VALVES
REQD
OUTLET
SIZE (IN.)
NO. OF
VALVES
REQD
OUTLET
SIZE (IN.)
NO. OF
VALVES
REQD
OUTLET
SIZE (IN.)
100 1 2 1 1 1 2
125 1 2-1/2 1 1-1/4 2 (1) 1-1/2
(1) 2
150 1 2-1/2 1 1-1/4 2 (1) 1-1/2
(1) 2
200 2 (1) 2-1/2
(1) 1
2 1 2 2
250 2 (1) 1-1/4
(1) 2-1/2
1 2 2 (1) 2
(1) 2-1/2
300 2 (1) 2-1/2
(1) 2
1 2 2 (1) 1-1/2
(1) 2
350 2 2-1/2 1 2-1/2 2 (2) 2-1/2
400 3 (1) 1
(2) 2-1/2
1 2-1/2 2 (1) 2-1/2
(1) 3
500 4 (1) 2
(2) 2-1/2
1 2-1/2 2 (1) 3
(1) 2-1/2
600 3 2-1/2 2 (1) 1
(1) 2-1/2
2 3
700 4 (4) 2-1/2 2 (1) 2-1/2
(1) 1-1/4
3 (2) 3
(1) 2-1/2
800 5 (1) 1
(4)2-1/2
2 (1) 2-1/2
(1) 2
3 3
BBA4_02-08
A4-23
02-08
Table A4-16. Model ICB Recommended Steam Nozzle Size
Table A4-17. Model ICB Recommended Non-Return Valve Size
OPERATING
PRESSURE BOILER HP
PSIG 100 125 150 200 250 300 350 400 500 600 700 800
15 8 8 8 10 10 12 12 12 12 12 12 12
30 6 6 6 8 8 8 10 10 10 12 12 12
40 6 6 6 6 8 8 8 10 10 10 12 12
50 4 6 6 6 6 8 8 8 10 10 10 12
75 4 4 4 6 6 6 8 8 8 8 10 10
100 4 4 4 6 6 6 6 6 8 8 8 10
125 4 4 4 4 6 6 6 6 8 8 8 8
150 2.5 3 3 4 4 6 6 6 6 6 8 8
200 2.5 2.5 3 4 4 4 4 6 6 6 6 6
250 2 2.5 3 3 4 4 4 4 6 6 6 6
NOTES:
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
BBA4_02-08
NOTE:
Valve sizes (300# flanges) given in inches).
Standard non-return valve selections limited to a maximum 2 to 1 turndown (50% of full boiler output); selection based on typical
valve sizing recommendations. For final valve selection contact your authorized C-B representative. For high turndown applications see
Boiler Book Section I3, Table I3-3.
*Indicates pressure drop of less than 7.5 psig. All other selections are less than 6 psig pressure drop.
BOILER BOILER CAPACITY OPERATING PRESSURE (PSIG)
HP (LBS/HR) 50 75 100 125 150 175 200 250
100 3450 2-1/2 2-1/2 NA NA NA NA NA NA
125 4313 3 2-1/2 2-1/2 2-1/2 NA NA NA NA
150 5175 3 3 2-1/2 2-1/2 2-1/2 2-1/2 NA NA
200 6900 3* 3 3 3 3 2-1/2 2-1/2 2-1/2
250 8625 4 3* 3 3 3 3 3 3
300 10350 4 4 4 3* 3 3 3 3
350 12025 4 4 4 4 4 3* 3 3
400 13800 5 4 4 4 4 4 4 3*
500 17210 6 5 5 4 4 4 4 4
600 20700 6 6 5 5 5 4 4 4
700 24150 6 6 6 5 5 5 5 4
800 27600 6 6 6 6 6 5 5 5
A4-24
02-08
Table A4-18. Model ICB Blowdown Tank Sizing Information
Table A4-20. Sound Levels in dBA for 4-Pass ICB Boilers at High Fire
100 75
125 94
150 102
200 135
250 125
300 150
350 174
400 191
500 206
600 248
700 266
800 297
NOTE: Quantity of water removed from boiler by lowering normal water line 4"
ALTITUDE
(FT.)
CORRECTION
FACTOR
ALTITUDE
(FT.)
CORRECTION
FACTOR
1000 1.04 6000 1.25
2000 1.07 7000 1.3
3000 1.11 8000 1.35
4000 1.16 9000 1.4
5000 1.21
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.
BHP
Sound Level dBA
ICB
100 80.0
125 84.5
150 84.5
200 84.5
250 84.5
300 91.0
350 94.0
400 91.5
500 93.5
600 93.5
700 93.7
800 93.7
A4-25
02-08
Table A4-21. Model ICB, Standard Emissions, Minimum Required Gas Pressure at Entrance to Standard,
FM & IRI Gas Trains (Upstream of Gas Pressure Regulator)
BOILER
HP
STD PIPE
SIZE
(Inches)
PRESSURE REQUIRED,
3-PASS ("WC)
PRESSURE REQUIRED,
4-PASS ("WC)
GPR* Minimum Maximum GPR* Minimum Maximum
100 2 RV91 8.5 27.7 RV91 10.5 27.7
125 2 RV91 13.5 27.7 RV91 16 27.7
150 2 RV91 17 27.7 RV91 21 27.7
200 2-1/2 RV111 20 27.7 210G 26 277
250 2-1/2 210G 32.5 277 210G 33 277
300 2-1/2 210G 45 277 210G 45.5 277
350 3 210G 46 277 210G 46.5 277
400
1.5-2 S 133 208 S 133 208
2-2.5 S 91 133 S 94 133
2.5 S 64 91 S 66 94
3 S 39 64 S 42 66
500
1.5-2.5 S 191 277 S 183 277
2-2.5 S 139 191 S 133 183
2.5 S 94 139 S 89 133
3 S 55 94 S 53 89
600
2-1.5-2.5 S 249 277 S 244 277
2-2.5 S 191 249 S 188 244
2.5 S 130 191 S 133 188
2.5-3 S 108 130 S 111 133
3 S 66 108 S 72 111
700
2-3 S 233 277 S 230 277
2.5-3 S 141 233 S 141 230
3 S 91 141 S 91 141
4 S 58 91 S 64 91
800
2.5-3 S 177 277 S 175 277
3 S 114 177 S 114 175
4 S 72 114 S 72 114
BBA4_02-08
A4-26
02-08
Table A4-22. Model ICB, Low NOx, Minimum Required Gas Pressure at Entrance to Standard,
FM & IRI Gas Trains (Upstream of Gas Pressure Regulator)
BOILER
HP
STD PIPE
SIZE
(Inches)
PRESSURE REQUIRED,
3-PASS ("WC)
PRESSURE REQUIRED,
4-PASS ("WC)
GPR* Minimum Maximum GPR* Minimum Maximum
100 2 RV91 13 27.7 RV91 15 27.7
125 2 RV91 19.5 27.7 RV91 17.5 27.7
150 2 RV91 20 27.7 RV91 21.5 27.7
200 2-1/2 210G 27 277 210G 32.5 277
250 2-1/2 210G 30 277 210G 35.5 277
300 2-1/2 210G 43 277 210G 47.5 277
350 3 210G 45 277 210G 49.5 277
400
1.5-2 S 133 208 S 133 208
2 S 91 133 S 91 133
2.5 S 66 91 S 66 91
3 S 39 66 S 42 66
500
1.5-2.5 S 188 277 S 186 277
2-2.5 S 136 188 S 136 186
2.5 S 91 136 S 94 136
3 S 53 91 S 55 94
600
2-1.5-2.5 S 252 277 S 247 277
2-2.5 S 194 252 S 191 247
2.5 S 130 194 S 133 191
2.5-3 S 108 130 S 111 133
3 S 69 108 S 75 111
700
2-3 S 235 277 S 230 277
2.5-3 S 144 235 S 141 230
3 S 91 144 S 91 141
4 S 61 91 S 61 91
800
2.5-3 S 175 277 S 175 277
3 S 111 175 S 114 175
4 S 69 111 S 3 114
A4-27
02-08
A4-28
02-08
Figure A4-9. Boiler Room Length (Typical Layouts) 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 sufficient aisle space at the front of the boiler but a tightspace
condition at the rear.
If space permits, approximately 1.5 additional feet should be allowed at the rear for additional aisle and work-
ing 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 work-
ing space.
Figure A4-10. Boiler Room Width (Typical Layout) Model ICB
BOILER HP 100 125 150 200 250 300 350 400 500 600 700 800
DIM. A 84-1/2 87 93 96 103 110
DIM. B 115-1/2 120 138 144 170 184
NOTES:
1. Recommended Minimum Distance Between Boiler and Wall.
Dimension "Aallows for a clear42" aisle between the water column on the boiler and
the wall. If space permits, this aisle should be widened.
Dimension Bbetween boilers allows for a clearaisle of:
42" 100-200 hp
48" 250-400 hp
60 500-800 hp
A4-29
03-05
Section A4
Model ICB
Sample Specifications
Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-28
General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-28
Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-30
Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-30
Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-35
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-36
Shop Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-36
Boiler Characteristics (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-37
Hot Water Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-38
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-42
Shop Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-42
Start-Up Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-42
Section A4
A4-30
03-05
SAMPLE SPECIFICATION
The following sample specification is provided by Cleaver-Brooks to assist you in meeting your customers
specific needs and application.
The Sample Specifications are typically utilized as the base template for the complete boiler specification.
Contact your local Cleaver-Brooks Authorized Representative for information on special insurance
requirements, special code requirements, optional equipment, or general assistance in completing the
specification.
PART 1 GENERAL
Model ICB Steam Boiler (100 800 hp, 15 300 psig)
1.1 BOILER CHARACTERISTICS (STEAM)
A. 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.
B. The boiler shall have a maximum output of _____Btu/hr, or _____horsepower when
fired 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.
PART 2 PRODUCTS
A. Number of Passes Select one of the following:
(Four-Pass) The boiler shall be a four-pass intercooled horizontal firetube updraft
boiler. It shall be mounted on a heavy steel frame with forced draft burner and
burner controls.
(Three-Pass) The boiler shall be a three-pass intercooled horizontal firetube
updraft boiler. It shall be mounted on a heavy steel frame with forced draft
burner and burner controls.
1. Approvals: The complete burner/boiler package shall be approved as a unit by
Underwriters Laboratories Inc. and bear the UL/cUL label.
connections.
B. Boiler Shell (Steam)
3. Front and rear doors on the boiler shall be davited.
4. The rear door shall be insulated with a blanket material and a steel covering to
give the surface a hard durable finish.
appurtenances.
Section A4
A4-31
03-05
6. The boiler shall be furnished with a manhole and handholes to facilitate boiler
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.
8. Observation ports for the inspection of flame conditions shall be provided at
each end of the boiler.
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.
10. The entire boiler based frame and other components shall be factory painted
before shipment using a hard finish enamel coating.
11. An inner rear turnaround access opening shall swing on a davit, to allow full
accessibility to the 2nd pass tubes and furnace.
12. Tubes shall be removable from either the front or rear of the boiler.
2.2 STEAM BOILER TRIM
A. 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.
The boiler feedwater pump control shall be included as an integral part of the
water column to automatically actuate a motor driven feedwater pump
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.
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.
The steam pressure gauge shall be located at the front of the boiler and include cock
and test connection.
D. Safety Relief Valves
Safety valves of a type and size to comply with ASME Code requirements shall be
shipped loose.
The steam pressure controls to regulate burner operation shall be mounted near the
water column.
Burner operation shall be the full modulation principle. The burner shall always
return to low fire position for ignition.
Section A4
A4-32
03-05
B. Blower
1. All air for combustion shall be supplied by a forced draft blower mounted on
the burner, to eliminate vibration and reduce noise level.
2. Maximum sound level of the boiler/burner package shall not exceed _____dBA
3. The impeller shall be fabricated aluminum with radial blade, carefully
balanced, and directly connected to the blower motor shaft.
C. 4.3 Combustion Air Control Select one of the following:
(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 flame according to load demand. Potentiometer type position
controls shall be provided to regulate operation of the damper control motor.
(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 flame according to load demand. Potentiometer type position
controls shall be provided to regulate operation of the damper control motor.
Fuel series 700 Gas fired (para 4.4.1).
Fuel series 100 Light oil (No. 2) fired (para 4.4.2).
Fuel series 200 Light oil or gas fired (para 4.4.3).
1. FUEL SERIES 700 GAS FIRED
a. 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.
b. Gas Pilot The gas pilot shall be a premix type with automatic electric
train shall include one (1) shut-off valve, solenoid valve, pressure
regulator, and one (1) plugged leakage test connection (Canada only).
c. Gas Burner Piping Select one of the following:
1) 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, flame failure, low water, or any abnormal shutdown
condition.
Section A4
A4-33
03-05
2) 125 250 hp. Gas burner piping on all units shall include two (2)
manual shut-off valves, gas pressure regulator, two (2) motorized
gas valves, one (1) 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, flame failure, low water, or any abnormal
shutdown condition.
3) 300 350 hp. Gas burner piping on all units shall include two (2)
manual shut-off valves, gas pressure regulator, two (2) motorized
gas valves, 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, flame 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, 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, flame failure, low water, or any abnormal shutdown
condition.
2. FUEL SERIES 100 LIGHT OIL FIRED
a. 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.
c. 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 field installed near the oil storage tank. Oil pump
motor starter shall also be provided.
d. Oil Burner Piping
1) Four-Pass Select one of the following:
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.
valves, atomizing air proving switch, low oil pressure switch, and
pressure gauge all integrally mounted on the unit.
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.
2) Three-Pass Select one of the following:
Section A4
A4-34
03-05
valves, atomizing air proving switch, low oil pressure switch, and
pressure gauge all integrally mounted on the unit.
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.
e. Oil Atomization Type Select one of the following:
1) 100 150 hp. Burner shall include a complete mechanical oil
atomizing system and be of the pressure atomizing type.
2) 200 800 hp. Burner shall be a low pressure air atomizing type,
including a shipped loose air compressor assembly.
3. FUEL SERIES 200 LIGHT OIL OR GAS FIRED
a. Burner Type Select one of the following:
1) 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.
2) 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.
b. Gas Pilot The gas pilot shall be premix type with automatic electric
shall include one (1) manual shut-off valve, solenoid valve, pressure
c. Oil Burner
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 field installed near the oil storage
tank. Oil pump motor starter shall also be provided.
2) Oil Burner Piping
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.
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.
Section A4
A4-35
03-05
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.
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
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.
200 800 hp. Burner shall be a low pressure air atomizing type, including a shipped loose air
compressor assembly.
d. 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, flame failure, low water, or any abnormal shutdown
condition.
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, flame failure, low water, or any
abnormal shutdown condition.
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, flame
failure, low water, or any abnormal shutdown condition.
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, flame failure, low
water or any abnormal shutdown condition.
E. 4.5 Control Panel and Flame Safeguard Controller
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.
2. The panel will have a NEMA 1A rating and contain the flame 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, flame
failure, low water, and fuel valve open.
3. The panel shall contain fuse protection for the burner motor, air compressor
motor, and oil metering pump.
Section A4
A4-36
03-05
4. The flame safeguard controller shall be a CB110 flame monitor with EPD170
program module. Flame detector shall be ultra-violet type.
A. The boiler must be guaranteed to operate at a minimum fuel-to-steam efficiency of
____percent at 100 percent of rating when burning natural gas and ________fuel-
to-steam efficiency at 100% firing rate when burning oil (Contact your local Cleaver-
Brooks Authorized Representative for efficiency details).
2.5 WARRANTY
A. 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 first.
PART 3 EXECUTION
3.1 SHOP TESTS
B. Start-Up Service
1. After boiler installation is completed, the manufacturer shall provide the
services of a field representative for starting the unit and training the operator
at no additional costs.
a. A factory approved and authorized start-up report shall be submitted to
the customer/user at the time of start-up.
Section A4
A4-37
03-05
Model ICB Hot Water Boiler (100 800 hp, 30 psig, 125 psig)
PART 1 GENERAL
1.1 BOILER CHARACTERISTICS (HOT WATER)
A. 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.
circuit.
PART 2 PRODUCTS
A. Number of Passes Select one of the following:
(Four-Pass) The boiler shall be a four-pass intercooled horizontal firetube updraft boiler. It
shall be mounted on a heavy steel frame with forced draft burner and burner controls.
(Three-Pass) The boiler shall be a three-pass intercooled horizontal firetube updraft boiler. It
shall be mounted on a heavy steel frame with forced draft burner and burner controls.
1. Approvals: The complete burner/boiler package shall be approved as a unit by
Underwriters Laboratories Inc. and bear the UL/cUL label.
connections.
line of the boiler. The boiler shall be designed to rapidly mix the return water
appurtenances.
9. Exhaust Vent Select one of the following:
(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.
Section A4
A4-38
03-05
(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.
12. The entire boiler based frame and other components shall be factory painted
13. An inner rear turnaround access opening shall swing on a davit, to allow full
accessibility to the 2nd pass tubes and furnace.
14. Tubes shall be removable from either the front or rear of the boiler.
A. 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.
B. 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.
C. 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.
D. Pressure and Temperature Gauges
E. Relief Valves
be shipped loose.
F. 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.
B. Blower
C. Combustion Air Control Select one of the following:
Section A4
A4-39
03-05
(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 flame
according to load demand. Potentiometer type position controls shall be provided to regulate
operation of the damper control motor.
(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 flame
according to load demand. Potentiometer type position controls shall be provided to regulate
operation of the damper control motor.
Fuel series 700 Gas fired (para 4.4.1).
Fuel series 100 Light oil (No. 2) fired (para 4.4.2).
Fuel series 200 Light oil or gas fired (para 4.4.3).
1. FUEL SERIES 700 GAS FIRED
a. 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.
c. Gas Burner Piping Select one of the following:
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
condition.
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
condition.
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
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
2. FUEL SERIES 100 LIGHT OIL FIRED
a. Burner Type The burner shall be mounted at the front of the boiler, and
Section A4
A4-40
03-05
c. Oil Pump An oil pump with a capacity of approximately twice the
maximum burning rate shall be included. Pump shall be motor driven and
d. Oil Burner Piping
1) Four-Pass Select one of the following:
controls, two (2) solenoid oil shut-off valves, atomizing air proving switch, low oil pressure switch,
2) Three-Pass Select one of the following:
controls, two (2) solenoid oil shut-off valves, atomizing air proving switch, low oil pressure switch,
e. Oil Atomization Type Select one of the following:
100 150 hp. Burner shall include a complete mechanical oil atomizing system and be of the
3. FUEL SERIES 200 LIGHT OIL OR GAS FIRED
a. Burner Type Select one of the following:
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
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
Section A4
A4-41
03-05
c. Oil Burner
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 field installed near the oil storage
tank. Oil pump motor starter shall also be provided.
2) Oil Burner Piping
a.Four-Pass Select one of the following:
b.Three-Pass Select one of the following:
c.Oil Atomization Type Select one of the following:
100 150 hp. Burner shall include a complete mechanical oil atomizing system and be of the
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, flame 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, flame 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
Section A4
A4-42
03-05
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,
flame 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,
flame failure, low water or any abnormal shutdown condition.
E. Control Panel and Flame Safeguard Controller
1. Control Panel
A factory prewired control panel shall be supplied with the boiler/burner
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, flame
failure, low water, and fuel valve open.
3. The panel shall contain fuse protection for the burner motor, air compressor
motor, and the oil metering pump.
A. The boiler must be guaranteed to operate at a minimum fuel-to-water efficiency of
____percent at 100 percent of
rating when burning natural gas and ________fuel-to-steam efficiency at 100%
firing rate when burning oil (Contact your local Cleaver-Brooks Authorized
Representative for efficiency details).
PART 3 EXECUTION
3.1 WARRANTY
for a period of 12 months from date of
3.2 SHOP TESTS
3.3 START-UP SERVICE
A. After boiler installation is completed, the manufacturer shall provide the services of
a field representative for starting the unit and training the operator at no additional
costs.
1. A factory approved and authorized start-up report shall be submitted to the
A5-1
03-08
TABLE OF CONTENTS
Three Pass or Four Pass Design: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-3
Front and Rear Doors: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-3
Natural Gas, No. 2 Oil, No. 6 Oil, or Combination Burners Available: . . . . . . . . . . . . . . . . . . . . . A5-3
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-9
Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-10
Burner/Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-10
Burner Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-10
Gas-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-11
Fuel Connections - Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-11
Fuel Connections - Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-11
Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-12
Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-12
Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-12
Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-12
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-21
Section A5
Model CBL 900-1800 HP
A5-2
Model CBL 900-1800 HP Section A5
03-08
ILLUSTRATIONS
Figure A5-1. CBL Steam Boiler Dimensions, 4 Pass (Page 1 of 2) (4 pass) . . . . . . . . . . . . . . . . . A5-7
Figure A5-2. Space Required to Open Rear Doors on CBL Boilers . . . . . . . . . . . . . . . . . . . . . . . . A5-9
Figure A5-3. CBL Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-9
Figure A5-4. CBL Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-10
Figure A5-5. No. 2 Oil Piping, Single Boiler Installation, Oil Pump Integral With Boiler . . . . . . . . . A5-19
Figure A5-6. No. 6 Oil Piping, Single Boiler Installation, Remote Oil Pumps . . . . . . . . . . . . . . . . . A5-19
Figure A5-7. Boiler Room Length (Typical Layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-19
Figure A5-8. Boiler Room Width (Typical Layouts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-20
TABLES
Table A5-1. CBL Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-5
Table A5-2. CBL Input Ratings (3-Pass Boilers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-5
Table A5-3. CBL Input Ratings (4-Pass Boilers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-6
Table A5-4. Predicted Fuel-to-Steam Efficiencies (%) CBL Boilers- 125 psig,
Natural Gas, 5sq. ft./BHP, 4 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-14
No. 2 Oil, 5sq. ft./BHP, 4 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-14
No. 6 Oil, 5sq. ft./BHP, 4 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-14
Natural Gas, 4 sq. ft./BHP, 3 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-15
No. 2 Oil, 4 sq. ft./BHP, 3 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-15
No. 6 Oil, 4 sq. ft./BHP, 3 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-15
Table A5-10. CBL Steam Boiler Safety Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-16
Table A5-11. CBL Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-16
Table A5-12. CBL Steam Volume and Disengaging Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-17
Table A5-13. CBL Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-17
Table A5-14. CBL Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-17
Table A5-15. CBL gas train connection size and gas pressure requirements . . . . . . . . . . . . . . . . . . A5-18
Table A5-16. Altitude Correction for Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-18
The following information applies to the Cleaver-Brooks CBL Boiler.
Section A5 Model CBL 900-1800 HP
A5-3
03-08
The CBL 900-1800 HP Firetube boiler is designed, manufactured, and packaged by
Cleaver-Brooks. All units are factory fire 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 CBL.
Three Pass or Four Pass Design:
The packaged boiler offers high efficiency, flexibility, 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.
Natural Gas, No. 2 Oil, No. 6 Oil, or Combination Burners Available:
adjustment.
PRODUCT OFFERING
Cleaver-Brooks CBL Boilers are available in low pressure and high pressure steam
and hot water designs. Burners are available to fire natural gas, No. 2 oil, No. 6 oil,
or a combination of oil and gas. Standard product offering is:
900 - 1800 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.
Available options include the following (contact your local Cleaver-Brooks authorized
representative for option details).
Boiler Options:
Blowdown valves.
Non-return valves.
Surge load baffles.
Seismic design.
Lead/lag system.
A5-4
03-08
Special insurance and code requirements (e.g., IRI, FM, NFPA8501).
Main disconnect.
Elapsed time meter.
NEMA enclosures.
Circuit breakers.
Day/night controls.
Low NOx Equipment.
HAWK ICS
Fuel Options:
Gas strainer.
Gas pressure gauge.
Optional Oil Pumps.
Dimensions and ratings for the CBL Boilers are shown in the following tables and
illustrations. The information is subject to change without notice.
Table A5-1. CBL Steam Boiler Ratings
Table A5-2. Heating Surface
Figure A5-1. CBL Steam Boiler Dimensions
Figure A5-2. CBL Boiler Space Requirements to Open Rear Door
Figure A5-3. Lifting Lug Location, CBL Boilers
Figure A5-4. CBL Boiler Mounting Piers
A5-5
03-08
BOILER HP 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800
RATINGS - SEA LEVEL TO 1000 FT
B
from and at 212 F)
27600 31050 34500 37950 41400 44850 48300 51750 55200 58650 62100
Btu Output (1000 Btu/hr) 26780 30125 33475 36820 40170 43515 46865 50210 53550 56905 60255
POWER REQUIREMENTS SEA LEVEL TO 1000 FT ( 60 HZ)
Blower Motor, hp
A
(Gas and
Oil)
60 60 60 75 75 100 100 100
Oil Pump Motor hp (#2 oil) 1 1 1 1 1-1/2 1-1/2 1-1/2 1-1/2
Oil Pump Motor hp (#6 oil) 1 1 1 1 1 1 1 1-1/2
Air Comp. Motor, hp (#2 oil) 7-1/2 15 15 15 15 15 15 15
Oil heater Kw (#6 oil) 10 10 10 15 15 15 15 15
NOTE:
A. Blower motor HP may increase if a low NOx option is added
B. Ratings based on nominal 80% efficiency.
C. Ratings based on 60 hertz, please verify 50 hertz ratings with factory.
Table A5-1. CBL Steam Boiler Ratings
Table A5-2. CBL Input Ratings (3-Pass Boilers)
C
o
n
t
a
c
t

F
a
c
t
o
r
y
Boiler Square Foot
Heating Surface
4000 4500 5000 5500 6000 6500 7000 7500
Approximate Fuel Consumption
D
Horsepower
(5 sq.ft./bhp)
800 900 1000 1100 1200 1300 1400 1500
Natural Gas
A
(cfh)
33475 37660 41845 46025 50215 54395 58585 62765
No. 2 Oil
B
(gph)
239.3 269.0 299.0 329.0 359.0 388.5 418.0 447.5
No. 6 Oil
C
(gph)
223.4 251.1 279.0 307.0 335.0 363.0 390.0 417.0
Horsepower
(4 sq.ft./bhp)
1000 1100 1200 1300 1500 1600 1700 1800
Natural Gas
A
(cfh)
41845 46025 50215 54395 62765 66950 71133 75318
No. 2 Oil
B
(gph)
299.0 329.0 359.0 388.5 447.5 477.3 507.2 537
No. 6 Oil
C
(gph)
279.0 307.0 335.0 363.0 417.0 444.8 472.6 500.4
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.
A5-6
03-08
Boiler Square Foot
Heating Surface
4000 4500 5000 5500 6000 6500 7000 7500
Approximate Fuel Consumption
D
Horsepower
(5 sq.ft./bhp)
800 900 1000 1100 1200 1300 1400 1500
Natural Gas
A
(cfh)
32659 36741 40824 44906 48989 53071 57153 61236
No. 2 Oil
B
(gph)
233.3 262.4 291.6 320.8 349.9 379.1 408.2 437.4
No. 6 Oil
C
(gph)
217.7 244.9 272.2 299.4 326.6 353.8 381.0 408.2
Horsepower
(4 sq.ft./bhp)
1000 1100 1200 1300 1500 1600 1700 1800
Natural Gas
A
(cfh)
40824 44906 48989 53071 57153 65317 69399 73481
No. 2 Oil
B
(gph)
291.6 320.8 349.9 379.1 437.4 466.6 495.7 524.9
No. 6 Oil
C
(gph)
272.2 299.4 326.6 353.8 408.2 435.4 462.6 489.9
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 82% efficiency.
Table A5-3. CBL Input Ratings (4-Pass Boilers)
A5-7
03-08
Figure A5-1. CBL Steam Boiler Dimensions, 4 Pass (Page 1 of 2)
A
B
C
H
E
J
L
M
N
O
Q
GG
CC
BB
RF/RD
Y
T
S
G
R
W
P
W
I
D
BOILER SQUARE FOOT
HEATING SURFACE
DIM 4000 4500 5000 5500 6000 6500 7000 7500
Boiler Horsepower@ 5 ft
2
/bhp 800 900 1000 1100 1200 1300 1400 1500
Boiler Horsepower @ 4 ft
2
/bhp 1000 1100 1200 1300 1500 1600 1700 1800
LENGTHS
Overall *
B
A 367 394 386 411 434 387 406 425
Shell B 293 323 288 312 335 304 323 342
Base Frame * C 285 317 282 304 327 296 315 334
Base Frame to Rear Flange H 26 26 26 26 26 26 26 26
Flange to Steam Nozzle E 148 148 148 148 148 148 148 148
WIDTHS
Overall With Trim I 144 144 156 156 156 168 168 168
I. D. Boiler J 114 114 126 126 126 138 138 138
Center to Water Column K 72 72 78 78 78 84 84 84
Center to Lagging L 59-1/2 59-1/2 65-3/4 65-3/4 65-3/4 71 3/4 71 3/4 71 3/4
Base Outside M 96 96 96 96 96 96 96 96
Base Inside N 80 80 80 80 80 80 80 80
* Approximate - varies with burner selection
Boiler Horsepower@ 5 ft
2
/bhp 800 900 1000 1100 1200 1300 1400 1500
Boiler Horsepower @ 4 ft
2
/bhp 1000 1100 1200 1300 1500 1600 1700 1800
F
K
A5-8
03-08
HEIGHTS
Base to piping
connections
F 149 149 161 161 161 168-1/8 168-1/8 168-1/8
Base to Boiler Centerline D 77-1/2 77-1/2 83-3/4 83-3/4 83-3/4 86-1/2 86-1/2 86-1/2
Base to Vent Outlet O 141 141 153-1/2 153-1/2 153-1/2 162-1/8 162-1/8 162-1/8
Base to Steam Outlet P 141 141 153-1/2 153-1/2 153-1/2 162-1/8 162-1/8 162-1/8
Base Frame Q 12 12 12 12 12 12 12 12
Base to Bottom Boiler R 20 20 20 20 20 17 17 17
CONNECTIONS
Chemical Feed G 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4
Feedwater Inlet (Both Sides) S 3 3 3 3 3 3 3 3
Steam Nozzle
A
(150 psig) Y 10 10 10 12 12 12 12 12
Blowdown - Front & Rear W 2 2 2 2 2 2 2 2
Surface Blowoff T 1 1 1 1 1 1 1 1
Vent Stack Diameter (Flanged) BB 32 32 36 36 36 42 42 42
Flange to Center Vent CC 17-1/2 17-1/2 19-1/2 19-1/2 19-1/2 24 24 24
MISCELLANEOUS
Rear Door Swing
c
AA - - - - - - - -
Tube Removal - Front Only GG 246 276 217 241 264 233 252 271
Min. Boiler Room Length For
Tube Removal Front
RF 537 597 538 586 632 665 703 741
Min. Boiler Room Length For
Tube Removal Thru Door
RD 484 514 489 513 536 528 547 566
Normal Water Weight (Lbs) 43800 49400 49300 54000 60000 61000 66000 71000
Flooded Water Weight (Lbs) 54500 61300 65300 71900 78300 83000 89000 96000
Approx. Wt. 15/30 psig (Lbs.) 58000 63000 73100 77200 82200 87000 91700 96600
Approx. Wt. 150 psig (Lbs.) 65000 71000 79600 85300 90900 97300 102600 108200
NOTES:
Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed 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. Overall height is 171 inches after trim is mounted on the boiler in the field.
BOILER SQUARE FOOT
HEATING SURFACE
DIM 4000 4500 5000 5500 6000 6500 7000 7500
Figure A5-1. CBL Steam Boiler Dimensions, 4 Pass (Page 2 of 2)
A5-9
03-08
Figure A5-3. CBL Boilers Lifting Lug Location
Figure A5-2. Space Required to Open Rear Doors on CBL Boilers
BOILER SQUARE
FOOT OF HEATING
SURFACE
BHP A B C D E
4 sq.ft. 5 sq.ft.
4000 1000 800 138 47 205 12 3
4500 1100 900 138 47 238 12 3
5000 1200 1000 150 47 200 12 3
5500 1300 1100 150 47 222 12 3
6000 1500 1200 150 47 247 12 3
6500 1600 1300 162 47 216 12 3
7000 1700 1400 162 47 235 12 3
7500 1800 1500 162 47 254 12 3
"B"
"D"
"A"
"E"
"C" REAR DOOR
MINIMUM REAR
MAXIUM SIDE
MAXIMUM REAR
MINIMUM SIDE
BOILER
ID
114"
DIMENSION (INCHES)
A
126"
138"
60
66
72 84
72
78
B
66
39
52
C
105
82
93
D
45
22
33
E
3-PASS BOILER SHOWN.
4 PASS VENT STUB ON
OPPOSITE END.
A5-10
03-08
Figure A5-4. CBL Boiler Mounting Piers
E
BOILER SQUARE FOOT
OF HEATING SURFACE
BHP A B C D E F G H
4 sq-ft 5 sq-ft
4000 1000 800 6 12 * 76 100 8 80 12
4500 1100 900 6 12 * 76 100 8 80 12
5000 1200 1000 6 12 * 76 100 8 80 15
5500 1300 1100 6 12 * 76 100 8 80 15
6000 1500 1200 6 12 * 76 100 8 80 15
6500 1600 1300 6 12 * 76 100 8 80 15
7000 1700 1400 6 12 * 76 100 8 80 15
7500 1800 1500 6 12 * 76 100 8 80 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-specific mounting pier
length.
H
PERFORMANCE DATA
Efficiency Tables A5-4, A5-5, A5-6, A5-7, A5-8, and A5-9 show predicted fuel-to-steam
efficiencies (including radiation and convection losses) for Cleaver-Brooks CBL
Firetube boilers. For specific efficiencies on firetube boiler offerings not listed here,
for CBL Firetube Boilers. The guarantee is based on the fuel-to-steam efficiencies
shown in the efficiency tables and the following conditions. The efficiency percent
number is only meaningful if the specific conditions of the efficiency calculations are
clearly stated in the specification (see Cleaver-Brooks publication CB-7767 for a
detailed description of efficiency calculations).
achieve fuel-to-steam efficiency (as shown in the tables listed above) at 100% firing
A5-11
03-08
rate (add efficiency guarantees at 25%, 50%, and 75% of rating, if required). If the
boiler(s) fail to achieve the corresponding guaranteed efficiency as published, the
boiler manufacturer will rebate, to the ultimate boiler owner, five thousand dollars
($5,000) for every full efficiency point (1.0%) that the actual efficiency is below the
guaranteed level. The specified boiler efficiency is based on the following conditions.
Natural Gas
Carbon,% (wt) = 69.98
Sulfur,% (wt) = 0.0
No. 2 Oil
Sulfur,% (wt) = 0.2
No. 6 Oil
2. Efficiencies are based on ambient air temperature of 80 F, relative humidity of 30%, and
15% excess air in the exhaust flue gas.
3. Efficiencies 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%.
ENGINEERING DATA
The following engineering information is provided for CBL Boilers. Additional detail
is available from your local Cleaver-Brooks authorized representative.
Boiler Information Table A5-12 shows steam volume and disengaging area for CBL boilers.
Table A5-10 lists quantity and outlet size for safety valves supplied on CBL boilers.
Table A5-11 gives recommended steam nozzle sizes on CBL Boilers.
Table A5-13 shows recommended non-return valve sizes for CBL Boilers.
Blowdown Water Requirements
water at normal operating level for Cleaver-Brooks CBL Boilers.
Burner/Control
Information
Note that altitude correction and burner changes are required for higher altitudes
A5-12
03-08
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 A5-15 gives gas train connection sizes and gas pressure requirements.
Table A5-16 shows correction factors for gas pressure at elevations over 1000 ft.
above sea level.
For oversized or undersized gas trains or altitude above 1,000 feet, contact your
A5-13
03-08
Boiler Room
Information
Stack Support
Capabilities
CBL Boilers can support up to 2000 lbs. without additional support.
CBL Boilers can be reinforced to support up to 3000 lbs.
Boiler Room
Combustion Air
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.
B. Ventilation Air = Maximum bhp x 2 cfm/bhp or a total of 10 cfm/bhp - up to 1000
Area Required: Area = cfm/fpm = 10000/250 = 40 Sq-ft total.
Notice
Stack/Breeching
Size Criteria
Although constant pressure at the flue gas outlet of the CBL is not required, it is
necessary to size the stack/breeching to limit flue gas pressure variation. The
allowable pressure range is 0.50 W.C. to +0.50 W.C. The maximum pressure
variation at any firing rate for the boiler is 0.50" W.C.
A5-14
03-08
The low NOx option allowable pressure range is -0.25 W.C. to +0.25 W.C. The
maximum pressure variation at any firing rate for the boiler is 0.25 W.C.
BOILER
HP
FIRING RATE (%)
25 50 75 100
800 82.0 82.3 82.7 82.5
900 82.3 82.0 82.5 82.5
1000 82.0 82.6 82.7 82.6
1100 82.3 82.7 82.7 82.7
1200 82.2 83.0 83.2 83.2
1300 82.5 82.8 83.0 83.0
1400 82.3 82.3 82.8 82.8
1500 82.0 83.0 83.0 83.0
Table A5-4. Predicted Fuel-to-Steam Efficiencies (%) CBL
Boilers- 125 psig, Natural Gas, 5sq. ft./BHP, 4 Pass
BOILER
HP
FIRING RATE (%)
25 50 75 100
800 85.2 85.9 85.9 86.0
900 85.3 85.8 86.0 86.0
1000 85.8 86.0 86.0 86.2
1100 85.5 85.6 85.6 86.0
1200 85.8 86.0 86.3 86.5
1300 85.3 86.0 86.4 86.6
1400 85.9 86.0 86.4 86.5
1500 86.0 86.6 86.5 86.6
Boilers- 125 psig, No. 2 Oil, 5sq. ft./BHP, 4 Pass
BOILER
HP
FIRING RATE (%)
25 50 75 100
800 86.5 86.0 86.5 86.8
900 86.6 86.5 86.5 86.9
1000 86.5 86.6 86.5 86.8
1100 86.5 86.7 86.6 86.9
1200 86.5 87.0 87.0 87.0
1300 86.3 86.6 87.0 87.0
1400 86.0 86.5 86.8 86.7
1500 86.0 86.5 86.8 86.6
Boilers- 125 psig, No. 6 Oil, 5sq. ft./BHP, 4 Pass
A5-15
03-08
BOILER
HP
FIRING RATE (%)
25 50 75 100
1000 81.4 81.5 81.5 81.5
1100 81.3 81.6 82.0 82.0
1200 81.2 81.4 82.0 82.0
1300 81.0 81.3 81.6 82.0
1400 81.0 81.3 81.4 81.8
1500 81.0 81.4 81.4 81.9
Boilers- 125 psig, Natural Gas, 4 sq. ft./BHP, 3 Pass
BOILER
HP
FIRING RATE (%)
25 50 75 100
1000 84.8 85.0 85.0 85.0
1100 84.7 85.0 85.0 85.0
1200 85.0 85.2 85.4 85.2
1300 85.0 85.0 84.8 85.5
1400 85.0 85.6 84.8 85.5
1500 85.0 85.5 84.9 85.6
Boilers- 125 psig, No. 2 Oil, 4 sq. ft./BHP, 3 Pass
BOILER
HP
FIRING RATE (%)
25 50 75 100
1000 86.2 86.2 85.8 85.6
1100 86.3 86.4 86.1 85.9
1200 86.2 86.2 85.8 86.0
1300 86.0 86.4 86.1 85.8
1400 86.0 86.4 86.0 85.8
1500 86.0 86.3 86.2 85.9
Boilers- 125 psig, No. 6 Oil, 4 sq. ft./BHP, 3 Pass
A5-16
03-08
BOILER HP
OPERATING PRES-
SURE PSIG
800 900 100
0
110
0
120
0
130
0
140
0
150
0
160
0
170
0
180
0
12 18 18 20 20 24 24 24 24 24 24 24
30 14 16 16 16 18 18 18 20 20 20 20
50 12 12 12 14 16 16 16 16 16 16 16
75 10 10 12 12 12 12 12 14 14 14 14
100 10 10 10 10 12 12 12 12 12 12 14
125 8 10 10 10 10 10 12 12 12 12 12
150 8 8 8 10 10 10 10 10 10 10 12
200 8 8 8 8 10 10 10 10 10 10 10
225 6 8 8 8 8 10 10 10 10 10 10
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.
VALVE
SETTING
15 PSIG STEAM 150 PSIG STEAM 200 PSIG STEAM 250 PSIG STEAM
BOILER
HP
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(FPT)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
( FPT)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
( FPT)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
( FPT)
800 - - 2 1 - 3
1 - 4
2 1 - 2 1/2
1 - 3
2 2 1/2
900 - - 2 1 - 3
1 - 4
2 3 2 1 - 2 1/2
1 - 3
1000 3 2 - 8
1 - 6
2 4 2 3 2 1 - 2 1/2
1 - 3
1100 3 2 - 8
1 - 6
2 4 2 1 - 3
1 - 4
2 3
1200 2 8 2 4 2 1 - 3
1 - 4
- -
1300 3 8 3 2 - 3
1 - 4
3 1 - 2 1/2
2 - 3
- -
1400 3 8 3 1 - 3
2 - 4
3 3 - -
1500 3 8 3 1 - 3
2 - 4
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 A5-10. CBL Steam Boiler Safety Valve Outlet Size
Table A5-11. CBL Recommended Steam Nozzle Size
A5-17
03-08
BOILER SQUARE FOOT OF HEATING
SURFACE
BHP
WATER (GAL)
4 SQ.FT. 5 SQ.FT.
4000
1000 800
356
4500
1100 900
400
5000
1200 1000
418
5500
1300 1100
460
6000
1500 1200
500
6500
1600 1300
500
7000
1700 1400
538
7500
1800 1500
575
NOTE: Quantity of water removed from boiler by lowering normal water line 4".
Optional level controls can alter water quantities.
NOTE:
Standard non-return valve selections limited to a maximum 2 to 1 turndown (50% of full boiler output); selection based on typical valve sizing recommenda-
tions. For final valve selection contact your authorized C-B representative. For high turndown applications see Boiler Book Section I3, Table I3-3.
BOILER
HP
CAPACITY
LBS.PER HR.
OPERATING PRESSURE
50 75 100 125 150 175 200 225
900 31050 8 6 6 6 6 6 6 5
1000 34500 8 6* 6 6 6 6 6 5
1100 37950 8 8 6 6 6 6 6 6
1200 41400 8 8 8 6 6 6 6 6
1300 44850 8 8 8 8 6 6 6 6
1400 48300 8 8 8 8 8 6 6 6
1500 51750 8 8 8 8 8 8 6 6
1600 55200 10 10 8 8 8 8 8 6
1700 58650 10 10 8 8 8 8 8 8
1800 62100 10 10 10 8 8 8 8 8
BOILER SQUARE FOOT OF
HEATING SURFACE
BHP
STEAM VOLUME (CU-FT) STEAM RELIEVING AREA (SQ-IN)
4 SQ.FT. 5 SQ.FT.
HIGH PRESSURE (A) HIGH PRESSURE (A)
4000
1000 800
155 20566
4500
1100 900
174 23105
5000
1200 1000
250 24141
5500
1300 1100
273 26372
6000
1500 1200
300 28908
6500
1600 1300
352 28918
7000
1700 1400
379 31079
7500
1800 1500
405 33242
Table A5-12. CBL Steam Volume and Disengaging Areas
01-06
NOTES:
Based on normal water level.
Values are based on standard controls. Optional controls may result in different values.
Table A5-14. CBL Blowdown Tank Sizing Information
Table A5-13. CBL Recommended Non-Return Valve Size
A5-18
03-08
ALTITUDE (FT) CORRECTION FACTOR ALTITUDE (FT) CORRECTION FACTOR
1000 1.04 6000 1.25
2000 1.07 7000 1.30
3000 1.11 8000 1.35
4000 1.16 9000 1.40
5000 1.21 - -
To obtain minimum required gas pressure at altitudes above 700 feet, multiply the pressure by the list-
ed 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.
Gas train
connection
Pressure
required
Gas train
connection
Pressure
required
Gas train
connection
Pressure
required
Gas train
connection
Pressure
required
1000 2.5 8.2 2.5 8.3 2.5 8.1 2.5 8.2
1100 3 5.4 3 5.4 3 5.4 3 5.6
1200 3 6.3 3 6.3 3 6.3 3 6.4
1300 3 7.2 3 7.3 3 7.2 3 7.3
1400 3 8.4 3 8.5 3 8.3 3 8.5
1500 4 5.4 4 5.5 4 5.6 4 5.8
Gas train
connection
Pressure
required
Gas train
connection
Pressure
required
Gas train
connection
Pressure
required
Gas train
connection
Pressure
required
900 2.5 7.4 2.5 7.4 2.5 7.3 2.5 7.4
1000 2.5 8.2 2.5 8.3 2.5 8.1 2.5 8.2
1100 3 5.3 3 5.4 3 5.3 3 5.4
1200 3 6.3 3 6.3 3 6.2 3 6.4
1300 3 7.2 3 7.3 3 7.2 3 7.3
1400 3 8.4 3 8.4 3 8.2 3 8.3
1500 4 5.4 4 5.5 4 5.4 4 5.6
Gas train
connection
Pressure
required
Gas train
connection
Pressure
required
Gas train
connection
Pressure
required
Gas train
connection
Pressure
required
800 2.5 6.0 2.5 6.1 2.5 5.9 2.5 6.0
900 2.5 7.4 2.5 7.4 2.5 7.3 2.5 7.4
1000 2.5 8.2 2.5 8.2 2.5 7.9 2.5 8.0
1100 3 5.3 3 5.4 3 5.3 3 5.4
1200 3 6.3 3 6.3 3 6.2 3 6.3
1300 3 7.2 3 7.2 3 7.1 3 7.2
1400 3 8.4 3 8.4 3 8.2 3 8.3
1500 4 5.4 4 5.5 4 5.4 4 5.6
Notes: 3 pass boilers are based on 80% efficiency
4 pass boilers are based on 82% efficiency
Pressure shown is minimum required and is listed as psi
Incoming pressure is not to exceed 10 psi
Ultra Low Nox (9 and 15ppm) are handled on a case by case basis
Boiler HP
Boiler HP
4 ft
2
/bhp
3 pass 4 pass
5 ft
2
/bhp
std 30 ppm
3 pass 4 pass
std 30 ppm
std 30 ppm std 30 ppm
Boiler HP
4.5 ft
2
/bhp
3 pass 4 pass
std 30 ppm std 30 ppm
Table A5-15. CBL gas train connection size and gas pressure requirements
A5-19
03-08
Installation, Oil Pump Integral With Boiler
BOILER SQUARE
FOOT OF HEATING
SURFACE
BHP A B
4 sq.ft. 5 sq.ft.
4000 1000 800 610 484
4500 1100 900 670 514
5000 1200 1000 606 489
5500 1300 1100 654 513
6000 1500 1200 700 536
6500 1600 1300 642 515
7000 1700 1400 680 534
7500 1800 1500 718 553
NOTE: A = Minimum length based on removing tubes in the boiler
room.
B = Minimum length based on removing tubes through a wall opening.
Figure A5-7. Boiler Room Length (Typical Layout)
A5-20
03-08
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 addi-
tional 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 addi-
tional aisle and working space.
Boiler Square Foot of Heating
Surface
4000-
4500
5000-
6000
6500-
7500
Dimension A (inches) 117 123 129
Dimension B (inches) 198 210 222
For reference to Boiler Horsepower per square foot see A11-
7
Figure A5-8. Boiler Room Width (Typical
Layouts)
A5-21
03-08
Section A5
Sample Specifications Model CBL
Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-22
Fuel Specification and Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-24
Boiler Flame Safeguard Controller and Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-28
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-29
Shop Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-29
SAMPLE SPECIFICATIONS
The following sample specifications are provided by Cleaver-Brooks to assist you in meeting your customers specific needs
and application.
The detailed burner and control specifications, and detailed control specifications for CB100E Flame Safeguard control are
provided. See Section D, Controls, for additional information on control options.
The Sample Specifications are typically utilized as the base template for the complete boiler specification. Contact your local
Cleaver-Brooks authorized representative for information on special insurance requirements, special code requirements,
optional equipment, or general assistance in completing the specification.
Sample Specifications Model CBL Section A5
A5-22
03-08
PART 1 GENERAL
CBL Steam Boiler (900-1800 hp, Steam 15-250 psig)
A. 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.
B. The boiler shall have a maximum output of ______ Btu/hr, or ______ horsepower when fired with
CS12-48 ______ oil and/or natural gas, ______ Btu/cu-ft. Electrical power available shall be
______ Volt ______ Phase ______ Cycle.
PART 2 PRODUCTS
A. The boiler shall be a three pass or four pass horizontal firetube 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.
1. The boiler shall be completely preassembled and fire tested at the factory. The unit shall be
ready for immediate mounting on floor or simple foundation and ready for attachment of
water, fuel, electrical, vent, and blowdown connections.
2. The boiler shall be built to comply with the following insurance and codes ______________
(Factory Mutual, Industrial Risk Insurance, ASME, NFPA 8501).
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. 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.
3. The front door shall be davited and the rear door shall be davited. Doors are to be sealed
with fiberglass tadpole gaskets and fastened tightly using heavy capscrews that thread into
replaceable brass nuts.
4. The boiler tubes shall not include turbulators, swirlers, or other add-on appurtenances.
5. The rear door shall be insulated with a blanket material with a steel covering to give the
surface a hard durable finish.
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.
7. Observation ports for the inspection flame conditions shall be provided at each end of the
boiler.
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.
9. The entire boiler base frame and other components shall be factory-painted before
shipment, using a hard-finish enamel coating.
10. The boiler shall contain a chemical feed connection.
Section A5 Sample Specifica-
A5-23
03-08
A. 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.
1. Modulating feedwater Control
The boiler modulating feedwater control and valve shall be included to automatically
maintain the boiler water level within normal limits.
2. Low Water Cutoff
The low water cutoff shall be included as an integral part of the boiler feedwater control and
wired into the burner control circuit to prevent burner operation if the boiler water level falls
below a safe level.
B. 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.
The steam pressure gauge shall be located at the front of the boiler and include cock and test
connection.
D. Safety Valves
Safety valves of a type and size to comply with ASME Code requirements shall be shipped loose.
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 firing rate control.
1. Burner operation shall be full modulation principle. The burner shall always return to low
fire position for ignition.
2. A low fire hold temperature control is mounted and wired on the boiler.
B. Blower
1. Air for combustion shall be supplied by a forced draft blower mounted on the burner, to
eliminate vibration and reduce noise level.
2. Maximum sound level of the boiler/burner package shall not exceed _____ dbA (when
measured in accordance with ABMA Sound Test Standards).
3. The impeller shall be fabricated aluminum with radial blade, carefully balanced, and
Combustion air damper and cam-operated fuel metering valve shall be operated by a single
damper control motor that regulates the flame according to load demand. Potentiometer type
position controls shall be provided to regulate operation of the damper control motor.
2.4 FUEL SPECIFICATION AND PIPING
Fuel series 700 - Gas-fired.
Fuel series 100 - Light oil (No. 2) fired .
Fuel series 200 - Light oil or gas-fired.
Fuel series 600 - No. 6 oil-fired.
A5-24
03-08
Fuel series 400 - No. 6 oil or gas-fired.
A. Fuel Series 700 - Gas-Fired
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.
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 flame has been established. The pilot train shall include one manual shut-off valve,
solenoid valve, pressure regulator and one (1) plugged leakage test connection (Canada
only).
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, flame 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. Burner Turndown: Turndown range shall be 8:1 when firing natural gas on standard burners
with uncontrolled emissions (100 ppm NOx). Consult Cleaver-Brooks representative
regarding turndown capability for low NOx burners 30 ppm and less.
B. Fuel Series 100 - Light Oil-Fired
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.
electronic detector shall monitor the pilot so that the primary oil valve cannot open until
solenoid valve, pressure regulator and one (1) plugged leakage test connection (Canada
only).
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. Oil Burner Piping
a. 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.
5. Low Pressure Air Atomizing: Separate air compressor module, shipped loose with burner
mounted low atomizing air pressure switch.
6. Turndown range shall be 6:1 when firing No. 2 oil on standard burners with uncontrolled
emissions. Consult Cleaver-Brooks representative regarding turndown capability for low NOx
burners.
C. Fuel Series 200 - Light Oil or Gas-Fired
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.
A5-25
03-08
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 flame 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).
3. Oil Burner
a. 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.
b. 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.
c. Low pressure Air Atomizing - Separate air compressor module, shipped loose with
burner-mounted low-atomizing air pressure switch.
d. Burner Turndown - Turndown range shall be 6:1 when firing No. 2 oil on standard
burners with uncontrolled emissions. Consult Cleaver-Brooks representative regarding
turndown capability for low NOx burners.
4. Gas Burner
a. 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, flame 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.
b. Burner Turndown - Turndown range shall be 8:1 when firing natural gas on standard
burners with uncontrolled emissions (100 ppm NOx). Consult Cleaver-Brooks
representative regarding turndown capability for low NOx burners 30 ppm and less.
D. Fuel Series 600 - No. 6 Oil-Fired
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.
electronic detector shall monitor the pilot so that the primary oil valve cannot open until
solenoid valve, pressure regulator and pressure gauge and one (1) plugged leakage test
(Canada only).
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. 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.
5. Low Pressure Air-Atomizing - Separate air compressor module, shipped loose with the
burner-mounted low-atomizing air pressure switch.
A5-26
03-08
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.
7. Burner Turndown - Turndown range will be 4:1 when firing No. 6 oil on standard burners
with uncontrolled emissions. Consult Cleaver-Brooks representative regarding turndown
capability for low NOx burners.
E. Fuel Series 400 - No. 6 Oil or Gas-Fired
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.
electronic detector shall monitor the pilot so that the primary fuel valve cannot open until
solenoid valve, pressure regulator and pressure gauge, and one (1) plugged leakage test
connection. (Canada only.)
3. Oil Burner
a. 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.
b. 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.
c. Low Pressure Air-Atomizing: Separate air compressor module shipped loose with
burner mounted low atomizing air pressure switch.
d. 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.
e. Burner Turndown - Turndown range will be 4:1 when firing No. 6 oil on standard
burners with uncontrolled emissions. Consult Cleaver-Brooks representative regarding
turndown capability for low NOx burners.
f. Gas Burner
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, flame 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.
2) Burner Turndown - Turndown range shall be 6:1 when firing natural gas on
standard burners with uncontrolled emissions (100 ppm NOx). Consult Cleaver-
Brooks representative regarding turndown capability for low NOx burners 30 ppm
and less.
A5-27
03-08
2.5 BOILER FLAME SAFEGUARD CONTROLLER AND CONTROL PANEL
A. CB100E Flame Safeguard
1. Each boiler shall be factory-equipped with flame 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 flame 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.
B. Control Panel
A factory prewired control panel shall be supplied with the boiler/burner package. Panel may be
mounted on the burner or boiler.
1. The panel will have a NEMA 1A rating and contain the flame 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, flame failure, low water, and fuel valve open.
2. The panel shall contain over-current protection for the burner motor, air compressor motor,
and oil metering pump.
A. The boiler must be guaranteed to operate at a minimum fuel-to-steam efficiency of ____ percent
at 100 percent of
rating when burning natural gas and ________ fuel-to-steam efficiency at 100% firing rate when
burning oil (Contact your local Cleaver-Brooks authorized representative for efficiency details).
PART 3 EXECUTION
3.1 WARRANTY
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 first.
3.2 SHOP TESTS
A. 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.
B. Start-up Service
1. After boiler installation is completed, the manufacturer shall provide the services of a field
representative for starting the unit and training the operator at no additional costs.
a. A factory-approved and authorized start-up report shall be submitted to the customer/
user at the time of start-up.
Section A5
A5-28
03-08
Notes:
A6-1
03-08
CONTENTS
Burner/Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-5
Fuel Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-6
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-15
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-16
Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-18
Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-18
Test Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-22
Sound Level Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-22
Sound Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-22
Typical Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-22
Octave Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-22
No. 6 Oil Piping, Storage Tank Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-23
Sample Specifications - Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-35
Section A6
MODEL CB BOILERS 15-100 HP
Firetube Boilers
A6-2
03-08
ILLUSTRATIONS
Figure A6-1 Model CB Steam Dimensions and Weights (15 and 150 psig -15 to 100 hp) . . . . A6-9
Figure A6-2 Model CB Hot Water Boiler Dimensions (30 psig and 125 psig - 15 to 100 hp) . A6-11
Figure A6-3 Space required to open rear head on model cb boilers with davits . . . . . . . . . . . A6-13
Figure A6-4 Model CB Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-13
Figure A6-5 Lifting Lug Locations, Model CB Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-14
Figure A6-6 Predicted Stack Temperature Increase for Pressure Greater Than 125 psig . . . . . A6-17
Figure A6-7 Standard Gas Train Connection Size and Location . . . . . . . . . . . . . . . . . . . . . . A6-24
Figure A6-8 Typical Gas Piping Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-25
Figure A6-9 Model CB Gas Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-26
Figure A6-10 No. 2 Oil Connection Size, Location and Recommended Line Sizes . . . . . . . . . A6-27
Figure A6-11 No. 6 Oil Connection Size, Location and Recommended Line Sizes . . . . . . . . . A6-27
Figure A6-12 No. 2 Oil Piping, Single Boiler Installation, Remote Oil Pump . . . . . . . . . . . . . A6-28
Figure A6-13 No. 2 Oil Piping, Multiple Boiler Installation, Remote Oil Pumps . . . . . . . . . . . A6-28
Figure A6-14 No. 2 Oil Piping, Multiple Boiler Installation . . . . . . . . . . . . . . . . . . . . . . . . . A6-29
Figure A6-15 No. 2 Oil Piping (elevated locations using an oil transfer pump and tank) . . . . . A6-30
Figure A6-16 Typical Fuel Storage Tank Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-30
Figure A6-17 Boiler Room Length (Typical Layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-33
Figure A6-18 Boiler Room Width (Typical Layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-33
Figure A6-19 Breeching Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-34
TABLES
Table A6-1 Model CB Steam Boiler Ratings (15 - 100 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . A6-7
Table A6-2 Model CB Hot Water Boiler Ratings (15 - 100 hp) . . . . . . . . . . . . . . . . . . . . . . . A6-7
Table A6-3 Steam Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-8
Table A6-4 HOT Water Boiler Relief Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-8
Table A6-5 Predicted Fuel-to-Steam Efficiencies - 10 psig, Natural Gas . . . . . . . . . . . . . . . . A6-16
Table A6-6 Predicted Fuel-to-Steam Efficiencies - 125 psig, Natural Gas . . . . . . . . . . . . . . . A6-16
Table A6-7 Predicted Fuel-to-Steam Efficiencies - 10 psig, No. 6 Oil . . . . . . . . . . . . . . . . . A6-17
Table A6-8 Predicted Fuel-to-Steam Efficiencies - 125 psig, No 6 Oil . . . . . . . . . . . . . . . . . A6-17
Table A6-9 Predicted Fuel-to-Steam Efficiencies - 10 psig, No. 2 Oil . . . . . . . . . . . . . . . . . A6-17
Table A6-10 Predicted Fuel-to-Steam Efficiencies - 125 psig, No 2 Oi . . . . . . . . . . . . . . . . A6-17
Table A6-11 Model CB Boiler Emission Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-18
Table A6-12 Heating Surface, Model CB Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-18
Table A6-13 Steam Volume and Disengaging Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-19
Table A6-14 Water circulation rate and temperature drop for hot water boiler . . . . . . . . . . . A6-19
Table A6-15 Recommended Steam Nozzle Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-20
Table A6-16 Model CB Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . A6-20
Table A6-17 Sound Pressure Level Summary (50-100 hp) . . . . . . . . . . . . . . . . . . . . . . . . A6-20
Table A6-18 Model CB Boiler Sound Pressure Level Details (40 hp) . . . . . . . . . . . . . . . . . . A6-21
Table A6-19 Model CB Boiler Sound Pressure Level Details (50 - 100 hp) . . . . . . . . . . . . . A6-21
Table A6-20 Minimum required gas pressure at entrance to gas train . . . . . . . . . . . . . . . . . A6-23
Table A6-21 Minimum Required Gas Pressure Altitude Conversion . . . . . . . . . . . . . . . . . . . A6-23
Table A6-22 Maximum Gas Consumption (CFH) for Natural Gas and Propane Vapor . . . . . . A6-24
Table A6-23 Gas Pilot Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-24
Firetube Boilers
A6-3
03-08
Section A6
A6-4
03-08
In addition to the features provided on all Cleaver-Brooks Firetube Boilers, the
following features apply specifically to Model CB Firetube Boilers. The CB four-pass
dryback boiler is the premium firetube boiler design available.
Four-Pass Dryback Design:
Four-pass design provides high flue gas velocities and low stack temperature for
guaranteed maximum efficiency.
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
efficiency and long boiler life.
Highest guaranteed fuel-to-steam efficiencies.
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.
Advanced burner design provides maximum combustion efficiencies and high
turndown.
Reduced boiler cycling and maintenance.
Boiler stays on line during low load conditions for optimum efficiency 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 efficiencies.
Air atomizing oil burner available for proper oil atomization, maximum
combustion efficiency, 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 firing gas.
Section A6
A6-5
03-08
PRODUCT OFFERING
Model CB Firetube Boilers are available in low pressure steam, high pressure steam,
and hot water designs. Burners are available to fire 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 100 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 firing.
The Model CB Boiler is the premium firetube product offering providing maximum
boiler efficiency, the widest range of size and pressures, and premium control
packages.
Available options: For option details, contact your Cleaver-Brooks authorized
representative. Options include the following:
Boiler Options
Auxiliary low water cut-off (standard on steam boilers).
Drain valves.
Special design pressures.
Surge load baffles.
Seismic design.
Internal hot water coils.
Blowdown valves.
Non-return valves.
Special doors, davited, hinged, left swing.
Special base rails.
Combustion relief door.
Weather-proofing.
Blend pump.
Burner/Control
Options
Special modulation controls.
Optional flame safeguard controller.
Lead/lag system.
High altitude design, up to 12,000 ft.
Special insurance and code requirements (e.g. FM, ASME CSD-1).
Section A6
A6-6
03-08
Remote contacts.
Special purpose indicator lights.
Main disconnect.
Elapsed time meter.
NEMA enclosures.
Low fire hold controls.
Circuit breaker.
Day/night controls.
Fuel Options Automatic fuel changeover.
Special gas pressure regulator.
Gas strainer.
Special fuel shut-off valves.
Special pilot.
Alternate fuel firing (propane, digester gas, etc.).
Special oil pumps.
Dimensions and ratings for the Model CB boilers are shown in the following
tables and illustrations:
Table A6-1. Model CB Steam Boiler Ratings (15 thru 100 hp)
Table A6-2. Model CB Hot Water Boiler Ratings (15 thru 100 hp)
Table A6-3. Safety Valve Openings
Table A6-4. Relief Valve Openings
Figure A6-1. Model CB Steam Boiler Dimensions (15 and 150 lb design
pressure) (15 thru 100 hp)
Figure A6-2 Model CB Hot Water Boiler Dimensions (15 and 150 lb design
pressure) (15 thru 100 hp)
Figure A6-3. Space Required to Open Rear Head on Model CB Boilers
Equipped with Davits
Figure A6-4. Model CB Boiler Mounting PiersL
Figure A6-5. Lifting Lug Locations, Model CB Boilers
Section A6
A6-7
03-08
BOILER HP 15
C
20
C
30
C
40
C
50 60 70 80 100
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
Light Oil (gph)
A
4.5 6.0 9.0 12.0 15.0 18.0 21.0 24.0 30.0
Heavy Oil (gph)
B
- - - - 14.0 16.5 19.5 22.5 28.0
Gas (cfh) 1000 Btu-Nat
Gas (Therm/hr)
625
6.3
835
8.4
1255
12.6
1675
16.8
2095
21.0
2510
25.1
2930
29.3
3350
33.5
4185
41.9
Blower Motor hp (except gas) 1 1 1-1/2 2 2 2 2 2
D
3
Gas Models (only) 1 1 1-1/2 2 2 2 2 2
D
3
Oil Pump Motor, hp No. 2 Oil Belt-Driven From Blower 1/3 1/3 1/3 1/3 1/3
Oil Pump Motor, hp No. 6 Oil - - - - 1/3 1/3 1/3 1/3 1/3
Oil Heater kW No. 6 Oil - - - - 5 5 5 5 5
(Oil firing Only)
Air Compressor Belt-Driven
from Blower Motor
2 2 2 2 2
NOTES:
1. For altitudes above 3000 ft, contact your local Cleaver-Brooks authorized representative for verification of blower motor hp.
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 A6-1. Model CB Steam Boiler Ratings (15 - 100 hp)
BOILER HP 15
c
20
c
30
c
40
c
50 60 70 80 100A 100 125A
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
4.5 6.0 9.0 12.0 15.0 18.0 21.0 24.0 30.0 30.0 37.5
Heavy Oil (gph)
B
- - - - 14.0 16.5 19.5 22.5 28.0 28.0 35.0
Gas (cfh)
MBtu- nat
Gas (Therm/hr)
625
6.3
835
8.4
1255
12.6
1675
16.8
2095
21.0
2510
25.1
2930
29.3
3350
33.5
4185
41.9
4185
41.9
5230
52.3
Blower Motor hp (except gas) 1 1 1-1/2 2 2 2 2 2
D
3 3 3
Gas Models (only) 1 1 1-1/2 2 2 2 2 2
D
3 3 3
Oil Pump Motor, hp No. 2 Oil Belt-Driven From Blower 1/3 1/3 1/3 1/3 1/3 1/3 1/2
Oil Pump Motor, hp No. 6 Oil - - - - 1/3 1/3 1/3 1/3 1/3 1/3 1/2
Oil Heater kW No. 6 Oil - - - - 5 5 5 5 5 5 5
(Oil firing Only)
Air Compressor Belt-Driven
from Blower Motor
2 2 2 2 2 2 2
NOTES:
1. For altitudes above 3000 ft, contact your local Cleaver-Brooks authorized representative for verification of blower motor hp.
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 A6-2. Model CB Hot Water Boiler Ratings (15 - 100 hp)
Section A6
A6-8
03-08
VALVE
SETTING
BOILER
HP
NO. OF
VALVES-
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES-
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES-
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES-
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
15 1 1-1/2 1 1 1 3/4 1 3/4 1 3/4 1 3/4
20 1 1-1/2 1 1 1 1 1 3/4 1 3/4 1 3/4
25 1 2 1 1 1 1 1 1 1 3/4 1 3/4
30 1 2 1 1-1/4 1 1 1 1 1 3/4 1 3/4
40 1 2-1/2 1 1-1/4 1 1-1/4 1 1 1 1 1 1
50 1 2-1/2 1 1-1/2 1 1-1/2 1 1-1/4 1 1 1 1
60 1 2 1 1-1/2 1 1-1/2 1 1-1/4 1 1-1/4 1 1
70 1 2 1 2 1 1-1/2 1 1-1/2 1 1-1/4 1 1-1/4
80 1 2-1/2 1 2 1 1-1/2 1 1-1/2 1 1-1/4 1 1-1/4
100 1 2-1/2 1 2 1 2 1 1-1/2 1 1-1/2 1 1-1/4
VALVE
SETTING
30 PSIG HW 60 PSIG HW 100 PSIG HW 125 PSIG HW
BOILER
HP
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
15 1 1 1 1 1 1 1 1
20 1 1 1 1 1 1 1 1
25 1 1-1/4 1 1 1 1 1 1
30 1 1-1/4 1 1 1 1 1 1
40 1 1-1/4 1 1 1 1 1 1
50 & 50A 1 2 1 1-1/4 1 1 1 1
60 1 2 1 1-1/4 1 1 1 1
70 1 2 1 2 1 1-1/4 1 1
80 1 2 1 2 1 1-1/4 1 1-1/4
100 1 2-1/2 1 2 1 1-1/4 1 1-1/4
100A 1 2-1/2 1 2 1 1-1/4 1 1-1/4
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.
Section A6
A6-9
03-08
BOILER HP DIM 15 20 30 40 50 60 70 80 100
LENGTHS
Overall A 96-5/8 96-5/8 114-5/8 140-5/8 129 129 168 168 187
Shell B 62-5/8 62-5/8 80-5/8 106-5/8 92 92 131 131 150
Base Frame C 59 59 77 103 91 91 130 130 148
Front Head Extension D 18-1/2 18-1/2 18-1/2 18-1/2 18-1/2 18-1/2 18-1/2 18-1/2 18-1/2
Rear Head Extension E 15-1/2 15-1/2 15-1/2 15-1/2 18-1/2 18-1/2 18-1/2 18-1/2 18-1/2
Front Ring Flange to
Nozzle - 15 psig
F 36 36 45 57 46 46 65-1/2 65-1/2 75
Front Ring Flange to Nozzle - 150 psig F 36 36 45 57 46 46 72-1/2 72-1/2 82
Ring Flange to Base G 1-13/16 1-13/16 1-13/16 1-13/16 5/8 1/2 1/2 1/2 1/2
WIDTHS
Overall I 61 61 61 61 73 73 73 73 73
ID, Boiler J 36 36 36 36 48 48 48 48 48
Center to Water Column K 33 33 33 33 39 39 39 39 39
Center to Outside Hinge KK 22 22 22 22 29 29 29 29 29
Center to Lagging L 20 20 20 20 27 27 27 27 27
Center to Auxiliary LWCO LL 28 28 28 28 34 34 34 34 34
Base, Outside M 28 28 28 28 37-5/8 37-3/8 37-3/8 37-3/8 37-3/8
Base, Inside N 22 22 22 22 29-5/8 29-5/8 29-5/8 29-5/8 29-5/8
Figure A6-1. Model CB Steam Boiler Dimensions and Weights (15 and 150 psig Design Pressure -
15 to 100 hp) Sheet 1 of 2
Section A6
A6-10
03-08
BOILER HP DIM 15 20 30 40 50 60 70 80 100
HEIGHTS
Base to Steam Outlet (15 psig only) PL 50-1/4 50-1/4 50-1/4 50-1/4 70-5/16 70-5/16 70-5/16 70-5/16 70-5/16
Overall OO 66 66 66 66 78-3/4 78-3/4 78-3/4 78-3/4 78-3/4
Base to Vent Outlet O 53-1/2 53-1/2 53-1/2 53-1/2 70 70 70 70 70
Base to Steam Outlet (150 psig only) PH 50-1/4 50-1/4 50-1/4 50-1/4 66-31/2 66-1/2 66-1/2 66-1/2 70-5/16
Height of Base Q 8 8 8 8 12 12 12 12 12
Base to Bottom of Boiler R 12 12 12 12 16 16 16 16 16
BOILER CONNECTIONS
Chemical Feed H 1 1 1 1 1 1 1 1 1
Feedwater, Right and Left S 1 1 1 1 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4
Low Pressure (15 psig only)
Steam Nozzle
U
W
4
1
4
1
4
1
6
A
1-1/4
6
A
1-1/4
6
A
1-1/4
6
A
1-1/2
6
A
1-1/2
8
A
1-1/2
High Pressure (150 psig only)
L
Steam Nozzle
T
Y
W
1
1-1/2
1
1
1-1/2
1
1
2
1
1
2
1
1
3
1-1/4
1
3
1-1/4
1
3
1-1/4
1
3
1-1/4
1
4
B
1-1/4
VENT STACK
Diameter (flgd connection) BB 6 6 8 8 10 10 12 12 12
Front Ring Flange to Vent C
L
CC 4 4 5 5 6 6 7 7 7
MINIMUM CLEARANCES
Rear Door Swing
C
DD 44 44 44 44 55 55 55 55 55
Front Door Swing
C
EE 44 44 44 44 55 55 55 55 55
Tube Removal, Rear FF 56 56 74 100 84 84 123 123 142
Tube Removal, Front GG 46 46 64 90 74 74 113 113 132
Rear of Boiler RR 163 163 199 251 231 231 309 309 347
Front of Boiler RF 153 153 189 241 221 221 299 299 337
Thru Window or Doorway RD 151 151 169 195 202 202 241 241 260
WEIGHT IN LBS
Normal Water Capacity 1340 1300 1710 2290 3130 2920 4620 4460 5088
Approx. Ship Wgt - 15 psig 3000 3100 3650 4350 6900 7000 8100 8200 9000
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.
C. 15 thru 100 hp standard hinged door.
Figure A6-1. Model CB Steam Boiler Dimensions and Weights (15 and 150 psig Design Pressure - 15 to 100 hp)
Sheet 2 of 2
Section A6
A6-11
03-08
Figure A6-2. Model CB Hot Water Boiler Dimensions (30 psig and 125 psig Design Press. - 15 to 100 hp)
Sheet 1 of 2
BOILER HP DIM 15 20 30 40 50 60 70 80/100A 100/
125A
LENGTHS
Overall A 97 97 114-5/8 140-5/8 129 129 168 168 187
Shell B 62-5/8 62-5/8 80-5/8 106-5/8 92 92 131 131 150
Base Frame C 59 59 77 103 91 91 130 130 148
Front Head Ext. D 18-1/2 18-1/2 18-1/2 18-1/2 18-1/2 18-1/2 18-1/2 18-1/2 18-1/2
Rear Head Ext. E 15-1/2 15-1/2 15-1/2 15-1/2 18-1/2 18-1/2 18-1/2 18-1/2 18-1/2
Front Ring Flange to Return F 43-5/8 43-5/8 62 81 69 69 108 108 127
Front Ring Flange to Outlet G 55-1/8 55-1/8 73-1/8 98-1/2 84-5/8 84-5/8 123-5/8 123-5/8 142-5/8
Ring Flange to Base H 1-13/16 1-13/16 1-13/16 1-13/16 5/8 5/8 5/8 5/8 1
WIDTHS
Overall I 48-3/4 48-3/4 48-3/4 48-3/4 63 63 63 63 63
ID, Boiler J 36 36 36 36 48 48 48 48 48
Center to Entrance Box K 28-3/4 28-3/4 28-3/4 28-3/4 36 36 36 36 36
Center to Outside Hinge KK 22 22 22 22 29 29 29 29 29
Center to Lagging L 20 20 20 20 27 27 27 27 27
Base, Outside M 28 28 28 28 37-5/8 37-5/8 37-5/8 37-5/8 37-5/8
Base, Inside N 22 22 22 22 29-5/8 29-5/8 29-5/8 29-5/8 29-5/8
Section A6
A6-12
03-08
BOILER HP DIM 15 20 30 40 50 60 70 80/100A 100/
125A
HEIGHTS
Overall OO 66 66 66 66 72-5/8 72-5/8 72-5/8 72-5/8 72-5/8
Base to Vent Outlet O 53-1/2 53-1/2 53-1/2 53-1/2 70 70 70 70 70
Base to Return and outlet P 50 50 50 50 70-5/16 70-5/16 70-5/16 70-5/16 70-5/16
Davit (Front) DF - - - - - - - - -
Davit (Rear) DR - - - - - - - - -
Height of Base Q 8 8 8 8 12 12 12 12 12
Base to bottom of boiler R 12 12 12 12 16 16 16 16 16
BOILER CONNECTION
Waterfill Conn. Right & Left S 1 1 1 1 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4
Water Return - Threaded T 2-1/2 2-1/2 3 3 4 4 4 4 4
Water Outlet - Threaded
A
U 2-1/2 2-1/2 3 3 4 4 4 4 4
Air Vent v 1 1 1 1 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4
Drain, Front and Rear W 1 1 1 1-1/4 1-1/4 1-1/4 1-1/2 1-1/2 1-1/2
Auxiliary Connection X 1 1 1 1 1 1 1 1 1
VENT STACK
Diameter (flgd. connection) BB 6 6 8 8 10 10 12 12 12
Front Ring Flange to vent C
L
CC 4 4 5 5 6 6 7 7 7
MINIMUM CLEARANCES
Rear Door Swing DD 44 44 44 44 55 55 55 55 55
Front Door Swing EE 44 44 44 44 55 55 55 55 55
Tube Removal, Rear FF 56 56 74 100 84 84 123 123 142
Tube, Removal, Front GG 46 46 64 90 74 74 113 113 132
MINIMUM BOLER ROOM LENGTH ALLOWING FOR DOOR SWING AND TUBE REMOVAL FROM:
Rear of Boiler RR 163 163 199 251 231 231 309 309 347
Front of Boiler RF 153 153 189 241 221 221 299 299 337
Thru Window or Doorway RD 151 151 169 195 202 202 241 241 260
WEIGHT IN LBS
Water Capacity Flooded 1500 1460 1915 2585 3665 3500 5420 5250 5960
3000
3300
3100
3400
3650
3880
4350
4580
6800
7100
7000
7300
8000
8350
8100
8450
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 A6-2. Model CB Hot Water Boiler Dimensions (30 psig Design Pressure -
15 to 100 hp) - Sheet 2 of 2
Section A6
A6-13
03-08
BOILER HP DIMENSION (INCHES)
A B C D E
15 - 40, 50A 20 36 28 45 20
50 - 100, 100A, 125A 27 48 38 60 26
NOTE:
1. Dimensions in inches.
2. 15 - 100 hp (100A & 125A)
boilers are standardly equipped with hinges. Davit available as an
option.
Figure A6-3. Space Required to Open Rear Head on Model CB Boilers Equipped with Davits
PLAN VIEW
BOILER HP A B C D E F G X1 X2
15-20 6 8 59 17 33 3 22 9-3/4 9-3/4
25-30 6 8 77 17 33 3 22 9-3/4 9-3/4
40-50A 6 8 103 17 33 3 22 9-3/4 9-3/4
50-60 6 8 91 26 42 4 29-5/8 8-1/4 8-1/4
70-80, 100A 6 8 130 26 42 4 29-5/8 8-1/4 8-1/4
100, 125A 6 8 148 26 42 4 29-5/8 8-1/4 8-1/4
NOTE:
2. 6-inch high mounting piers recommended for use beneath the boiler base frame. The use of these piers provides increased inspection ac-
cessibility to the piping beneath the boiler and added height for washing down the area beneath the boiler.
Figure A6-4. Model CB Boiler Mounting Piers
Section A6
A6-14
03-08
BOILER HP VIEW ALL DIMENSIONS IN INCHES
A B C D E
15 Steam A 51-3/4 12 38-3/4 - 2-1/2
Hot Water B 50-1/2 12 38-3/4 6 2-1/2
20 Steam A 51-3/4 12 38-3/4 - 2-1/2
Hot Water B 50-1/2 12 38-3/4 6 2-1/2
25 Steam A 51-3/4 12 56-3/4 - 2-1/2
Hot Water B 50-1/2 12 56-3/4 6 2-1/2
30 Steam A 51-3/4 12 56-3/4 - 2-1/2
Hot Water B 50-1/2 12 56-3/4 6 2-1/2
40 Steam A 51-3/4 12 82-3/4 - 2-1/2
Hot Water B 50-1/2 12 82-3/4 6 2-1/2
50A
Water B 50-1/2 12 82-3/4 6 2-1/2
50 All B 68 18 57 10 2-1/2
60 All B 68 18 57 10 2-1/2
70 All B 68 27 67 10 2-1/2
80 All B 68 27 67 10 2-1/2
100 All B 68 27 86 10 2-1/2
100A Hot Water B 68 27 67 10 2-1/2
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 A6-5. Lifting Lug Locations, Model CB Boilers
NEAR
SIDE
VIEW B
FAR
SIDE
FRONT
FLANGE
VIEWA
E DIA. HOLE
A
C
L
B
D
D
C
Section A6
A6-15
03-08
PERFORMANCE DATA
Efficiency Tables A6-5 through A6-10 show predicted fuel-to-steam efficiencies (including
radiation and convection losses) for Cleaver-Brooks Model CB Firetube boilers. For
specific efficiencies on firetube boiler offerings not listed here, contact your local
for Model CB Firetube Boilers. The guarantee is based on the fuel-to-steam
achieve fuel-to-steam efficiency (as shown in the tables listed above) at 100% firing
rate (add efficiency guarantees at 25%, 50%, and 75% of rating, if required). If the
boiler(s) fail to achieve the corresponding guaranteed efficiency as published, the
boiler manufacturer will rebate, to the ultimate boiler owner, five thousand dollars
($5,000) for every full efficiency point (1.0%) that the actual efficiency is below the
guaranteed level. The specified boiler efficiency is based on the following conditions.
Natural Gas
Carbon, % (wt) = 69.98
No. 2 Oil
Carbon, % (wt) = 85.8
No. 6 Oil
Carbon, % (wt) = 86.6
Sulfur, % (wt) = 2.09
guarantee conditions to maximize the effectiveness of your efficiency specification. If
you have any questions regarding the efficiency specifications, please contact your
local Cleaver-Brooks authorized representative. For efficiencies and stack
Section A6
A6-16
03-08
temperatures at operating pressures not listed, follow these procedures:
Example:
Boiler: 100 hp.
Fuel: natural gas.
Find the fuel-to-steam efficiency at 100% firing rate. From Figure A6-6 for a 100 hp
boiler operating at 100% firing rate and an operating steam pressure of 125 psig,
the efficiency is 88.0%.
pressure is calculated as follows: 36/40 = .9%. Therefore, the boiler efficiency at
200 psig operating pressure is 82.5 - .9 = 81.6%.
Emissions The emission data included in this section consists of typical uncontrolled emission
levels for Cleaver-Brooks Model CB Firetube Boilers.
Notice
The data in Table A6-13 represents typical emission levels only. Guaranteed emis-
sion levels are available from your local Cleaver-Brooks authorized representative.
BOILER
HP
FIRING RATE (%)
25 50 75 100
50 80.2 80.5 80.4 80.1
60 80.1 80.4 80.3 80.1
70 81.7 82.0 81.9 81.7
80 81.8 82.1 82.0 81.8
100 81.5 82.4 82.3 82.2
Table A6-6. Predicted Fuel-to-Steam Efficiencies (%),
Model CB Boilers - 125 psig, Natural Gas
BOILER
HP
FIRING RATE (%)
25 50 75 100
50 83.0 83.2 82.9 82.4
60 82.9 83.1 82.7 82.3
70 84.5 84.7 84.3 83.9
80 84.6 84.8 84.5 84.0
100 84.4 85.0 84.8 84.4
Model CB Boilers - 10 psig, Natural Gas
Section A6
A6-17
03-08
BOILER
HP
FIRING RATE (%)
25 50 75 100
50 83.9 84.2 84.0 83.8
60 83.8 84.1 83.9 83.8
70 85.5 85.8 85.6 85.4
80 85.6 85.9 85.7 85.6
100 84.6 85.8 85.9 85.8
Model CB Boilers - 125 psig, No 6 Oil
BOILER
HP
FIRING RATE (%)
25 50 75 100
50 86.8 87.0 86.6 86.1
60 86.7 86.9 86.5 86.0
70 88.4 88.6 88.2 87.7
80 88.5 88.7 88.3 87.8
100 88.2 88.5 88.3 88.0
Model CB Boilers - 10 psig, No. 6 Oil
BOILER
HP
FIRING RATE (%)
25 50 75 100
50 86.5 86.7 86.3 85.8
60 86.3 86.6 86.2 85.7
70 87.9 88.2 87.8 87.3
80 88.1 88.3 87.9 87.4
100 87.8 88.4 88.1 87.7
Model CB Boilers - 10 psig, No. 2 Oil
BOILER
HP
FIRING RATE (%)
25 50 75 100
50 83.6 84.0 83.8 83.5
60 83.5 83.8 83.7 83.5
70 85.1 85.4 85.3 85.1
80 85.2 85.6 85.4 85.3
100 84.8 85.7 85.6 85.5
Model CB Boilers - 125 psig, No 2 Oi
Section A6
A6-18
03-08
ENGINEERING DATA
The following engineering information is provided for Model CB Firetube Boilers.
representative.
Blowdown Water
Requirements
Sound Level Table A6-17 summarizes predicted sound pressure levels for Model CB Boilers.
Table A6-18 and A6-19 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
POLLUTANT
ESTIMATED LEVELS - UNCONTROLLED
NATURAL GAS NO. 2 OIL
B
NO. 6 OIL
C
CO
ppm
A
200 90 95
Lb/MMBtu 0.15 0.07 0.075
NOx
ppm
A
100 185 502
Lb/MMBtu 0.12 0.25 0.67
SOx
ppm
A
1 278 278
Lb/MMbtu 0.001 0.52 0.52
HC/VOCs
ppm
A
40 50 70
Lb/MMBtu 0.016 0.025 0.035
PM
ppm
A
- - -
Lb/MMBtu 0.01 0.025 0.160
NOTES:
Refer to Section E for detailed emission information.
A. ppm levels corrected to 3% O
2
, dry basis.
B. Based on fuel constituent levels of:
Fuel-bound nitrogen content = 0.015% by weight
Ash content = 0.01% by weight
C. Based on fuel constituent levels of:
Fuel-bound nitrogen content = 0.7% by weight
Ash content = 0.1% by weight
Conradson carbon residue = 16% by weight
Table A6-11. Model CB Boiler Emission Data
BOILER
HP
FIRESIDE WATERSIDE
15 75 85
20 100 109
25 125 144
30 150 162
40 200 219
50 250 266
60 300 323
70 350 388
80 400 441
100 500 544
Table A6-12. Heating Surface, Model CB Boilers
Section A6
A6-19
03-08
BOILER HP STEAM VOLUME CU-FT STEAM RELIEVING AREA, SQ-IN
HIGH PRESSURE
A
LOW PRESSURE
B
HIGH PRESSURE
A
LOW PRESSURE
B
15 2.9 5.9 1356 1637
20 2.9 5.9 1356 1637
25 & 30 3.9 7.9 1817 2195
40 5.3 10.8 2485 2999
50 9.7 16.0 2959 3372
60 9.7 16.0 2959 3372
70 14.3 23.7 4367 4975
80 14.3 23.7 4367 4975
100 16.6 27.4 5053 5757
NOTE: Based on normal water level.
BOILER
HP
BOILER
OUTPUT
(1000)
BTU/HR
SYSTEM TEMPERATURE DROP - DEGREES F
10 20 30 40 50 60 70 80 90 100
MAXIMUM CIRCULATING RATE - GPM
15 500 100 50 33 25 20 17 14 12 11 10
20 670 134 67 45 33 27 22 19 17 15 13
30 1005 200 100 67 50 40 33 29 25 22 20
40 1340 268 134 89 67 54 45 38 33 30 27
50 1675 335 168 112 84 67 56 48 42 37 33
60 2010 402 201 134 101 80 67 58 50 45 40
70 2345 470 235 157 118 94 78 67 59 52 47
80 2680 536 268 179 134 107 90 77 67 60 54
100 &
100A
3350 670 335 223 168 134 112 96 84 75 67
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.
Table A6-14. Water Circulation Rate and Temperature Drop for Hot Water Boiler
Section A6
A6-20
03-08
BOILER HP
OPERATING
PRESSURE
PSIG
15 20 25 30 40 50 60 70 80 100
15 4 4 4 4 6 6 6 6 6 8
30 2 2 2.5 2.5 3 4 4 4 4 6
40 2 2 2.5 2.5 3 3 4 4 4 6
50 1.5 2 2 2.5 2.5 3 3 4 4 4
75 1.5 2 2 2 2.5 3 3 3 4 4
100 1.5 1.5 2 2 2 3 3 3 3 4
125 1.5 1.5 2 2 2 3 3 3 3 4
150 1.5 1.5 2 2 2 2.5 2.5 2.5 2.5 2.5
200 1.5 1.5 2 2 2 2.5 2.5 2.5 2.5 2.5
250 1.5 1.5 2 2 2 2 2 2 2 2
NOTES:
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.
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 A6-15. Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity)
BOILER HP WATER (GAL.)
15-20 26
25-30 34
40 47
50-60 55
70-80 80
100 93
NOTE: Quantity of water removed from boiler by lowering normal wa-
ter line 4".
Table A6-16. Model CB Blowdown Tank Sizing Information
BOILER HP 50 60 70 80 100
HFO, dBA 79 79 79 79 81
LFO, dBA 78 78 78 78 79
HFG, dBA 77 77 78 78 78
LFG, dBA 72 73 74 75 75
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:
NOTE:
ABBREVIATIONS:
HF = High Fire
LF = Low Fire
O = Oil
G = Gas
Table A6-17. Sound Pressure Level Summary (50-100 hp)
Section A6
A6-21
03-08
FIRING
RATE
FUEL
SOUND
LEVEL
dBA
OCTAVE BAND SOUND PRESSURE LEVELS IN dB RE .0002 MICROBAR
31Hz 63Hz 125Hz 250Hz 500Hz 1kHz 2kHz 4kHz 8kHz 16kHz
40HP
A
LFG 76 73 75 72 74 76 70 67 68 64 57
LFO 77 73 75 75 76 75 72 67 66 66 58
HFG 79 81 78 74 80 78 71 69 68 64 58
HFO 79 72 77 77 81 78 73 69 66 66 58
NOTE:
ABBREVIATIONS:
HF = High Fire
LF = Low Fire
O = Oil
G = Gas
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 re-
quired for the 15 thru 30 hp, use the values shown for the 40 hp.
Table A6-18. 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 500Hz 1kHz 2kHz 4kHz 8kHz 16kHz
50 HP
LFG 72 71 65 71 71 70 68 63 60 53 46
LFO 78 71 76 78 73 72 72 76 61 56 54
HFG 77 72 68 75 76 74 74 66 61 54 47
HFO 79 72 70 75 75 77 77 70 63 56 54
60 HP
LFG 73 70 75 72 72 73 68 61 56 50 45
LFO 78 68 77 74 74 75 74 71 58 53 48
HFG 77 73 75 72 72 75 76 63 55 50 44
HFO 79 75 75 75 75 77 77 72 59 52 45
70 HP
LFG 74 70 70 75 74 73 71 62 56 51 46
LFO 78 70 73 77 74 75 74 70 59 53 57
HFG 78 72 72 77 78 75 76 68 58 52 57
HFO 79 73 73 80 77 77 76 70 60 54 48
80 HP
LFG 75 70 75 75 73 75 76 66 62 62 53
LFO 78 69 77 76 74 76 74 73 63 62 57
HFG 78 72 74 78 75 75 76 57 61 59 52
HFO 79 75 75 75 74 76 75 69 62 59 54
100 & 100A HP
LFG 75 69 69 75 76 73 71 65 63 59 50
LFO 79 68 73 78 78 75 79 76 63 59 54
HFG 78 69 70 77 77 74 74 69 63 59 50
HFO 81 68 70 77 78 78 77 71 64 59 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.
Table A6-19. Model CB Boiler Sound Pressure Level Details (50 - 100 hp)
Section A6
A6-22
03-08
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.
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
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 finally, 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 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 Table A6-20 shows minimum gas pressure requirements for Model CB Boilers.
Table A6-22 shows maximum gas consumption for natural gas and propane vapor.
Figure A6-7 shows standard gas train sizes and locations for Model CB Firetube
Boilers.
Figure A6-9 shows gas train components.
firing No. 2 oil.
firing No. 5 and No. 6 oil.
Figure A6-12 through A6-14 show typical oil systems and layouts.
Figure A6-15 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.
Section A6
A6-23
03-08
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. Provide a tank suction heater and bundling the steam or water lines to the heater
with the oil lines.
2. 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 temper-
atures could cause vapor binding of the oil pump and decreased oil flow.
See Figure A6-16 for an example of tank heating method.
Table A6-20. Minimum required gas pressure at entrance to gas train
Gas Supply Pressure Less Then 27" W.C. Gas Supply Pressure Up To 10 Psi
Boiler Hp
Train Size
Regulator Model*
Min. Supply Press
"W.C. Regulator Model*
Min. Supply Press
"W.C.
15 1-1/4 Maxitrol 1-1/4", RV-61 4 Maxitrol 1", 210-D 4
20 1-1/4 Maxitrol 1-1/4", RV-61 7 Maxitrol 1", 210-D 7
30 1-1/2 Maxitrol 1-1/2", RV-81 6 Maxitrol 1-1/4", 210-D 7
40 1-1/2 Maxitrol 1-1/2", RV-81 9 Maxitrol 1-1/4", 210-D 10
50 2 Maxitrol 2", RV-91 6 Maxitrol 1-1/4", 210-D 6
*Maxitrol RV series is standard; 210 series is optional
ALTITUDE
(FT)
CORRECTION
FACTOR
ALTITUDE
(FT)
CORRECTION
FACTOR
1000 1.04 6000 1.25
2000 1.07 7000 1.30
3000 1.11 8000 1.35
4000 1.16 9000 1.40
5000 1.21 - -
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.
Table A6-21. Minimum required gas
pressure altitude conversion
Section A6
A6-24
03-08
BOILER
HP
NATURAL GAS
1000 (Btu/cu-ft)
PROPANE GAS
2550 (Btu/cu-ft)
15 625 245
20 835 330
25 1045 410
30 1255 490
40 1675 655
50A 2095 820
50 2095 820
60 2510 985
70 2930 1150
80 3350 1315
100A 4185 1640
100 4185 1640
NOTES:
BHP followed by A designates hot water boilers furnished in a
smaller vessel size with additional tubes in upper portion of vessel.
Table A6-22. Maximum Gas Consumption (CFH)
for Natural Gas and Propane Vapor
BOILER
HP
MODEL CB
CONNECTION
SIZE
(IN.) (NPT)
LOCATION
DIMENSION
"A"(IN.)
15,20 1-1/4 65-1/2
30 1-1/2 68
40,50A 1-1/2 68
50 2 74
60, 70, 80 2 74
100A, 100 2 74
NOTE: BHP followed by A designates hot water boil-
er furnished in a smaller vessel size with additional
tubes in upper portion of vessel.
A
PLAN VIEW
BOILER
FRONT
Figure A6-7. Standard Gas Train Connection Size and Location
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.
Table A6-23. Gas Pilot Data
BHP Connection (inch-
es) NPT
Min. Required Gas
Pressure (Up to
700) Inches WC
Max. Permissible Gas
Pressure (psig)
50-100 1/2 4 5
BHP Manufactured 500
Btu/Cu. Ft
Natural 1000 Btu/
Cu. Ft
Propane 2500 Btu/
Cu Ft
50-100 120 60 25
Section A6
A6-25
03-08
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 connec-
tion point and the gas main in the street are representative of a typical installation. Actual require-
ments may vary depending on local codes or local gas company requirements which should be
investigated prior to preparation of specifications and prior to construction.
C. Gas meter.
The size of the gas line from the meter to the gas pressure regulator at the boiler can be very im-
portant if gas pressures are marginal. The gas line sizing is dependent on:
The local gas utility will advise the pressure that is available at the outlet of their meter.
MODEL
CB-LE
BOILERS
PLUG
COCK
A
B
C
D CONTRACTOR
CONNECTION
POINT
GAS TRAIN
ON BOILER
STREET GAS MAIN
MODEL
CB-LE
BOILERS
Section A6
A6-26
03-08
PILOT GAS LINE
FLOW
1
4
5
6
To
Burner
Gas
Supply
2
3
8
10
9
7
11
MAIN GAS LINE
Figure A6-9. Model CB Gas Train Components
ITEM DESCRIPTION
INS UL FM CSD-1
BOILER HP 15-20 30-50
60-
100
15-
20
30-
100
15-20 30-50
60-
100
1 Pilot Shut Off Cock x x x x x x x x
2 Manual Shut Off Valve x x x x x x x x
3 Manual Shut Off Valve x x x x x x x x
4 Pilot Pressure Regulator x x x x x x x x
5 Pilot Pressure Gauge x x x x x x x x
6 Gas Pilot Valve x x x x x x x x
7 High Gas Pressure Switch x x x x
8 Low Gas Pressure Switch x x x x
9 Main Gas Valve with POC x x x x x x x x
10 Main Gas Regulator x x x x x x x x
11 Butterfly Valve x x x x x
Section A6
A6-27
03-08
BOILER BASE FRAME
BOILER
FRONT
A
CONTRACTOR
CONNECTIONS
BOILER
HP
MODEL CB
SUPPLY
AND
RETURN
CONN
SIZES
(IN.)
(NPT)
DIM. A
(IN.)
A
SIZES
(STANDARD PIPE)
(IN.)
STORAGE
TANK TO
BOILER
OR PUMP
CONNECT
PUMP TO
BOILER
RETURN
LINE TO
TANK
15, 20 3/4 8-1/4 3/4 NONE 3/4
30, 40 3/4 8-1/4 3/4 NONE 3/4
50, 60 3/4 11-1/2 3/4 1 3/4
70,80 3/4 11-1/2 3/4 1 3/4
100 3/4 11-1/2 1 1 1
NOTE: See No. 2 Oil Line Sizing Instruction for systems with other con-
ditions.
total of 100 equivalent feet of suction line.
B. This table is based on a single boiler installation.
C
PLAN VIEW
BOILER
FRONT
B
A
Figure A6-10. No. 2 Oil Connection Size, Location and Recommended Line Sizes
BOILER
HP
SUPPLY
CONNECTION
RETURN
CONNECTION
SIZES
(STANDARD PIPE)
(IN.)
SIZE
(IN.)
(NPT)
A (IN.) SIZE
(IN.)
(NPT)
B (IN.) STORAGE
TANK TO
PUMP
PUMP TO
BOILER
RETURN
LINE TO
TANK
50, 60, 70, 80, 100 1-1/4 27-3/4 3/4 19-3/4 2 1-1/4 1-1/4
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 A6-11. No. 6 Oil Connection Size, Location and Recommended Line Sizes, Model CB Boiler
Section A6
A6-28
03-08
BOILER
BASE FRAME
BOILER
FRONT
F.O.S.
F.O.R.
CONTRACTOR
CONNECTIONS
AT THIS POINT
GATE VALVE
OIL PUMP
CHECK
VALVE
VACUUM
GAUGE
STRAINER
GATE VALVE
RELIEF VALVE
UNION
GATE VALVE
CHECK VALVE
F.O.R.
F.O.S.
BOILER
BASE FRAME
BOILER
FRONT
F.O.S.
F.O.R.
CONTRACTOR
CONNECTIONS
AT THIS POINT
GATE VALVE
OIL PUMP NO. 1
OIL
PUMP
NO. 2
GATE VALVE
GATE VALVE
CHECK VALVE
RELIEF
VALVE
(100 PSIG)
UNION
GATE VALVE
CHECK VALVE
F.O.S.
F.O.R.
Section A6
A6-29
03-08
Figure A6-14. No. 2 Oil Piping, Multiple Boiler Installation
STANDBY
OIL PUMP
UNION
GATE VALVE
CHECK
GATE
RELIEF
VACUUM GAUGE
STRAINER
GATE VALVE
F.O.S.
F.O.R.
PRESSURE
ADJUSTABLE
GATE VALVE
CHECK VALVE
USE LAYOUT FOR: MODEL CB . . . . . . . 50 THRU 800 HP
BOILER
CONTACTOR
BOILER
F.O.S.
F.O.R.
must be set at 100 psig
so that adjustable
pressure relief valve in
the loop
VALVE
VALVE
VALVE
(100 PSIG) GAUGE
PRESSURE
RELIEF VALVE
(75 PSIG)
FRONT
CONNECTIONS
AT THIS POINT
BASE FRAME
Section A6
A6-30
03-08
(For elevated boiler room locations using an oil
transfer pump and tank)
level switch
tion from transfer
pump
tion
connection
McD
F.O.R.
OIL LEVEL
TEST VALVE
OIL TRANSFER PUMP
NEAR STORAGE TANK
SUPPLY TO BOILER
TERMINAL BLOCK OR
TO BOILER OIL PUMP
GATE
VALVE
GATE
VALVE
OIL TRANSFER TANK
AT LOCATION NEAR
BOILER
VENT
H
F.O.S.
F.O.R.
F.O.S.
CHECK
VALVE STRAINER
VACUUM
GAUGE
UNION
RELIEF VALVE
(100 PSIG)
3/8" MTL
D
4" OR 6"
STD
BLACK
PIPE
F
E
22"
33"
3"
2"
60"
G
A
B
C
5"
3"
3/16"
S
3/16"
S
OIL STORAGE
TANK
MANHOLE
OIL RETURN
OIL SUCTION
STEAM OR HOT WATER
AND SUPPLY SYSTEMS.
Section A6
A6-31
03-08
Boiler Room
Information
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
Although constant pressure at the flue gas outlet of the Model CB is not required, it
is necessary to size the stack/breeching to limit flue 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 firing 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.
Boiler Room
Combustion Air
recommended. Locate one at each end of the boiler room, preferably below a height
D. Under no condition should the total area of the air supply openings be less than (1)
square foot.
Area (sq-ft) = cfm/fpm
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).
Section A6
A6-32
03-08
Area Required: Area = cfm = 3000/250 = 12 Sq-ft total.
Notice
Section A6
A6-33
03-08
A B
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
FRONT
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
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.
2. Next shortest boiler room length (Dwg B) is obtained by allowing for possible future tube replacement from the front of the boiler. Allow-
ance is only made for minimum door swing at the rear.
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.
DWG A
DWG B
DWG C
BOILER HP 15-40 50-100
Dimension A 75" 81"
Dimension B 103" 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.
42" - 15-100 hp
Section A6
A6-34
03-08
STACK
DRAIN
CONNECTION
CLEAN-
OUT
MANUAL
DAMPER
LOCK (OPEN)
TIGHT SEAL
CLEANOUT
STACK
DRAIN
CONNECTION
CLEAN-
OUT
MANUAL
DAMPER
LOCK (OPEN)
TIGHT SEAL
CLEANOUT
STACK
DRAIN
CONNECTION
CLEAN-
OUT
MANUAL
DAMPER
LOCK (OPEN)
TIGHT SEAL
CLEANOUT
MAXIMUM 10
CONE ANGLE
NOTE: These stack breeching arrangements for
multiple boilers are typical and not intended for your
specific 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 specific
criteria. Your local CLeaver-Brooks authorized
representative is capable of assisting in your
evaluation of stack and breeching design.
A6-35
03-08
Section A6
Model CB 15-100 HP
Steam Boiler Specifications
Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-36
General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-36
Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-37
Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-38
Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-44
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-45
Shop Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-45
Start-up Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-45
Model CB 15-100 HP Section A6
A6-36
03-08
Model CB 15-100 HP
Model CB Steam Boiler (15-100 hp, Steam 15-350 psig)
The following sample specification is provided by Cleaver-Brooks to assist you in meeting your
customers specific needs and application.
A separate specification for steam boilers and hot water boilers is provided. Burner
specifications and detailed control specifications 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 Specifications are typically utilized as the base template for the complete boiler
specification. Contact your local Cleaver-Brooks authorized representative for information on
special insurance requirements, special code requirements, optional equipment, or general
assistance in completing the specification.
A. 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.
B. The boiler shall have a maximum output of _____Btu/hr, or _____horsepower
when fired with CS 12-48 _____oil and/or natural gas, _____Btu/cu-ft.
Electrical power available will be _____Volt _____Phase _____Cycle.
A. The boiler shall be a four pass horizontal firetube updraft boiler with five (5)
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.
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.
1. The boiler shall be completely preassembled and fire tested at the factory.
The unit shall be ready for immediate mounting on floor or simple
foundation and ready for attachment of water, steam, fuel, electrical, vent
and blowdown connections.
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.
Section A6 Model CB 15-100 HP
A6-37
03-08
3. Front and rear doors on the boiler shall be hinged or davited. Doors are to
be sealed with fiberglass tadpole gaskets and fastened tightly using heavy
4. Rear refractory and insulation shall be contained in the formed door, which
must swing open for inspection of brick work.
appurtenances.
6. Front and rear tube sheets and all flues 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.
center line and shall be capable of supporting:
15-100 hp. 1000 lbs and shall contain a stack thermometer
8. The boiler shell shall contain a chemical feed connection.
C. Observation ports for the inspection of flame conditions shall be provided at
D. The boiler insulation shall consist of a 2 inch blanket under a sectional
E. The entire boiler base frame and other components shall be factory painted
A. 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.
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.
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.
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.
connection.
D. Safety Valves
Safety valves of a type and size to comply with ASME Code requirements shall be shipped
loose.
A6-38
03-08
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 firing rate
control (30-100 hp).
1. 15 and 20 hp. Burner operation shall be on-off principle.
2. 30 and 40 hp. Burner operation shall be high-low-off principle. The burner
shall always return to low fire position for ignition.
3. 50 - 100 hp. Burner operation shall be full modulation principle. The
burner shall always return to low fire position for ignition.
B. Blower
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.
2. Maximum sound level of the boiler/burner package shall not exceed _____
dbA (when measured in accordance with ABMA Sound Test Standards).
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 firing rate.
C. 50 - 100 hp. Combustion air damper and cam operated fuel metering valves shall be
operated by a single damper control motor that regulates the fire according to load demand.
Potentiometer type position controls shall be provided to regulate operation of the damper
control motor.
Fuel series 600 - No. 6 oil fired (4.4.4).
Fuel series 400 - No. oil or gas fired (4.4.5).
a. 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.
A6-39
03-08
ignition. An electronic detector shall monitor the pilot so that the
primary gas valve cannot open until pilot flame has been established.
The pilot train shall include two manual shut-off valves, solenoid
valve, pressure regulator and pressure gauge.
c. Gas Burner Piping - Gas burner piping on all units shall include
pressure regulator, 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, flame failure, low water or any safety shutdown
condition. A lubricating plug cock or butterfly shutoff valve shall be
provided as a means for a tightness check of the primary shut off
valve. An additional plug cock on butterfly valve shall be furnished at
entrance to gas train. Select one of the following:
1) 15-50 hp. Burners equipped as shown above.
2) 60-100 hp. High and low gas pressure switches shall be
provided.
1) 15 and 20 hp. Burner shall operate on the on/off principle.
2) 30 and 40 hp. Burner shall operate on the high-low-off principle
with a turndown of 3:1 when firing natural gas.
natural gas.
boiler, and shall be a low pressure air atomizing type approved for
operation with CS12-48, Commercial No. 2 oil.
3. 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 flame has been
established.
4. 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 100 hp. Separate motor driven pump set, shipped
loose to be installed in a location favorable to the oil storage tank,
shall be provided.
5. Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure
gauges and fuel strainer, all integrally mounted on the unit. Select one of
the following:
a. 50 hp through 100 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 100 hp. A low oil pressure switch shall be included in
the oil piping.
A6-40
03-08
6. 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 filter, air pressure gauge, and low atomizing
air pressure switch.
b. 50 hp through 100 hp. Separate air compressor module mounted on
7. 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 firing No. 2 oil.
c. 50 hp through 100 hp. Turndown range shall be 4:1 when firing No.
2 oil.
E. Fuel Series 200 - Light Oil or Gas Fired
1. Burner Type - The burner, integral with the front head of the boiler, shall be
with either CS12-48 Commercial No. 2 Oil or natural gas.
2. Gas Pilot - The gas pilot shall be premix type with automatic electric
and pressure gauge.
3. Oil Burner
a. Oil Pump - An oil pump with a capacity of approximately twice the
1) 15 hp through 40 hp. The oil pump shall be integral with the
burner and belt driven from the blower motor.
2) 50 hp through 100 hp. Separate motor driven pump set,
shipped loose, to be installed in a location favorable to the oil
storage tank, shall be provided.
gauges and fuel strainer, all integrally mounted on the unit. Select one of
the following:
the oil piping.
5. Low pressure air atomizing. Select one of the following:
oil level indicator, inlet air filter, air pressure gauge and low atomizing
A6-41
03-08
6. Gas Burner
a. Gas Burner Piping - gas burner piping on all units shall include
provided as a means for a tightness check of the primary shut off
valve. An additional plug cock or butterfly valve shall be furnished at
1) 15-50 hp. Burners equipped as shown above.
provided.
7. Burner Turndown
15 and 20 hp. Burner shall operate on the on/off principle.
30 and 40 hp. Burner shall operate on the high-low-off principle with a turndown of 3:1
A. Fuel Series 600 - No. 6 Oil Fired
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.
2. Gas Pilot - The gas pilot shall be a premix type with automatic electric
oil valve cannot open until pilot flame has been established. The pilot train
and pressure gauge.
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. 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 100 hp, a low oil pressure switch shall be included in the oil piping.
A6-42
03-08
a. 50 through 100 hp. Separate air compressor module mounted on
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 100 hp. Electric preheater size shall be 5 kW.
B. Fuel Series 400 - No. 6 Oil or Gas Fired
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
oil valve cannot open until pilot flame has been established. The pilot train
and pressure gauge.
3. Oil Burner
a. Oil Pump - An oil pump set with a capacity of approximately twice the
b. 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.
2. 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
A6-43
03-08
available.
3. Gas Burner
a. Gas Burner Piping - Gas burner piping on all units shall include
provided as means for a tightness check of the primary shutoff valve.
An additional plug cock or butterfly valve shall be furnished at
1) 50 hp. Burner equipped as shown above.
2) 60 through 100 hp. High and low gas pressure switches shall
be provided.
b. Burner Turndown - Turndown shall be 4:1.
C. Boiler Flame Safeguard Controller and Control Panel
a. Boilers with CB780E Control - Each boiler shall be factory equipped
with flame safeguard controller providing technology and functions
equal to the Cleaver-Brooks Model CB780E.
Controller shall be computerized solid state having sequence and flame-on lights and alpha-
numeric first out fault indications of flame safeguard trip functions. It shall include dynamic
self-check logic. The controller shall have a fixed operating sequence incapable of being
manually altered. The sequence shall include start, pre-purge, pilot and main fuel ignition run
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 flame failure, high and low
fire proving switch faults, locking interlocks open, false flame 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 firing rate motor, damper
b. 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 have a removable sub-base for mounting the flame safeguard controller, blower
motor starter, and terminal blocks. For combination gas-oil and heavy oil fired boilers the panel
will contain the fuel selector and/or oil heater selector switch.
a. Lights
A6-44
03-08
Red - low water.
2. Control Switches
Burner On-Off.
Manual-Automatic.
3. Oil, heat and moisture resistant wire shall be used and identified with
4. All electrical equipment and wiring shall be in conformance with
5. Boiler to be supplied with a control circuit transformer and fuse protection
6. Control Panel: The control panel shall be mounted on the front door of the
will have NEMA 1A rating that includes a neoprene dust seal and a Yale
The panel shall contain the boiler flame safeguard controller, indicating lights and selector
switches.
Panel shall have a removable sub-base for mounting the flame safeguard controller, and
terminal blocks. For combination gas-oil and heavy oil fired boilers the panel will contain the
fuel selector and/or oil heater selector switch.
7. Oil, heat, and moisture resistant wire shall be used and identified with
The boiler manufacturer shall guarantee that, at the time of startup, the boiler will achieve
________fuel-to-steam efficiency at 100% firing rate when burning natural gas and ________
fuel-to-steam efficiency at 100% firing rate when burning oil (add efficiency guarantees at 25%,
50%, and 75% of rating, if required). If the boiler(s) fail to achieve the corresponding
guaranteed efficiency as published, the boiler manufacturer will rebate, to the ultimate boiler
owner, five thousand dollars ($5,000) for every full efficiency point (1.0%) that the actual
efficiency is below the guaranteed level.
A. Fuel specification used to determine boiler efficiency:
1. Natural Gas
Carbon, % (wt) = 69.98
A6-45
03-08
B. No. 2 Oil
Carbon, % (wt) = 85.8
C. No. 6 Oil
Carbon, % (wt) = 86.6
Sulfur, % (wt) = 2.09
D. Efficiencies are based on ambient air temperature of 80 F, relative humidity of
E. Efficiencies are based on manufacturers published radiation and convection
F. Any efficiency verification testing will be based on the stack loss method.
EXECUTION
1.06 Warranty
A. 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 first.
1.07 Shop Tests
A. 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.
1.08 Start-up Service
1.09 After boiler installation is completed, the manufacturer shall provide the services of a
field representative for starting the unit and training the operator at no additional
costs.
A. A factory approved and authorized start-up report shall be submitted to the
A6-46
03-08
Notes:
A6-47
03-08
Section A6
Model CB 15-100 HP
Sample Specifications, Hot Water Boiler
Boiler Characteristics (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-48
General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-48
Hot Water Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-49
Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-49
Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-49
Combustion Air Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-49
Fuel Specification and Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-50
Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-56
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-56
Shop Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-56
A6-48
03-08
Model CB Hot Water Boiler (15-100 hp, 30 psig, 125 psig)
A. 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.
when fired with CS 12-48 _____oil and/or natural gas, _____Btu/cu-ft. Electrical
power available will be _____Volt _____Phase _____Cycle.
A. The boiler shall be a four pass horizontal firetube updraft boiler with five (5)
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. The
complete package boiler shall be approved as a unit by Underwriters Laboratories
and shall bear the UL/ULC label.
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.
6. Rear refractory and insulation shall be contained in the formed door, which
must swing open for inspection of brick work.
appurtenances.
inspection and cleaning when the doors are swung open. The shell must be
furnished with adequate handholes to facilitate boiler inspection and
cleaning.
15-100 hp. 1000 lbs and shall contain a stack thermometer
A6-49
03-08
C. Observation ports for the inspection of flame conditions shall be provided at each
end of the boiler.
sheet metal lagging. This insulation must be readily removable and capable of
being reinstalled, if required.
E. The entire boiler based frame and other components shall be factory painted
A. 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.
Pressure and temperature gauges shall be mounted on the boiler with temperature sensing
element located adjacent to the hot water outlet.
C. Relief Valves
Water relief valves of a type and size to comply with ASME Code requirements shall be shipped
loose.
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 firing rate control (30-100 hp).
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 fire position for ignition.
C. 50 - 100 hp. Burner operation shall be full modulation principle. The burner shall
always return to low fire position for ignition.
1.05 Blower
A. 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.
B. Maximum sound level of the boiler/burner package shall not exceed _____dbA
C. The impeller shall be cast aluminum, radial blade, carefully balanced, and
1.06 Combustion Air Control
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 firing rate.
A6-50
03-08
C. 50 - 100 hp. Combustion air damper and cam operated fuel
metering valves shall be operated by a single damper control motor
that regulates the fire 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).
1.07 Fuel Specification and Piping
Fuel series 600 - No. 6 oil fired (4.4.4).
Fuel series 400 - No. oil or gas fired (4.4.5).
A. Fuel Series 700 - Gas Fired
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.
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 flame has
been established. The pilot train shall include two manual
shut-off valves, solenoid valve, pressure regulator and pressure
gauge.
3. Gas Burner Piping - Gas burner piping on all units shall include
pressure regulator, 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, flame failure, low
water or any safety shutdown condition. A lubricating plug
cock or butterfly shutoff valve shall be provided as a means for
a tightness check of the primary shut off valve. An additional
plug cock on butterfly 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.
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 firing natural gas.
c. 50-100 hp. Turndown range of burner shall be 4:1 when
firing natural gas.
B. Fuel Series 100 - Light Oil Fired
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.
A6-51
03-08
2. Oil Pilot - The oil pilot shall be air atomizing type with automatic electric
established.
3. Oil Pump - An oil pump with a capacity of approximately twice the
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 100 hp. Separate motor driven pump set, shipped loose
to be installed in a location favorable to the oil storage tank, shall be
provided.
gauges and fuel strainer, all integrally mounted on the unit. Select one of the
following:
the oil piping.
oil level indicator, inlet air filter, air pressure gauge, and low atomizing
6. Burner Turndown - Turndown range of the burner shall be 4:1 when firing
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 firing No. 2 oil.
c. 50 hp through 100 hp. Turndown range shall be 4:1 when firing No. 2
oil.
C. Fuel Series 200 - Light Oil or Gas Fired
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.
and pressure gauge.
3. Oil Burner
1) 15 hp through 40 hp. The oil pump shall be integral with the
A6-52
03-08
burner and belt driven from the blower motor.
2) 50 hp through 100 hp. Separate motor driven pump set, shipped
loose, to be installed in a location favorable to the oil storage
tank, shall be provided.
b. Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure
pressure gauges and fuel strainer, all integrally mounted on the unit.
1) 50 hp through 100 hp. A fuel oil controller shall be provided to
mounted on the front door of the unit. A single tip retractable
nozzle shall be used for the low pressure air atomizing burner.
2) 70 hp through 100 hp. A low oil pressure switch shall be
3) Low pressure air atomizing - Select one of the following:
15 hp through 40 hp. Belt driven air compressor, lubricating oil tank, oil level indicator,
inlet air filter, air pressure gauge and low atomizing air pressure switch.
50 hp through 100 hp. Separate air compressor module mounted on boiler base rail with
low atomizing air pressure switch.
4. Gas Burner
a. Gas Burner Piping - gas burner piping on all units shall include
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
additional plug cock or butterfly valve shall be furnished at entrance to
gas train.
15-50 hp. Burners equipped as shown above.
60-100 hp. High and low gas pressure switches shall be provided.
15 and 20 hp. Burner shall operate on the on/off principle.
30 and 40 hp. Burner shall operate on the high-low-off principle with a turndown of 3:1
6. Fuel Series 600 - No. 6 Oil Fired
boiler and low pressure air atomizing type approved for operation with
CS12-48, Commercial No. 6 Oil.
primary oil valve cannot open until pilot flame has been established.
The pilot train shall include two manual shut-off valves, solenoid valve,
pressure regulator and pressure gauge.
A6-53
03-08
c. Oil Pump - An oil pump set with a capacity of approximately twice the
A separate motor driven pump set shall be included shipped loose for
location favorable to the oil storage tank.
d. Oil Burner Piping - A fuel oil controller combining all of the fuel oil
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.
e. Low Pressure Air Atomizing
1) 50 through 100 hp. Separate air compressor module mounted on
f. 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.
1) 50 through 100 hp. Electric preheater size shall be 5 kW.
7. Fuel Series 400 - No. 6 Oil or Gas Fired
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.
primary oil valve cannot open until pilot flame has been established.
The pilot train shall include two manual
shut-off valves, solenoid valve, pressure regulator and pressure gauge.
8. Oil Burner
a. Oil Pump - An oil pump set with a capacity of approximately twice the
A6-54
03-08
b. Oil Burner Piping - A fuel oil controller combining all of the fuel oil
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.
9. Low Pressure Air Atomizing
10. 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:
11. Gas Burner
a. Gas Burner Piping - Gas burner piping on all units shall include
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
lubricating plug cock or butterfly shutoff valve shall be provided as
means for a tightness check of the primary shutoff valve. An additional
plug cock or butterfly valve shall be furnished at entrance to gas train.
1) 50 hp. Burner equipped as shown above.
2) 60 through 100 hp. High and low gas pressure switches shall be
provided.
3) Burner Turndown - Turndown shall be 4:1.
D. Boiler Flame Safeguard Controller and Control Panel
2. 4.5.1.1 Boilers with CB780E Control - Each boiler shall be factory equipped
with flame safeguard controller providing technology and functions equal to
the Cleaver-Brooks Model CB780E.
Controller shall be computerized solid state having sequence and flame-on lights and digital first
out fault code indications of flame safeguard trip functions. It shall include dynamic self-check
logic. The controller shall have a fixed 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 flame failure, high and low fire
A6-55
03-08
proving switch faults, running interlocks open, false flame 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 firing rate motor, damper
3. 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 have a removable sub-base for mounting the flame safeguard controller, blower
motor starter, and terminal blocks. For combination gas-oil and heavy oil fired boilers the panel
will contain the fuel selector and/or oil heater selector switch.
4. Lights
Red - low water.
5. Control Switches
Burner On-Off.
Manual-Automatic.
6. Oil, heat and moisture resistant wire shall be used and identified with circuit
numbers corresponding to the electrical wiring diagram.
9. 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 flame safeguard controller, indicating lights and selector
switches.
Panel shall have a removable sub-base for mounting the flame safeguard controller, and terminal
blocks. For combination gas-oil and heavy oil fired boilers the panel will contain the fuel selector
and/or oil heater selector switch.
10. Oil, heat, and moisture resistant wire shall be used and identified with
A6-56
03-08
The boiler manufacturer shall guarantee that, at the time of startup, the boiler will achieve
________fuel-to-steam efficiency at 100% firing rate when burning natural gas and ________
fuel-to-steam efficiency at 100% firing rate when burning oil (add efficiency guarantees at 25%,
50%, and 75% of rating, if required). If the boiler(s) fail to achieve the corresponding guaranteed
efficiency as published, the boiler manufacturer will rebate, to the ultimate boiler owner, five
thousand dollars ($5,000) for every full efficiency point (1.0%) that the actual efficiency is below
the guaranteed level.
A. Fuel specification used to determine boiler efficiency:
1. Natural Gas
Carbon, % (wt) = 69.98
2. No. 2 Oil
Carbon, % (wt) = 85.8
3. No. 6 Oil
Carbon, % (wt) = 86.6
Sulfur, % (wt) = 2.09
B. Efficiencies are based on ambient air temperature of 80 F, relative humidity of
C. Efficiencies are based on manufacturers published radiation and convection
D. Any efficiency verification testing will be based on the stack loss method.
1.09 Warranty
A. 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 first.
EXECUTION
2.01 Shop Tests
A. 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.
B. Start-up Service
services of a field representative for starting the unit and training the
operator at no additional costs.
A7-1
03-08
CONTENTS
Three-Pass Dryback Design: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-3
Five Square Feet of Heating Surface per Boiler Horsepower: . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-3
Low Furnace Location: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-3
Front and Rear Doors: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-3
Natural Gas, No. 2 Oil, or Combination Burners Available: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-3
Boiler Options: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-3
Burner/Control Options: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-4
Fuel Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-4
Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-13
Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-13
Burner Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-15
Gas Fired - Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-15
Fuel Connections - Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-15
Fuel Connections - Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-15
Section A7
Model CBE Boilers
60-80 HP
Model CBE Boilers 60-80 HP Section A7
A7-2
03-08
Sample Specifications - Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-23
Sample Specifications - Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-29
ILLUSTRATIONS
Figure A7-1. Model CBE Steam Boiler Dimensions (Page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . A7-7
Figure A7-2. Model CBE Hot Water Boiler Dimensions (Page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . A7-9
Figure A7-3. Space Required to Open Rear Head on Model CBE Boilers Equipped with Davits . . . . A7-11
Figure A7-4. Model CBE Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-11
Figure A7-5. Model CBE Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12
Figure A7-7. Boiler Room Length (Typical Layouts) - Model CBE . . . . . . . . . . . . . . . . . . . . . . . . . A7-21
Figure A7-8. Boiler Room Width (Typical Layout) - Model CBE . . . . . . . . . . . . . . . . . . . . . . . . . . A7-22
TABLES
Table A7-1. Model CBE Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-6
Table A7-2. Model CBE Hot Water Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-6
Table A7-3. Heating Surface, Model CBE Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-14
Table A7-4. Model CBE Steam Volume and Disengaging Area . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-14
Table A7-5. Model CBE Steam Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-14
Table A7-6. Model CBE Hot Water Boiler Relief Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . A7-16
Table A7-7. Model CBE Recommended Steam Nozzle Size
(To Maintain 4000 to 5000 fpm Nozzle Velocity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-16
Table A7-8. Model CBE Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-17
Table A7-9. Sound Pressure Levels in DbA (Profire F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-17
Table A7-10. Model CBE Burner Selections(Profire Burner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-18
Table A7-11. Minimum Required Gas Pressure Altitude Conversion . . . . . . . . . . . . . . . . . . . . . . . A7-18
Table A7-12. Maximum Gas Consumption (CFH) for Natural Gas - Model CBE . . . . . . . . . . . . . . . A7-18
Table A7-13. Minimum Required Gas Pressure at Entrance to Standard, FM and IRI Gas Trains -
Model CBE (Upstream of Gas Pressure Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-19
The following information applies to the Cleaver-Brooks Model CBE Boiler.
Section A7 Model CBE Boilers 60-80 HP
A7-3
03-08
The Model CBE Boiler is available as a baseline alternative to the Cleaver-Brooks
Models CB Boilers. The Cleaver-Brooks 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 flue gas velocities and low stack temperatures
to maximize efficiency.
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 efficiency.
Long boiler life.
Low Furnace Location:
Davit, front and rear doors, all sizes.
Provides access to front and rear tube sheet and furnace.
Reduced maintenance costs.
Natural gas or No. 2 oil compatibility.
Fuel changeover without burner adjustment.
PRODUCT OFFERING
Cleaver-Brooks Firetube Boilers are available in low pressure steam, high pressure
steam, and hot water designs. Burners are available to fire natural gas, No. 2 oil, or
a combination of oil and gas. The CBE boiler is:
60 - 80 hp.
A7-4
03-08
Boiler Options: Drain valves.
Blowdown valves.
Non-return valves.
Surface blowdown systems
Combustion relief door.
Blend pump.
Surge load baffles.
Seismic design.
Burner/Control
Options:
Lead/lag system.
High altitude design (up to 10,000 ft).
Special insurance and code requirements (e.g., IRI, FM, CSD1).
Special purpose indicator lights.
Main disconnect.
Elapsed time meter.
NEMA enclosures.
Circuit breaker.
Day/night controls.
Stack thermometer.
Fuel Options Gas strainer.
Gas pressure gauge.
A7-5
03-08
Dimensions and ratings for the Model CBE Boilers are shown in the following tables
and illustrations.
Table A7-1 Model CBE Steam Boiler Ratings
Table A7-2 Model CBE Hot Water Boiler Ratings
Figure A7-1 Model CBE 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
A7-6
03-08
BOILER HP 60 70 80
Rated Capacity (lbs/steam/hr at
212 F)
2070 2415 2760
Btu Output (1000 Btu/hr) 2009 2343 2678
Light Oil GPH (140,000 Btu/gal) 18 21 24
Gas CFH (1000 Btu) 2510 2930 3350
Gas (Therm/hr) 25.1 29.3 33.5
POWER REQUIREMENTS SEA LEVEL TO 1000 FT (60 HZ)
Oil Pump Motor hp (No. 2 oil) * * *
Blower Motor - Series 100/200 3/4 3/4 1
Blower Motor - Series 700 3/4 1/2 3/4
Air Compressor Motor ** ** **
BOILER DATA
Heating Surface sq-ft (Fireside) 300 350 400
* 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.
BOILER HP 60 70 80
Btu Output (1000 Btu/hr) 2009 2343 2678
Light Oil gph (140,000 Btu/gal) 18 21 24
Gas CFH (1000 Btu) 2510 2930 3350
Gas (Therm/hr) 25.1 29.3 33.5
Oil Pump Motor hp (No. 2 oil) * * *
Blower Motor - Series 100/200 3/4 3/4 1
Blower Motor - Series 700 3/4 1/2 3/4
Air Compressor Motor ** ** **
BOILER DATA
Heating Surface sq-ft (Fireside) 300 350 400
* 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 A7-1. Model CBE Steam Boiler Ratings
Table A7-2. Model CBE Hot Water Boiler Ratings
A7-7
03-08
Figure A7-1. Model CBE Steam Boiler Dimensions (Page 1 of 2)
DD
W X S R W
U V Y
HH
JJ
GG
A
T
L
O
M
N
D
Q
K
I
LL B
E
H
AA P
J
C
F G
FF
LENGTHS
Overall Length A 163-1/8 186-1/16 201-1/16
Shell Length B 123-5/8 141-5/8 157-5/8
Base Frame Length C 133-3/8 152-3/8 173-9/16
Front Flange To Steam Outlet F 49-1/4 60-1/4 70-1/4
Steam Outlet To Vent Outlet G 65-1/2 72-1/2 78-1/2
Base Frame To Rear Head H 22-1/4 22-1/4 22-1/4
WIDTHS
Overall Width I 73 73 73
Boiler Centerline To Water
Column
K 39 39 39
Boiler Centerline To Lagging L 26-1/2 26-1/2 26-1/2
Boiler Centerline To Aux. Water Column LL 34 34 34
Base Outside M 37-3/4 37-3/4 37-3/4
Base Inside N 29-3/4 29-3/4 29-3/4
A7-8
03-08
Figure A7-1. Model CBE Steam Boiler Dimensions (Page 2 of 2)
HEIGHTS
Base To Boiler Centerline D 40 40 40
Boiler ID J 48 48 48
Base To Vent Outlet O 70-1/4 70-1/4 70-1/4
Base To Steam Outlet (15 psig) P 70-1/4 70-1/4 70-1/4
Base To Steam Outlet (150 psig) P 67-7/8 67-7/8 67-7/8
Base Frame Q 12 12 12
Base To Rear Davit T 72-5/8 72-5/8 72-5/8
Base To Lifting Lug AA 68-3/4 68-3/4 68-3/4
CONNECTIONS
Chemical Feed R 1 1 1
Feedwater Inlet (Both Sides) S 1-1/4 1-1/4 1-1/4
Surface Blowoff (150 psig Only) V 1 1 1
Steam Outlet (15 psig) U 6
A
6
A
6
A

Steam Outlet (150 psig) U 3 3 3
Vent Outlet ID Y 10 12 12
Boiler Blowdown (36 Dia Only) X - - -
Boiler Blowdown (15 psig) W 1-1/4 1-1/2 1-1/2
Boiler Blowdown (150 psig) W 1-1/4 1-1/4 1-1/4
MISCELLANEOUS
Door Swing (Rear Minimum) DD 30 30 30
Tube Removal Rear FF 82 100 109
Tube Removal Front GG 90 108 124
Min. Boiler Room Length For Tube Removal
Front
HH 244 280 312
Min. Boiler Room Length For Tube Removal
Rear
C
JJ 287 327 352
WEIGHTS
Normal Water Weight - 3940 4720 5375
Shipping Weight (15 psig) - 6455 7220 7715
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.
A7-9
03-08
LENGTHS
Overall Length A 163-1/8 186-1/16 201-1/16
Shell Length B 123-5/8 141-5/8 157-5/8
Rear Frame Length C 133-3/8 152-3/8 173-9/16
Front Flange To Water Return F 70-1/4 88-1/4 104-1/4
Water Return To Water Supply G 24 24 24
Base Frame To Rear Head H 22-1/4 22-1/4 22-1/4
Water Supply To Vent Outlet R 20-1/2 20-1/2 20-1/2
WIDTHS
Overall Width I 53 53 53
Boiler Centerline To Lagging L 26-1/2 26-1/2 26-1/2
Base Outside M 37-3/4 37-3/4 37-3/4
Base Inside N 29-3/4 29-3/4 29-3/4
W X S
V U U
W
Y
DD
HH
JJ
GG
T
O
L
N
M
D
Q
I
K
B
A
H
E
AA P
J
C
F G R
FF
Figure A7-2. Model CBE Hot Water Boiler Dimensions (Page 1 of 2)
A7-10
03-08
HEIGHTS
Base To Boiler Centerline D 40 40 40
Boiler ID J 48 48 48
Base To Vent Outlet O 70-1/4 70-1/4 70-1/4
Base To Supply & Return Ports (30 & 125 psig) P 62-1/4 62-1/4 62-1/4
Base To Supply And Return Ports (150 psig) P 70-1/4 70-1/4 70-1/4
Base Frame Q 12 12 12
Base To Rear Davit T 72-5/8 72-5/8 72-5/8
Base To Lifting Lug AA 68-3/4 68-3/4 68-3/4
CONNECTIONS
Waterfill (Both Sides) S 1-1/4 1-1/4 1-1/4
Air Vent V 1-1/4 1-1/4 1-1/4
Hot Water Supply & Return
(30 & 125 psig)
U 4 4 4
Hot Water Supply & Return (150 psig) U 4
B
4
B
4
B
Vent Outlet ID Y 10 12 12
Boiler Drain W 1-1/4 1-1/2 1-1/2
Boiler Drain X
MISCELLANEOUS
Door Swing (Minimum Rear) DD 30 30 30
Tube Removal Rear FF 82 100 109
Tube Removal Front GG 90 108 124
Min. Boiler Room Length For Tube Removal Front HH 244 280 312
Min. Boiler Room Length For Tube Removal Rear
C
JJ 287 327 352
WEIGHTS
Normal Water Weight (lbs) - 4340 5195 5920
Shipping Weight (125 psig - 6705 7740 8420
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 Hot Water Boiler Dimensions (Page 2 of 2)
A7-11
03-08
BOILER HP DIMENSION (INCHES)
A B C D E
60 thru 100 27 45 38 61 30
Figure A7-4. Model CBE Boilers Lifting Lug Location
Figure A7-3. Space Required to Open Rear Head on Model CBE Boilers Equipped with Davits
BOILER HP ALL DIMENSIONS IN INCHES
A B C D E
60 68 14 187 10 2-1/2
70 68 14 105 10 2-1/2
80 68 14 121 10 2-1/2
NOTE: A, B and C Dimensions may vary by 1/2 inch.
A
D
D NEAR SIDE FAR SIDE E (DIA OF HOLE)
B C
A7-12
03-08
BOILER HP A B C D E F G X
60 6 8 137 25-3/4 41-3/4 4 29-5/8 8
70 6 8 156 25-3/4 41-3/4 4 29-5/8 8
80 6 8 177 25-3/4 41-3/4 4 29-5/8 8
NOTE:
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 add-
ed height for washing down the area beneath the boiler.
Figure A7-5. Model CBE Boiler Mounting Piers
A F
G
F
B B
D
E
C
X
A7-13
03-08
PERFORMANCE DATA
Contact your local Cleaver-Brooks authorized representative for emissions or additional infor-
mation.
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 A7-3 shows heating surfaces for model CBE Firetube boilers.
Table A7-4 shows steam volume and disengaging area for model CBE Firetube boilers.
Table A7-5 lists quantity and outlet size for safety valves supplied on Model CBE steam boil-
ers.
Table A7-6 lists quantity and outlet size for relief valves supplied on Model CBE hot water
boilers.
Table A7-7 gives recommended steam nozzle sizes based on 4000-5000 fpm steam velocity
on Model CBE Boilers.
Blowdown Water
Requirements
Some local codes require blowdown tanks to be constructed in accordance with recommen-
dations 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 A7-8 lists the approximate quantity of water represented by 4 inches of water at nor-
mal operating level for Cleaver-Brooks Power Boilers.
Sound Level Table A7-9 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.
A7-14
03-08
VALVE
SETTING
BOILER
HP
NO. OF
VALVES-
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES-
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES-
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES-
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
60 1 2 1 1-1/2 1 1-1/2 1 1-1/4 1 1-1/4 1 1
70 1 2 1 2 1 1-1/2 1 1-1/2 1 1-1/4 1 1-1/4
80 1 2-1/2 1 2 1 1-1/2 1 1-1/2 1 1-1/4 1 1-1/4
NOTE:
1.Valve manufacturers are Kunkle, Consolidated or Conbraco, depending on availability.
BOILER HP HEATING SURFACE (SQ-FT)
FIRESIDE WATERSIDE
60 300 322
70 350 376
80 400 429
Table A7-3. Heating Surface, Model CBE Boilers
BOILER HP STEAM VOLUME (CU-FT) STEAM RELIEVING AREA (SQ-IN)
HIGH PRESSURE
A
LOW PRESSURE
B
HIGH PRESSURE
A
LOW PRESSURE
B
60 6.39 12.92 2936 3588
70 7.58 15.35 3486 4261
80 8.65 17.50 3974 4859
NOTE:
2. Values are based on standard controls. Optional controls may result in different values.
Table A7-4. Model CBE Steam Volume and Disengaging Area
Table A7-5. Model CBE Steam Boiler Safety Valve Openings
A7-15
03-08
Burner/Control
Information
Burner information is shown in Table A7-10. Note that the model selection may vary for
actual application factors (altitude, gas pressure, etc.).
Gas Fired - Burners
Table A7-11 shows conversion factors for gas pressure at elevations over 700 ft above sea
level.
Table A7-12 shows maximum gas consumption (CFH) for Natural Gas.
Table A7-13 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
The local gas company should be consulted for requirements and authorization for installa-
tion 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 con-
nections made to the boiler should be arranged so that all components remain accessible for
A drip leg should be installed in the supply piping before the connection to the gas pressure
regulator. The drip leg should be at least as large as the inlet fitting supplied with the boiler.
Consideration must be given to both volume and pressure requirements when choosing gas
supply piping size. Refer to the boiler dimension diagram provided by Cleaver-Brooks for the
particular installation. Connections to the burner gas train should be made with a union, so
that gas train components or the burner may be easily disconnected for inspection or ser-
vice. Upon completion of the gas piping installation, the system should be checked for gas
leakage and tight shutoff of all valves.
Oil-fired 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 firing rate. Fuel not delivered to the noz-
zle is returned to the storage tank. A two-pipe (supply and return) oil system is recom-
mended for all installations. Figure A7-6 shows a typical fuel oil supply arrangement. Oil
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 noz-
zle(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
A7-16
03-08
VALVE SETTING 30 PSIG HW 60 PSIG HW 100 PSIG HW 125 PSIG HW
BOILER HP NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
60 1 2 1 1-1/4 1 1 1 1
70 1 2 1 2 1 1-1/4 1 1
80 1 2 1 2 1 1-1/4 1 1-1/4
NOTES:
1.Hot water relief valves are Kunkle #537.
Table A7-6. Model CBE Hot Water Boiler Relief Valve Openings
BOILER HP
OPERATING PRESSURE PSIG 60 70 80
15 6 6 6
30 4 4 4
40 4 4 4
50 3 4 4
75 3 3 4
100 3 3 3
125 3 3 3
150 2.5 2.5 2.5
200 2.5 2.5 2.5
250 2 2 2
NOTES:
2. Recommended steam nozzle sizes based on 4000 to 5000
fpm steam velocity. Spool pieces (300 psig flanges) are avail-
able in the following sizes (in inches): 3x2-1/2x30, 4x3x30,
6x4x36, 8x6x48, 10x8x48, and 12x8x48.
Table A7-7. Model CBE Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity)
A7-17
03-08
BOILER HP 60 70 80
GAS
HIGH FIRE 77.0 75.0 76.5
LOW FIRE 78.0 74.0 76.5
NO. 2 OIL
HIGH FIRE 77.0 74.0 76.5
LOW FIRE 75.5 72.0 76.0
Table A7-9. Sound Pressure Levels in DbA (Profire F)
60 51
70 60
80 69
NOTE: Quantity of water removed from boiler by low-
ering normal water line 4"
Table A7-8. Model CBE Blowdown Tank Sizing
Information
A7-18
03-08
BOILER HP
MAX ALTITIUDE
(FT)
BURNER SIZE
60 2000 1
70 3500 2
80 1500 2
Table A7-10. Model CBE Burner Selections(Profire Burner)
ALTITUDE
(FT)
CORRECTION FACTOR ALTITUDE
(FT)
CORRECTION FACTOR
1000 1.04 6000 1.25
2000 1.07 7000 1.30
3000 1.11 8000 1.35
4000 1.16 9000 1.40
5000 1.21 - -
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.
Table A7-11. Minimum Required Gas Pressure Altitude Conversion
BOILER HP NATURAL GAS1000 (BTU/CU-FT)
60 2510
70 2930
80 3350
Table A7-12. Maximum Gas Consumption (CFH) for Natural Gas - Model CBE
A7-19
03-08
BOILER HP
STD PIPE
SIZE
(Inches)
MAX 1 PSIG INLET, MIN SUPPLY
PRESSURE (WC)
MAX 10 PSIG INLET**, MIN SUPPLY
PRESSURE (WC)
UL FM IRI UL FM IRI
60 2* 11.0 11.0 11.5 13.0 13.0 13.5
70 2* 8.5 8.5 9.0 12.5 12.5 13.0
80 2* 11.0 11.0 11.5 14.5 14.5 15.0
* Gas pressure regulator is 1-1/2 inch.
** Use max 10 psig for all boilers destined for Canada.
Table A7-13. Minimum Required Gas Pressure at Entrance to Standard, FM and IRI Gas
Trains - Model CBE (Upstream of Gas Pressure Regulator)
A7-20
03-08
Boiler Room
Information
Stack Support
Capabilities
60-80 hp Model CBE Boilers can support up to 1000 lbs without additional support.
Boiler Room
Combustion Air
When determining boiler room air requirements, the size of the room, air flow, and velocity
of air must be reviewed as follows:
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.
square foot.
C. Total recommended air = 10 cfm/bhp - up to 1000 feet elevation. Add 3 percent more
Example: Determine the area of the boiler room air supply openings for (1) 80 hp boiler at
800 feet altitude. The air openings are to be 5 feet above floor level.
Area Required: Area = cfm = 800/250 = 3.2 Sq-ft total.
Area/Opening: 3.2/2 = 1.6 sq-ft/opening (2 required).
Notice
Stack/Breeching
Size Criteria
The design of the stack and breeching must provide the required draft at each boiler flue gas
outlet. Proper draft is critical to burner performance.
Although constant pressure at the flue gas outlet of the Model CBE is not required, it is nec-
essary to size the stack/breeching to limit flue gas pressure variation. The allowable pressure
range is 0.25"W.C. to +0.25"W.C.
A7-21
03-08
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.
Figure A7-7. Boiler Room Length (Typical Layouts) - Model CBE
FRONT
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
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 replace-
ment 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.
Dwg A
Dwg B
Dwg C
A7-22
03-08
BOILER HP 60-80
Dimension A (inches) 78
Dimension B (inches) 105
NOTES:
1. Recommended Minimum Distance Between Boiler and Wall. Di-
mension 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.
42" - 60-80 hp
Figure A7-8. Boiler Room Width (Typical Layout) - Model CBE
A B
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
A7-23
03-08
Section A7
Model CBE Boilers
60-80 HP Steam 15-300 psig
Sample Specification
Control Panel and Flame Safeguard Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-27
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-27
Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-27
Model CBE Boilers Firetube Boilers
A7-24
03-08
MODEL CBE BOILERS
60-80 HP Steam 15-300 psig
The following sample specification are provided by Cleaver-Brooks to assist you in meeting your
PART 1 GENERAL
A. The Steam Boiler shall be Cleaver-Brooks Model CBE, Fuel Series ______(100,
200, 700), _____hp designed for _____psig (15, 150, 200, or other psig
B. 1.2 The boiler shall have a maximum output of _____Btu/hr, or _____
horsepower when fired 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.
PART 2 PRODUCTS
A. The boiler shall be a three pass horizontal firetube updraft boiler with five (5)
on a heavy steel frame with forced draft burner and burner controls.
1. Approvals: Underwriters Laboratories Inc. The complete boiler package
shall be approved and listed as a unit by Underwriters Laboratories.
4. Refractory and insulation shall be contained in the rear smoke box and
door; door shall swing open for inspection.
appurtenances.
6. Front and rear tube sheets and all flues 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.
Firetube Boilers Model CBE Boilers
A7-25
03-08
7. The exhaust gas vent shall be located near the rear of the boiler on the top
60-80 hp. 1000 lbs
8. Observation ports for the inspection of flame conditions shall be provided
at each end of the boiler.
preformed sheet metal lagging. This insulation must be readily removable
and capable of being reinstalled, if required.
10. The entire boiler based frame and other components shall be factory
painted before shipment using a hard finished enamel coating.
A. 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.
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
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.
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.
The steam pressure gauge shall be located at the front of the boiler and include
cock and test connection.
Safety valves of a type and size to comply with ASME Code requirements shall
be shipped loose.
The steam pressure controls to regulate burner operation shall be mounted near
the water column.
B. Blower
1. All air for combustion shall be supplied by a forced draft blower mounted
on the burner, to eliminate vibration and reduce noise level.
Model CBE Boilers Firetube Boilers
A7-26
03-08
Combustion air damper and fuel control valve shall be operated by a single
damper control motor that regulates the flame according to load demand.
Potentiometer type position controls shall be provided to regulate operation of
the damper control motor.
1. Fuel series 700 - Gas fired.
2. Fuel series 100 - Light oil (No. 2) fired.
3. Fuel series 200 - Light oil or gas fired.
Fuel Series 700 - Gas Fired
Fuel Series 100 - Light oil (No. 2) fired.
Fuel Series 200 - Light oil or gas fired.
a. 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
primary gas valve cannot open until pilot flame 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).
c. Gas Burner Piping
60-80 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,
flame failure, low water, or any abnormal shutdown condition.
a. 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.
b. Ignition System - Select one of the following:
60-80 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.
c. Oil Pump - An oil pump with the capacity of approximately twice the
Pump shall be an integral part of the burner and mechanically driven.
60 to 80 hp. Fuel oil piping on the unit shall include oil pressure
Oil Atomization Type-Select one of the following:
d. 60-80 hp. Burner shall include a complete mechanical oil atomizing
system and be of the pressure atomizing type.
Firetube Boilers Model CBE Boilers
A7-27
03-08
e. 60-80 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.
60-80 hp. Pump shall be an integral part of the burner and
mechanically driven.
1) Oil Burner Piping - Select one of the following:
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.
2) Oil Atomization Type - Select one of the following:
60-80 hp. Burner shall include a complete mechanical oil atomizing
system and be of the pressure atomizing type.
5. Gas Burner Piping:
60-80 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, flame failure, low water, or any
2.4 Control Panel and Flame Safeguard Controller
A. Control Panel
A factory prewired control panel shall be supplied with the boiler-burner
B. The panel will have a NEMA 1A rating and contain the flame safeguard
controller, burner motor starter, control circuit fuse, selector switches, indicating
light and terminal strips. Lights shall indicate load demand, 80 hp. The panel
shall contain a control circuit transformer and fuse protection.
C. The flame safeguard controller shall be a CB110 flame monitor with EPD170
A. The boiler must be guaranteed to operate at a minimum fuel-to-steam efficiency
of ____percent at 100 percent of rating when burning natural gas and ________
fuel-to-steam efficiency at 100% firing rate when burning oil (Contact your local
Cleaver-Brooks authorized representative for efficiency details).
PART 3 EXECUTION
3.1 WARRANTY
workmanship for a period of 12 months from date of start-up or 18 months from
date of shipment, whichever comes first.
3.2 Execution
1. Shop Tests
2. 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.
Model CBE Boilers Section A
A7-28
03-08
B. Start-up Service
a. A factory approved and authorized start-up report shall be submitted
to the customer/user at the time of start-up.
A7-29
03-08
Section A7
Model CBE Hot Water Boiler
(60-350 hp, 30 psig, 125 psig)
Boiler Characteristics (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-30
Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-31
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-33
Model CBE Hot Water Boiler Section A7
A7-30
03-08
Model CBE Hot Water Boiler (60-350 hp, 30 psig, 125 psig)
PART 1 GENERAL
1.01 BOILER CHARACTERISTICS (HOT WATER)
A. 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.
when fired 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.
PART 2 PRODUCTS
A. The boiler shall be a three pass horizontal firetube updraft boiler with five (5)
on a heavy steel frame with forced draft burner and burner controls.
1. Approvals: Underwriters Laboratories Inc. The complete boiler package
shall be approved and listed as a unit by Underwriters Laboratories.
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. 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.
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.
6. Refractory and insulation shall be contained in the rear smoke box and
door; door shall swing open for inspection.
appurtenances.
inspection and cleaning when the doors are swung open. The shell must
cleaning.
9. For boilers over 100 horsepower, a manhole shall be provided.
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:
Section A7 Model CBE Hot Water Boiler
A7-31
03-08
60-100 hp. 1000 lbs.
preformed sheet metal lagging. This insulation must be readily removable
and capable of being reinstalled, if required.
13. The entire boiler based frame and other components shall be factory
painted before shipment using a hand finished enamel coating.
A. 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.
B. 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 entrained air.
C. 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.
D. 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.
E. Relief Valves
F. Water relief valves of a type and size to comply with ASME Code requirements
shall be shipped loose.
G. Temperature Controls
temperature sensing elements located adjacent to the hot water outlet.
1.04 Burner
Burner operation shall be the full modulation principle. The burner shall always return to low
fire position for ignition.
B. 4.2 Blower
on the burner, to eliminate vibration and reduce noise level.
3. 4.2.3 The impeller shall be cast aluminum, radial blade, carefully
Combustion air damper and fuel control valve shall be operated by a single damper control
motor that regulates the flame according to load demand. Potentiometer type position controls
shall be provided to regulate operation of the damper control motor.
Model CBE Hot Water Boiler Section A7
A7-32
03-08
a. 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
b. 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 flame 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).
c. Gas Burner Piping - Select one of the following:
A. 60-80 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, flame failure, low water, or any
a. 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.
b. Ignition System - Select one of the following:
60-80 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.
60-80 hp. Pump shall be an integral part of the burner and mechanically driven.
3. Oil Burner Piping - Select one of the following:
A. 60-80 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.
4. Oil Atomization Type - Select one of the following:
A. 60-80 hp. Burner shall include a complete mechanical oil atomizing system and be
of the pressure atomizing type.
a. Burner Type - Select one of the following:
60-80 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.
Section A7 Model CBE Hot Water Boiler
A7-33
03-08
shall include one (1) manual shut-off valve, solenoid valve, and pressure
regulator.
7. Oil Burner
60-80 hp. Pump shall be an integral part of the burner and mechanically driven.
b. Oil Burner Piping - Select one of the following:
60-80 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.
c. Oil Atomization Type - Select one of the following:
8. 60-80 hp. Burner shall include a complete mechanical oil atomizing
system and be of Gas Burner Piping - Select one of the following:
60-80 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, flame failure,
low water, or any abnormal shutdown condition.
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.
controller, burner motor starter, control circuit fuse, selector switches,
indicating light and terminal strips. Lights shall indicate load demand,
flame failure, low water, and fuel valve open.
3. 80 hp. The panel shall contain a control circuit transformer and fuse
protection.
4. The flame safeguard controller shall be a CB110 flame monitor with
EPD170 program module. Flame detector shall be ultra-violet type.
A. The boiler must be guaranteed to operate at a minimum fuel-to-water
efficiency of ____percent at 100 percent of
rating when burning natural gas and ________fuel-to-steam efficiency at
100% firing rate when burning oil (Contact your local Cleaver-Brooks
authorized representative for efficiency details).
1.06 Warranty
workmanship for a period of 12 months from date of
start-up or 18 months from date of shipment, whichever comes first.
PART 3 EXECUTION
A. Shop Tests
Model CBE Hot Water Boiler Firetube Boilers
A7-34
BBA6 03-08
B. Start-up Service
A8-1
03-08
CONTENTS
Unique Dimple Tube Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-3
358 Square Feet of Heating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-3
Low Furnace Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-3
Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-10
Burner Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-15
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-25
Section A8
MODEL CB OHIO SPECIAL BOILERS
MODEL CB OHIO SPECIAL BOILERS Firetube Boilers
A8-2
03-08
ILLUSTRATIONS
Figure A8-1. Model CB Ohio Special Steam Boiler Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . A8-7
Figure A8-2. Space Required to Open Rear Head on Model CB Ohio Special Boilers
Equipped with Davits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-9
Figure A8-3. Model CB Ohio Special Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . . A8-9
Figure A8-4. Model CB Ohio Special Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-10
Figure A8-5. Secondary Air Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-12
Figure A8-6. Complete Linkage Assembly, Combination Gas and Oil . . . . . . . . . . . . . . . . . . . . . . A8-13
Figure A8-7. Gas Modulating Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-14
Figure A8-8. Model CB Ohio Special Gas Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-18
Figure A8-9. Typical Gas Piping Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-19
Figure A8-10. Model CB Ohio Special Firetube Boilers Standard Gas
Train Connection Size and Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-20
Figure A8-11. CB a Ohio Special Boilers, No. 2 Oil Connection Size,
Location and Recommended Line Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-20
Figure A8-12. No. 2 Oil Piping, Single Boiler Installation, Remote Oil Pump . . . . . . . . . . . . . . . . A8-21
Figure A8-13. No. 2 Oil Piping, Multiple Boiler Installation, Remote Oil Pumps . . . . . . . . . . . . . . A8-21
Figure A8-14. No. 2 Oil Piping, Multiple Boiler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-22
Figure A8-15. No. 2 Oil Transfer Tank Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-22
Figure A8-16. Boiler Room Length (Typical Layouts), Model CB Ohio Special . . . . . . . . . . . . . . . A8-23
Figure A8-17. Boiler Room Width (Typical Layout), Model CB Ohio Special . . . . . . . . . . . . . . . . . A8-23
TABLES
Table A8-1. Model CB Ohio Special Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-6
Table A8-2. Model CB Ohio Special Boilers Heating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-10
Table A8-3. Model CB Ohio Special Boilers Steam Volume and Disengaging Area . . . . . . . . . . . . . A8-11
Table A8-4. Model CB Ohio Special Boilers Steam Boiler Safety Valve Openings . . . . . . . . . . . . . A8-11
Table A8-5. Model CB Ohio Special Firetube Boilers Recommended Steam Nozzle Size
(To Maintain 4000 to 5000 fpm Nozzle Velocity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-11
Table A8-6. Model CB Ohio Special Firetube Boilers Recommended Non-Return Valve Size . . . . . A8-12
Table A8-7. Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-12
Table A8-8. CB Ohio Special Firetube Boilers Minimum Required Gas Pressure
at Entrance to Gas Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-14
Table A8-9. Minimum Required Gas Pressure Altitude Conversion . . . . . . . . . . . . . . . . . . . . . . A8-16
Table A8-10. Maximum Gas Consumption, Natural Gas and Propane Gas . . . . . . . . . . . . . . . . . . A8-16
Section A8 MODEL CB OHIO SPECIAL BOILERS
A8-3
03-08
The Cleaver-Brooks Ohio Special Firetube boiler is designed, manufactured, and
packaged by Cleaver-Brooks specifically 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 fire 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 efficiency without turbulators,
spinners, and other high maintenance devices.
Dimple tubes also reduce the film coefficient 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 efficiencies.
Low Furnace Location:
PRODUCT OFFERING
Cleaver-Brooks Ohio Special Firetube boilers are available high pressure steam
designs. Burners are available to fire 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).
150, 200, and 250 psig high pressure steam
Natural gas or light oil firing.
Available options: For option details, contact your local Cleaver-Brooks authorized
representative. In summary, options include the following:
Boiler Options
Drain valves.
Surge load baffles.
Seismic design.
Blowdown valves.
MODEL CB OHIO SPECIAL BOILERS Section A8
A8-4
03-08
Non-return valves.
Special doors, davited, hinged, left swing.
Special base rails.
Weather-proofing.
Burner/Control Options
Special modulation controls.
Low NOx equipment.
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 fired hold controls.
Circuit breaker.
Day/night controls.
Fuel Options
Automatic fuel changeover.
Gas strainer.
Special pilot.
Alternate fuel firing.
Special oil pumps.
For dimension and rating information for Ohio Special boilers, refer to the following
Table A8-1. Model CB Ohio Special Steam Boiler Ratings.
Figure A8-1. Model CB Ohio Special Steam Boiler Dimensions.
A8-5
03-08
Figure A8-2. Space Required to Open Rear Head on Model CB Ohio Special
Boilers Equipped with Davits.
Figure A8-3. Lifting Lug Locations, Model CB Ohio Special Boilers.
Figure A8-4. Model CB Ohio Special Boiler Mounting Piers.
PERFORMANCE DATA
For efficiency and emission data for Ohio Special Boilers, contact your local Cleaver-
Brooks authorized representative.
A8-6
03-08
BOILER HP 100S 125S 150S 175S 200S 225S
WEIGHT IN POUNDS
Approx Wt -15 psig 7800 9300 9300 12600 12600 12600
Approx Wt -150 psig 8500 9900 9900 13500 13500 13500
Approx Wt - 200 psig 9000 10500 10500 14200 14200 14200
Water Capacity Flooded 5420 8673 8673 10485 10485 10485
Steam - lbs/hr (212F) 3450 4313 5175 6038 6900 7763
Btu Output (1000 Btu/hr) 3348 4184 5021 5858 6695 7531
APPROXIMATE FUEL CONSUMPTION AT RATED CAPACITIES
Light Oil gph
(140,000 Btu/gal)
30 37.4 44.8 52.5 59.8 67.5
Nat Gas CFH
(1000 Btu/cu-ft)
4185 5230 6277 7323 8369 9415
Nat Gas -Therms/hr 41.9 52.3 62.8 73.2 83.7 94.2
POWER REQUIREMENTS - ELECTRIC (60 Hz)
Blower Motor, hp (all models) 3 5 7-1/2 10 15 20
Oil Pump Motor, hp (No. 2 Oil) 1/3 1/2 1/2 1/2 1/2 1/2
(Oil Fired Only)
2
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 A8-1. Model CB Ohio Special Steam Boiler Ratings
A8-7
03-08
MODEL HP DIM 100S 125S 150S 175S 200S 225S
LENGTH
Overall A 171-1/2 163-1/2 163-1/2 200-1/2 204-1/2 207-1/2
Shell B 131 113 113 149 149 149
Base Frame C 130 100 100 136 136 136
Front Head Extension (Ap-
prox)
D 22 31 31 32 36 39
Rear Head Extension E 18-1/2 19-1/2 19-1/2 19-1/2 19-1/2 19-1/2
Flange to Nozzle (15 psig) F 65-1/2 53 53 74.5 74.5 74.5
Flange to Nozzle (150 psig) F 72.5 53 53 66 66 66
Figure A8-1. Model CB Ohio Special Steam Boiler Dimensions - Sheet 1 of 2
Q
Z
W W
S
SIGHT
PORT
ELECTRICAL SERVICE
CONNECTIONS
(CONTROL CIRCUIT
120/1/60)
CC
R
BB
E
Y
T
H
A
M
N
OO
O
L
LL
I
KK
.5"
C
P
J
K
GG
D
EE
F
B
RR/RF/RD
DD
FF
A8-8
03-08
MODEL HP DIM 100S 125S 150S 175S 200S 225S
WIDTH
Overall I 73 85 85 85 85 85
ID Boiler J 48 60 60 60 60 60
Center to Water Column K 39 45 45 45 45 45
Center to Auxiliary LWCO LL 34 40 40 40 40 40
Base-Outside M 37-5/8 52-1/2 52-1/2 52-1/2 52-1/2 52-1/2
Base-Inside N 29-5/8 44-1/2 44-1/2 44-1/2 44-1/2 44-1/2
HEIGHT
Overall OO 78-3/4 86 86 86 86 86
Base to Steam Outlet P 66 77 77 77 77 77
Base Frame Q 12 12 12 12 12 12
Base to Bottom Boiler R 16 16 16 16 16 16
CONNECTIONS
Chemical Feed H 1 1 1 1 1 1
Feedwater, Right & Left S 1-1/4 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2
Auxiliary Connection Z 1 1 1 1 1 1
Steam Nozzle (15 psig)
A Y 8 FLG 8 FLG 8 FLG 8 FLG 10 FLG 10 FLG
B Y 4 FLG 4 FLG 4 FLG 4 FLG 4 FLG 4 FLG
Drain-Front & Rear (15 psig only)W 1-1/2 1-1/2 1-1/2 2 2 2
Blowdown-Front & Rear (150
psig)
W 1-1/4 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2
Surface Blow (150 psig only) T 1 1 1 1 1 1
Vent Stack Dia. (Flanged) BB 12 16 16 16 16 16
Flange to Center Vent CC 7 9 9 9 9 9
CLEARANCES
Min Room Length for Rear Tube
Removal
RR 309 283 283 355 355 355
Min Room Length for Front Tube
Removal
RF 299 236 236 308 308 308
Tube Removal thru Door RD 241 212 212 248 248 248
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 A8-1. Model CB Ohio Special Steam Boiler Dimensions - Sheet 2 of 2
A8-9
03-08
NEAR
SIDE
VIEW B
FAR
SIDE
FRONT
FLANGE
VIEWA
E DIA. HOLE
A
C
L
B
D
D
C
BOILER HP
(CB)
ALL DIMENSIONS IN INCH-
ES
A B C D
100S 68 27 67 2-1/2
125S-150S 80 29-1/2 66 3
175S-225S 80 29-1/2 88 3
NOTE: A, B and C Dimensions may vary by 1/2 inch.
Figure A8-3. Model CB Ohio Special Boilers Lifting Lug Location
BOILER HP
DIMENSION (INCHES)
A B C D E
CB 100S 27 48 38 60 26
CB 125S thru 225S 33 55 45 68 32
Figure A8-2. Space Required to Open Rear Head on Model CB Ohio Special Boilers Equipped with Davits
A8-10
03-08
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.
representative.
Boiler Information Table A8-2 shows heating surfaces for Model CB Ohio Special Boilers.
Table A8-3 shows steam volume and disengaging area for Model CB Ohio Special
Boilers.
Table A8-4 lists quantity and outlet size for safety valves supplied on Model CB Ohio
Special Boilers.
Table A8-5 gives recommended steam nozzle sizes based on 4000-5000 fpm
steam velocity. Model CB Ohio Special Firetube Boilers.
Table A8-6 shows recommended non-return valve sizes for Model CB Ohio Special
Firetube Boilers.
CB 100S 6 8 130 26 42 4 29-5/8 8-1/4
CB 125S, 150S 6 9 100 39-1/2 57-1/2 4 44-1/2 10-1/4
CB 175S, 200S, 225S 6 9 136 39-1/2 57-1/2 4 44-1/2 10-1/4
NOTES:
2. 6-inch high mounting piers recommended for use beneath the boiler base frame. The use of these piers provides increased inspection ac-
cessibility to the piping beneath the boiler and added height for washing down the area beneath the boiler.
Figure A8-4. Model CB Ohio Special Boiler Mounting Piers
BOILER
HP
FIRESIDE WATERSIDE
100S 350 388
125S-150S 358 386
175S, 200S, 225S 358 384
Table A8-2. Model CB Ohio Special Boilers Heating Surface
A8-11
03-08
BOILER HP STEAM VOLUME CU-FT STEAM RELIEVING AREA SQ-IN
HIGH PRESSURE
A
LOW PRESSURE
B
HIGH PRESSURE
A
LOW PRESSURE
B
100S 14.3 23.7 4367 4975
125S, 150S 28.4 38.9 5086 5473
175S, 200S, 225S 38.5 52.7 6899 7423
NOTES: Based on normal water level.
Table A8-3. Model CB Ohio Special Boilers Steam Volume and Disengaging Area
VALVE
SETTING
BOILER
HP
NO. OF
VALVES-
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES-
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES-
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES-
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
100S 1 2-1/2 1 2 1 2 1 1-1/2 1 1-1/2 1 1-1/4
125S 1 2-1/2 1 2-1/2 2 (1) 2
(1) 1-1/2
1 2 1 1-1/2 1 1-1/2
150S 1 3 1 2-1/2 1 2-1/2 1 2 1 1-1/2 1 1-1/2
175S 1 3 1 2-1/2 1 2-1/2 1 2 1 2 1 1-1/2
200S 1 3 2 2 1 2-1/2 1 2-1/2 1 2 1 2
225S 2 2-1/2 2 2 1 2-1/2 1 2-1/2 1 2 1 2
NOTE:
Valve manufacturers are Kunkle, Consolidated or Conbraco, depending on availability.
Table A8-4. Model CB Ohio Special Boilers Steam Boiler Safety Valve Openings
BOILER HP
OPERATING
PRESSURE
PSIG
100S 125S 150S 175S 200S 225S
15 8 8 8 8 10 10
30 6 6 6 6 8 8
40 6 6 6 6 6 8
50 4 6 6 6 6 6
75 4 4 4 6 6 6
100 4 4 4 4 6 6
125 4 4 4 4 4 4
150 2.5 3 3 4 4 4
200 2.5 2.5 3 3 4 4
NOTES:
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.
Table A8-5. Model CB Ohio Special Firetube Boilers
Recommended Steam Nozzle Size
(To Maintain 4000 to 5000 fpm Nozzle Velocity)
A8-12
03-08
BOILER
HP
BOILER CA-
PACITY
(LB/HR)
50 75 100 125 150 175 200
100S 3450 2-1/2 2-1/2 NA NA NA NA NA
125S 4313 3 2-1/2 2-1/2 2-1/2 NA NA NA
150S 5175 3 3 2-1/2 2-1/2 2-1/2 2-1/2 NA
175S 6038 3 3 2-1/2 2-1/2 2-1/2 2-1/2 NA
200S 6900 3* 3 3 3 3 2-1/2 2-1/2
225S 7736 3 3 3 3 3 2-1/2 2-1/2
NOTE:
Standard non-return valve selections limited to a maximum 2 to
1 turndown (50% of full boiler output); selection based on typical
valve sizing recommendations. For final valve selection contact
your authorized C-B representative. For high turndown applica-
tions see Boiler Book Section I3, Table I3-2.
*Indicates pressure drop of less than 7.5 psig. All other selections
are less than 6 psig pressure drop.
Blowdown Water
Requirements
Table A8-6. Model CB Ohio Special Firetube Boilers Recommended Non-Return Valve Size
100S 80
125S-150S 87
175S-225S 118
NOTE: Quantity of water removed from boiler by lowering normal wa-
ter line 4"
Table A8-7. Blowdown Tank Sizing Information
Figure A8-5. Secondary Air Flow Diagram
03-08
A8-13
03-08
45
45
J ACK S HAFT
GAS MODULATING CAM
CAM ADJ US TING
S CR E W
GAS MODULATING
CAM FOLLOWE R
GAS ME TE R ING
VALVE
R OTAR Y AIR
DAMPE R
R OD
MODULATING MOTOR
MOTOR
MODULATING
MOTOR AR M
S PR ING LOADE D
BUTTE R FLY GAS VALVE AR M
OVE R TR AVE L LINKAGE
BUTTE R FLY GAS VALVE
R OTAR Y AIR
DAMPE R AR M
FUE L OIL
CONTR OLLE R
NOTICE :
S E TTINGS IN DIAGR AM
INDICATE LOW FIR E
S E TTING OF LINKAGE .
R OTAR Y AIR
DAMPE R S HAFT
OIL ME TE R ING VALVE
OIL MODULATING
CAM FOLLOWE R
OIL MODULATING
CAM
CAM
ADJ US TING
S CR E W
R OTAR Y AIR DAMPE R
J ACKS HAFT AR M
BUTTE R FLY
GAS VALVE R OD
60
J ACK S HAFT
DR IVING AR M
MODULATING
MOTOR R OD
Figure A8-6. Complete Linkage Assembly, Combination Gas and Oil
A8-14
03-08
Figure A8-7. Gas Modulating Cam
Table A8-8. Gas pressure requirements, CB Ohio Special
Boiler HP Gas Train Size (In.) Min. Pressure Max. Pressure PSI
100 1.5 14 WC 2
2 9 WC 1
125 1.5 19 WC 2
2 13 WC 1
150 1.5 25 WC 3
2 17 WC 2
175 1.5 35 WC 3
2 21 WC 2
200 1.5 45 WC 3
2 30 WC 2
2.5 24 WC 1.5
225 1.5 56 WC 3
2 37 WC 2.5
2.5 31 WC 2
300 2 4.4 PSI 6.5
Table is based on Siemens gas train, which includes a regulating STANDARD
actuator. OVERSIZE
A8-15
03-08
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 A8-5 shows secondary air flow in the Ohio Special Firetube Boiler.
The rotary air damper design provides standard turn down of 4:1.
Figure A8-6 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 A8-7.
Gas-Fired Burners
Table A8-8 shows regulated gas pressure requirements for gas trains for CB
Ohio Special Firetube Boilers.
Table A8-10 shows maximum gas consumption for natural gas and propane
vapor.
Figure A8-8 shows typical gas train components, and Figure A8-9 shows
typical gas train piping layouts for multiple boiler applications.
Figure A8-10 shows standard gas train sizes and locations for Model CB
Ohio Special Firetube Boilers.
Oil-Fired Burners
Fuel oil consumption information is shown on the boiler rating sheets in the
Figure A8-11 shows the oil connection sizes and locations for Ohio Special
Boilers firing No. 2 oil.
Figures A8-12 through A8-15 show typical oil systems and layouts.
Boiler Room
Information
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.
A8-16
03-08
Boiler Room Combustion Air
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
qualities and is subject to clogging by dust or dirt.
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.
Area (sq-ft) = cfm/fpm
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
B.Above (7) foot height - 500 fpm.
C. Duct from air supply to boiler - 1000 fpm.
BOILER
HP
NATURAL GAS
1000 (Btu/cu-ft)
PROPANE GAS
2550 (Btu/cu-ft)
100S 4185 1640
125S 5230 2050
150S 6280 2465
175S 7350 2870
200S 8370 3280
225S 9415 3690
Table A8-10. Maximum gas consumption, natural
gas and propane
ALTITUDE
(FT)
CORRECTION
FACTOR
ALTITUDE
(FT)
CORRECTION
FACTOR
1000 1.04 6000 1.25
2000 1.07 7000 1.30
3000 1.11 8000 1.35
4000 1.16 9000 1.40
5000 1.21 - -
To obtain minimum required gas pressure at altitudes above 700
feet, multiply the pressure by the listed factors:
Table A8-9. Minimum required gas pressure
altitude conversion
A8-17
03-08
Notice
Stack/Breeching
Size Criteria
Although constant pressure at the flue gas outlet of the Ohio Special is not required,
it is necessary to size the stack/breeching to limit flue gas pressure variation. The
A8-18
03-08
100S
125S -
225S
100S
125S -
225S
100S
125S -
225S
7 Main Gas Valve w/o POC X X X
ITEM DESCRIPTION
UL FM CSD-1
S
1
3
4
2
PILOT GAS LINE
FLOW
MAIN GAS LINE
M
M
To
Burner
Gas
Supply
7
5
8
9
6
10
11
Figure A8-8. Model CB Ohio Special Gas Train Components
A8-19
03-08
MODEL
CB-LE
BOILERS
PLUG
COCK
A
B
C
D CONTRACTOR
CONNECTION
POINT
GAS TRAIN
ON BOILER
STREET GAS MAIN
MODEL
CB-LE
BOILERS
This figure illustrates the basic gas valve arrangement on Cleaver-Brooks boil-
ers and shows the contractor's connection point. The valves and controls be-
tween the contractor connection point and the gas main in the street are
representative of a typical installation. Actual requirements may vary depend-
ing on local codes or local gas company requirements which should be inves-
tigated prior to preparation of specifications and prior to construction.
C. Gas meter.
The size of the gas line from the meter to the connection point at the boiler can
be very important if gas pressures are marginal. The gas line sizing is depen-
dent on:
The local gas utility will advise the pressure that is available at the outlet of their
meter.
A8-20
03-08
A
PLAN VIEW
BOILER
FRONT
BOILER
HP
MODEL CB
CONNEC-
TION SIZE
(IN.) (NPT)
LOCATION
DIMENSION
A (IN.)
100S 1 1/2 46 1/2
125S-200 1 1/2 52
225S 2 55
Figure A8-10. Model CB Ohio Special Firetube Boilers Standard Gas Train Connection Size and Location
BHP
SUPPLY
AND
RETURN
CONN
SIZES (IN.)
(NPT)
A
(IN.)
A
SIZES
(STANDARD PIPE)
(IN.-IPS)
STORAGE
TANK TO
BOILER OR
PUMP
CONNECT
PUMP TO
BOILER
RETURN
LINE TO
TANK
100S 3/4 11-1/2 1 1 1
125S-225S 3/4 12-1/2 1 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 A8-11. CB Ohio Special Boilers, No. 2 Oil Connection Size, Location and Recommended Line Sizes
A8-21
03-08
BOILER
BASE FRAME
BOILER
FRONT
F.O.S.
F.O.R.
CONTRACTOR
CONNECTIONS
AT THIS POINT
GATE VALVE
OIL PUMP
CHECK
VALVE
VACUUM
GAUGE
STRAINER
GATE VALVE
RELIEF VALVE
UNION
GATE VALVE
CHECK VALVE
F.O.R.
F.O.S.
BOILER
BASE FRAME
BOILER
FRONT
F.O.S.
F.O.R.
CONTRACTOR
CONNECTIONS
AT THIS POINT
GATE VALVE
OIL PUMP NO. 1
OIL
PUMP
NO. 2
GATE VALVE
GATE VALVE
CHECK VALVE
RELIEF
VALVE
(100 PSIG)
UNION
GATE VALVE
CHECK VALVE
F.O.S.
F.O.R.
USE LAYOUT FOR: MODEL CB . . 100S - 225S
A8-22
03-08
level switch
tion from transfer
pump
tion
connection
McD
F.O.R.
OIL LEVEL
TEST VALVE
OIL TRANSFER PUMP
NEAR STORAGE TANK
SUPPLY TO BOILER
TERMINAL BLOCK OR
TO BOILER OIL PUMP
GATE
VALVE
GATE
VALVE
OIL TRANSFER TANK
AT LOCATION NEAR
BOILER
VENT
H
F.O.S.
F.O.R.
F.O.S.
CHECK
VALVE STRAINER
VACUUM
GAUGE
UNION
RELIEF VALVE
(100 PSIG)
3/8" MTL
D
4" OR 6"
STD
BLACK
PIPE
F
E
22"
33"
3"
2"
60"
G
A
B
C
5"
3"
3/16"
S
3/16"
S
USE LAYOUT FOR: MODEL CB . . . . . . . 100S - 225S
MODEL CBW . . . . . 125S - 200S
STANDBY
OIL PUMP
UNION
GATE VALVE
CHECK
GATE
RELIEF
VACUUM GAUGE
STRAINER
GATE VALVE
F.O.S.
F.O.R.
PRESSURE
USE LAYOUT FOR: MODEL CB . . . . . . . 50 THRU 800 HP
BOILER
CONTACTOR
BOILER
F.O.S.
F.O.R.
VALVE
VALVE
VALVE
(100 PSIG)
GAUGE
FRONT
CONNECTIONS
AT THIS POINT
BASE FRAME
CHECK
GATE
VALVE
VALVE
ADJUSTABLE
PRESSURE
RELIEF VALVE
(75 PSIG)
A8-23
03-08
FRONT
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
A B
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
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 ad-
ditional aisle and working space.
ance 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 A8-16. Boiler Room Length (Typical Layouts), Model CB Ohio Special
Figure A8-17. Boiler Room Width (Typical Layout), Model CB Ohio Special
BOILER HP 100S 125S-225S
Dimension A 78 82"
Dimension B 105 115"
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.
Dimension B between boilers allows for a clear aisle of 42 .
DWG A - MODEL CB
DWG B - MODEL CB
DWG C - MODEL CB
A8-24
03-08
Notes
A8-25
03-08
Section A8
Model CB Ohio Special Steam Boiler
100-225 hp, Steam 15, 150, 200, or 250 psig)
Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-27
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-32
Model CB Ohio Special Steam Boiler Section A8
A8-26
03-08
Model CB Ohio Special Steam Boiler
100-225 hp, Steam 15, 150, 200, or 250 psig)
The following sample specifications are provided by Cleaver-Brooks to assist you in specifying
your customer's specific needs and application.
PART 1 GENERAL
A. 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.
B. The boiler shall have a maximum output of ____Btu/hr, or ____horsepower
when fired 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.
PART 2 PRODUCTS
A. The boiler shall be a multi-pass horizontal firetube updraft boiler with 350
square feet of total heating surface for the 100 hp and 358 square feet of total
heating surface for the 125-225 hp boilers. 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
controls.
shall bear the UL/ULC label, except in the case where 50 Hz has been selected.
foundation and ready for attachment of water, steam, fuel, electrical,
vent, steam, and blowdown connections.
copy of the inspection report shall be furnished the purchaser.
4. Rear refractory and insulation shall be contained in the formed door
which must swing open for inspection of brick work.
5. The boiler tubes shall not include swirlers, turbulators, or other add-on
devices.
Section A8 Model CB Ohio Special Steam Boiler
A8-27
03-08
6. Front and rear tube sheets and all tubes must be fully accessible for
cleaning.
7. For boilers 125 horsepower and over, a manhole shall be provided.
8. The exhaust gas vent shall be located near the front of the boiler on the
100 hp 1000 lbs. and shall contain a stack thermometer.
125-225 hp 2000 lbs. and shall contain a stack thermometer.
10. The boiler insulation shall consist of a 2 inch fiberglass blanket under a
sectional preformed sheet metal lagging. This insulation must be readily
removable and capable of being reinstalled, if required.
11. The entire boiler base frame and other components shall be factory
painted before shipment using a hard-finish enamel coating.
A. 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.
B. Feedwater Pump Control
automatically actuate a motor driven feedwater pump maintaining the boiler water level within
normal limits.
C. Low Water Cutoff
safe level.
D. 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.
E. Steam Pressure Gauge
connection.
F. Safety Relief Valves
loose.
G. Steam Pressure Controls
The steam pressure control to regulate burner operation shall be mounted near the water
column.
2.03 BURNER
Burner operation shall be full modulation principle. The burner shall always return to low fire
A8-28
03-08
B. Forced Draft Blower
in the front boiler door, above the burner, to eliminate vibration and
reduce noise level.
2. Maximum sound level of the boiler/burner package shall not exceed ____
dBA (when measured in accordance with ABMA Sound Test Standards).
3. The impeller shall be cast aluminum, radial blade, carefully balanced,
and directly connected to the blower motor shaft.
Combustion air damper and cam operated fuel metering valves shall be operated by a single
damper control motor that regulates the fire according to load demand. Single point
positioning controls shall be provided to regulate operation of the damper control motor.
Refer to the following fuel series specifications:
Fuel series 700 - gas fired.
Fuel series 100 - light oil fired.
Fuel series 200 - light oil or gas fired.
E. Fuel Series 700 - Gas Fired
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.
3. Gas Burner Piping - Gas burner piping on all units shall include pressure
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
means for a tightness check of the primary shut off valve. An additional
plug cock or butterfly shutoff valve shall be furnished at entrance to gas
train. Select one of the following:
100 hp High and low gas pressure switches shall be provided.
4. 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.
natural gas.
a. Fuel Series 100 - Light Oil Fired
A8-29
03-08
b. Burner Type - The burner shall be integral with the front head of the
c. 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 flame has been established.
d. 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
e. 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
f. Low Pressure Air Atomizing - Select one of the following:
100 hp. Separate air compressor module mounted on boiler base rail with low
atomizing air pressure switch shall be provided.
125 hp-225 hp. Belt driven air compressor, lubricating air tank, oil level indicator,
inlet air filter, air pressure gauge, and low atomizing air pressure switch shall be
provided.
No. 2 oil.
F. Fuel Series 200 - Light Oil or Gas Fired
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 on 100 hp. The burner shall be approved for operation with either
CS12-48 Commercial No. 2 Oil or natural gas.
shall include two manual shut-off valves, solenoid valve, pressure
3. Oil Burner
pump set, shipped loose, to be installed in a location favorable to
the oil storage tank, shall be provided.
A8-30
03-08
b. Oil Burner Piping - Fuel oil piping on the unit shall include oil
c. Low pressure Air Atomizing - Select one of the following:
100 hp. Separate air compressor module mounted on boiler base rail with low
atomizing air pressure switch shall be provided.
125-225 hp. Belt driven air compressor, lubricating air tank, oil level indicator, inlet air
filter, air pressure gauge and low atomizing air pressure switch shall be provided.
d. Gas Burner
1) Gas Burner Piping - gas burner piping on all units shall include
pressure regulating 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, flame failure,
low water or any safety shutdown condition. A lubricating plug
plug cock or butterfly shutoff valve shall be furnished at
100 hp High and low gas pressure switches shall be provided.
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.
e. Burner Turndown - Turndown range of the burner shall be 4:1.
G. Boiler Flame Safeguard Controller and Control Panel
1. CB780E Flame Safeguard Controller
Each boiler shall be factory equipped with flame safeguard controller providing technology and
functions equal to the Cleaver-Brooks Model CB780E.
Controller shall be computerized solid state having sequence and flame-on lights and digital
first out fault code indications of flame safeguard trip functions. It shall include dynamic
self-check logic. The controller shall have a fixed operating sequence incapable of being
manually altered. The sequence shall include start, pre-purge, pilot and main fuel ignition run
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 flame failure, high and
low fire proving switch faults, running interlocks open, false flame signal and fuel valve open
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 firing rate motor, damper
a. Control Panel - The control panel shall be mounted on the front door
A8-31
03-08
The panel shall have a removable sub-base for mounting the flame safeguard controller,
blower motor starter, and terminal blocks. For combination gas-oil fired boilers, the panel
shall contain the fuel selector switch.
b. Lights
White - load demand.
Red - low water.
c. Control Switches
Burner On-Off.
Manual-Automatic.
d.Oil, heat and moisture resistant wire shall be used and identified
with circuit numbers corresponding to the electrical wiring diagram.
e. All electrical equipment and wiring shall be in conformance with
f. Boiler to be supplied with a control circuit transformer and fuse
protection for the control circuit.
2. Control Panel
a. 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
b. The panel shall contain the boiler flame safeguard controller, blower
motor starter, indicating lights and selector switches.
c. Panel shall have a removable sub-base for mounting the flame
combination gas-oil fired boilers the panel shall contain the fuel
selector switch.
d. Oil, heat, and moisture resistant wire shall be used and identified
A. The boiler must be guaranteed to operate at a minimum fuel-to-steam
efficiency of ____percent from 25 to 100 percent of rating when burning
natural gas and ________fuel-to-steam efficiency at 100% firing rate when
burning oil.
A8-32
03-08
2.05 WARRANTY
workmanship for a period of 12 months from date of start-up or 18 months
from date of shipment, whichever comes first.
PART 3 EXECUTION
A. 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.
B. Start-up Service
services of a field representative for starting the unit and timing the
A9-1
03-08
Table of Contents
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-3
Less than 360 Square Feet of Heating Surface: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-3
Front and Rear Doors: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-3
Natural Gas, No. 2 Oil, or Combination Burners Available: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-3
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-4
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-9
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-9
Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-9
Blowdown Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-9
Burner/Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-10
Burner Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-10
Gas-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-10
Fuel Connections - Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-10
Fuel Connections - Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-10
Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-11
Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-11
Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-11
Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-12
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-19
Section A9
Model CEW Ohio Special
100-225 HP
Model CEW Ohio Special Firetube Boilers
A9-2
03-08
ILLUSTRATIONS
Figure A9-1. Model CEW Ohio Special Steam Boiler Dimensions (Page 1 of 2) . . . . . . . . . . . . . . . A9-6
Figure A9-2. Space Required to Open Rear Head on Model CEW Ohio Special Boilers . . . . . . . . . . A9-8
Figure A9-3. Model CEW Ohio Special Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . A9-8
Figure A9-4. Model CEW Ohio Special Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-9
Figure A9-6. Boiler Room Length (Typical Layouts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-17
Figure A9-7. Boiler Room Width (Typical Layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-17
TABLES
Table A9-1. Model CEW Ohio Special Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-5
Table A9-2. Model CEW Ohio Special Steam Volume and Disengaging Areas . . . . . . . . . . . . . . . . A9-13
Table A9-3. Model CEW Ohio Special Steam Boiler Safety Valve Outlet Size . . . . . . . . . . . . . . . . . A9-13
Table A9-4. Model CEW Ohio Special Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . A9-14
Table A9-5. Model CEW Ohio Special Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . A9-14
Table A9-6. Model CEW Ohio Special Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . A9-15
Table A9-7. Altitude Correction for Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-15
Table A9-8. Model CEW Ohio Special Minimum and Maximum Required Gas Pressure at
Entrance to Standard, FM and IRI Gas Trains (Upstream of Gas Pressure Regulator) . . . . . . A9-16
Section A9 Model CEW Ohio Special
A9-3
03-08
The Model CEW Ohio Special Firetube boiler is designed, manufactured, and
packaged by Cleaver-Brooks specifically 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 fire 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 efficiencies.
Davited, front and rear doors, all sizes.
Provides access to front and rear tube sheet.
adjustment.
PRODUCT OFFERING
Cleaver-Brooks Model CEW Ohio Special Boilers are available in low pressure steam
and high pressure steam designs. Burners are available to fire natural gas, No. 2 oil,
or a combination of oil and gas. Standard product offering is:
100 - 225 hp.
Three pass wetback design.
Boiler Options:
Drain valves.
Blowdown valves.
Non-return valves.
Surge load baffles.
Seismic design.
Model CEW Ohio Special Section A9
A9-4
03-08
Lead/lag system.
Main disconnect.
Elapsed time meter.
NEMA enclosures.
Circuit breakers.
Day/night controls.
Stack thermometer.
Fuel Options:
Gas strainer.
Gas pressure gauge.
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 A9-1. Model CEW Ohio Special Steam Boiler Ratings
Figure A9-1. Model CEW Ohio Special Steam Boiler Dimensions
Figure A9-2. Model CEW Ohio Special Boiler Space Requirements to Open Rear
Door
Figure A9-3. Lifting Lug Location, Model CEW Ohio Special Boilers
Figure A9-4. Model CEW Ohio Special Boiler Mounting Piers
A9-5
03-08
BOILER HP 100S 125S 150S 175S 200S 225S
Rated Capacity (lbs-steam/hr from and
at 212 F)
3450 4312 5175 6037 6900 7762
Btu Output (1000 Btu/hr) 3348 4184 5021 5858 6695 7532
Light Oil gph (140,000 Btu/gal) 29.9 37.4 44.8 52.3 59.8 67.2
Gas CFH (1000 Btu/ft
3
) 4184 5230 6277 7323 8369 9415
Gas (Therm/hr) 41.8 52.3 62.8 73.2 83.7 94.1
Oil Pump Motor hp (oil firing only) 1/2 1/2 1/2 1/2 1/2 1/2
Blower Motor, hp (NO. 2 oil& combina-
tion)
2 3 5 5 7.5 10
Blower Motor, hp 1-1/2 3 5 5 7-1/2 10
Air Comp. Motor, hp 2 2 2 3 3 3
WEIGHTS IN POUNDS
Approx. Wt. -15 psig 10311 10311 10311 11150 11150 11150
Approx. Wt. -150 psig 12558 12558 12558 13515 13515 13515
Approx. Wt. -200 psig 13632 13632 13632 14465 14465 14465
Approx. Wt. -250 psig 15079 15079 15079 16029 16029 N/A
BOILER DATA
Heating Surface sq-ft (Fireside) 354 354 354 358 358 358
NOTE: All fractional hp motors will be single phase voltage, integral hp motors will be 3-
phase voltage.
Table A9-1. Model CEW Ohio Special Steam Boiler Ratings
A9-6
03-08
BOILER HP
DIM
100S-
150S
175S-
225S
(inches)
LENGTHS
Overall A 207-1/2 228-1/2
Shell B 157-3/8 170-3/8
Base Frame C 174-7/8 196-1/2
Base Frame to Rear Flange H 13-1/2 13-1/2
Flange to Steam Nozzle E 63-7/8 56-1/4
WIDTHS
Overall
C
I 85 85
I. D. Boiler J 60 60
Center to Water Column K 45 45
Center to Lagging L 33 33
Center to Auxiliary LWCO LL 40 40
Figure A9-1. Model CEW Ohio Special Steam Boiler Dimensions (Page 1 of 2)
DD
W S R W
U V Y
HH
GG
A
H
AA
C
G
B
LL
L
I
O
M
N
D
P
J
T
Q
K
F
A9-7
03-08
Base Outside M 52-1/2 52-1/2
Base Inside N 44-1/2 44-1/2
HEIGHTS
Base to Boiler Centerline D 46 46
Base to Vent Outlet O 85 85
Base to rear Door Davit OA 86-1/2 86-1/2
Base to Steam Outlet P 82-3/8 82-3/8
Base Frame Q 12 12
Base to Bottom Boiler R 16 16
CONNECTIONS
Chemical Feed G 1 1
Feedwater Inlet (Both Sides) S 1-1/2 1-1/2
A
Y
8 10
B
Y
4 4
Drain - Front & Rear (15 psig) W 1-1/2 2
Blowdown - Front & Rear (150 psig) W 1-1/2 1-1/2
Surface Blowoff (150 psig) T 1 1
Surface Blowoff (15 psig) T 1-1/2 1-1/2
Vent Stack Diameter (Flanged) BB 16 16
Flange to Center Vent CC 10-1/8 10-1/8
MISCELLANEOUS
Rear Door Swing DD 36 36
Tube Removal - Front Only GG 124 137
Min. Boiler Room Length For Tube Removal Front RF 318 344
Min. Boiler Room Length For Tube Removal Thru Door RD 276 297
NOTES:
Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed 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.
BOILER HP
DIM
100S-
150S
175S-
225S
(inches)
Figure A9-1. Model CEW Ohio Special Steam Boiler Dimensions (Page 2 of 2)
A9-8
03-08
Figure A9-3. Model CEW Ohio Special Boilers Lifting Lug Location
Figure A9-2. Space Required to Open Rear Head on Model CEW Ohio Special Boilers
BOILER
HP
A B C D E
100S-
150S
Steam 80 19 120-1/2 10 3
175S-
225S
Steam 80 19 133-1/2 10 3
NEAR
SIDE
VIEW B
FAR
SIDE
FRONT
FLANGE
VIEWA
E DIA. HOLE
A
C
L
B
D
D
C
BOILER
HP
DIMENSION (INCHES)
A B C D E
100S-225S 33 42 54 77 36
A9-9
03-08
100S-150S 6 9 175 39-1/2 57-1/2 4 44-1/2 9-1/2
175S-225S 6 9 196-1/2 39-1/2 57-1/2 4 44-1/2 9-1/2
PERFORMANCE DATA
Contact your local Cleaver-Brooks authorized representative for efficiencies or
additional information.
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
Boiler Information Table A9-2 shows steam volume and disengaging area for Model CEW Ohio Special
boilers.
Table A9-3 lists quantity and outlet size for safety valves supplied on Model CEW
Ohio Special boilers.
Table A9-4 gives recommended steam nozzle sizes on Model CEW Ohio Special
Boilers.
Table A9-5 shows recommended non-return valve sizes for Model CEW Ohio Special
Boilers.
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 A9-4. Model CEW Ohio Special Boiler Mounting Piers
E
A9-10
03-08
Blowdown Water
Requirements
water at normal operating level for Cleaver-Brooks Model CEW Ohio Special Boilers.
Burner/Control
Information
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 Table A9-7 shows correction factors for gas pressure at elevations over 700 ft
above sea level.
Table Table A9-8 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
A9-11
03-08
Boiler Room
Information
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
D. Under no condition should the total area of the air supply openings be less than one (1)
square foot.
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.
Area Required: Area = cfm/fpm = 3000/250 = 12 Sq-ft total.
A9-12
03-08
Notice
Stack/Breeching
Size Criteria
Although constant pressure at the flue gas outlet of the Model CEW Ohio Special is
not required, it is necessary to size the stack/breeching to limit flue gas pressure
variation. The allowable pressure range is 0.25 W.C. to +0.25 W.C. and up to
+0.5 at high fire, when an economizer is used.
The maximum pressure variation at any firing rate for the boiler is 0.25" W.C.
A9-13
03-08
VALVE
SET-
TING
15 PSIG STEAM 150 PSIG
STEAM
200 PSIG
STEAM
250 PSIG
STEAM
BOILER
HP
NO. OF
VALVES
REQ'D
OUT-
LET
SIZE
(IN.)
NO. OF
VALVE
S
REQ'D
OUT-
LET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUT-
LET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUT-
LET
SIZE
(IN.)
100S 1 2-1/2 1 1-1/2 1 1-1/2 1 1-1/4
125S 1 2-1/2 1 2 1 1-1/2 1 1-1/2
150S 1 3 1 2 1 1-1/2 1 1-1/2
175S 1 3 1 2 1 2 1 1-1/2
200S 1 2-1/2 1 2-1/2 1 2 1 2
225S 2 2-1/2 1 2-1/2 1 2 N/A N/A
NOTE:
Valve manufacturers are Kunkle, Consolidated or Conbraco, depending on avail-
ability.
Valve requirements can vary with special pressure settings.
BOILER
HP
STEAM VOLUME (CU-FT) STEAM RELIEVING AREA (SQ-IN)
HIGH PRESSURE (
A)
LOW PRESSURE (
B)
HIGH PRESSURE (
A)
LOW PRESSURE (
B)
100S-
150S
23.5 27.1 5990 6221
175S-
225S
25.8 29.7 6566 6826
NOTE:
Based on normal water level.
Values are based on standard controls. Optional controls may result in different values.
Table A9-2. Model CEW Ohio Special Steam Volume and Disengaging Areas
Table A9-3. Model CEW Ohio Special Steam Boiler Safety Valve Outlet Size
A9-14
03-08
BOILER HP
OPERATING PRES-
SURE PSIG
100S 125S 150S 175S 200S 225S
15 8 8 8 8 10 10
30 6 6 6 6 8 8
40 6 6 6 6 6 8
50 4 6 6 6 6 6
75 4 4 4 6 6 6
100 4 4 4 4 6 6
125 4 4 4 4 4 4
150 2.5 3 3 4 4 4
200 2.5 2.5 3 3 4 4
NOTES:
2. Recommended steam nozzle sizes based on 4000 to 5000 FPM
steam velocity.
3. 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
4. For incremental operating pressures, see Table I3-1 Steam Systems
Fundamentals
Table A9-5. Model CEW Ohio Special Recommended Non-Return Valve Size
Table A9-4. Model CEW Ohio Special Recommended Steam Nozzle Size
NOTE:
Standard non-return valve selections limited to a maximum 2 to 1 turndown (50% of full boiler output); selection based on typical
valve sizing recommendations. For final valve selection contact your authorized C-B representative. For high turndown applications
see Boiler Book Section I3, Table I3-3.
BOILER
HP
BOILER CAPACITY
(LB/HR)
50 75 100 125 150 175 200
100S 3450 2-1/2 2-1/2 NA NA NA NA NA
125S 4313 3 2-1/2 2-1/2 2-1/2 NA NA NA
150S 5175 3 3 2-1/2 2-1/2 2-1/2 2-1/2 NA
175S 6038 3 3 2-1/2 2-1/2 2-1/2 2-1/2 NA
200S 6900 3* 3 3 3 3 2-1/2 2-1/2
225S 7736 3 3 3 3 3 2-1/2 2-1/2
A9-15
03-08
Table A9-6. Model CEW Ohio Special Blowdown Tank Sizing Information
100S-150S 110
175S-225S 120
NOTE: Quantity of water removed from boiler by low-
ering normal water line 4".
Optional level controls can alter water quantities.
ALTITUDE
(FT)
CORRECTION
FACTOR
ALTITUDE
(FT)
CORRECTION
FACTOR
1000 1.04 6000 1.25
2000 1.07 7000 1.30
3000 1.11 8000 1.35
4000 1.16 9000 1.40
5000 1.21 - -
above 700 feet, multiply the pressure by the listed fac-
tors:
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.
A9-16
03-08
BOILER HP
PIPE SIZE
(Inches)
PRESSURE REQUIRED (WC)
PRESSURE (WC)
PRESSURE (WC)
UL FM IRI UL FM IRI
100S 2 14 14 15.5 19.5 19.5 21
125S 2 23.5 23.5 23.5 32.5 32.5 32.5
150S 2 22 22 22 27 27 27
175S 2-1/2 20.5 20.5 20.5 22.5 22.5 22.5
200S 2-1/2 25.5 25.5 25.5 28.5 28.5 28.5
225S 2-1/2 N/A N/A N/A 36 36 36
Note: For undersized or oversized gas trains or altitudes above 1,000 feet, contact your local Cleaver-
Brooks representative.
Table A9-8. Model CEW Ohio Special Minimum and Maximum Required Gas Pressure at
Entrance to Standard, FM and IRI Gas Trains (Upstream of Gas Pressure Regulator)
A9-17
03-08
FRONT
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
A B
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
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 con-
dition at the rear.
space.
Dwg A
Dwg B
Dwg C
BOILER HP 100S-225S
Dimension A (inches) 82
Dimension B (inches) 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.
Dimension B between boilers allows for a clear aisle of 42.
A9-18
03-08
Notes
A9-19
03-08
Section A9
Model CEW Ohio Special
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-24
A9-20
03-08
MODEL CEW OHIO SPECIAL
The following sample specification is provided by Cleaver-Brooks to assist you in meeting your
specification. Contact your local Cleaver-Brooks authorized representative for information on special
insurance requirements, special code requirements, optional equipment, or general assistance in
completing the specification.
PART 1 GENERAL
1.01 BOILER CHARACTERISTICS (STEAM 100-225 HP, STEAM 15, 150, 200 OR 250
PSIG)
A. The Steam Boiler shall be Cleaver-Brooks Model CEW Ohio Special, Fuel Series
______(100, 200, 700), _____hp designed for _____psig (15, 150, 250 psig
circuit.
PART 2 PRODUCTS
A. The boiler shall be a three pass wetback horizontal firetube updraft boiler with less
than 358 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.
connections.
appurtenances.
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.
A9-21
03-08
10. The entire boiler base frame and other components shall be factory painted
A. 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.
automatically actuate a motor driven feed water pump maintaining the boiler water level within
normal limits.
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.
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.
connection.
Safety valves of a type and size to comply with ASME Code requirements shall be shipped loose.
The steam pressure controls to regulate burner operation shall be mounted near the water column.
Burner operation shall be the full modulation principle. The burner shall always return to low fire
B. Blower
Combustion air damper and fuel control valve shall be operated by a single damper control motor
that regulates the flame according to load demand. Potentiometer type position controls shall be
provided to regulate operation of the damper control motor.
A9-22
03-08
Fuel series 700 - Gas fired (para 4.4.1).
Fuel series 100 - Light oil (No. 2) fired (para 4.4.2).
Fuel series 200 - Light oil or gas fired (para 4.4.3).
a. 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.
train shall include one (1) shutoff valve, solenoid valve, and pressure
regulator.
c. Gas Burner Piping - Select one of the following:
100 hp. Gas burner piping on all units shall include two (2) manual shutoff valves, gas
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, flame
a. Burner Type - The burner shall be mounted at the front of the boiler, and
train shall include one (1) shutoff valve, solenoid valve, and pressure
regulator.
c. Oil Pump - An oil pump with a capacity sufficient for the maximum
burning rate shall be included. Pump shall be motor driven and shipped
loose to be field installed near the oil storage tank. Oil pump motor starter
shall also be provided.
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.
e. Oil Atomization Type - Burner shall be a low pressure air atomizing type,
including a shipped loose air compressor assembly.
a. 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
A9-23
03-08
either CS12-48 Commercial No. 2 oil or natural gas.
fuel valve cannot open until pilot flame has been established. The pilot
train shall include one (1) manual shutoff valve, solenoid valve, and
pressure regulator.
c. Oil Burner
1) Oil Pump - An oil pump with a capacity sufficient for the maximum
burning rate shall be included. Pump shall be motor driven and
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
3) Oil Atomization Type - Burner shall be a low pressure air atomizing
type, including a shipped loose air compressor assembly.
d. Gas Burner Piping - Select one of the following:
100 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas
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, flame
1. Control Panel
A factory prewired control panel shall be supplied with the boiler/burner package. Panel will be
mounted on the burner.
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, flame failure, low water, and fuel valve
open.
3. The panel shall contain fuse protection for the burner motor and air
compressor motor.
A. The boiler must be guaranteed to operate at a minimum fuel-to-steam efficiency of
____percent at 100 percent of rating when burning natural gas and ________fuel-
to-steam efficiency at 100% firing rate when burning oil (Contact your local Cleaver-
Brooks authorized representative for efficiency details).
A9-24
03-08
2.05 WARRANTY
for a period of 12 months from date of start-up or 18 months from date of
PART 3 EXECUTION
A. Shop Tests
B. Start-up Service
services of a field representative for starting the unit and training the operator
at no additional costs.
A10-1
03-08
CONTENTS
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-13
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-13
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-13
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-15
Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-15
Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-15
Test Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-15
Sound Level Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-15
Sound Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-18
Typical Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-18
Octave Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-18
Gas Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-18
No. 6 Oil Piping, Storage Tank Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-19
Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-27
STEAM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-31
HOT WATER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-41
Section A10
MODEL CBR BOILERS
125 - 800 HP
Model CBR Boilers 125-800 HP Firetube Boilers
A4-2
ILLUSTRATIONS
Figure A10-1. Model CBR Steam Boiler Dimensions and Weights - Sheet 1 of 2 . . . . . . . . . . . . . A10-5
Figure A10-2. Model CBR Hot Water Boiler Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . A10-7
Figure A10-3. Space Required to Open Rear Head on Model CBR Boilers Equipped with Davits . . . A10-10
Figure A10-4. Model CBR Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-11
Figure A10-5. Lifting Lug Locations, Model CBR Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-12
Figure A10-6. Predicted Stack Temperature Increase for Pressure Greater Than 125 psig . . . . . . . A10-14
Figure A10-7. Typical Fuel Storage Tank Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-19
Figure A10-8. Typical Cross Section of Bundled Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-19
Figure A10-9. Schematic of Standard Alstrom Hot Water Safety-Type Preheating System . . . . . . . A10-20
Figure A10-10. Typical Gas Piping Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-22
Figure A10-11. No. 2 Oil Piping, Single Boiler Installation, Remote Oil Pump . . . . . . . . . . . . . . . A10-23
Figure A10-12. No. 2 Oil Piping, Multiple Boiler Installation, Remote Oil Pumps . . . . . . . . . . . . . A10-23
Figure A10-13. No. 2 Oil Piping, Multiple Boiler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-24
Figure A10-14. No. 2 Oil Transfer Tank Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-25
Figure A10-15. Boiler Room Length (Typical Layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-28
Figure A10-16. Boiler Room Width (Typical Layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-28
Figure A10-17. Breeching Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-29
TABLES
Table A10-1. Model CBR Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-4
Table A10-2. Model CBR Hot Water Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-4
Table A10-3. Steam Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-9
Table A10-4. Hot Water Boiler Relief Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-9
Table A10-5. Predicted Fuel-to-Steam Efficiencies (%), Model CBR Boilers, Natural Gas . . . . . . . . A10-13
Table A10-6. Predicted Fuel-to-Steam Efficiencies (%), Model CBR Boilers - No.6 Oil . . . . . . . . . A10-14
Table A10-7. Predicted Fuel-to-Steam Efficiencies (%), Model CBR Boilers - No. 2 Oil . . . . . . . . . A10-14
Table A10-8. Model CBR Boiler Emission Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-15
Table A10-9. Steam Volume and Disengaging Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-16
Table A10-10. Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity) A10-16
Table A10-11. Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-17
Table A10-12. Model CBR Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . A10-17
Table A10-13. Predicted Sound Levels (30 ppm NOx Systems) at High Fire . . . . . . . . . . . . . . . . A10-17
Table A10-14. CBR Gas Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-21
Table A10-15. Minimum Required Gas Pressure Altitude Conversion . . . . . . . . . . . . . . . . . . . . . A10-21
Section A10 MODEL CBR BOILERS 125 - 800 HP
A10-3
03-08
125-800hp.
Steam and hot water.
Same available pressures as equivalent Model CB/CBLE/CBW/4WI.
Capable of firing natural gas, #2-#6 oil, bio-gas, digester gas or town gas.
Low NOx capabilitiesnatural gas only.
Containerization from 125-800 hp will reduce delivered to job site price for
large boilers that would otherwise be shipped on flatracks.
Enhanced heat transfer technology enables Cleaver-Brooks to reduce the
number of tubes, thus reducing the overall weight and shell diameters while
maintaining high fuel-to steam efficiency.
Integral burner design.
Allows interchangeability of burner spare parts for Models CB/CBLE/CBR.
Enables us to offer 50/60Hz with no price surcharge.
Corrugated furnace will be standard equipment.
.095 tubes will be standard. (.105 tubes can be supplied at an additional
cost.)
Level master will be standard equipment.
The CBR can be ordered with Hawk ICS as well as all other boiler extras
which are available for Model CB/CBLE/4WI boilers.
Same factory warranty as is applied to all other Cleaver-Brooks products.
The CBR will be manufactured in the U.S. at our facility in Thomasville,
Georgia.
Locally available spare parts and after sales services through exclusive
Cleaver-Brooks representatives around the world.
Dimensions and ratings for the Model CBR boilers are shown in the
following tables and illustrations:
Table A10-1. Model CBR Steam Boiler Ratings
Table A10-2. Model CBR Hot Water Boiler Ratings
Table A10-3. Safety Valve Openings
Table A10-4. Relief Valve Openings
Figure A10-1. Model CBR Steam Boiler Dimensions
Figure A10-2 Model CBR Hot Water Boiler Dimensions
Figure A10-3. Space Required to Open Rear Head on Model CBR Boilers
Equipped with Davits
Figure A10-4. Model CBR Boiler Mounting Piers
Figure A10-5. Lifting Lug Locations, Model CBR Boilers
MODEL CBR BOILERS 125 - 800 HP Section A10
A10-4
03-08
Table A10-2. Model CBR Hot Water Boiler Ratings
Table A10-1. Model CBR Steam Boiler Ratings
BOILER H.P. 125 150 200 250 300 350 400 500 600 700 800
from and at 212
0
F)
4313 5175 6900 8625 10350 12075 13800 17250 20700 24150 27600
Btu Output (1000 Btu/hr) 4184 5021 6694 8368 10042 11715 13389 16736 20083 23430 26778
Light Oil gph (140,000 Btu/gal) 37.4 44.8 59.8 74.7 89.7 104.6 119.5 149.4 179.3 209.2 239.1
Heavy Oil gph (150,000 Btu/gal) 34.9 41.8 55.8 69.7 83.7 97.6 111.6 139.5 167.4 195.3 223.1
Gas CFH (1000 Btu) 5230 6276 8368 10460 12552 14644 16736 20920 25104 29288 33472
Gas (Therm/hr) 52.3 62.8 83.7 104.6 125.5 146.4 167.4 209.2 251.0 292.9 334.7
A
7 1/2 10 15 7 1/2 15 20 10 15 30 40 50
A
10 15 20 15 20 30 15 25 40 60 75
Oil Pump Motor, hp, No. 2 Oil 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4 1 1
Oil Pump Motor, hp, No. 6 Oil 1/2 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4 3/4
Air Compressor Motor hp 3 3 3 3 3 3 7-1/2 7-1/2 7-1/2 7-1/2 7-1/2
Heavy Oil Heater kW
B
5 5 5 7 1/2 7 1/2 7 1/2 7 1/2 7 1/2
C
7 1/2
C
7 1/2
C
7 1/2
C
Heating Surface sq-ft. (Fireside) 459 459 641 764 966 1238 1226 1374 1794 2535 2535
BOILER DATA
BOILER H.P. 125 150 200 250 300 350 400 500 600 700 800
Btu Output (1000 Btu/hr) 4184 5021 6694 8368 10042 11715 13389 16736 20083 23430 26778
Light Oil gph (140,000 Btu/gal) 37.4 44.8 59.8 74.7 89.7 104.6 119.5 149.4 179.3 209.2 239.1
Heavy Oil gph (150,000 Btu/gal) 34.9 41.8 55.8 69.7 83.7 97.6 111.6 139.5 167.4 195.3 223.1
Gas CFH (1000 Btu) 5230 6276 8368 10460 12552 14644 16736 20920 25104 29288 33472
Gas (Therm/hr) 52.3 62.8 83.7 104.6 125.5 146.4 167.4 209.2 251.0 292.9 334.7
Blower Motor hp (60 ppm) 7 1/2 10 15 7 1/2 15 20 10 15 30 40 50
Blower Motor hp (30 ppm) 10 15 20 15 20 30 15 25 40 60 75
Oil Pump Motor, hp, No. 2 Oil 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4 1 1
Oil Pump Motor, hp, No. 6 Oil 1/2 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4 3/4
Air Compressor Motor hp 3 3 3 3 3 3 7-1/2 7-1/2 7-1/2 7-1/2 7-1/2
Heavy Oil Heater kW
A
5 5 5 7 1/2 7 1/2 7 1/2 10 10 10 10 10
Heating Surface sq-ft. (Fireside) 459 459 644 764 966 1238 1226 1374 1794 2535 2535
Notes:
A. Oil heater sized as a straight electric heater.
BOILER DATA
Notes:
A. Blower motor size for boiler operating pressures 125 psig and less, contact your local Cleaver-Brooks authorized representative for higher pressures and altitude.
B. Oil heater sized as a combination steam-electric heater. For straight electric heaters, contact your local Cleaver-Brooks authorized representative.
C. 10 KW Oil heater for low pressure.
A10-5
03-08
s
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F G
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W
S
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BB
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D E
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T
60" DIA. (125-200HP) ARE HINGED
67" DIA. (250-350HP) AS SHOWN
83" DIA. (400-800HP) SPECIAL DAVIT
EE
N
M
KK
O
OO
K
L
LL
I
GG
C
X
J
V
DD
FF
H
B
A
RR / RF / RD
Figure A10-1. Model CBR Steam Boiler Dimensions and Weights - Sheet 1 of 2
A10-6
03-08
Figure A10-1. Model CBR Steam Boiler Dimensions and Weights - Sheet 2 of 2
BOILER H.P. DIM 125 150 200 250 300 350 400 500 600 700 800
LENGTHS
Overall Length (60 PPM system) A 196.5 199.5 231.5 207 226 258 224 230 266 300 301
Shell B 149 149 180 156 171 201 163 168 200 233 233
Base Frame C 136 136 167 143 158 188 150 155 187 220 220
Front Head Extension (60 PPM system) D 28 31 32 28 32 34 29 30 34 35 36
Rear Head Extension E 19.5 19.5 19.5 23 23 23 32 32 32 32 32
Shell Ring Flange to Base F 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Rear Ring Flange to Base G 12.5 12.5 12.5 12.5 12.5 12.5 12.5 12.5 12.5 12.5 12.5
Shell Flange to Steam Nozzle H 66 66 78 71.5 73 88 76.25 77.75 96.25 112.75 112.75
Front Shell Extension P 12 12 12 15 15 15 17 17 17 17 17
Over Tubesheets V 137 137 168 141 156 186 146 151 183 216 216
WIDTHS
Overall Width I 85 85 85 92 92 92 109 109 109 109 109
I.D. Boiler J 60 60 60 67 67 67 83 83 83 83 83
Center to Water Column K 45 45 45 48.5 48.5 48.5 56.5 56.5 56.5 56.5 56.5
Center to Outside Davit/Hinge KK 35 35 35 45.5 45.5 45.5 45.5 45.5 45.5 45.5 45.5
Center to Lagging L 33 33 33 36.5 36.5 36.5 44.5 44.5 44.5 44.5 44.5
Center to Auxiliary LWCO LL 40 40 40 43.5 43.5 43.5 52.5 52.5 52.5 52.5 52.5
Base Outside M 52.5 52.5 52.5 51 51 51 60 60 60 60 60
Base Inside N 44.5 44.5 44.5 43 43 43 47 47 47 47 47
HEIGHTS
Overall Height OO 86 86 86 102.5 102.5 102.5 120.5 120.5 120.5 120.5 120.5
Base to Vent Outlet O 85 85 85 94.5 94.5 94.5 112 112 112 112 112
Height of Base Frame Q 12 12 12 12 12 12 12 12 12 12 12
Base to Bottom of Boiler R 16 16 16 14 14 14 16 16 16 16 16
Base to Steam Outlet X 82.375 82.375 82.375 90.25 90.25 90.25 108 108 108 108 108
BOILER CONNECTIONS
Feedwater Inlet (Both Sides) S 1.5 1.5 2 2 2 2.5 2.5 2.5 2.5 2.5 2.5
Surface Blowoff (150 lb only) T 1 1 1 1 1 1 1 1 1 1 1
Steam Nozzle 15 lb
(See Note "A")
U 8 8 10 10 12 12 12 12 12 12 12
Steam Nozzle 150 lb
(See Note "B")
U 4 4 4 6 6 6 6 8 8 8 8
Blowdown-Front & Rear (15 lb) W 1.5 1.5 2 2 2 2 2 2 2 2 2
Blowdown-Front & Rear (150 lb) W 1.5 1.5 1.5 1.5 1.5 1.5 2 2 2 2 2
Chemical Feed Z 1 1 1 1 1 1 1 1 1 1 1
VENT STACK
Vent Stack Diameter (Flanged) BB 16 16 16 20 20 20 24 24 24 24 24
MINIMUM CLEARANCES
Rear Door Swing DD 32 32 32 36 36 36 45 45 45 45 45
Front Door Swing EE 67 67 67 75 75 75 80 80 80 80 80
Tube Removal - Rear FF 139 139 170 143 157 187 147 152 184 217 217
Tube Removal - Front GG 127 127 158 128 142 172 130 135 167 200 200
Thru Window or Door RD 248 248 279 267 282 312 288 293 325 358 358
Front of Boiler RF
308 308 370 320 349 409 338
348 412 478 478
Rear of Boiler RR 355 355 417 374 403 463 390 400 464 530 530
WEIGHTS IN LBS
6,950 6,950 8,350 8,400 9,050 10,550 11,650 11,900 14,150 15,700 15,700
11,850 11,850 13,550 15,400 17,550 19,750 26,450 27,100 30,700 35,700 35,700
13,000 13,000 14,850 18,100 19,300 20,750 29,050 29,750 32,400 37,600 37,600
13,200 13,200 15,100 19,250 20,300 23,300 29,800 30,150 34,850 38,800 38,800
Normal Water Weight
Approx. Shipping Weight - (15 psig)
NOTES:
Note "A": ANSI 150 psig Flange
Note "B": ANSI 300 psig Flange
A10-7
03-08
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C
R
F G
W
W S
P
BB
D E
Q
Z
Y T U
RR / RF / RD
60" DIA. (125-200HP) ARE HINGED
67" DIA. (250-350HP) AS SHOWN
83" DIA. (400-800HP) SPECIAL DAVIT
EE
N
M
KK
O
OO
K L
I
GG
C
X
J
V
DD
FF
H
B
A
HH
Figure A10-2. Model CBR Hot Water Boiler Dimensions - Sheet 1 of 2
A10-8
03-08
Figure A10-2. Model CBR Hot Water Boiler Dimensions - Sheet 2 of 2
BOILER H.P. DIM 125 150 200 250 300 350 400 500 600 700 800
LENGTHS
Shell B 149 149 180 156 171 201 163 168 200 233 233
Base Frame C 136 136 167 143 158 188 150 155 187 220 220
Rear Head Extension E 19.5 19.5 19.5 23 23 23 32 32 32 32 32
Shell Ring Flange to Base F 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Rear Ring Flange to Base G 12.5 12.5 12.5 12.5 12.5 12.5 12.5 12.5 12.5 12.5 12.5
Shell Flange to Return H 102 102 131 115.5 130 160 120 125 151.1 185 185
Shell Flange to Outlet HH 136 136 167 143 158 188 155.5 156.5 182.5 216.5 216.5
Front Shell Extension P 12 12 12 15 15 15 17 17 17 17 17
Over Tubesheets V 137 137 168 141 156 186 146 151 183 216 216
WIDTHS
Overall Width I 75.5 75.5 75.5 82 82 82 100 100 100 100 100
I.D. Boiler J 60 60 60 67 67 67 83 83 83 83 83
Center to Entrance Box K 42.5 42.5 42.5 45.5 45.5 45.5 55.5 55.5 55.5 55.5 55.5
Center to Outside Davit/Hinge KK 35 35 35 45.5 45.5 45.5 45.5 45.5 45.5 45.5 45.5
Center to Lagging L 33 33 33 36.5 36.5 36.5 44.5 44.5 44.5 44.5 44.5
Base Outside M 52.5 52.5 52.5 51 51 51 60 60 60 60 60
Base Inside N 44.5 44.5 44.5 43 43 43 47 47 47 47 47
HEIGHTS
Overall Height OO 86 86 86 102.5 102.5 102.5 120.5 120.5 120.5 120.5 120.5
Base to Vent Outlet O 85 85 85 94.5 94.5 94.5 112 112 112 112 112
Height of Base Frame Q 12 12 12 12 12 12 12 12 12 12 12
Base to Bottom of Boiler R 16 16 16 14 14 14 16 16 16 16 16
Base to Return & Outlet X 82.375 82.375 82.375 90.25 90.25 90.25 108 108 108 108 108
BOILER CONNECTIONS
Waterfill Connection (Both Sides) S 1.5 1.5 2 2 2 2.5 2.5 2.5 2.5 2.5 2.5
Water Return (See Note "A") T 6 6 6 8 8 8 10 10 12 12 12
Water Outlet (See Notes "A & B") U 6 6 6 8 8 8 10 10 12 12 12
Drain-Front & Rear W 1.5 1.5 2 2 2 2 2 2 2 2 2
Air Vent Y 1.5 1.5 1.5 1.5 1.5 1.5 2 2 2 2 2
VENT STACK
Vent Stack Diameter (Flanged) BB 16 16 16 20 20 20 24 24 24 24 24
MINIMUM CLEARANCES
Rear Door Swing DD 32 32 32 36 36 36 45 45 45 45 45
Front Door Swing EE 67 67 67 75 75 75 80 80 80 80 80
Tube Removal - Rear FF 139 139 170 143 157 187 147 152 184 217 217
Tube Removal - Front GG 127 127 158 128 142 172 130 135 167 200 200
Thru Window or Door RD 248 248 279 267 282 312 288 293 325 358 358
Front of Boiler RF
308 308 370 320 349 409 338
348 412 478 478
Rear of Boiler RR 355 355 417 374 403 463 390 400 464 530 530
WEIGHTS IN LBS
10,800 10,800 13,050 11,750 12,750 15,000 16,900 17,150 20,500 23,250 23,250
11,850 11,850 13,550 15,400 17,550 19,750 26,400 27,100 30,700 35,700 35,700
13,200 13,200 15,100 18,350 18,400 20,700 29,400 28,150 31,900 37,050 37,050
NOTES:
Normal Water Weight
A10-9
03-08
BOILER HP
NO. OF
VALVES
REQ'D
OUTLET
SIZE (IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE (IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE (IN.)
125 1 2-1/2 1 1-1/4 2
(1) 1-1/2 (1)
2
150 1 2-1/2 1 2 2
(1) 1-1/2 (1)
2
200 2
(1) 2-1/2 (1)
1-1/4
1 2 2 2
250 2
(1) 2 (1) 2-
1/2
1 2 2
(1) 2 (1) 2-
1/2
300 2 2-1/2 1 2-1/2 2 2-1/2
350 3
(2) 2-1/2 (1)
1
1 2-1/2 2
(1) 2-1/2 (1)
3
400 3
(1) 2 (2) 2-
1/2
1 2-1/2 2
(1) 2-1/2 (1)
3
500 4
(1) 1 (3) 2-
1/2
2
(1) 1 (1) 2-
1/2
2 3
600 4
(3) 2-1/2 (1)
2
2
(1) 1-1/4 (1)
2-1/2
3
(2) 3 (1) 2-
1/2
700, 800 5
(1) 1 (4) 2-
1/2
2
(1) 2-1/2 (1)
2
3 3
NOTE: Relief valve is Kunkle #537 for 30#& 125#(Section IV) boiler and is
Kunkle #927 for 150#HTHW(Section I) boiler.
BOILER HP
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
NO. OF
VALVES
REQ'D
OUTLET
SIZE
(IN.)
125 1 3 2
(1) 1-1/2
(1) 1-1/4
2
(1) 1-1/4
(1) 1
2 1
150 1 3 2
(1) 1-1/2
(1) 1-1/4
2 1-1/4 2
(1) 1
(1) 1-1/4
200 2 2-1/2 2 1-1/2 2
(1) 1-1/2
(1) 1-1/4
2 1-1/4
250 2
(1) 2-1/2
(1) 3
2
(1) 2
(1) 1-1/2
2 1-1/2 2
(1) 1-1/2
(1) 1-1/4
300 2 3 2 2 2
(1) 2
(1) 1-1/2
2 1-1/2
350 3
(1) 2
(2) 3
2
(1) 2-1/2
(1) 2
2 2 2
(1) 1-1/2
(1) 2
400 3
(2) 3
(1) 2-1/2
2
(1) 2-1/2
(1) 2
2 2 2
(1) 1-1/2
(1) 2
500 3 3 2 2-1/2 2
(1) 2-1/2
(1) 2
2 2
600 4
(3) 3
(1) 2-1/2
3
(2) 2-1/2
(1) 2
2 2-1/2 2
(1) 2
(1) 2-1/2
700, 800 5
(3) 3
(2) 2-1/2
3
(2) 2-1/2
(1) 2
2 2-1/2 2 2-1/2
A10-10
03-08
Figure A10-3. Space Required to Open Rear Head on Model CBR Boilers Equipped with Davits
MAXIMUM REAR
MINIMUM SIDE
MINIMUM REAR
MAXIMUM SIDE
DIMENSIONS (INCHES)
H.P.
250-350
125-200
A
33"
BOILER
400-800
36.5"
44.5"
65"
86"
55"
B
51"
64"
45"
C
83"
99"
68"
D
35"
57"
32"
E
B
D
A
E
C
A10-11
03-08
Figure A10-4. Model CBR Boiler Mounting Piers
DIMENSIONS (INCHES)
A
6"
B
9"
D
39.5"
C
136"
E
57.5"
H.P.
125-150
BOILER
200
600
700-800
400-500
F
4"
G
44.5"
H
10"
J
9.75"
9.75" 44.5" 4" 57.5" 39.5" 9" 10" 167" 6"
22" 143" 6" 10" 12" 48" 72" 4" 56" 250
300
350
22" 12" 48" 72" 56" 158" 4" 10" 6"
22" 12" 48" 72" 56" 188" 4" 10" 6"
22.75" 154.75" 6" 12" 6.5" 58.88" 79.38" 51.38" 14"
22.75" 6.5" 186.75" 51.38" 79.38" 58.88" 12" 14" 6"
22.75" 6.5" 219.75" 51.38" 79.38" 58.88" 12" 14" 6"
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.
C
J H
E
D B B
F F
A
A10-12
03-08
Figure A10-5. Lifting Lug Locations, Model CBR Boilers
C
L
FRONT
FLANGE
NEAR
SIDE SIDE
FAR
E DIA.
HOLE (TYP.)
DIMENSIONS (INCHES)
ALL
ALL
A
80.25"
B
29.75"
D
10"
C
83.5"
E
3"
H.P.
125-150
BOILER
200 114.5" 29.75" 80.25" 3" 10"
STEAM
250
36" 87.12" 3" 10" 84"
HOT WATER 87.12" 36" 93" 10" 3"
108" 3" 10" 36" 87.12"
36" 99" 87.12" STEAM
HOT WATER
300
10" 3"
138"
129"
350
3" 10"
HOT WATER
STEAM 87.12" 36"
87.12" 36" 10" 3"
99" 35.75" 105.5" 11" 3" ALL
600 ALL 3" 105.5" 131" 11" 35.75"
700-800 ALL 3" 105.5" 164" 11" 35.75"
NOTE: A, B, AND C DIMENSIONS MAY VARY BY 1/2".
400-500
C B
A
D D
A10-13
03-08
PERFORMANCE DATA
Efficiency Tables A10-5, A10-6, and A10-7 show predicted fuel-to-steam efficiencies
(excluding radiation and convection losses) for Cleaver-Brooks Model CBR Firetube
boilers. For specific efficiencies on firetube boiler offerings not listed here, contact
Emissions The emission data included in this section (Table A10-8) consists of typical
uncontrolled emission levels for Cleaver-Brooks Model CBR Firetube Boilers.
Cleaver-Brooks Firetube boilers are available with the standard burner package for
Model CBR, or optional internal flue gas recirculation on.
The Cleaver-Brooks IFGR packages are integrated boiler/burner/control packages
designed specifically for Cleaver-Brooks boilers. For detailed information on Cleaver-
Brooks IFGR packages, refer to Model CB (LE) in Section A2.
Notice
The data in Table A10-8 represents typical emission levels only. Guaranteed emis-
sion levels are available from your local Cleaver-Brooks authorized representative.
Table A10-5. Predicted Fuel-to-Steam Efficiencies (%), Model CBR Boilers, Natural Gas
25% 50% 75% 100% 25% 50% 75% 100%
125 84.4 84.5 84.0 83.4 81.6 81.8 81.5 81.0
150 84.3 84.4 83.7 83.0 81.5 81.6 81.2 80.7
200 84.5 84.9 84.5 84.1 81.7 82.2 82.0 81.7
250 84.2 84.2 83.5 82.6 81.4 81.5 80.9 80.3
300 84.4 84.5 84.0 83.4 81.5 81.8 81.5 81.0
350 84.6 85.1 84.8 84.5 81.8 82.4 82.3 82.1
400 84.8 84.3 83.6 82.7 82.0 81.8 81.1 80.4
500 84.7 84.2 83.4 82.5 82.0 81.7 81.0 80.1
600 85.0 84.8 84.4 83.8 82.3 82.3 81.9 81.4
700 85.3 85.3 85.1 84.8 82.6 82.8 82.7 82.4
800 85.2 85.3 85.0 84.6 82.5 82.7 82.6 82.3
BHP
% OF LOAD
% OF LOAD
A10-14
03-08
Table A10-6. Predicted Fuel-to-Steam Efficiencies (%), Model CBR Boilers - No.6 Oil
Table A10-7. Predicted Fuel-to-Steam Efficiencies (%), Model CBR Boilers - No. 2 Oil
25% 50% 75% 100% 25% 50% 75% 100%
125 87.8 88.0 87.4 86.8 85.0 85.2 84.9 84.5
150 87.7 87.8 87.2 86.4 84.9 85.1 84.6 84.1
200 88.0 88.3 88.0 87.5 85.2 85.6 85.4 85.2
250 87.6 87.6 86.9 86.1 84.8 84.9 84.3 83.7
300 87.8 88.0 87.4 86.8 85.0 85.2 84.9 84.4
350 88.1 88.5 88.3 87.9 85.3 85.8 85.7 85.6
400 88.2 87.7 87.0 86.1 85.5 85.2 84.5 83.8
500 88.1 87.6 86.8 85.9 85.4 85.1 84.4 83.6
600 88.5 88.3 87.8 87.2 85.7 85.7 85.4 84.9
700 88.7 88.8 88.5 88.2 86.0 86.2 86.1 85.8
800 88.7 88.7 88.4 88.1 85.9 86.2 86.0 85.7
BHP
% OF LOAD
% OF LOAD
25% 50% 75% 100% 25% 50% 75% 100%
125 88.3 88.4 87.8 87.2 85.3 85.6 85.2 84.7
150 88.2 88.2 87.5 86.8 85.2 85.4 84.9 84.3
200 88.4 88.8 88.4 87.9 85.5 85.9 85.7 85.5
250 88.1 88.0 87.3 86.4 85.1 85.2 84.6 84.0
300 88.3 88.4 87.8 87.1 85.3 85.5 85.2 84.7
350 88.5 89.0 88.7 88.3 85.6 86.1 86.1 85.9
400 88.6 88.1 87.3 86.5 85.8 85.5 84.8 84.0
500 88.6 88.0 87.2 86.2 85.7 85.4 84.6 83.8
600 88.9 88.7 88.2 87.6 86.1 86.1 85.7 85.1
700 89.2 89.2 89.0 88.6 86.3 86.6 86.4 86.2
800 89.1 89.1 88.9 88.5 86.3 86.5 86.3 86.0
BHP
% OF LOAD
% OF LOAD
A10-15
03-08
ENGINEERING DATA
The following engineering information is provided for Model CBR Firetube Boilers.
representative.
Blowdown Water
Requirements
Sound Level Table A10-13 summarizes predicted sound pressure levels for Model CBR 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 Table A10-13 were obtained from tests in accordance
with the "ABMA Test Code for the Measurement of Sound from Packaged 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.
POLLUTANT
ESTIMATED LEVELS - UNCONTROLLED
NATURAL GAS NO. 2 OIL
B
NO. 6 OIL
C
60 PPM System 30 PPM System
60 PPM
SYSTEM
30 PPM
SYSTEM
CO
ppm
A
50/150
B
50/150
B
50 50 95
Lb/MMBtu 0.04/0.11 0.04/0.11 0.04 0.04 0.075
NOx
ppm
A
60 30 185 140 502
Lb/MMBtu 0.07 0.035 0.25 0.187 0.67
SOx
ppm
A
1 1 278 278 278
Lb/MMbtu 0.001 0.001 0.52 0.52 0.52
HC/VOCs
ppm
A
10 10 4 4 70
Lb/MMBtu 0.004 0.004 0.002 0.002 0.035
PM
ppm
A
- - - -
Lb/MMBtu 0.01 0.01 0.025 0.256 0.160
NOTES:
Refer to Section E for detailed emission information.
A. ppm levels are given on a dry volume basis and corrected to 3% oxygen (15% excess air)
B. CO emission is 50 ppm when boiler is operating above 50% of rated capacity. CO emission is 150 ppm when boiler is operating below 50% of rated
capacity.
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
Conradson carbon residue =16% by weight
Table A10-8. Model CBR Boiler Emission Data
A10-16
03-08
(A) (B) (A) (B)
125 61.8 67.7 7675 7790
150 61.8 67.7 7675 7790
200 75.8 83 9403 9561
250 53.7 64.7 8093 8453
300 59.4 71.5 8957 9345
350 70.8 85.3 10670 11145
400 84.7 98.8 10627 11016
500 84.7 98.8 10627 11016
600 102.6 119.7 12873 13363
700 121.1 141.3 15206 15768
800 121.1 141.3 15206 15768
NOTE:
BOILER HP
Table A10-10. Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity)
OPERATING PRESSURE
PSIG 125 150 200 250 300 350 400 500 600 700 800
15 8 8 10 10 12 12 12 12 12 12 12
30 6 6 8 8 8 10 10 10 12 12 12
40 6 6 6 8 8 8 10 10 10 12 12
50 6 6 6 6 8 8 8 10 10 10 12
75 4 4 6 6 6 8 8 8 8 10 10
100 4 4 6 6 6 6 6 8 8 8 10
125 4 4 4 6 6 6 6 8 8 8 8
150 3 4 4 4 6 6 6 6 6 8 8
200 2.5 3 4 4 4 4 6 6 6 6 6
250 2.5 3 3 4 4 4 4 6 6 6 6
NOTES:
2. Standard nozzle size for 15-psi steam boiler is as listed above for 15-psig operating pressure
3. Standard steam nozzle for a 150-psig or higher design steam boiler is listed above for 125-psig operqting pressure.
It will be changed only if requested at the time of order.
4. For expanded operating pressure table, see Table I3-1 (System Fundamentals)
5. Shaded area denotes special surge load baffles must be installed.
BOILER HP
A10-17
03-08
Table A10-12. Model CBR Blowdown Tank Sizing Information
125 136
150 136
200 167
250 145
300 161
350 191
400 190
500 190
600 230
700 272
800 272
NOTE: Quantity of water
removed from boiler by lowering
Table A10-13. Predicted Sound Levels (30 ppm NOx Systems) at High Fire
BHP Sound Level-dbA
125 84
150 84
200 84
250 83
300 84
350 85
400 84
500 85
600 85
700 88
800 90
BOILER BOILER CAPACITY OPERATING PRESSURE (PSIG)
HP (LBS/HR) 50 75 100 125 150 175 200 250
125 4313 3 2-1/2 2-1/2 2-1/2 NA NA NA NA
150 5175 3 3 2-1/2 2-1/2 2-1/2 2-1/2 NA NA
200 6900 3* 3 3 3 3 2-1/2 2-1/2 2-1/2
250 8625 4 3* 3 3 3 3 3 3
300 10350 4 4 4 3* 3 3 3 3
350 12025 4 4 4 4 4 3* 3 3
400 13800 5 4 4 4 4 4 4 3*
500 17210 6 5 5 4 4 4 4 4
600 20700 6 6 5 5 5 4 4 4
700 24150 6 6 6 5 5 5 5 4
800 27600 6 6 6 6 6 5 5 5
NOTE: Valve sizes (300 psig flanges) given in inches.
Standard Non-Return valve selections limited to a maximum 2 to 1turndown (50% of full boiler output)
NA Indicates that there is not a standard 2:1 turndown valve selection available
* Indicates pressure drop of less than 7.5psig. All other selections are less than 6 psig pressure drop
A10-18
03-08
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
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 finally, 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., dBA 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 though the
low and high frequencies of octave band measurement do not closely correspond).
Gas-Fired Burners Table A10-14 shows gas pressure requirements for Model CBR Boilers.
Dimensions and Ratings Section.
Figure A10-11 through Figure A10-13 show typical oil systems and layouts.
Figure A10-14 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.
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. Provide a tank suction heater and bundle the steam or water tracers from the
tank to the oil heater.
2. 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 Figure A10-7 and Figure A10-8 for an example of (No. 1 above) tank heating
method.
See Figure A10-9 for an example of a preheating system.
A10-19
03-08
+
+
OIL STORAGE
TANK
MANHOLE
OIL RETURN
OIL SUCTION
STEAM OR HOT WATER
AND SUPPLY SYSTEMS.
Figure A10-8. Typical Cross Section of Bundled Lines
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 a corrugated steel is
recommended.
INSULATION
OIL RETURN
TO TANK
SEE NOTES
1 AND 2 STEAM OR HOT WATER
TO TANK HEATER
OIL SUCTION
CONDENSATE OR
HOT WATER FROM
TANK HEATER
A10-20
03-08
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 A10-9. Schematic of Standard Alstrom Hot Water Safety-Type Preheating System
OIL RETURN FROM BOILER
OIL TO BURNER
ELECTRIC
HEATER
F.O.R.
F.O.S.
CONTRACTOR CONNECTIONS
(AT BOILER BASE FRAME)
BOILER WATER-TO-HEAT
TRANSFER SOLUTION-TO-OIL
HEAT EXCHANGER
(ALSTROM HEATER)
BOILER WATER PUMP
(CONTROLLED BY THERMOSTAT
IN OIL LINE)
MINIMUM 200 F
WATER FROM SIDE
OF BOILER
WATER RETURN TO
SIDE OF BOILER
GATE
VALVE
A10-21
03-08
ALTITUDE
(FT)
CORRECTION
FACTOR
ALTITUDE
(FT)
CORRECTION
FACTOR
1000 1.04 6000 1.25
2000 1.07 7000 1.30
3000 1.11 8000 1.35
4000 1.16 9000 1.40
5000 1.21 - -
To obtain minimum required gas pressure at altitudes above 700
feet, multiply the pressure by the listed factors:
Table A10-15. Minimum Required Gas Pressure Altitude Conversion
Table A10-14. CBR Gas Pressure Requirements
CBR 30 PPM CBR 60 PPM
Boiler HP
125 1.5 0.8 - 3.0 1.5 0.7 - 3.0
150 1.5 1.0 - 3.0 1.5 1.0- 3.0
200
1.5 1.6 -4.0 1.5 1.6 -4.0
2 1.1 - 1.6 2 1.1 - 1.6
250
1.5 2.7 - 5.0 1.5 2.7 - 5.0
2 1.8 - 2.7 2 1.8 - 2.7
300
1.5-2 3.5 - 5.0 1.5-2 3.5 - 5.0
2 2.5 - 3.5 2 2.5 - 3.5
3 1.6 - 2.5 3 1.6 - 2.5
350
1.5-2 4.0 - 6.0 1.5-2 4.0 - 6.0
2 3.0 - 4.0 2 2.9 - 4.0
2.5 2.2 - 3.0 2.5 2.1 - 2.9
3 1.4 - 2.2 3 1.4 - 2.1
400
1.5-2 4.8 - 7.0 1.5-2 4.7 - 7.0
2 3.3 - 4.8 2 3.1 - 4.7
2.5 2.3 - 3.3 2.5 2.3 - 3.1
3 1.4 - 2.3 3 1.4 - 2.3
500
1.5-2.5 7.0 - 10 1.5-2.5 7.0 - 10
2-2.5 5.1 - 7.0 2-2.5 5.1 - 7.0
2.5 3.5 - 5.1 2.5 3.5 - 5.1
3 2.1 - 3.5 3 2.1 - 3.5
600
2-2.5 7.3 - 10 2-2.5 7.3 - 10
2.5 5.1 - 7.3 2.5 5.0 - 7.3
2.5-3 4.3 - 5.1 2.5-3 4.3 - 5.0
3 2.9 - 4.3 3 2.9 - 4.3
700
2-3 9.0 - 10.0 2-3 9.0 - 10.0
2.5-3 5.7 - 9.0 2.5-3 5.7 - 9.0
3 3.8 - 5.7 3 3.8 - 5.7
4 2.8 - 3.8 4 2.8 - 3.8
800
2.5-3 7.3 - 10 2.5-3 7.3 - 10
3 5.0 - 7.3 3 5.0 - 7.3
4 3.6 - 5.0 4 3.6 - 5.0
increases in size after the regulating valve. The first number
is the customer connection size.
UNDERSIZE
STANDARD
OVERSIZE
A10-22
03-08
PLUG
COCK
A
B
C
D CONTRACTOR
CONNECTION
POINT
GAS TRAIN
ON BOILER
STREET GAS MAIN
This figure illustrates the basic gas valve arrangement on Cleaver-Brooks Model CBR Boiler and
shows the contractor's connection point. The valves and controls between the contractor connec-
tion point and the gas main in the street are representative of a typical installation. Actual require-
ments may vary depending on local codes or local gas company requirements which should be
investigated prior to preparation of specifications and prior to construction.
C. Gas meter.
The size of the gas line from the meter to the gas pressure regulator at the boiler can be very im-
portant if gas pressures are marginal. The gas line sizing is dependent on:
The local gas utility will advise the pressure that is available at the outlet of their meter.
A10-23
03-08
BOILER
BASE FRAME
BOILER
FRONT
F.O.S.
F.O.R.
CONTRACTOR
CONNECTIONS
AT THIS POINT
GATE VALVE
OIL PUMP
CHECK
VALVE
VACUUM
GAUGE
STRAINER
GATE VALVE
RELIEF VALVE
UNION
GATE VALVE
CHECK VALVE
F.O.R.
F.O.S.
BOILER
BASE FRAME
BOILER
FRONT
F.O.S.
F.O.R.
CONTRACTOR
CONNECTIONS
AT THIS POINT
GATE VALVE
OIL PUMP NO. 1
OIL
PUMP
NO. 2
GATE VALVE
GATE VALVE
CHECK VALVE
RELIEF
VALVE
(100 PSIG)
UNION
GATE VALVE
CHECK VALVE
F.O.S.
F.O.R.
A10-24
03-08
STANDBY
OIL PUMP
UNION
GATE VALVE
CHECK
GATE
RELIEF
VACUUM GAUGE
STRAINER
GATE VALVE
F.O.S.
F.O.R.
PRESSURE
ADJUSTABLE
GATE VALVE
CHECK VALVE
USE LAYOUT FOR: MODEL CBR. . . . . . . 125 THRU 800 HP
BOILER
CONTRACTOR
BOILER
F.O.S.
F.O.R.
VALVE
VALVE
VALVE
(100 PSIG)
GAUGE
PRESSURE
RELIEF VALVE
(75 PSIG)
FRONT
CONNECTIONS
AT THIS POINT
BASE FRAME
A10-25
03-08
Figure A10-14. No. 2 Oil Transfer Tank Detail
level switch
tion from transfer
pump
tion
connection
McD
F.O.R.
OIL LEVEL
TEST VALVE
OIL TRANSFER PUMP
NEAR STORAGE TANK
SUPPLY TO BOILER
TERMINAL BLOCK OR
TO BOILER OIL PUMP
GATE
VALVE
GATE
VALVE
OIL TRANSFER TANK
AT LOCATION NEAR
BOILER
VENT
H
F.O.S.
F.O.R.
F.O.S.
CHECK
VALVE STRAINER
VACUUM
GAUGE
UNION
RELIEF VALVE
(100 PSIG)
3/8" MTL
D
4" OR 6"
STD
BLACK
PIPE
F
E
22"
33"
3"
2"
60"
G
A
B
C
5"
3"
3/16"
S
3/16"
S
A10-26
03-08
Boiler Room
Information
Stack Support
Capabilities
Cleaver-Brooks 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
Although constant pressure at the flue gas outlet of the Model CBR is not required, it
is necessary to size the stack/breeching to limit flue gas pressure variation. For
boiler sizes 125 800 horsepower, the allowable pressure range is 0.25" W.C. to
+0.25" W.C.
Boiler Room
Combustion Air
square foot.
Area (sq-ft.) = cfm/fpm
C. Total recommended air, 10 cfm/bhp - up to 1000 feet elevation. Add 3 percent more
3. Acceptable air velocity in boiler room (fpm).
A10-27
03-08
Notice
A10-28
03-08
A B
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
FRONT
FEEDWATER
TANK
BOILER
FEEDWATER
PUMP
DRAIN
TRENCH
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.
ance is only made for minimum door swing at the rear.
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.
DWG A
DWG B
DWG C
BOILER HP 125-200 250-350 400-800
Dimension A 87 91 99"
Dimension B 120 127 149"
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.
42" - 125-200 hp
48" - 250-350 hp
60" - 400-800 hp
A10-29
03-08
STACK
DRAIN
CONNECTION
CLEAN-
OUT
MANUAL
DAMPER
LOCK (OPEN)
TIGHT SEAL
CLEANOUT
STACK
DRAIN
CONNECTION
CLEAN-
OUT
MANUAL
DAMPER
LOCK (OPEN)
TIGHT SEAL
CLEANOUT
STACK
DRAIN
CONNECTION
CLEAN-
OUT
MANUAL
DAMPER
LOCK (OPEN)
TIGHT SEAL
CLEANOUT
MAXIMUM 10
CONE ANGLE
NOTE: These stack breeching arrangements for
multiple boilers are typical and not intended for your
specific 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 specific
criteria. Your local CLeaver-Brooks authorized
representative is capable of assisting in your
evaluation of stack and breeching design.
A10-31
03-08
Section A10
Model CBR Steam Boiler
125-800 hp, Steam 15, 150, 200, or 250 psig)
Boiler Shell (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-32
Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-34
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-39
Model CBR Steam Boiler Section A10
A10-32
03-08
Model CBR Steam Boiler
125-800 hp, Steam 15, 150, 200, or 250 psig)
The following sample specifications are provided by Cleaver-Brooks to assist you in specifying
your customer's specific needs and application.
PART 1 GENERAL
A. The Steam Boiler shall be Cleaver-Brooks Model CBR Fuel Series ____ (100,
200, 700), ____ hp designed for ____ psig (15 or ____ psig steam). The
maximum operating pressure shall be ____ psig.
B. The boiler shall have a maximum output of ____ Btu/hr, or ____ horsepower
when fired 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.
PART 2 PRODUCTS
A. The boiler shall be a two-pass horizontal firetube updraft boiler with
__________ square feet of total heating surface for the _______ hp boiler. 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 controls.
shall bear the UL/cUL label, except in the case where 50 Hz has been selected.
foundation and ready for attachment of water, steam, fuel, electrical,
vent, steam, and blowdown connections.
2.02 BOILER SHELL (STEAM)
copy of the inspection report shall be furnished the purchaser.
4. Rear refractory and insulation shall be contained in the formed door
which must swing open for inspection of brick work.
5. The boiler tubes shall be rifled tube design, extending heat transfer
surfaces.
Section A10 Model CBR Steam Boiler
A10-33
03-08
6. Front and rear tube sheets and all tubes must be fully accessible for
cleaning.
7. For boilers 125 horsepower and over, a manhole shall be provided.
8. The exhaust gas vent shall be located near the front of the boiler on the
125-225 hp 2000 lbs. and shall contain a stack thermometer.
10. The boiler insulation shall consist of a 2 inch fiberglass blanket under a
sectional preformed sheet metal lagging. This insulation must be readily
removable and capable of being reinstalled, if required.
11. The entire boiler base frame and other components shall be factory
painted before shipment using a hard-finish enamel coating.
1. WATER COLUMN/LOW WATER CUTOFF AND WATER LEVEL CONTROL
SYSTEM
(150-250 psig design): Shall be a CB LEVEL MASTER Water level control
system and shall be comprised of a microprocessor-based electronic
controller, a non-contact, non-wearing, continuously reading absolute
level sensor and pressure chamber. The control system shall be designed
as follows: The electronic controller shall be panel mounted and operate
in ambient temperatures from 32 degrees F to 125 degrees F, the
pressure chamber shall be boiler mounted and operate to pressures of
250PSIG and the level sensor shall operate to pressures of 250 PSIG and
temperatures to 400 degrees F. The pressure containing components
shall be constructed in accordance with ASME Code. A shielded, four
conductor cable with ground shall be run in metal conduit between the
level sensor and the controller. Supply power shall be 115VAC-1 phase-
60 Hz. All wiring shall be in compliance with the National Electrical
Code.
The pressure chamber shall have a sight glass mounted on the side. The
level sensor shall have an accuracy of.01" or greater. The electronic
controller shall have level and error indicating lights, alphanumeric
display for messaging, reset/menu switch and the following features:
a. Continuous Level Indication
b. Low Water Cutoff & Alarm
c. High Water Alarm
d. Low & High Water Warning
e. Full Modulating Control of Modulating Feedwater Control Valve
f. Continuous Monitoring of Float Operation
g. Column Blowdown Detection and Reminder
h. Auto or Manual Reset
i. Real Time Clock
j. Alarm Annunciation
k. Alarm History Files with Time Stamp
A10-34
03-08
l. Water Column Blowdown Record
m. Auxiliary Low Water Cutoff Check
n. RS 232 Interface
o. Maximum Contacts Rating 15 amps Resistive Load
B. Feedwater Pump Control
automatically actuate a motor driven feedwater pump maintaining the boiler water level within
normal limits.
C. Low Water Cutoff
safe level.
D. 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.
E. Steam Pressure Gauge
connection.
F. Safety Relief Valves
loose.
G. Steam Pressure Controls
The steam pressure control to regulate burner operation shall be mounted near the water
column.
2.04 BURNER
Burner operation shall be full modulation principle. The burner shall always return to low fire
B. Forced Draft Blower
in the front boiler door, above the burner, to eliminate vibration and
reduce noise level.
2. Maximum sound level of the boiler/burner package shall not exceed ____
dBA (when measured in accordance with ABMA Sound Test Standards).
3. The impeller shall be cast aluminum, radial blade, carefully balanced,
and directly connected to the blower motor shaft.
Combustion air damper and cam operated fuel metering valves shall be operated by a single
damper control motor that regulates the fire according to load demand. Single point
positioning controls shall be provided to regulate operation of the damper control motor.
A10-35
03-08
Refer to the following fuel series specifications:
Fuel series 700 - gas fired.
Fuel series 100 - light oil fired.
Fuel series 200 - light oil or gas fired.
Series 400 (heavy oil and gas) and series 600 (heavy oil only) also available. Check with
your local Cleaver-Brooks representative for specification details.
boiler and of high radiant annular gas entry on 125-225 hp. and of
high radiant multi-port type for gas burner 300-800 hp.The burner
shall be approved for operation on natural gas fuel.
b. 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 flame has been
established. The pilot train shall include two manual shut-off
valves, solenoid valve, pressure regulator and pressure gauge.
c. Gas Burner Piping - Gas burner piping on all units shall include
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, flame failure, low water
or any safety shutdown condition. A lubricating plug cock or
butterfly shutoff valve shall be provided as a means for a tightness
check of the primary shut off valve. An additional plug cock or
butterfly shutoff valve shall be furnished at entrance to gas train.
provided. A second motorized safety shutoff valve, plus an
additional plugged leakage test connection shall be provided.
additional plugged leakage test connection shall be provided. A
valve proving switch shall be located between the safety shutoff
valves.
d. Burner Turndown - Turndown range of the burner shall be 4:1 when
firing natural gas.
1) 125-200 hp. Turndown range of burner shall be 4:1 when
firing natural gas.
2) 250-800 hp. Turndown range of the burner shall be 10:1
when firing natural gas with a 60 or 30 ppm LE option.
3) Gas Pilot - The gas pilot shall be premix type with automatic
so that the primary fuel valve cannot open until flame has been
A10-36
03-08
pump set, shipped loose to be installed in a location favorable to the
d. Oil Burner Piping - Fuel oil piping on the unit shall include oil
e. Low Pressure Air Atomizing - Select one of the following:
additional plugged leakage test connection shall be provided.
additional plugged leakage test connection shall be provided. A
vent valve shall be located between the safety shutoff valves.
1) 125-200 hp. Turndown range of burner shall be 4:1 when
firing natural gas.
2) 250-800 hp. Turndown range of the burner shall be 10:1
when firing natural gas with a 60 or 30 ppm LE option.
g. Fuel series 200 - Light Oil or Gas Fired
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 on 100 hp. The burner shall
be approved for operation with either CS12-48 Commercial
No. 2 Oil or natural gas.
2) Gas Pilot - The gas pilot shall be premix type with automatic
so that the primary fuel valve cannot open until flame has been
A10-37
03-08
3) Oil Burner
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.
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
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.
Low pressure air atomizing - Separate air compressor module
mounted on boiler base rail with low atomizing air pressure
switch.
h. Gas Burner
1) Gas Burner Piping - gas burner piping on all units shall include
pressure regulating 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, flame failure,
low water or any safety shutdown condition. A lubricating plug
plug cock or butterfly shutoff valve shall be furnished at
125-250 hp. High and low gas pressure switches shall be
additional plugged leakage test connection shall be
provided.
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 valve proving switch shall be located between
the safety shutoff valves.
2) Burner Turndown - Select one of the following:
250-800 hp. Turndown range of the burner shall be 10:1
when firing natural gas and 8:1 on No. 2 oil.
E. Boiler Flame Safeguard Controller and Control Panel
1. CB780E Flame Safeguard Controller
Each boiler shall be factory equipped with flame safeguard controller
providing technology and functions equal to the Cleaver-Brooks Model
CB780E.
Controller shall be computerized solid state having sequence and flame-
A10-38
03-08
on lights and digital first out fault code indications of flame safeguard
trip functions. It shall include dynamic self-check logic. The controller
shall have a fixed operating sequence incapable of being manually
altered. The sequence shall include start, pre-purge, pilot and main fuel
ignition run and post-purge cycles.
a. Control Panel - The control panel shall be mounted on the front door
The panel shall contain the boiler flame safeguard controller, blower
combination gas-oil fired boilers, the panel shall contain the fuel
selector switch.
b. Lights
White - load demand.
Red - low water.
c. Control Switches
Burner On-Off.
Manual-Automatic.
d. Oil, heat and moisture resistant wire shall be used and identified
2. Control Panel
a. 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
A10-39
03-08
b. The panel shall contain the boiler flame safeguard controller, blower
c. Panel shall have a removable sub-base for mounting the flame
combination gas-oil fired boilers the panel shall contain the fuel
selector switch.
d. Oil, heat, and moisture resistant wire shall be used and identified
The boiler must be guaranteed to operate at a minimum fuel-to-steam efficiency of ____
percent from 25 to 100 percent of rating when burning natural gas and ________ fuel-to-
steam efficiency at 100% firing rate when burning oil.
F. Fuel specification used to determine boiler efficiency:
Natural Gas
Carbon, % (wt) = 69.98
No. 2 Oil
Carbon, % (wt) = 85.8
No. 6 Oil
Carbon, % (wt) = 86.6
Sulfur, % (wt) = 2.09
2.06 WARRANTY
workmanship for a period of 12 months from date of start-up or 18 months
from date of shipment, whichever comes first.
PART 3 EXECUTION
A. Shop Tests
A10-40
03-08
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.
B. Start-up Service
services of a field representative for starting the unit and timing the
A10-41
03-08
Section A10
Model CBR Hot Water Specifications
(125-800 hp, 30 psig, 125 psig)
Table Of Contents
Boiler Characteristics (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-42
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-48
Shop Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-48
Model CBR Hot Water Boiler Specifications Firetube Boilers
A10-42
03-08
Model CBR Hot Water Boiler Specifications
(125-800 hp, 30 psig, 125 psig)
PART 1 GENERAL
A. The Hot Water Boiler shall be Cleaver-Brooks Model CBR, 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.
B. The boiler shall have a maximum output of _____ Btu/hr., or _____ horsepower when
available shall be _____Volt _____ Phase _____ Cycle.
PART 2 PRODUCTS
A. The boiler shall be a two-pass horizontal firetube updraft boiler with __________
square feet of total heating surface for the _______ hp boiler. 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
controls.
The complete package boiler shall be approved as a unit by Underwriters Laboratories and shall
bear the UL/cUL label, except in the case where 50 Hz has been selected.
1. The boiler shall be completely pre assembled and fire tested at the factory. The
connections.
____________________ (Factory Mutual, Industrial Risk Insurance, ASME CSD-
1).
line of the boiler. The boiler shall be designated to rapidly mix the return water
6. Rear refractory and insulation shall be contained in the formed door, which must
7. The boiler tubes shall be rifled tube design, extending heat transfer surfaces.
Firetube Boilers Model CBR Hot Water Boiler Specifications
A10-43
03-08
8. Front and rear tube sheets and all flues 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.
9. A manhole shall be provided.
center line and shall be capable of supporting 2000 lbs and shall contain a
stack thermometer.
C. Observation ports for the inspection of flame conditions shall be provided at each end
of the boiler.
E. The entire boiler based frame and other components shall be factory painted before
shipment using a hand finish enamel coating.
F. Emission Controls
1. Boiler shall be equipped with a low emission (LE) option for guaranteed NOx
performance at ________ ppm, dry volume basis and corrected to 3% O
2
when
firing natural gas.
2. The low emission option shall include an integral front head, burner, and boiler
package, providing NOx reduction through an internal flue 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
efficiency and rated boiler capacity shall be guaranteed while the boiler is
operating at the low NOx performance levels.
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
field assembly of the burner or low NOx equipment shall be required.
A. 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
C. Relief Valves
be shipped loose.
temperature sensing elements located adjacent to the hot water outlet. Controls shall
be high limit (manual reset), operating limit (auto reset), and firing rate control.
A10-44
03-08
B. Blower
used).
Series 400 (heavy oil and gas) and series 600 (heavy oil only) and available.
Check with your local Cleaver-Brooks representative for specification details.
A10-45
03-08
natural gas.
natural gas when equipped with a 60 or 30 ppm LE option.
b. Oil Pilot - The oil pilot shall be air atomizing type with automatic electric
established.
shall be provided.
e. Low Pressure Air Atomizing - Separate air compressor module mounted on
No. 2 oil.
No. 2 oil.
and pressure gauge.
c. Oil Burner
A10-46
03-08
d. Gas Burner
1) Gas Burner Piping - Gas burner piping on all units shall include
closure switch and plugged leakage test connection. The main gas
valve(s) shall be wired to close automatically in the event of power
additional plug cock or butterfly valve shall be furnished at entrance
to gas train. Select one of the following:
safety shutoff valve, plus an additional plugged leakage test connection shall be provided.
safety shutoff valve, plus and additional plugged leakage test connection shall be provided. A
valve proving switch shall be located between the safety shutoff valves.
250-800 hp. Turndown range of the burner shall be 10:1 when firing 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 firing natural gas.)
E. Boiler Flame Safeguard Controller and Control Panel
a. Boilers with CB780E Control - Each boiler shall be factory equipped with
flame safeguard controller providing technology and functions equal to the
Cleaver-Brooks Model CB780E.
Controller shall be computerized solid state having sequence and flame-on
lights and digital first out fault code indications of flame safeguard trip
functions. It shall include dynamic self-check logic. The controller shall
have a fixed operating sequence incapable of being manually altered. The
sequence shall include start, pre-purge, pilot and main fuel ignition run
A10-47
03-08
b. Control Panel - The control panel shall be mounted on the front door of the
The panel shall contain the boiler flame safeguard controller, blower motor
starter, indicating lights and selector switches.
combination gas-oil fired boilers the panel shall contain the fuel selector
switch.
c. Lights
Red - low water.
d. Control Switches
Burner On-Off.
Manual-Automatic.
e. Oil, heat and moisture resistant wire shall be used and identified with
f. All electrical equipment and wiring shall be in conformance with
g. Boiler to be supplied with a control circuit transformer and fuse protection
h. Control Panel: The control panel shall be mounted on the front door of the
The panel shall contain the boiler flame safeguard controller, indicating
Panel shall have a removable sub-base for mounting the flame safeguard
controller, and terminal blocks. For combination gas-oil fired boilers the
panel shall contain the fuel selector switch.
i. Oil, heat, and moisture resistant wire shall be used and identified with
j. All electrical equipment and wiring shall be in conformance with
k. Boiler to be supplied with a control circuit transformer and fuse protection
A10-48
03-08
A. The boiler manufacturer shall guarantee that, at the time of startup, the boiler will
level.
B. Fuel specification used to determine boiler efficiency:
Natural Gas
Carbon,% (wt) = 69.98
Sulfur,% (wt) = 0.0
No. 2 Oil
Sulfur,% (wt) = 0.2
No. 6 Oil
C. Efficiencies are based on ambient air temperature of 80 F, relative humidity of 30%,
D. Efficiencies are based on manufacturers published radiation and convection losses.
E. Any efficiency verification testing will be based on the stack loss method.
PART 3 EXECUTION
3.1 Warranty
3.2 Shop Tests
B. Start-up Service
1. After boiler installation is completed, the manufacturer shall provide the services
of a field representative for starting the unit and training the operator at no
additional costs.
a. A factory approved and authorized start-up report shall be submitted to the
A11-1
08-08
CONTENTS
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-8
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-10
ILLUSTRATIONS
Dimension Diagram, Optimized Boiler Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-4
Efficiencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-8
Piping Diagram, Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-9
TABLES
Dimensions, Optimized Boiler Package (Model CB-LE Boiler) . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-5
Dimensions, Optimized Boiler Package (Model 4WI Boiler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-6
Economizer weights, C2X condensing economizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-7
Section A11
OPTIMIZED BOILER PACKAGE
Section A11
A11-2
08-08
This section describes the Cleaver-Brooks Optimized Boiler Package (OBP), which combines a premium C-B
firetube dry-back or wet-back boiler with additional C-B equipment for maximum system performance. For
more information on individual package components, see these Boiler Book sections:
Section A1 CB-LE Boilers
Section A2 4WI Boilers
Section D Controls (Hawk ICS Advanced System w/Parallel Positioning)
Section G Economizers (Model C2X 2-Stage Condensing Economizer)
Section A11
A11-3
08-08
The Cleaver-Brooks Optimized Boiler Package combines a CB-LE or 4WI high
pressure steam boiler with the C2X 2-stage condensing economizer. The boiler,
economizer, and burner are exactly matched, resulting in reduced energy usage and
the best possible performance without compromising boiler capacity. The OBP is
capable of delivering up to 90% fuel-to-steam efficiency.
90% fuel-to-steam efficiency
Maximum heat recovery
Boiler fan motor and impeller are exactly matched with the economizer,
providing the most compact/efficient system possible
Utilization of cool makeup water in the economizer upper coil enables the
system to operate in condensing mode more than any other design, further
maximizing efficiency
Entire system is controlled by Advanced Hawk ICS with O
2
Trim to ensure
maximum combustion efficiency
Design eliminates steaming in the economizer coils, reducing scaling and stress
Deaerator preheated during cold startup
Variable Speed Drive for combustion air fan reduces electrical usage (optional)
Reduced installation cost and improved appearance - economizer is fully
supported by the boiler shell, eliminating additional support structures
Automatic near-condensing operation when firing oil
PRODUCT OFFERING
CB-LE or 4WI 250-800 HP high pressure steam firetube boiler; 80-125 psig
operating pressure with natural gas and/or #2 oil firing
Model C2X 2-stage condensing economizer
Hawk ICS Advanced control system with parallel positioning and O
2
trim -
includes fuel savings accumulator to track dollars saved by reduced fuel
expenditure
C-B Level Master water level control
Modulating feedwater valve with three-valve bypass
Feedwater stop and check valves
Economizer pressure relief valves for both coils
Valve package for optimum efficiency and continuous flow through economizer
Optimized Boiler Package dimensions are given in Figure A11-1, Table A11-1 and
Table A11-2.
Economizer wet and dry weights are shown in Table A11-3.
Section A11
A11-4
08-08
Figure A11-1. Dimension Diagram, Optimized Boiler Package
V
A
B
C
D
E
F
G
H
I
R
J
T
S
O
N
P Q
L M
K
U
Section A11
A11-5
08-08
Table A11-1. Dimensions, Optimized Boiler Package (Model CB-LE Boiler)
Dimension (see Figure A11-1) - all
dimensions in inches
Boiler HP
250-300 350 400 500 600 700 800
A Economizer width 72 72 72 82 82 90 90
B Economizer height 62 72 72 73 84 87 97
C Boiler height w/economizer support 117 117 117 137 137 137 137
D Boiler width (not incl. trim & panel) 91 91 91 111 111 111 111
E Econ. door swing 70 70 70 80 80 88 88
F Overall height 179 189 209 210 221 224 234
G Boiler flange to econ. front 28 28 24 30 30 33 33
H Stack center to boiler flange 10.5 10.5 13 13 13 13 13
I Stack center to econ. manifold 26 26 27 30 30 33 33
J Makeup inlet to base 26 30 30 30 34 34 38
K Feedwater inlet to base 5 5 5 5 5 5 5
L Center to feedwater inlet manifold 22 22 22 25 25 28 28
M Center to feedwater outlet manifold 16 16 16 19 19 22 22
N Feedwater outlet to base 29 33 33 33 37 37 41
O Makeup outlet to base 56 66 66 68 76 77 88
P Center to makeup inlet manifold 16 16 16 19 19 22 22
Q Center to makeup outlet manifold 22 22 22 25 25 28 28
R Makeup in 2 NPT 2 NPT 3 150# Flg 3 150# Flg 3 150# Flg 3 150# Flg 3 150# Flg
S Makeup out 2 NPT 2 NPT 3 150# Flg 3 150# Flg 3 150# Flg 3 150# Flg 3 150# Flg
T Feedwater in 2 NPT 2 NPT 2 NPT 2.5 NPT 2.5 NPT 2.5 NPT 2.5 NPT
U Feedwater out 2 NPT 2 NPT 2 NPT 2.5 NPT 2.5 NPT 2.5 NPT 2.5 NPT
V Stack (by others) 20 20 24 24 24 24 24
Section A11
A11-6
08-08
Table A11-2. Dimensions, Optimized Boiler Package (Model 4WI Boiler)
Dimension (see Figure A11-1) - all
dimensions in inches
Boiler HP
250-300 350-400 500 600 700 800
A Economizer width 72 72 82 82 90 90
B Economizer height 62 72 73 84 87 97
C Boiler height 117 126 137 137 146 146
D Boiler width 91 99 111 111 121 121
E Econ. door swing 70 70 80 80 88 88
F Overall height 179 198 210 221 233 243
G Boiler flange to econ. front 28 24 30 30 33 33
H Stack center to boiler flange 10.5 13 13 13 13 13
I Stack center to makeup manifold 26 27 30 30 33 33
J Makeup inlet to base 26 30 30 34 34 38
K Feedwater inlet to base 5 5 5 5 5 5
L Center to feedwater inlet manifold 22 22 25 25 28 28
M Center to feedwater outlet manifold 16 16 19 19 22 22
N Feedwater outlet to base 29 33 33 37 37 41
O Makeup outlet to base 56 66 65 76 77 88
P Center to makeup inlet manifold 16 16 19 19 22 22
Q Center to makeup outlet manifold 22 22 25 25 28 28
R Makeup in 2 NPT 3 150# Flg 3 150# Flg 3 150# Flg 3 150# Flg 3 150# Flg
S Makeup out 2 NPT 3 150# Flg 3 150# Flg 3 150# Flg 3 150# Flg 3 150# Flg
T Feedwater in 2 NPT 2 NPT 2.5 NPT 2.5 NPT 2.5 NPT 2.5 NPT
U Feedwater out 2 NPT 2 NPT 2.5 NPT 2.5 NPT 2.5 NPT 2.5 NPT
V Stack (by others) 20 24 24 24 24 24
Section A11
A11-7
08-08
Table A11-3. Economizer weights, C2X condensing economizer
4WI Boilers
Boiler HP
Economizer
Model
Economizer
Dry Weight
Economizer
Wet Weight
250-300 C2X-2M386AL 1980 2130
350-400 C2X-2M3A6AL 2220 2410
500 C2X-2R3A6AL 2520 2730
600 C2X-2R3B6AL 2820 3070
700 C2X-2S3B6AL 3240 3530
800 C2X-2S3C6AL 3720 4060
CBLE Boilers
Boiler HP
Economizer
Model
Economizer
Dry Weight
Economizer
Wet Weight
250-300 C2X-2M386AL 1980 2130
350-400 C2X-2M3A6AL 2220 2410
500 C2X-2R3A6AL 2520 2730
600 C2X-2R3B6AL 2820 3070
700 C2X-2S3B6AL 3240 3530
800 C2X-2S3C6AL 3720 4060
Section A11
A11-8
08-08
PERFORMANCE DATA
Figure A11-2 shows CB-LE and 4WI efficiencies using the C2X 2-stage economizer.
Efficiencies are based on the following conditions:
C-B published stack-loss method and condensate removal
Ambient air temperature of 80 deg F
15% excess air in exhaust
Feed water at 227 deg F circulated through lower economizer stage
Includes C-B published radiation and convection losses
Figure A11-2. Optimized Boiler efficiencies
ENGINEERING DATA
Figure A11-3 shows a typical piping configuration for the Optimized Boiler Package.
CBLE & 4WI Boiler Efficiency with 2-stage economizer
Natural Gas, Operating 80-125 psig
84
85
86
87
88
89
90
91
25 50 75 100
Makeup water @50
0
F
% Makeup water
E
f
f
i
c
i
e
n
c
y

%
Section A11
A11-9
08-08
Figure A11-3. Typical piping diagram, Optimized Boiler Package
NOTE: Deaerator piping (including shutoff valves and check valves), boiler feed
system, and stack not included. See brochure CB-8183 for additional details.
Section A11
A11-10
08-08
SPECIFICATIONS
Optimized Boiler Package
The following sample specification is provided by Cleaver-Brooks to assist you in
meeting your customers specific needs and applications.
The Optimized Boiler Package shall cover the Four-Pass Firetube Boiler (Wetback or
Dryback), 250-800hp, 80-125 psig operating pressure with Natural Gas and/or #2
Oil operation.
The Optimized System Package shall include the following:
150psig boiler design pressure
60ppm NOx on Natural Gas (options available to 9ppm)
Advanced Hawk ICS Control Package
Parallel Positioning Control with FGR
O2 Trim with Cleaver Brooks Probe
Level Master water level control
Modulating boiler feedwater valve with three-valve bypass
Mounted boiler feedwater stop and check valves
Two Stage Condensing Economizer
Economizer Pressure Relief Valves for both coils
Automatic three-way system make-up water valve
Upper coil recirculating pump system
Lower coil bypass orifice and solenoid valve
Integrated economizer support structure
The Optimized Boiler Package includes the Advanced Hawk ICS control system with
parallel positioning - a totally integrated control system embodying precise boiler/
burner management control and safety with logic-based ancillary devices and
functions. The Hawk ICS also controls the condensing economizer system, ensuring
maximum efficiency during all operating scenarios.
When firing natural gas, the system is controlled to maximize condensing. This is
accomplished by routing all of the available cold makeup water through the upper
economizer coil before it enters the deaerator. Water from the deaerator is then
routed through the lower coil before it is used as boiler feed water.
When firing #2 oil, the system is controlled to operate in the near-condensing mode
and not in the condensing mode. Condensing operation would cause sulfur from the
#2 oil to combine with condensate, forming sulfuric acid which would destroy the
metallic components. In near-condensing mode, any cold makeup water is routed to
Section A11
A11-11
08-08
the dearator and not through the upper coil. The recirculation pump skid provides a
small flow through the upper coil to prevent steaming. Water from the deaerator is
routed through the lower coil before it is used as boiler feed water.
1) Steam Boiler (250-800 hp, Steam 80-125 psig)
a) Boiler Characteristics
i) The Steam Boiler shall be a packaged Cleaver-Brooks high turn-down
boiler
ii) Model CBLE (4-Pass Dryback) or Model 4WI (4-Pass Wetback)
iii) Fuel Series ______ (700 Gas Only or 200 Gas/Oil)
iv) Horsepower _____
v) Designed for _150_ psig
vi) Maximum operating pressure shall be _____ psig (between 80-125
psig)
b) General Boiler Design
i) The boiler shall be a horizontal Firetube updraft boiler mounted on a
heavy steel frame with integral forced draft burner and burner controls.
ii) The boiler shall be designed to accommodate a rectangular economizer
supporting its weight directly off the boiler shell. No additional
economizer supports shall be required.
c) Refer to appropriate Steam Boiler Sample Specification for additional boiler
requirements.
2) Economizer
a)The economizer shall be a Cleaver Brooks 2-Stage Condensing type
economizer.
b)Model to be C2X type rectangular economizer.
c)Economizer shall be designed to support outlet stack up to 500 lb. without
external reinforcement or supports.
d)Economizer to have integral condensate collection system with a single
connection for removal.
3) Exhaust Gases
a)Exhaust gas temperature entering economizer: _____F
b)Exhaust gas temperature exiting economizer: _____F
c)Percent efficiency gain: _____%
d)Inner liner of the stack to be stainless steel construction.
e)The stack out of the economizer shall weigh no more than 500 lb.
f)If field conditions require stack lengths which will exceed the 500 lb. weight
limit, additional considerations will be made for field support of excess stack
(by others).
Section A11
A11-12
08-08
4) Make-Up Water
a)System make-up water to be softened and treated to Cleaver Brooks
recommended levels.
b)Make-up water temperature as supplied to first stage (upper coil) of
economizer: _____F
c)Make-up water flow rate: _____ gpm at _____ psig
d)Make-up water amount: _____% (0-100%)
e)Make-up water temperature exiting the first stage (upper coil) of economizer:
_____F
f)Make-up water percent efficiency gain: _____%
g)Make-up water to be piped from the outlet of the economizer to the deaerator
inlet.
5) Boiler Feedwater
a)Boiler feedwater shall be field piped from the deaerator to the inlet of the
second stage (or lower coil) of the economizer.
b)Feedwater temperature entering the economizer to be: ______F
c)Feedwater temperature exiting the economizer to be: ______F
d)Boiler feedwater percent efficiency gain: _____%
6) Installation and Start-up
a)All equipment to be installed in strict compliance with the manufacturers
installation instructions along with applicable State, local, NFPA and other
governing standards.
b)The manufacturer's representative shall provide start-up and instruction of
each new boiler system, including burner, boiler and economizer control
systems as specified herein. Start-up and instruction shall cover all
components assembled and furnished by the manufacturer.
7) Efficiency Guarantee
a)The boiler manufacturer shall guarantee that, at the time of startup, the boiler
will achieve _____ fuel-to-steam efficiency at 100% firing rate when burning
natural gas and _____ fuel-to-steam efficiency at 100% firing rate when
burning oil (add efficiency guarantees at 25%, 50%, and 75% of rating, if
required). If the boiler(s) fails to achieve the corresponding guaranteed
efficiency as published, the boiler manufacturer will rebate, to the ultimate
boiler owner, ten thousand dollars ($10,000) for every full efficiency point
(1.0%) that the actual efficiency is below the guaranteed level at 100%
firing rate.
b)The specified boiler efficiency is based on the following conditions.
i)Fuel specification used to determine boiler efficiency:
(1)Natural Gas
(a)Carbon, % (wt) = 69.98
Section A11
A11-13
08-08
(b)Hydrogen, % (wt) = 22.31
(c)Sulfur, % (wt) = 0.0
(d)Heating value, Btu/lb = 21,830
(2)No. 2 Oil
(a)Carbon, % (wt) = 85.8
(b)Hydrogen, % (wt) = 12.7
(c)Sulfur, % (wt) = 0.2
(d)Heating value, Btu/lb = 19,420
c)Efficiencies are based on ambient air temperature of 80 F, relative humidity of
d)Efficiencies are based on manufacturers published radiation and convection
losses. (For Cleaver-Brooks radiation and convection losses, see Boiler
Efficiency Facts Guide, publication number CB-7767).
e)Any efficiency verification testing will be based on the stack loss method.
Section A11
A11-14
08-08
B-1
03-08
Model FLX Boilers
Section B
COMMERCIAL BOILERS
Model 4 Boilers
Model 5 Boilers
Electric Boilers
ClearFire Model CFC
B1
B2
B3
B4
B5
B6 ClearFire Model CFH
B7 ClearFire Model CFV
B-2
Notes:
B1-1
03-08
TABLE OF CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-4
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-5
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-5
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-12
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-12
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-12
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-12
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-13
Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-13
Burner/Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-15
Outdoor Reset Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-18
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-21
Steam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-21
Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-27
Section B1
Flexible Watertube Boilers
Model FLX Boilers Commercial Boilers
B1-2
03-08
Illustrations
Figure B1-1. Model FLX Hot Water Boiler Dimensions (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . B1-8
Figure B1-2. Model FLX Steam Boiler Dimensions (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-10
Figure B1-3. Model FLX Tube Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-13
Figure B1-4. Model FLX Oil Burner Supply Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-16
Figure B1-5. Model FLX Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-17
Figure B1-6. Model FLX Breeching Arrangement - Single or Multiple Boiler Installation . . . . . . . . . B1-19
TABLES
Table B1-1. Model FLX Watertube Boiler Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-4
Table B1-2. Model FLX Hot Water Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-7
Table B1-3. Model FLX Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-7
Table B1-4. Expected Emissions (ppm, corrected to 3% O
2
), Natural Gas Fired Boiler . . . . . . . . . . B1-12
Table B1-5. Model FLX Hot Water Boiler Flow Rates and Pressure Drops . . . . . . . . . . . . . . . . . . B1-12
Table B1-6. Model FLX Circulating Rates, Hot Water Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-14
Table B1-7. Model FLXMinimum Over Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . B1-14
Table B1-8. Model FLX Boiler Heat Release Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-14
Table B1-9. Model FLX Burner Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-15
Table B1-10. Model FLX Minimum Required Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-15
Table B1-11. Model FLX Sound Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-17
Table B1-12. Model FLX Combustion Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-19
This section contains information on the Flexible Watertube boiler. The product model name is FLX for factory-assem-
bled boilers, and FLE for field-erectable boilers. It is available in sizes ranging from 1.5 to 12 MMBtu/hr input.
Cleaver-Brooks offers the Model FLX bent-tube boiler to meet todays demanding commercial users needs. The flexible
watertube design has distinct advantages, including resistance to thermal shock and easy boiler maintenance. In addition
Model FLX boilers offer high operating efficiency. These combined factors equate to a real increase on the return from your
boiler room investment.
Commercial Boilers Model FLX Boilers
B1-3
03-08
Patented Vessel and Tube Design:
Ensures that all tubes are subject to radiant heat from the burner flame.
Creates high water-flow-rates at all loads, and increases heat transfer
throughout the boiler.
Large Downcomer, Located Outside the Fire Zone:
Guarantees positive natural internal circulation, minimizing the impact of
exterior pumping conditions.
True Tangent-Wall Design:
No fins or strips to substitute for tubes.
Ensures maximum cooling and uniform heat transfer throughout the boiler.
Five-Pass Boiler Design:
Creates high flue gas velocities to rapidly and efficiently transfer heat to the
water.
Higher efficiencies compared to other tangent-tube designs.
1.5-Inch Diameter Tube Design:
Eliminates possible damage from thermal shock stresses.
Prolongs equipment life.
Swedge-Fitted Tube Attachment:
Eliminates the need for rolling or welding tubes.
Lessens repair or replacement requirements.
Ease of tube replacement reduces downtime.
Burner Supported by the Front Door:
No crane/hoist is required to remove burner and components for inspection.
Provides easy inspection access.
Insulated Construction:
Reduces thermal losses.
Increases efficiency.
Low NOx Capability:
NOx reduction to 20 ppm available.
Meets stringent emission requirements with no loss in operating
performance.
ASME Construction:
Ensures high quality design and manufacturing standards.
Ensures safety and reliability.
Cleaver-Brooks Forced Draft Burner:
Provides high pressure drop for low CO and maximum combustion
performance.
B1-4
03-08
Reduces stack draft requirements.
Optimum fuel and air mixing.
Long-life reverse curve impeller.
Ensures maximum combustion efficiency, as low as 10% excess air.
Burner/Boiler by single manufacturer.
Removable Side Panels:
Provides easy access for inspection.
Ensures containment of furnace gases.
Rugged construction for durability.
20-Year Pressure Vessel Warranty:
Guaranteed to last.
Backed by Cleaver-Brooks.
Field Erectable (Optional):
Complete package for ease of assembly.
Pieces fit through standard doorway.
PRODUCT OFFERING
Information in this section applies to steam and hot water boiler sizes ranging from
1.5 to 12 MMBtu/hr input, as shown in Table B1-1
The Flexible Watertube Boiler is a five-pass steel boiler with flexible tubes formed
and arranged to direct the flow of combustion gases through the boiler. The pressure
vessel conforms to Section I or Section IV of the ASME Code, and consists of the
MODEL
CAPACITY
INPUT
BTU/HR
HEAT OUTPUT
BTU/HR
EQUIV
HP
FLX-150 1,500,000 1,200,000 36
FLX-200 2,000,000 1,600,000 48
FLX-250 2,500,000 2,000,000 60
FLX-300 3,000,000 2,400,000 72
FLX-350 3,500,000 2,800,000 84
FLX-400 4,000,000 3,200,000 96
FLX-450 4,500,000 3,600,000 108
FLX-500 5,000,000 4,000,000 119
FLX-550 5,500,000 4,400,000 132
FLX-600 6,000,000 4,800,000 143
FLX-700 7,000,000 5,600,000 167
FLX-800 8,000,000 6,400,000 191
FLX-900 9,000,000 7,200,000 215
FLX-1000 10,000,000 8,000,000 239
FLX-1100 11,000,000 8,800,000 263
FLX-1200 12,000,000 9,600,000 287
NOTES:
1. Design Pressure: 150 psig Hot Water, 15 psig Steam, 150 psig
Steam.
2. Also available in Model FLE (field erectable).
Table B1-1. Model FLX Watertube Boiler Sizes
B1-5
03-08
formed tubes and the external downcomer connected to the top and bottom drums.
The heated area of the pressure vessel is contained within a gas-tight, insulated
casing that is composed of removable, formed-steel panels. The boiler/burner
package is manufactured by Cleaver-Brooks and UL/cUL approved as a package.
Standard Equipment Equipment described below is for the standard boiler offering.
1. Boiler:
A. All boilers are designed and constructed in accordance with the ASME Code
and are mounted on an integral frame. All refractories for boiler and burner
are installed.
B. Factory fire test.
2. Cleaver-Brooks ProFire Forced Draft Burner:
A. Mounted on a hinged backing plate for easy access to furnace.
B. Pressure atomizing type for No. 2 oil burner. This includes the oil pump.
C. Stainless steel flame-retention type combustion head for gas, with UV
scanner, and gas pressure regulator.
D. External access to flame scanner for ease of maintenance.
3. Water/Steam Controls:
A. ASME safety relief valve(s).
B. Pressure and temperature gauges for hot water boilers.
C. Pressure gauge for steam boilers.
D. Operating and limit controls:
E. High limit control - manual reset.
F. Operating limit control - automatic reset.
G. Modulating or proportional controller.
H. Low water cutoff:
I. Probe type - hot water.
J. Float type main and probe type auxiliary- steam.
K. Pump Control - steam boilers.
Notice
Hot water boilers with design pressures up to 150 psig, and with design
temperatures less than 250 F, are constructed under Section IV of the ASME Code,
and H stamped for low- pressure heating boilers.
Notice
Steam boilers with design pressure of 30 psig, and maximum allowable operating
pressure of 15 psig, are constructed under Section IV of the ASME Code, and H
stamped for low pressure heating boilers.
Notice
Steam boilers with design pressure of 150 psig are constructed under Section I of
the ASME code and S stamped for high pressure steam boilers.
4. Altitude: Standard boilers attain full ratings at altitudes up to 1,500 feet.
Altitude compensation for most models is available for altitudes up to 11,000
ft above sea level.
Optional Equipment For option details, contact your local Cleaver-Brooks authorized representative. In
summary, options include the following:
B1-6
03-08
1. Boiler Options
Auxiliary low water cut-off (hot water).
Stack thermometer.
Insulated downcomer(s).
Drain valves.
Additional screwed tappings.
Packaged for field erection.
2. Burner/Control Options
Special burner modulation controls.
Low NOx burner.
Lead/lag system.
High altitude design, up to 11,000 ft.
Special insurance and code requirements (e.g., IRI, FM, ASME CSD-1).
Remote contacts.
Additional relay points and indicator lights.
Main disconnect (fusible/circuit breaker).
Elapsed time meter.
NEMA enclosures.
Key lock panel.
System pump interlock.
Low fire hold controls.
Assured low fire cut-off.
Flow switches.
High stack temperature cut-off/alarm.
Remote emergency shutoff (115V).
3. Fuel Options
Oversized gas trains.
Gas strainer.
Remote oil pump set.
Special pilot.
Direct spark oil ignition.
Automatic fuel changeover.
B1-7
03-08
Table 1:
MODEL NO. 150 200 250 300 350 400 450 500 550 600 700 800 900 1000 1100 1200
Fuel Consumption .......Gas (cfh)
A

Oil (gph)
B
1500
10.7
2000
14.3
2500
17.9
3000
21.4
3500
25.0
4000
28.6
4500
32.1
5000
35.7
5500
39.3
6000
42.9
7000
50.0
8000
57.2
9000
64.3
10000
71.4
11000
78.6
12000
85.7
Output (MBH) ..............Gas Firing
Oil Firing
1200
1245
1600
1660
2000
2075
2400
2490
2800
2905
3200
3320
3600
3735
4000
4150
4400
4565
4800
4980
5600
5810
6400
6640
7200
7470
8000
8300
8800
9130
9600
9960
Approximate bhp 36 48 60 72 84 96 108 119 131 143 167 191 215 239 263 287
Natural Gas Input: CFH (1000
Btu)
1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 7000 8000 9000 10000 11000 12000
Natural Gas: Therms/Hour 15 20 25 30 35 40 45 50 55 60 70 80 90 100 110 120
Shipping Weight (lbs) 3900 3900 3900 5000 5000 6100 6100 6100 6100 6100 8500 8500 8500 10000 10000 10000
Operating Weight (lbs) 4700 4700 4700 5900 5900 7600 7600 7600 7600 7600 10500 10500 10500 12300 12300 12300
Water Content (US gal) 91 91 91 106 106 174 174 174 174 174 228 228 228 270 270 270
Blower Motor hp 1/3
A
1/2
B
1/2 3/4 1/2
A
3/4
B
3/4
A
1
B
1-1/2 1-1/2
A
2
B
2 3 3 5 5 7-1/2
B
5
A
7-1/2
B
7 1/2 10
NOTES: 212F Feedwater.
A. Natural Gas @ 1000 Btu/cu-ft.
B. No. 2 Oil @ 140,000 Btu/gal.
MODEL NO. 150 200 250 300 350 400 450 500 550 600 700 800 900 1000 1100 1200
Fuel Consumption ...Gas(h)
A
Oil (gph)
B
1500
10.7
2000
14.3
2500
17.9
3000
21.4
3500
25.0
4000
28.6
4500
32.2
5000
35.7
5500
39.3
6000
42.9
7000
50.0
8000
57.2
9000
64.3
10000
71.4
11000
78.6
12000
85.7
Rated Capacity: lbs steam/hr 1237 1649 2062 2479 2887 3299 3711 4124 4536 4949 5773 6598 7422 8248 9072 9897
Output (MBH) .......Gas Firing
Oil Firing
1200
1245
1600
1660
2000
2075
2400
2490
2800
2905
3200
3320
3600
3735
4000
4150
4400
4565
4800
4980
5600
5810
6400
6640
7200
7470
8000
8300
8800
9130
9600
9960
Approximate bhp 36 48 60 72 84 96 107 119 131 143 167 191 215 239 263 287
Natural Gas Input:
CFH (1000Btu) 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 7000 8000 9000 10000 11000 12000
Natural Gas: Therms/Hour 15 20 25 30 35 40 45 50 55 60 70 80 90 100 110 120
Shipping Weight (lbs) 5700 5700 5700 6200 6200 7900 7900 7900 7900 7900 10200 10200 10200 11700 11700 11700
Operating Weight (lbs) 6600 6600 6600 7200 7200 9200 9200 9200 9200 9200 12500 12500 12500 14100 14100 14100
Operating Water Content
(US gal)
85 85 85 95 95 140 140 140 140 140 210 210 210 252 252 252
Blower Motor hp 1/3
A
1/2
B
1/2 3/4 1/2
A
3/4
B
3/4
A
1
B
1-1/2 1-1/2
A
2
B
2 3 3 5 5 7-1/2
B
5
A
7-1/2
B
7 1/2 10
NOTES: 212 F feedwater.
A. Natural Gas @ 1000 Btu/cu-ft.
B. No. 2 Oil @ 140,000 Btu/gal.
Table B1-2. Model FLX Hot Water Boiler Ratings
Table B1-3. Model FLX Steam Boiler Ratings
B1_02-06
B1-8
03-08
MODEL NO. 150 200 250 300 350 400 450 500 550 600
A - Length Of Base 71-13/16 71-13/16 71-13/16 77-13/16 77-13/16 98-15/16 98-15/16 98-15/16 98-15/16 98-15/16
B - Boiler Height (Top of casing)) 76 76 76 80 80 86 86 86 86 86
B1 - Height of Lifting Lug 77-3/8 77-3/8 77-3/8 81-3/8 81-3/8 87-3/8 87-3/8 87-3/8 87-3/8 87-3/8
B2 - Height of Flue Gas Outlet 77-1/2 77-1/2 77-1/2 81-1/2 81-1/2 87-1/2 87-1/2 87-1/2 87-1/2 87-1/2
C - Boiler Width 41-1/2 41-1/2 41-1/2 45-1/2 45-1/2 47-1/2 47-1/2 47-1/2 47-1/2 47-1/2
D - Center Lower Drum - Center Upper Drum 56-1/2 56-1/2 56-1/2 60-1/2 60-1/2 63-1/2 63-1/2 63-1/2 63-1/2 63-1/2
E - Center Of Lower Drum To Bottom 8-13/16 8-13/16 8-13/16 8-13/16 8-13/16 9-7/8 9-7/8 9-7/8 9-7/8 9-7/8
F - Center Of Burner Opening To Bottom 25-7/8 25-7/8 25-7/8 31-3/4 31-3/4 35-3/4 35-3/4 35-3/4 35-3/4 35-3/4
G - Center Of F.G. Outlet To Rear Of Jacket 16-1/4 16-1/4 16-1/4 16-1/4 16-1/4 18-1/4 18-1/4 18-1/4 18-1/4 18-1/4
H - Drum Clearance Past Base, Front 8-3/4 8-3/4 8-3/4 8-3/4 8-3/4 8-3/4 8-3/4 8-3/4 8-3/4 8-3/4
J - Tube Removal Clearance 28 28 28 32 32 34 34 34 34 34
K - Inlet/Outlet Flange (See Note 5) 3 3 3 4 4 5 5 5 5 5
L - Upper/lower Drum OD 8-5/8 8-5/8 8-5/8 8-5/8 8-5/8 10-3/4 10-3/4 10-3/4 10-3/4 10-3/4
M - Flue Gas Outlet ID 10 10 10 12 12 16 16 16 16 16
N - No. Of Holes In Flue Gas Outlet Flange 4 4 4 4 4 6 6 6 6 6
O - Diameter Of Bolt Circle 12-1/2 12-1/2 12-1/2 14-1/2 14-1/2 18-1/2 18-1/2 18-1/2 18-1/2 18-1/2
P - Flue Gas Outlet Flange OD 15 15 15 17 17 21 21 21 21 21
R - Drum Clearance Past Base - Rear 17-15/16 17-15/16 17-15/16 17-7/8 17-7/8 18-3/4 18-3/4 18-3/4 18-3/4 18-3/4
S - Burner Clearance (See Note 4) 22-9/16 22-9/16 22-9/16 26-1/2 26-1/2 26-1/2 26-1/2 33-5/16 33-5/16 33-5/168
T - Drain Connection 1-1/2 1-1/2 1-1/2 11/2 1-1/2 2 2 2 2 2
U - Rear Downcomer (NPS) Size 4 4 4 4 4 5 5 5 5 5
V - Relief Valve Outlet (160 lb) 1 1 1 1 1 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4
W - Total Length (See Note 4) 121-1/16 121-1/16 121-1/16 130-15/16130-15/16152-15/16152-15/16 159-3/4 159-3/4 159-3/4
Figure B1-1. Model FLX Hot Water Boiler Dimensions (1 of 2)
NOTES:
1. Measurements in inches.
2. Rear drain connection on Model 600 and larger specification subject to chang
without notice.
3. Models 150 thru 350 supplied with one front drain only.
4. Contact your local Cleaver-Brooks authorized representative regarding total
length for altitude-compensated boilers.
5. Inlet and outlet flanges: Model 150 thru 900 - studded flange.
Models 1000 thru 1200 - nozzle flange.
B1-9
03-08
Figure B1-1. Model FLX Hot Water Boiler Dimensions (2 of 2)
MODEL NO. 700 800 900 1000 1100 1200
A - Length Of Base 120-1/16 120-1/16 120-1/16 144-3/16 144-3/16 144-3/16
B - Boiler Height (Top of casing)) 94 94 94 94 94 94
B1 - Height of Lifting Lug 95-3/8 95-3/8 95-3/8 95-3/8 95-3/8 95-3/8
B2 - Height of Flue Gas Outlet 95-1/2 95-1/2 95-1/2 95-1/2 95-1/2 95-1/2
C - Boiler Width 53-1/2 53-1/2 53-1/2 53-1/2 53-1/2 53-1/2
D - Center Lower Drum - Center Upper Drum 69-1/2 69-1/2 69-1/2 69-1/2 69-1/2 69-1/2
E - Center Of Lower Drum To Bottom 11-7/8 11-7/8 11-7/8 11-7/8 11-7/8 11-7/8
F - Center Of Burner Opening To Bottom 37-3/4 37-3/4 37-3/4 37-3/4 37-3/4 37-3/4
G - Center Of F.G. Outlet To Rear Of Jacket 20-1/4 20-1/4 20-1/4 20-1/4 20-1/4 20-1/4
H - Drum Clearance Past Base, Front 8-5/8 8-5/8 8-5/8 8-5/8 8-5/8 8-5/8
J - Tube Removal Clearance 40 40 40 40 40 40
K - Inlet/Outlet Flange & Nozzle (NPS) Size. See Note 5. 6 6 6 8 8 8
L - Upper/lower Drum OD 10-3/4 10-3/4 10-3/4 10-3/4 10-3/4 10-3/4
M - Flue Gas Outlet ID 18 18 18 24 24 24
N - No. Of Holes In Flue Gas Outlet Flange 8 8 8 8 8 8
O - Diameter Of Bolt Circle 20-1/2 20-1/2 20-1/2 26-1/2 26-1/2 26-1/2
P - Flue Gas Outlet Flange OD 23 23 23 29 29 29
R - Drum Clearance Past Base - Rear 19-5/16 19-5/16 19-5/16 20 20 20
S - Burner Clearance (See Note 4) 34-5/16 34-5/16 34-5/16 41-1/16 41-1/16 41-1/16
T - Drain Connection 2 2 2 2 2 2
U - Rear Downcomer (NPS) Size 5 5 5 5 5 5
V - Relief Valve Outlet (160 lb) 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2
W - Total Length (See Note 4) 181-7/16 181-7/16 181-7/16 213-7/8 213-7/8 213-7/8
NOTES:
1. Measurements in inches.
2. Rear drain connection on Model 600 and larger specification subject to change without notice.
3. Models 150 thru 350 supplied with one front drain only.
4. Contact your local Cleaver-Brooks authorized representative regarding total length for altitude-compensated boilers.
5. Inlet and outlet flanges: Models 150 thru 900 - studded flange
Models 1000 thru 1200 - nozzle flange
B1-10
03-08
MODEL NO. 150 200 250 300 350 400 450 500 550 600
A. Length of Base 71-13/16 71-13/16 71-13/16 77-13/16 77-13/16 98-15/16 98-15/16 98-15/16 98-15/16 98-15/16
B. Boiler Height (Top of casing) 85-3/4 85-3/4 85-3/4 90 90 93-7/8 93-7/8 93-7/8 93-7/8 93-7/8
B1 - Top of Lifting Lug 86-13/16 86-13/16 86-13/16 90-13/16 90-13/16 94-7/8 94-7/8 94-7/8 94-7/8 94-7/8
C. Boiler Width 41-1/2 41-1/2 41-1/2 45-1/2 45-1/2 47-1/2 47-1/2 47-1/2 47-1/2 47-1/2
D. Center of Lower Drum - Center Upper
Drum
60 60 60 64 64 67 67 67 67 67
E. Center of Lower Drum to Bottom 8-13/16 8-13/16 8-13/16 8-13/16 8-13/16 9-7/8 9-7/8 9-7/8 9-7/8 9-7/8
F. Center of Burner Opening to Bottom 25-7/8 25-7/8 25-7/8 31-3/4 31-3/4 35-3/4 35-3/4 35-3/4 35-3/4 35-3/4
G. Center of FG Outlet to Rear of Jacket 14-11/16 14-11/16 14-11/16 14-5/8 14-5/8 17-1/8 17-1/8 17-1/8 17-1/8 17-1/8
H. Drum Clearance Past Base - Front 15-1/8 15-1/8 15-1/8 15-1/8 15-1/8 15-1/2 15-1/2 15-1/2 15-1/2 15-1/2
J. Tube Removal Clearance 28 28 28 32 32 34 34 34 34 34
K. Steam Nozzle 15psig * 4 flg. 4 flg. 4 flg. 5 flg. 5 flg. 6 flg. 6 flg. 6 flg. 6 flg. 6 flg.
K. Steam Nozzle 150psig * 2 mpt 2 mpt 2 mpt 2 mpt 2-1/2 mpt 3 flg. 3 flg. 3 flg. 3 flg. 3 flg.
L. Lower Drum OD 8-5/8 8-5/8 8-5/8 8-5/8 8-5/8 10-3/4 10-3/4 10-3/4 10-3/4 10-3/4
M. Flue Gas Outlet ID 10 10 10 12 12 16 16 16 16 16
N. No. of Holes in Flue Gas Outlet Flange 4 4 4 4 4 6 6 6 6 6
O. Diameter of Bolt Circle (FG Outlet) 12-1/2 12-1/2 12-1/2 14-1/2 14-1/2 18-1/2 18-1/2 18-1/2 18-1/2 18-1/2
P. Flue Gas Outlet Flange OD 15 15 15 17 17 21 21 21 21 21
Q. Upper Drum OD 20 20 20 20 20 20 20 20 20 20
R. Drum Clearance Past Base - Rear 11-1/8 11-1/8 11-1/8 11-1/8 11-1/8 11-9/16 11-9/16 11-9/16 11-9/16 11-9/16
S. Burner Clearance (See Note 4) 16-3/16 16-3/16 16-3/16 20-1/8 20-1/8 19-3/4 19-3/4 26-9/16 26-9/16 26-9/16
T. Drain Connection (15 psig) 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2 2 2
T. Drain Connection (150 psig) 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4
U. Downcomer (NPS) Size 4 4 4 4 4 5 5 5 5 5
W. Height of Steam Nozzle 86-13/16 86-13/16 86-13/16 90-13/16 90-13/16 94-7/8 94-7/8 94-7/8 94-7/8 94-7/8
X. Height of Stack Flange 87-1/4 87-1/4 87-1/4 91-1/2 91-1/2 95-3/8 95-3/8 95-3/8 95-3/8 95-3/8
Y. Relief Valve Outlet Size (Qty) (15 psig) 2 2 2 2-1/2 2-1/2 3 3 3 3 3
Y. Relief Valve Outlet Size (Qty) (150 psig) 1-1/4 1-1/4 1-1/4 1-1/2 1-1/2 (2)
1-1/4
(2)
1-1/4
(2)
1-1/4
(2)
1-1/4
(2)
1-1/4
Z. Feed Water Connection Size 3/4 3/4 3/4 3/4 3/4 1 1 1 1 1
ZA. Feed Water Location 38-13/16 38-13/16 38-13/16 42-13/16 42-13/16 46-7/8 46-7/8 46-7/8 46-7/8 46-7/8
ZZ.Steam Nozzle Location 36-3/8 36-3/8 36-3/8 39-3/8 39-3/8 50-3/8 50-3/8 50-3/8 50-3/8 50-3/8
AA. Total Length (See Note) 114-1/4 114-1/4 114-1/4 124-3/16 124-3/16 145-3/4 145-3/4 152-9/16 152-9/16 152-9/16
Inspection Handhole Size (Lower) 4x5 4x5 4x5 4x5 4x5 4x5 4x5 4x5 4x5 4x5
Note: Contact your local Cleaver-Brooks authorized representative regarding total length for altitude-compensated boilers.
* flg = Class 150# F.F.
Figure B1-2. Model FLX Steam Boiler Dimensions (1 of 2)
B1-11
03-08
MODEL NO. 700 800 900 1000 1100 1200
A. Length of Base 120-1/16120-1/16120-1/16 144-3/16 144-3/16 144-3/16
B. Boiler Height (Top of casing) 108-5/8 108-5/8 108-5/8 108-5/8 108-5/8 108-5/8
B1 - Top of Lifting Lug 108-7/8 108-7/8 108-7/8 108-7/8 108-7/8 108-7/8
C. Boiler Width 53-1/2 53-1/2 53-1/2 53-1/2 53-1/2 53-1/2
D. Center of Lower Drum - Center Upper Drum 77 77 77 77 77 77
E. Center of Lower Drum to Bottom 11-7/8 11-7/8 11-7/8 11-7/8 11-7/8 11-7/8
F. Center of Burner Opening to Bottom 37-3/4 37-3/4 37-3/4 37-3/4 37-3/4 37-3/4
G. Center of FG Outlet to Rear of Jacket 17-5/8 17-5/8 17-5/8 20-1/4 20-1/4 20-1/4
H. Drum Clearance Past Base - Front 17 17 17 17-5/16 17-5/16 17-5/16
J. Tube Removal Clearance 40 40 40 40 40 40
K. Steam Nozzle 15psig * 8 flg. 8 flg. 8 flg. 10 flg. 10 flg. 10 flg.
K. Steam Nozzle 150psig * 4 flg. 4 flg. 4 flg. 6 flg. 6 flg. 6 flg.
L. Lower Drum OD 10-3/4 10-3/4 10-3/4 10-3/4 10-3/4 10-3/4
M. Flue Gas Outlet ID 18 18 18 24 24 24
N. No. of Holes in Flue Gas Outlet Flange 8 8 8 8 8 8
O. Diameter of Bolt Circle (FG Outlet) 20-1/2 20-1/2 20-1/2 20-1/2 20-1/2 20-1/2
P. Flue Gas Outlet Flange OD 23 23 23 29 29 29
Q. Upper Drum OD 24 24 24 24 24 24
R. Drum Clearance Past Base - Rear 13 13 13 20-1/2 20-1/2 20-1/2
S. Burner Clearance (See Note 4, page B1-7) 25-1/16 25-1/16 25-1/16 32-3/8 32-3/8 32-3/8
T. Drain Connection (15 psig) 2 2 2 2 2 2
T. Drain Connection (150 psig) 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4
U. Downcomer (NPS) Size 6 6 6 6 6 6
W. Height of Steam Nozzle 108-7/8 108-7/8 108-7/8 108-7/8 108-7/8 108-7/8
X. Height of Stack Flange 110-1/8 110-1/8 110-1/8 110-1/8 110-1/8 110-1/8
Y. Relief Valve Outlet Size (Qty) (15 psig) (2) 2-1/2 (2) 2-1/2 (2) 2-1/2 (2) 3 (2) 3 (2) 3
Y. Relief Valve Outlet Size (Qty) (150 psig) (2) 1-1/2 (2) 1-1/2 (2) 1-1/2 (2) 2 (2) 2 (2) 2
Z. Feed Water Connection Size 1 1 1 1 1 1
ZA. Feed Water Location 58-7/8 58-7/8 58-7/8 58-7/8 58-7/8 58-7/8
ZZ.Steam Nozzle Location 60-1/2 60-1/2 60-1/2 60-3/16 60-3/16 60-3/16
AA. Total Length (See Note) 175-1/8 175-1/8 175-1/8 214-3/8 214-3/8 214-3/8
Inspection Handhole Size (Lower) 4x5 4x5 4x5 4x5 4x5 4x5
Figure B1-2. Model FLX Steam Boiler Dimensions (2 of 2)
B1-12
03-08
Ratings for steam and hot water boilers are shown in Table B1-2 andTable B1-3. Dimen-
sions for steam and hot water boilers are shown in Figure B1-1 and Figure B1-2.
PERFORMANCE DATA
Efficiency Fuel-to-steam (fuel-to-water) efficiency is based on specific operating conditions (fuel, pres-
sure, temperature). Nominal efficiency on all FLX hot water and low pressure steam boilers
is 81% firing natural gas, and 84% firing No. 2 oil. For high pressure steam applications,
contact your local Cleaver-Brooks representative for expected efficiencies.
Emissions Expected emissions for natural gas fired FLX boilers are shown in Table B1-4.
FLUE GAS
COMPONENT
HIGH-FIRE
LEVEL
A
PPM
V
LOW-FIRE
LEVEL
B
PPM
V
CO 0- 50 0 - 50
NOx 40 - 60 30 - 60
NOTE: NOx levels based on standard product offering.
A. Based on 12% excess air.
B. Based on 15% excess air.
Table B1-4. Expected Emissions (ppm, corrected to
3% O
2
), Natural Gas Fired Boiler
MODEL
NO.
T = 20F T = 40F T = 60F T = 80F T = 100F
P (PSIG) GPM P (PSIG) GPM P (PSIG) GPM P (PSIG) GPM P (PSIG) GPM
FLX-150 1.14 122.0 0.30 61.1 0.13 41.1 0.08 30.8 0.05 24.4
FLX-200 1.14 162.3 0.30 81.1 0.13 54.1 0.08 40.6 0.05 32.5
FLX-250 1.77 202.8 0.46 101.4 0.21 67.6 0.12 50.7 0.08 40.6
FLX-300 1.85 243.4 0.48 121.7 0.22 81.1 0.12 60.9 0.08 48.7
FLX-350 2.49 284.0 0.65 142.0 0.29 94.7 0.17 71.0 0.11 56.8
FLX-400 1.35 324.5 0.35 162.3 0.16 108.2 0.09 81.1 0.06 64.9
FLX-450 1.71 365.1 0.44 182.6 0.20 121.7 0.11 91.2 0.08 73.0
FLX-500 2.03 405.7 0.54 202.8 0.25 135.2 0.14 101.4 0.09 81.1
FLX-550 2.50 446.3 0.67 223.1 0.31 148.7 0.17 111.5 0.11 89.2
FLX-600 2.99 486.8 0.77 243.4 0.35 162.3 0.20 121.7 0.13 97.4
FLX-700 1.75 567.9 0.45 284.0 0.21 189.3 0.12 142.0 0.08 113.6
FLX-800 2.27 649.1 0.59 324.5 0.27 216.4 0.15 162.3 0.10 129.8
FLX-900 2.85 730.2 0.74 365.1 0.33 243.4 0.19 182.6 0.12 146.0
FLX-1000 4.08 811.4 1.02 405.6 0.42 270.4 0.25 202.8 0.15 163.6
FLX-1100 4.42 892.6 1.15 446.2 0.48 297.4 0.28 223.0 0.18 178.4
FLX-1200 6.20 973.6 1.60 486.8 0.59 324.6 0.31 243.4 0.22 194.8
Table B1-5. Model FLX Hot Water Boiler Flow Rates and Pressure Drops
B1-13
03-08
ENGINEERING DATA
Boiler Information Flow Rates and Pressure Drops
Flow rates and pressure drops for the FLX hot water boilers are shown in Table B1-5. This
table can be used to determine the boiler pressure drop in relation to full boiler output and
system temperature drop.
Table B1-6 can be used to determine the maximum gpm circulating rate in relation to full
boiler output and system temperature drop. The maximum gpm can be determined by know-
ing the boiler size and expected system temperature drop.
System Operating Parameters (Hot Water)
System over pressure requirements are shown in Table B1-7.
Minimum return water temperature is 120 F; minimum supply (boiler outlet) water temper-
ature is 150 F in order to prevent fireside corrosion.
System Operating Parameters (Steam Boilers)
The following operating limitations must be observed for optimum operation of the boiler:
1. Minimum make-up temperature 60 F.
2. Maximum make-up rate (for on/off make-up control) 2.0 times the evaporation rate.
3. Minimum operating pressure 6 psig. on low pressure steam and 40 psig. on high pressure
steam.
4. Maximum operating pressure 12 psig. on low pressure steam.
5. Maximum load tracking rate 0 - 100% load or 100% - 0 load, 30 seconds on low
pressure steam and 20% per minute on high pressure steam.
Maximum boiler water chemistry parameters: Silica: 150 ppm; specific conductance: 3500
mho/cm un-neutralized; total alkalinity: 300 ppm as CaCO3; hardness: 0; oxygen: 7 ppb;
pH: 7 - 10; total iron: 0.05 ppm; oil matter: 1 ppm.
Boiler Heat Release Information
Boiler heat release information is shown in Table B1-8.
Tube Attachment
Construction of the Flexible Watertube Boiler includes a special tube-to-drum attachment
that requires no welding or rolling (see Figure B1-3). The tube is fitted with a tapered ferrule,
which is press-fit into the tube hole in the drum. The ferrule is welded to the tube at the fac-
tory for both new and replacement tubes, so no field welding is required. The tube is held in
place with a keeper plate.
This tube attachment design reduces repair and maintenance costs, and also reduces the
cost of field erection of new units.
Figure B1-3. Model FLX Tube Attachment
B1-14
03-08
MODEL NO. (HP)
SYSTEM TEMPERATURE DROP F
10 20 30 40 50 60 70 80 90 100
FLX-150 (36) 243 122 81 61 49 41 35 31 27 24
FLX-200 (48) 324 162 108 81 65 54 46 41 36 32
FLX-250 (60) 404 202 135 101 81 68 58 51 45 41
FLX-300(72) 488 244 162 122 97 81 70 61 54 49
FLX-350 (84) 568 284 189 142 114 95 81 71 63 57
FLX-400 (96) 648 324 216 162 130 108 93 81 72 65
FLX-450 (108) 729 365 243 182 146 122 105 91 81 73
FLX-500 (119) 812 406 270 203 162 135 116 101 90 81
FLX-550 (131) 893 447 297 223 178 149 128 111 99 89
FLX-600 (143) 972 486 325 243 195 162 139 122 108 97
FLX-700 (167) 1136 568 379 284 227 189 162 142 126 114
FLX-800 (191) 1300 650 433 325 260 216 185 162 144 130
FLX-900 (215) 1460 730 487 365 292 243 209 183 162 146
FLX-1000 (239) 1622 811 541 406 324 270 232 203 180 164
FLX-1100 (263) 1784 893 595 446 357 297 255 223 198 178
FLX-1200 (287) 1947 974 649 487 389 325 279 243 216 195
Table B1-6. Model FLX Circulating Rates, Hot Water Boiler
MAXIMUM
OUTLET
TEMPERATURE
(F)
MINIMUM SYSTEM
PRESSURE
(PSIG)
180 12
190 15
200 18
210 21
220 24
230 27
240 30
MODEL
NO.
FURNACE
PROJECTED
AREA (FT
2
)
FURNACE
VOLUME
(FT
3
)
FURNACE
HEAT
RELEASE
BTU/HR (FT
3
)
FURNACE
HEAT
RELEASE BTU/
HR (FT
2
)
FLX-150 38.4 24.2 61,983 39,063
FLX-200 38.4 24.2 82,645 52,083
FLX-250 38.4 24.2 103,306 65,104
FLX-300 48.7 34.9 85,960 61,602
FLX-350 48.7 34.9 100,287 71,869
FLX-400 70.6 54.7 73,126 56,657
FLX-450 70.6 54.7 82,267 63,739
FLX-500 70.6 54.7 91,408 70,822
FLX-550 70.6 54.7 100,548 77,904
FLX-600 70.6 54.7 109,689 84,986
FLX-700 104.6 94.6 73,996 66,922
FLX-800 104.6 94.6 84,567 76,482
FLX-900 104.6 94.6 95,137 86,042
FLX-1000 128.9 116.5 85,837 77,580
FLX-1100 128.9 116.5 94,421 85,337
FLX-1200 128.9 116.5 103,004 93,095
Table B1-7. Model FLX Minimum Over
Pressure Requirements
Table B1-8. Model FLX Boiler Heat Release Information
B1-15
03-08
Burner/Control
Information
Burner information is shown inTable B1-9. Note that the model selection may vary for actual
application factors (altitude, gas pressure, etc.).
Minimum Required Gas Pressures
Approximate gas pressure required at rated input is shown in Table B1-10. For oversized gas
trains or altitudes above 1,000 feet, contact your local Cleaver-Brooks authorized represen-
tative.
The local gas company should be consulted for requirements and authorization for installa-
tion 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 con-
nections made to the boiler should be arranged so that all components remain accessible for
A drip leg should be installed in the supply piping before the connection to the gas pressure
regulator. The drip leg should be at least as large as the inlet fitting supplied with the boiler.
Consideration must be given to both volume and pressure requirements when choosing gas
MODEL NO.
BOILER
MAXIMUM
INPUT
MBH
BURNER
MODEL
MOTOR 3450
RPM VOLTAGE
FLX-150 1500 GP-200-1-1.5 120-60-1
FLX-200 2000 GP-200-1-2.0 120-60-1
FLX-250 2500 GP-200-1-2.5 120-60-1
FLX-300 3000 GP-200-2-3.0 120-60-1
FLX-350 3500 GP-200-2-3.5 240-60-3
FLX-400 4000 GP-200-2-4.0 240-60-3
FLX-450 4500 GP-200-2-4.5 240-60-3
FLX-500 5000 GP-200-3-5.0 240-60-3
FLX-550 5500 GP-200-3-5.5 240-60-3
FLX-600 6000 GP-200-3-6.0 240-60-3
FLX-700 7000 GP-200-3-7.0 240-60-3
FLX-800 8000 GP-200-3-8.0 240-60-3
FLX-900 9000 GP-200-3-9.0 240-60-3
FLX-1000 10,000 GP-200-4-10.0 240-60-3
FLX-1100 11,000 GP-200-4-11.0 240-60-3
FLX-1200 12,000 GP-200-4-12.0 240-60-3
NOTES:
1. Burner model selection shown is subject to change
based on actual application (altitude, gas pressure,
etc.).
2. Standard voltage in Canada is 575/3/60.
3. All burners feature full mod operation, with high-low-
high available as an option.
4. Burner models shown are for gas/oil burners.
MODEL
NO.
STD GAS
TRAIN
SIZE
(IN.)
MIN GAS
PRESSURE
(IN. WC)
BURNER
MODEL
FLX-150 2.0 3.7 GP-700-1-1.5
FLX-200 2.0 6.3 GP-700-1-2.0
FLX-250 2.0 8.1 GP-700-1-2.5
FLX-300 2.0 8.0 GP-700-2-3.0
FLX-350 2.0 11.0 GP-700-2-3.5
FLX-400 2.0 13.3 GP-700-2-4.0
FLX-450 2.0 16.9 GP-700-2-4.5
FLX-500 2.0 21.4 GP-700-3-5.0
FLX-550 2.0 19.0 GP-700-3-5.5
FLX-600 2.0 17.7 GP-700-3-6.0
FLX-700 2.0 23.8 GP-700-3-7.0
FLX-800 2.0 38.4 GP-700-3-8.0
FLX-900 2.0 48.3 GP-700-3-9.0
FLX-1000 2-1/2 31.2 GP-700-4-10.0
FLX-1100 2-1/2 37.9 GP-700-4-11.0
FLX-1200 3 37.2 GP-700-4-12.0
NOTES:
1. Table is based on 1,000 Btu/cu-ft natural gas and ele-
vation up to 1,000 ft.
2. Minimum gas pressure also applies to 200 fuel series
burner.
3. Standard regulators suitable for 1 psig maximum inlet
pressure.
Table B1-10. Model FLX Minimum Required Gas
Pressure
Table B1-9. Model FLX Burner Characteristics
B1-16
03-08
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 ser-
vice. Upon completion of the gas piping installation, the system should be checked for gas
Oil-fired 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 firing rate. Fuel not delivered to the noz-
zle is returned to the storage tank. A two-pipe (supply and return) oil system is recom-
mended for all installations. Figure B1-4 shows a typical fuel oil supply arrangement. Oil
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 noz-
zle(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.
Figure B1-4. Model FLX Oil Burner Supply Pump Installation
B1-17
03-08
SOUND LEVEL
FIRING RATE
MODEL NO.
150 200 250 300 350 400 450 500 550 600 700 800 900 1000 1100 1200
Low Fire (dBA) 75 75 76 75 75 77 78 79 79 79 81 81 83 79 82 85
High Fire (dBA) 76 76 77 76 76 78 79 80 80 80 82 82 83 81 83 86
Measurement: Three feet from front center of boiler, and 3-1/2 feet above boiler base. Measurements are decibel
ratings on the A-weighted scale, registered without addition of sound attenuators, mufflers, or silencers. Sound
pressure data taken on combination fuel burners firing oil. Sound pressure levels firing natural gas will be 0.5
dBA lower.
Table B1-11. Model FLX Sound Levels
MODEL NO.
SIDES
A
TOP
B
FRONT
C
REAR
D
FLX-150 - 250 28 18 48 24
FLX-300 - 350 32 18 48 24
FLX-400 - 600 34 18 60 24
FLX-700 -
1200
40 18 60 24
NOTE: Top Dimension from boiler to top of stack based
on stack selection.
Figure B1-5. Model FLX Clearance Requirements
03-08
B1-18
03-08
Upon completion of the oil piping installation, the system should be checked for oil or air
Sound Levels (dBA)
Refer toTable B1-11 for sound level information.
Outdoor Reset
Control
Cleaver-Brooks does not recommend the use of outdoor controls which reset the boiler
water outlet temperature below 150 F, or the utilization of the boiler as a system thermo-
stat.
Boiler Room Information
The boiler must be installed on a non-combustible floor. If the floor is not level, piers, or a
raised pad, slightly larger in length and width than the boiler base dimensions, will make
boiler installations and leveling easier. Installation on a raised pad or piers will make boiler
drain connections more accessible. The floor, pad, or piers must be of sufficient load bearing
strength to safely support the operating weight of the boiler and any additional equipment
installed with it. Approximate operating weights for Model FLX series steam and hot water
boilers are shown in Dimensions and Ratings.
After the boiler is in place it must be leveled. Both side-to-side and front-to-back level can
be verified using the vertical connection between the upper and lower drums at the back of
the boiler. If shims are required to level the boiler, the weight of the boiler must be evenly
distributed at all points of support.
The boiler must be installed so that all components remain accessible for inspection, clean-
ing, or maintenance. Field- installed piping and electrical connections to the burner and
boiler must be arranged to allow removal of the casing panels, and swinging of the burner.
Minimum clearances to walls or other obstructions and combustible materials are shown
iFigure B1-5. The top view shaded sections in Figure B1-5show areas that must be kept
clear of field installed connections to the boiler for access or maintenance purposes.
A positive means of supplying a volume of outside air for complete fuel combustion is
required. Proper ventilation of the boiler room must be provided. The amount of air
required, and the required duct and air supply opening areas, are determined by the maxi-
mum fuel input rating of the burner and the altitude of the installation. Refer to Table B1-
12. Air inlets must be sized in accordance with applicable engineering guidelines and regu-
latory code.
Breechings
For single boiler installations, use breeching of the same diameter as the vent outlet on the
boiler. For multiple boiler installations, and when a number of boilers of the same size
(input) are to be connected to a common breeching, use the table on Figure B1-6 to size the
breeching diameter. For more information on breechings and stacks, refer to Stacks, Sec-
tion F.
Flextube boilers can support up to 200 lbs without additional support.
B1-19
03-08
MODEL NO. 150 200 250 300 350 400 450 500 550 600 700 800 900 1000 1100 1200
Comb
Air
(Dry)
Gas (scfh)
(lb/hr)
15480 20640 25800 30960 36120 41280 46440 51600 56760 61920 72240 82560 92280 103200 113520 123840
1207 1609 2012 2414 2817 3219 3621 4024 4426 4828 5633 6438 7243 8048 8853 9657
Oil (scfh)
(lb/hr)
17050 22733 28414 34098 39782 45463 51146 56831 62514 68196 79562 90928 102294 113662 125028 136394
1269 1692 2115 2538 2961 3384 3807 4231 4654 5077 5923 6769 7640 8462 9308 10154
Flue
Gas
(Dry)
Gas (scfh)
(lb/hr)
17520 23360 29200 35040 40880 46720 52560 58400 64240 70080 81760 93440 105120 116800 128480 140160
1278 1704 2130 2556 2983 3409 3835 4261 4687 5113 5965 6817 7669 8521 9373 10225
Oil (scfh)
(lb/hr)
17915 23886 29855 35827 41799 47769 53740 59713 65684 71655 83598 95541 107484 119427 131370 143312
1357 1809 2261 2714 3166 3618 4070 4523 4975 5427 6330 7237 8142 9047 9951 10856
NOTES:
1. Natural gas @ 1000 Btu/cu-ft.
2. No. 2 oil @ 140,000 Btu/gal.
Table B1-12. Model FLX Combustion Air Requirements
Figure B1-6. Model FLX Breeching Arrangement - Single or Multiple Boiler Installation
B1-20
03-08
Notes
B1-21
Section B1
Model FLX Boilers
(Steam Boiler Specifications)
Boiler Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-22
General Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-22
Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-22
Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-23
Burner Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-23
Pilot Gas Train for Each Burner (Mounted, Piped, and Wired) . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-24
Oil Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-24
Gas Valve Train for Each Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-24
Burner Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-25
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-26
Field Erectable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-26
The following sample specifications are provided by Cleaver-Brooks to assist you in specifying your customers
specific needs and application. A separate specification is provided for hot water boiler and steam boiler
packages.
FLX Steam Boiler Specifications Section B1
B1-22
PART 1 GENERAL 1.1 BOILER CAPACITY
A. The _____ (low or high) pressure steam boiler shall be Cleaver-
Brooks Model FLX (FLE for field erected) designed for _______ (15
or 150) psig steam.
B. The boiler shall have a maximum output of __________ lbs/hr at
____ psig when fired with No. 2 oil and/or natural gas, ________
Btu/cu-ft. Electrical power available will be ________ Volt, _______
phase, _____ Hz.
PART 2 PRODUCTS 2.1 GENERAL DESIGN
A. The boiler shall be of a two-drum flexible watertube design with a
tangent tube waterwall furnace mounted on a heavy steel frame.
Top, bottom and sides of the furnace shall be water cooled.
B. The boiler pressure vessel shall be constructed in accordance with
ASME Boiler Code, and must receive authorized boiler inspection
prior to shipment. A copy of the inspection report shall be furnished
to the purchaser. The complete packaged boiler - burner unit shall
be listed by Underwriters Laboratories, and shall have the UL/cUL
label affixed to the front head.
1. The boiler drums shall be furnished with handholes to facilitate
2. Boiler tubes shall be 1.5" diameter, 0.095" wall thickness, and
shall be easy to remove and replace without expanding or
welding the tube attachment to the drums.
3. The boiler shall have sufficiently sized downcomers to provide
positive natural internal circulation.
4. The burner shall be mounted on a hinged backing plate for easy
access to furnace.
C. Observation ports for the inspection of flame conditions shall be
provided at rear end of the boiler and in the burner assembly at the
front end.
D. The tangent wall tubes shall be covered with 1-1/2 inches of
insulation under a gas-tight, 16-gauge inner casing. There shall be 2
inches of insulation between the inner and outer casing. The outer
casing shall be 20 gauge. The boiler base frame and other
components shall be factory-painted before shipment, using a hard
enamel finish.
A. The following items shall be installed on the boiler:
1. Low Water Cutoff - A low water cut-off control of the float-type
shall be mounted in a water column to the upper drum. It is to
be wired to the burner control circuit to prevent burner
operation if the boiler water falls below proper levels.
2. Feedwater Pump Control - The boiler feedwater pump control
switch shall be included. It shall provide automatic actuation of
a motor-driven feedwater pump, or solenoid valve, to maintain
the boiler water level within normal limits.
Section B1 FLX Steam Boiler Specifications
B1-23
3. Steam Pressure Controls - A minimum of three controls shall be
provided: one auto reset type for burner on-off control, one for
burner firing rate, and one manual reset type for burner cutout
in excessive steam pressure conditions.
4. Miscellaneous - A pressure gauge shall be mounted to the
boiler. Pressure controls (for regulation of burner operation)
shall be mounted to the boiler. Steam relief valves shall be of a
type and size to comply with ASME Code requirements
(shipped loose).
A. The boiler shall be provided with a UL/cUL approved fuel burning
system in full accordance with the requirements of state, provincial
and local codes, the local gas utility, and other applicable regulatory
bodies. The boiler shall be a Cleaver-Brooks Profire burner.
B. (Option as required)
C. The complete fuel burning system shall further be in full accordance
with Factory Mutual (FM) requirements.
D. The complete fuel burning system shall further be in full accordance
with Industrial Risk Insurers (IRI) requirements.
2.4 BURNER DESCRIPTION
A. Option (specify 1, 2, or 3)
1. The burner shall include a gas burner having rated capacity to
burn ________ MMBtu/hr of ______ Btu/cu-ft of __________
gas at a pressure of _______ (lbs/sq-inch) (inches of water
column) at the inlet of the burner gas control train.
2. The burner shall include an oil burner having rated capacity to
burn ______ gph of No. 2 fuel oil.
3. The burner shall include a combination gas-oil burner having
rated capacity to burn _______ MMBtu/hr of _____ Btu/cu-ft
gas at a pressure of _________ lbs/sq-inch (inches of water
column) at the inlet to the burner gas control train (or _______
gph of No. 2 fuel).
B. The burner shall be forced draft type with full firing rate modulation.
All combustion air shall be furnished by the burner fan, which shall
be an integral part of the burner. Each burner motor shall not be
larger than ______ hp, ____ phase.
C. Option (specify 1, 2, or 3)
1. The gas burner shall burn the specified quantity of fuel without
objectionable vibration, noise, or pulsation, with not more than
15% excess air and less than 50 ppm (corrected to 3% O
2
) CO
in the products of combustion. In addition, when firing gas, the
burner shall be guaranteed to produce less than 60 ppm
(corrected to 3% O
2
) NOx emissions.
2. The light oil burner shall burn the specified quantity of fuel
without objectionable vibration, noise, or pulsation, with not
more than 15% excess air and a maximum of No. 1 smoke
spot, as measured on the Bacharach Scale.
B1-24
3. The gas-oil burner shall burn the specified quantity of fuel
more than 15% excess air and less than 50 ppm (corrected to
3% O
2
) CO in the products of combustion on gas firing, and a
maximum of No. 1 smoke, as measured on the Bacharach
Scale when burning oil. In addition, when firing gas, the burner
shall be guaranteed to produce less than 60 ppm (corrected to
3% O
2
) NOx emissions.
D. Primary-secondary air control shall be a design function of the
combustion head. Combustion heads requiring an internal
adjustment shall not be acceptable.
E. The burner shall be equipped with an aluminum reverse curve fan
for lower fan motor hp requirements and self-cleaning
characteristics.
F. A permanent observation port shall be provided in the burner to
allow observation of both the pilot and main flame. Both the pilot
and the flame scanner shall be easily accessible without opening or
disassembling the burner.
G. Supply voltage available shall be ______ Volts, ______ phase, 60
Hz. All motors shall be suitable for use on this voltage. All burner
controls are to be for use on 120 volts, 1 phase, 60 hz.
H. The burner shall be factory fire-tested to ensure proper operation
before shipment.
2.5 PILOT GAS TRAIN FOR EACH BURNER (MOUNTED, PIPED, AND
WIRED)
A separate pilot gas cock, gas pressure regulator, and pilot safety shutoff gas valve shall be
provided for the ignition gas supply.
2.6 OIL BURNER
A. The oil burner shall be of the mechanical pressure atomizing type.
B. A two-stage oil pump shall be provided for each burner as an
integral part of the burner.
C. Two approved automatically operated safety shutoff valve(s) shall be
provided in the oil supply line to the burner valves to be piped in
series but wired parallel.
D. Supply an oil pressure gauge to indicate the discharge oil pump
pressure.
E. Install a manual valve, fuel oil filter, or strainer and vacuum gauge
on the suction side of the oil pump (optional).
F. Install a fusible-link-actuated oil safety shutoff valve in the oil supply
line between the oil tank and the manual gate valve at the oil pump
(optional).
G. Oil pressure monitoring shall be provided by an approved pressure
switch interlocked to accomplish a non-recycling safety shutdown in
the event of low oil pressure (optional).
2.7 GAS VALVE TRAIN FOR EACH BURNER
A. Provide a pressure gauge to indicate the gas burner manifold
pressure (optional).
Section B1 FLX Steam Boiler Specifications
B1-25
B. Furnish and install one manually operated, ________ inch, ball valve
upstream of all valves.
C. Provide one _______ inch, main gas pressure regulator (of tight
shutoff type) with vent to outside atmosphere, in accordance with
local codes.
Specify a tight shutoff type gas pressure regulator when the inlet gas pressure ex-
ceeds 1-1/2 psig.
D. Provide one ________ inch, automatically operated motorized safety
gas valve.
E. One safety shutoff valve shall be proven closed during pre- ignition
by proof of valve closure interlock switch on valve.
F. Provide a second _______ inch, automatically operated gas safety
shutoff valve to operate simultaneously with the above gas valve.
G. A manually operated gas valve shall be located downstream of both
automatic gas valves to permit leakage testing of the valves.
H. Gas pressure monitoring shall be provided by approved pressure
switches interlocked to accomplish a non-recycling safety shutdown
in the event of either high or low gas pressure (optional on sizes
150-250).
2.8 BURNER CONTROLS
A. The full modulation of the burner shall be controlled by steam
pressure by means of a pressure control.
B. An additional high limit safety pressure control of the manual reset
type shall be provided to control the burner.
C. Pre-purge and post-purge operation of the burner fan shall be
provided per current UL/cUL requirements.
D. The burner shall utilize a Fireye E110 type flame safeguard
programmer incorporating 7 LED indicator lights to annunciate the
current operating status of the burner.
E. A manual restart of the burner shall be necessary in the event of
shutdown due to flame failure.
F. All three-phase motors shall be controlled and protected by an
automatic starter with thermal overload protection. The starter shall
be inter-locked to prevent burner operation when over-load relays are
tripped out.
G. Supply a burner-mounted diaphragm air flow switch to prevent the
energization of the main fuel valves in the event of insufficient
combustion air, or to provide safety shutdown in the event of
combustion air interruption.
H. A factory-wired control cabinet shall be supplied and mounted on
the burner. The control cabinet shall house the flame safeguard
control, programming timer, burner motor starter, fuses, control
circuit transformer, control switches, indicating lamps and relays as
required.
I. Provide four individual lights with nameplates on the control cabinet
to indicate call for heat, main fuel valve on, low water, and
main flame failure.
B1-26
J. Option (specify A or B)
1. The changing from one fuel to the other shall be manual by
means of a fuel selector switch. No burner adjustments shall be
required to switch from one fuel to the other.
2. Changing from one fuel to the other shall be automatically
controlled by the outdoor temperature switch, or other external
device. No burner adjustment shall be required to switch from
one fuel to the other.
K. The burner shall be equipped with suitable fuel and air controls to
assure smooth main flame ignition. The burner shall utilize a
proportional air flow damper design, including independent low-fire
and high-fire air flow shutter assemblies for ease of adjustment and
consistent excess air performance throughout the firing range.
L. Fuel-air control shall be synchronized. The fuel air drive unit shall be
provided with a position indicating switch interlocked with the flame
safeguard system to assure starting at the low fire position. The
flame safeguard system shall further program this drive unit to
provide a full open louver of sufficient time to provide a four air
change pre-ignition of the combustion chamber, heat exchanger, and
flue passages.
M. Pre-ignition pure air flow rate shall not be less than 60% maximum
firing rate air flow. Interlocks shall be provided to monitor and prove
60% air flow purge when air inlet louvers are automatically opened
to obtain this rate.
N. Full modulation of fuel input shall be provided. A modulating
pressure control shall be supplied to modulate a burner mounted
damper motor controlling both fuel and air supply by means of direct
mechanical linkage.
O. Electronic safety combustion controls shall be supplied, complete
with ultra-violet flame scanner to monitor the pilot and main flame.
It shall be so utilized as to provide intermittent type gas-electric
ignition and pre-ignition timer. Flame rod will not be permitted for
proving pilot or main flame.
PART 3 EXECUTION 3.1 WARRANTY
All equipment is to be guaranteed against defects in material and/or workmanship
for a period of 12 months from the date of start-up or 18 months from the date of
shipment, which ever comes first. In addition the boiler pressure vessel shall be
warranted against damage resulting from thermal stress for a period of 20 years
from date of shipment provided the boiler is operated and maintained in accordance
with the conditions specified in the owners Operator and Maintenance Manual.
Refer to the FLX Boiler warranty.
3.2 FIELD ERECTABLE
The specified boiler/burner package shall be shipped disassembled for field
assembly. All pieces and components must fit through a standard doorway.
Assembly shall be accomplished with ordinary hand tools, with no welding or rolling
required. Major casing components are to be shipped with insulation and refractory
installed for ease of assembly.
B1-27
Section B1
Model FLX Boilers
(FLX Hot Water Boiler Specifications)
Boiler Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-28
General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-28
Hot Water Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-28
Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-29
Pilot Gas Train for Each Burner (Mounted, Piped, and Wired) . . . . . . . . . . . . . . . . . . . . . . . . B1-30
Oil Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-30
Gas Valve Train for Each Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-30
Burner Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-31
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-32
Field Erectable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-32
packages.
FLX Hot Water Boiler Speecifications Section B1
B1-28
A. The hot water boiler shall be Cleaver-Brooks Model FLX (FLE for
field erected), designed for 150 psig (hot water). Maximum water
temperature shall be _______ F, and maximum system temperature
drop shall be _______ F.
B. 1.2 The boiler shall have a maximum output of ____________ Btu/
hr when fired with No. 2 oil, and/or ________________ Btu/cu- ft
when fired with natural gas. Available electrical power will be _____
Volt, _____ phase, ____ Hz.
PART 2 PRODUCTS 2.1 GENERAL BOILER DESIGN
A. The boiler shall be a two-drum, flexible watertube design with a
tangent-tube waterwall furnace mounted on a heavy steel frame.
Top, bottom and sides of the furnace shall be water cooled.
B. The boiler pressure vessel must be constructed in accordance with
ASME Boiler Code, and must receive authorized boiler inspection
prior to shipment. A copy of the inspection report shall be furnished
to the purchaser. The complete packaged boiler - burner unit shall
be listed by Underwriters Laboratories, and shall have the UL/cUL
label affixed to the front head.
1. The boiler drums shall be furnished with handholes to facilitate
2. Boiler tubes shall be 1.5" diameter, with 0.095" wall thickness,
and shall be easy to remove and replace without expanding or
welding the tube attachment to the drums.
3. The boiler shall have a sufficiently sized downcomer to provide
natural internal circulation.
4. The burner shall be mounted on a hinged backing plate for easy
access to the furnace.
C. Observation ports for the inspection of flame conditions shall be
provided at the rear of the boiler, and in the burner assembly at the
front.
D. The tangent wall tubes shall be covered with 1-1/2 inches of
insulation under a gas-tight, 16-gauge inner casing. There shall be 2
inches of insulation between the inner and outer casing. The outer
casing shall be 20 gauge. The boiler base frame and other
components shall be factory-painted before shipment, using a hard
enamel finish.
A. The following items will be installed on the boiler.
1. Low Water Cut-Off: A probe-type, low water cut-off control
shall be mounted in the upper drum. It is to be wired to the
burner control circuit to prevent burner operation if the boiler
2. Miscellaneous: A combustion temperature and pressure gauge
shall be mounted on the boiler. Temperature controls, for
regulation of burner operation, shall be mounted on the boiler
and the temperature sensing element shall be located adjacent
to the boiler outlet. Water relief valves (shipped loose) shall be
of a type and size to comply with ASME Code requirements.
Section B1 FLX Hot Water Boiler Specifications
B1-29
A. The boiler shall be provided with a UL/cUL approved fuel burning
system in full accordance with the requirements of state, provincial
and local codes, the local gas utility, and other applicable regulatory
bodies. The burner shall be a Cleaver-Brooks ProFire burner or
approved equal.
B. Option (specify 1.) or 2.), as required)
1. The complete fuel burning system shall be in full accordance
with Factory Mutual (FM) requirements.
2. The complete fuel burning system shall be in full accordance
with Industrial Risk Insurers (IRI) requirements.
C. Burner Description
1. Option (specify a, b, or c)
a. The boiler shall include a gas burner having rated capacity
to burn ________ MMBtu/hr of ______ Btu/cu-ft of
__________ gas at a pressure of _______ (lbs/sq-in.)
(inches of water column) at the inlet of the burner gas
control train.
b. The boiler shall include an oil burner having rated
capacity to burn ______ gph of No. 2 fuel oil.
c. The boiler shall include a combination gas-oil burner
having rated capacity to burn _______ MMBtu/hr of Btu/
cu-ft ______ gas at a pressure of _________ (lbs/sq-in.)
(inches of water column) at the inlet to the burner gas
control train or _______ gph of No. 2 fuel.
2. The burner shall be forced draft type with full firing rate
modulation. All combustion air shall be furnished by the burner
fan, which shall be an integral part of the burner. Each burner
motor shall not be larger than ______ hp, ____ phase.
D. Option (specify 1.), 2.), or 3.))
1. The gas burner shall burn the specified quantity of fuel without
objectionable vibration, noise, or pulsation, with not more than
15% excess air and less than 50 ppm (corrected to 3% O
2
) CO
in the products of combustion. In addition, when firing gas, the
burner shall be guaranteed to produce less than 60 ppm
(corrected to 3% O
2
) NOx emissions.
2. B. The light oil burner shall burn the specified quantity of fuel
more than 15% excess air and a maximum of No. 1 smoke
spot, as measured on the Bacharach Scale.
3. C. The gas-oil burner shall burn the specified quantity of fuel
more than 15% excess air and less than 50 ppm (corrected to
3% O
2
) CO in the products of combustion on gas firing, and a
maximum of No. 1 smoke spot, as measured on the Bacharach
Scale when burning oil. In addition, when firing gas, the burner
shall be guaranteed to produce less than 60 ppm (corrected to
3% O
2
) NOx emissions.
B1-30
E. Primary-secondary air control shall be a design function of the
combustion head. Combustion heads requiring an internal
adjustment shall not be acceptable.
F. The burner shall be equipped with an aluminium reverse curve fan
for lower fan motor hp requirements and self-cleaning
characteristics.
G. A permanent observation port shall be provided in the burner to
allow observation of both the pilot and main flame. Both the pilot
and the flame scanner shall be easily accessible without opening or
disassembling the burner.
H. Supply voltage available shall be ______ Volts, ______ phase, 60
Hz. All motors shall be suitable for use on this voltage. All burner
controls are to be for use on 120 volts, 1 phase, 60 Hz.
I. The burner shall be factory fire-tested to ensure proper operation
before shipment.
2.4 PILOT GAS TRAIN FOR EACH BURNER (MOUNTED, PIPED, AND
WIRED)
A separate pilot gas cock, gas pressure regulator, and pilot safety shutoff gas valve,
shall be provided for the ignition gas supply.
2.5 OIL BURNER
A. The oil burner shall be of the mechanical pressure atomizing type.
B. A two-stage oil pump shall be provided for each burner as an
integral part of the burner.
C. Two approved automatically operated safety shutoff valve(s) shall be
provided in the oil supply line to the burner valves to be piped in
series but wired parallel.
D. Supply an oil pressure gauge to indicate the discharge oil pump
pressure.
E. Install a manual valve, fuel oil filter, or strainer and vacuum gauge
on the suction side of the oil pump (optional).
F. Install a fusible-link-actuated oil safety shutoff valve in the oil supply
line between the oil tank and the manual gate valve at the oil pump
(optional).
G. Oil pressure monitoring shall be provided by an approved pressure
switch interlocked to accomplish a non-recycling safety shutdown in
the event of low oil pressure (optional).
2.6 GAS VALVE TRAIN FOR EACH BURNER
A. Provide a pressure gauge to indicate the gas burner manifold
pressure (optional).
B. Furnish and install one manually operated, ________ inch, ball valve
upstream of all valves.
C. Provide one _______ inch, main gas pressure regulator (of tight
shutoff type) with vent to outside atmosphere, in accordance with
local codes.
Notice
Specify a tight shutoff type gas pressure regulator when the inlet gas pressure
exceeds 1-1/2 psig.
Section B1 FLX Hot Water Boiler Specifications
B1-31
D. Provide one ________ inch, automatically operated motorized safety
gas valve. One safety shutoff valve shall be proven closed during pre-
ignition by proof of valve closure interlock switch on valve.
E. Provide a second _______ inch, automatically operated gas safety
shutoff valve to operate simultaneously with the above gas valve.
F. A manually operated gas valve shall be located downstream of both
automatic gas valves to permit leakage testing of the valves.
G. Gas pressure monitoring shall be provided by approved pressure
switches interlocked to accomplish a non-recycling safety shutdown
in the event of either high or low gas pressure (optional on sizes
150-250).
2.7 BURNER CONTROLS
A. The full modulation of the burner shall be controlled by water
temperature by means of a temperature control.
B. An additional high limit safety temperature control of the manual
reset type shall be provided to control the burner.
C. Pre- and post- operation of the burner fan shall be provided per
current UL/cUL requirements.
D. The burner shall utilize a Fireye type flame safeguard programmer,
incorporating 7 LED indicator lights to annunciate the current
operating status of the burner.
E. A manual restart of the burner shall be necessary in the event of
shutdown due to flame failure.
F. All three-phase motors shall be controlled and protected by an
automatic starter with thermal overload protection. The starter shall
be inter-locked to prevent burner operation when over-load relays are
tripped out.
G. Supply a burner-mounted diaphragm air flow switch to prevent
energizing the main fuel valves in the event of insufficient
combustion air, or to provide safety shutdown in the event of
combustion air interruption.
H. A factory-wired control cabinet shall be supplied and mounted on
the burner. The control cabinet shall house the flame safeguard
control, programming timer, burner motor starter, fuses, control
circuit transformer, control switches, indicating lamps, and relays as
required.
I. Provide four individual lights with nameplates on the control cabinet
to indicate call for heat, main fuel valve on, low water, and
main flame failure.
J. Option (specify 1.) or2.))
1. The changing from one fuel to the other shall be manual by
means of a fuel selector switch. No burner adjustments shall be
required to switch from one fuel to the other.
2. Changing from one fuel to the other shall be automatically
controlled by an outdoor temperature switch, or other external
device. No burner adjustment shall be required to switch from
one fuel to the other.
B1-32
K. The burner shall be equipped with suitable fuel and air controls to
assure smooth main flame ignition. The burner shall utilize a
proportional air flow damper design, including independent low-fire
and high-fire air flow shutter assemblies for ease of adjustment and
consistent excess air performance throughout the firing range.
L. Fuel-air control shall be synchronized. The fuel air drive unit shall be
provided with a position indicating switch interlocked with the flame
safeguard system to assure starting at the low fire position. The
flame safeguard system shall further program this drive unit to
provide a full open louver of sufficient time to provide a four air
change pre-ignition of the combustion chamber, heat exchanger, and
flue passages.
M. Pre-ignition pure air flow rate shall not be less than 60% maximum
firing rate air flow. Interlocks shall be provided to monitor and prove
60% air flow purge when air inlet louvers are automatically opened
to obtain this rate.
N. Full modulation of fuel input shall be provided. A modulating
temperature control shall be supplied to modulate a burner mounted
damper motor, controlling both fuel and air supply by means of
direct mechanical linkage.
O. Electronic safety combustion controls shall be supplied, complete
with ultra-violet flame scanner to monitor the pilot and main flame.
It shall be so utilized as to provide intermittent type gas-electric
ignition and pre-ignition timer. Flame rod will not be permitted for
proving pilot or main flame.
All equipment is to be guaranteed against defects in material and/or workmanship
for a period of 12 months from the date of start-up or 18 months from the date of
shipment, which ever comes first. The boiler pressure vessel shall be warranted
against damage resulting from thermal stress for a period of 20 years from date of
shipment, provided the boiler is operated and maintained in accordance with the
conditions specified in the owners Operating and Maintenance Manual.
3.2 FIELD ERECTABLE
The specified boiler/burner package shall be shipped disassembled for field
assembly. All pieces and components must fit through a standard doorway.
Assembly shall be accomplished with ordinary hand tools, with no welding or rolling
required. Major casing components are to be shipped with insulation and refractory
installed for ease of assembly.
B2-1
03-08
CONTENTS
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4
Insurance/Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-7
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-15
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-16
Feedwater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-16
Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-17
Boiler Stacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-17
Oil Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-20
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-20
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-27
Section B2
Model 4 Boilers
Section B2 Model 4 Boilers
B2-2
04-02
ILLUSTRATIONS
Figure B2-1. Model 4 Dimension Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-9
Figure B2-2. Model 4 Standard Pilot and Main Gas Trains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-2
Figure B2-3. Boiler room air supply - Engineered Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-19
Figure B2-4. Typical gas header piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-26
TABLES
Table B2-1. Model 4 Boiler Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5
Table B2-2. Model 4 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-10
Table B2-3. Model 4 Steam Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-11
Table B2-4. Recommended Steam Nozzle Size (to maintain 4000 to 5000 fpm nozzle velocity) . . . B2-11
Table B2-5. Min. req. NATURAL GAS pressure STANDARD UL, FM, & XL GAP gas trains . . . . . . . B2-13
Table B2-6. Min. req. NATURAL GAS pressure OVERSIZED UL, FM, & XL GAP gas trains . . . . . . . B2-13
Table B2-7. Min. req. PROPANE GAS pressure STANDARD UL, FM, & XL GAP gas trains . . . . . . . B2-14
Table B2-8. Min. req. PROPANE GAS pressure OVERSIZED UL, FM, & XL GAP gas trains . . . . . . . B2-14
Table B2-9. Safety valve outlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-15
Table B2-10. Predicted efficiency, 10 psig operating (includes radiation and convection losses) . . . B2-15
Table B2-11. Model 4 emission data - Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-16
Table B2-12. Model 4 emission data - No. 2 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-16
Table B2-13. Feedwater makeup rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-17
Table B2-14. Water quality parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-17
Table B2-15. Model 4 fuel, combustion air, and flue gas flow rates . . . . . . . . . . . . . . . . . . . . . . . B2-19
Table B2-16. Gas line capacity - Schedule 40 metallic pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-22
This section contains information on the Model 4 Commercial Watertube Boiler product line for low and high
pressure steam applications. Sizes range from 1.5 to 6 MMBtu/hr. The Model 4 Boiler is an excellent choice
where high outputs are needed but space limitations exist. The model number designation is 1500 through
6000, representing MBtu/hr input (1,500,000 to 6,000,000 Btu/hr).
Fuel series designation is as follows:
Series 100: No. 2 oil firing.
Series 700: Natural gas firing.
Series 200: No. 2 oil/natural gas firing.
Design pressure designation is stated as 15 psig, 150 psig, and 250 psig for steam. For example, an M4P-
700-2500-150ST boiler designates a gas-fired, 2,500,000 Btu/hr, 150 psig, steam boiler.
Model 4 Boilers Section B2
B2-3
03-08
The following features and benefits apply to the Model 4 Boiler product line.
33" Cased Width:
Boiler fits through most standard doorways.
Reduced installation costs.
Direct Driven, Vibration-Free Centrifugal Impeller:
Quiet operation.
Sound levels below 79 dBA.
Ideal for noise critical areas such as hospitals, churches, etc.
Minimum Refractory:
Membrane waterwalls reduce the need for refractory by 95%.
Reduced maintenance costs and refractory repair requirements.
Membrane Waterwalls:
Enhanced heat transfer area in compact design.
Full water wall furnace improves heat transfer for high efficiency.
Small Boiler Footprint:
Savings of up to 50% in floor space.
Weighs up to 40% less than Comparable Boilers:
Lower freight and rigging costs.
Reduced structural requirements.
Standard Built-in Soot Washers:
Boiler fireside cleaning without shutdown.
Maintains peak boiler performance.
Packaged Forced Draft Burner:
High pressure drop design.
Improved combustion efficiency.
Burner/Windbox Davit:
Easy access to furnace with swing-open windbox.
Reduced maintenance costs.
Steam Design Pressures to 500 psig (optional):
High performance in a compact design.
Proven vessel design for high design pressure applications.
B2-4
03-08
PRODUCT OFFERING
The Model 4 (M4) Boiler is a compact carbon steel, extended fin, watertube boiler.
Heat transfer design is configured in a "3-pass" gas travel across the watertube
surfaces. The pressure vessel is constructed to conform to the A.S.M.E. Code, either
Section IV for low pressure steam @ 15 PSIG MAWP (maximum allowable working
pressure) or Section I for MAWP greater than 15 PSIG.
The vessel (boiler) consists of two rows on each side of the vessel, of formed
seamless tubes with extended fin surfaces and downcomers connected to the steam
drum and lower drum. To reduce standby losses, the vessel is insulated with a
fiberglass blanket and removable steel jacket.
Complete with an integral burner for either No.2 fuel oil or Natural Gas, the
complete burner/boiler package is UL Approved, listed, and labeled.
Standard Equipment The standard boiler/burner package is described below. Optional controls, trim, and
devices may be added to meet project requirements. Some of those options are
noted following this standards list.
1. Boiler
A. Designed, constructed, and hydrostatically tested in accordance with the
A.S.M.E. Boiler and Pressure Vessel Code. The complete vessel is mounted on a
structural steel frame.
B. Steam drum includes a hand hole in the rear head for drum water side
inspection. Connections are included for the following:
Feedwater Makeup w/internal dispersion tube.
Surface Blowoff.
Steam Supply.
Safety Relief Valve.
C. Lower Drum includes hand holes at each end for waterside inspection. A drain/
blowoff tapping is provided at the front, bottom centerline.
D. Soot washer lances are provided on each side of the vessel between the two
rows of tubes for fireside cleaning. Soot washer drains are located at the bottom of
the boiler, with connections to drain located on each side of the lower drum at the
rear.
E. Refractory is limited to the furnace floor, lower drum, and burner throat tile.
High temperature insulation is installed on the front water wall and furnace access
door.
F. Two lifting eyes are provided on the top centerline of the upper drum for ease of
installation.
G. Furnace inspection/access door is provided in the furnace front wall.
H. The exhaust gas vent is located at the top rear centerline of the boiler. A stack
thermometer is shipped loose for field installation by the installing contractor into
the stack.
I. The complete vessel is fully insulated (2" fiberglass blanket) under a preformed,
sectional steel jacket.
J. Factory painted using hard-finish enamel.
B2--5
04-02
2. Forced Draft Burner
A. The burner is a high radiant multi-port type approved for operation on natural gas
and a pressure atomizing type approved for operation with commercial grade No. 2
fuel oil.
B. Consisting of the fan which is direct connected to the fan motor, wind box, air
damper that is linkage connected to a damper drive motor, the complete assembly is
factory mounted and tested.
C. To ensure proper air for pre purge and combustion is provided by the fan, a
combustion air proving switch is provided.
D. The complete burner/wind box swings open via a davit arm attached to the upper
drum. This permits fireside inspection of the furnace and burner internals.
E. Responding to steam demand from the drum mounted pressure control, the burner
operates in the low-high-low-off firing mode. Ultra-violet (UV) flame scanner is
provided for flame presence during firing.
F. An Ignition transformer is provided.
G. Ignition is direct spark on straight oil fired burners, and gas pilot on straight gas or
combination gas/oil burners.
H. Oil Train consists of the following:
4 Solenoid Shutoff Valves providing low fire, intermediate transitional firing from low
to high and high fire.
An oil pump is mounted (belt driven from the fan motor) for pressure atomization of
the fuel oil.
Oil Pressure Gauge.
Suction and return tubing connected to an oil connection block.
Gas Train consists of the following:
Primary gas shutoff valve with integral proof of closure switch.
A manual shutoff valve located ahead of the primary gas valve.
MODEL
NO.
INPUT
MBH
HEAT
OUTPUT
MBH
EQUIV
HP
STEAM
OUTPUT
LB/HR
SHIPPING
WEIGHT
LBS
1500 1500 1200 35 1237 3100
2000 2000 1600 47 1649 3100
2500 2500 2000 59 2062 3700
3000 3000 2400 71 2474 3700
3500 3500 2800 83 2887 4100
4000 4000 3200 95 3299 4100
4500 4500 3600 107 3711 4700
5000 5000 4000 119 4124 4700
6000 6000 4800 143 4949 5400
NOTE: Steam output from and at 212 F.
Table B2-1. Model 4 Boiler Sizes
B2-6
03-08
A plugged leakage test connection and a second manual shutoff valve for tightness
checking of the primary shutoff valve.
Separate Gas Pressure Regulators for the pilot train and main gas train.
Low Gas Pressure and High Gas Pressure Switches for units at 3000 and greater.
A second motorized gas valve is provided in addition to the primary valve on size
6000 units.
The pilot gas train includes a manual shutoff valve and solenoid shutoff valve.
3. Boiler Trim and Controls
A. 15 psig or 150 psig set A.S.M.E. safety relief valves.
B. Steam pressure gauge with inspectors test cock and connection.
C. Primary Water Column complete with gauge glass and column drain valve.
D. Low Water cutoff switch and pump control switch, integrally mounted in the
primary water column.
E. Auxiliary Low Water Cutoff, manual reset type.
F. Steam Pressure Controls:
Operating Limit.
Excess Steam Pressure (High Limit), manual reset.
Burner firing rate, low high low.
4. Burner Control Panel and Controls
A. The control panel is enclosed within a NEMA 1A Rated enclosure, mounted on
the burner wind box at approximately eye level height.
B. Mounted within or on the control panel box are the following controls. Panel
wiring is factory tested.
Combustion Flame Safeguard Control, Model CB120 that provides pre purge, post
purge, trial for ignition, main flame/burner operation, and safety shutdown.
Fan Motor Starter wired into the non recycling circuit of the flame safeguard
control.
Indicating Lights for low water, flame failure, load demand, and fuel valve on.
Burner On/Off Switch.
Damper Positioning Switch.
Fuel Selector Switch for combination fuel fired burners.
Control Circuit Step-down Transformer with primary fuse protection.
Terminals for interface wiring connection of controls.
Oil, heat, and moisture resistant wire used. Each wire is number coded relative to
the wiring diagram.
5. Electric Service Panel
An electric service panel (entrance box) is provided on the side of the boiler for all
external wiring connections to remote control devices and the main power for the
boiler. Wiring to this panel eliminates the need to disconnect wiring when the front
burner wind box is opened for burner or boiler servicing.
B2-7
03-08
Optional Equipment For more detailed information on optional equipment, contact your local Cleaver-
Brooks authorized representative. In summary, options include the following:
1. Boiler
Larger pressure gauges or specific manufacturer type.
Bottom Drain Valves for low pressure applications.
Bottom Blowoff Valves for high pressure applications.
Surface Blowoff Valve with internal collector pipe.
Feedwater Stop and Check Valves.
Steam Stop Valve.
ASME Hydro Test of Valves and Valve Piping.
Design pressures above 150 PSIG.
Full Modulation Firing on Gas.
Lead/Lag Control.
Day-Night Controls.
Low Fire Hold Control.
Elapsed Time Meter.
Alarm with silence switch.
Additional Indicator Lights.
Main Power Disconnect.
Remote Oil Pump.
Optional NEMA Enclosures.
Special Fan Motor requirements (TEFC).
3. Fuel Options
Automatic Fuel Changeover (combination burner).
Propane Fuel Firing.
Special Gas Pressure Regulators.
Dual Pilots (gas and oil).
Gas strainer.
Insurance/Codes The boiler package can be equipped to meet various insurance or code
requirements. Some of these insurance/code requirements are:
Factory Mutual (FM)
XL GAP (Formerly GE GAP/IRI).
A.S.M.E. CSD-1.
A. Factory Mutual (FM Global) - Recommended guidelines as described by FM
pertain to boilers rated at greater than 2.5 MMBtu/hr input on gas and 2.8 MMBtu/
hr input on oil. Boilers that are labeled and tested in accordance with an
independent testing lab such as UL or CSA and are below these inputs are exempt
from these recommendations.
The Model 4 boiler is UL listed and labeled. In addition to the standard UL
requirements the following are needed to comply with FM when required.
Alarm Bell with silence switch for low water and safety shutdowns.
Low Oil Pressure Switch if the oil pump is not direct driven from the fan motor.
B. XL GAP (Formerly GE GAP/IRI) Recommended guidelines as described by XL
GAP pertain to boilers rated at 400,000 Btu/hr input to 12.0 MMBtu/hr input. For
these boilers, the requirements are the same as for A.S.M.E CSD-1 requirements.
Above 12.0 MMBtu/hr input, the requirements defer to the NFPA 85 standards for
single burner boilers.
B2-8
03-08
C. A.S.M.E. CSD-1 - Recommended guidelines as described by this Code pertain to
boilers rated at 400,000 Btu/hr input to 12.0 MMBtu/hr input. Above 12.0
MMBtu/hr input, the requirements defer to the NFPA 85 standards for single burner
boilers. For the sizes this Code covers, the requirements are as follows, in addition
to the standard UL package:
Low Oil Pressure Switch for oil firing
"Pressure Control Piping
If gas supply is > 5 psig, a relief valve is required after the gas pressure regulator in
the main and pilot gas trains.
Lever Handled shutoff cock for the pilot gas train.
Non-fused disconnect to remove boiler from all sources of power.
For layout purposes, the nominal dimensions and connections for the Model 4
Standard Package Boiler are shown in Figure B2-1 and Table B2-2. Ratings of each
boiler size are noted in Table B2-3. Additional information is shown in the following
figures, tables, and illustrations.
Table B2-4: Recommended steam nozzle sizes for high pressure boilers operating at
lower and higher pressures.
Figure B2-2: Standard gas train dimensions and components.
Table B2-5: Natural Gas Pressure Requirements, standard gas train size.
Table B2-6: Natural Gas Pressure Requirements, oversized gas train.
Table B2-7: Propane Gas Pressure Requirements, standard gas train size.
Table B2-8: Propane Gas Pressure Requirements, oversized gas train.
Table B2-9: Safety Valve Outlet Sizes.
B2-9
03-08
Figure B2-1. Model 4 Dimension Drawing
B2-10
03-08
Table B2-2. Model 4 Dimensions
Note 1 1500 2000 2500 3000 3500 4000 4500 5000 6000
Lengths
A Overall 84.25 84.25 100.25 100.25 117.375 117.375 136.75 136.75 152.375
B Pressure Vessel w/casing 61 61 77 77 92.375 92.375 109 109 124.625
C Base Frame 54 54 69.625 69.625 85.25 85.25 101 101 116.5
C
1 Base to Burner/Windbox 9.625 9.625 9.625 9.625 9.625 9.625 10 10 10
C
2 Base Frame Anchor Holes 51.5 51.5 67.125 67.125 82.75 82.75 98.375 98.375 114
CC Rear Casing to Stack Connection 25.8 25.8 26.25 26.25 26.25 26.25 30.375 30.375 30.375
D Burner/Windbox Extension 20.1 20.1 20.1 20.1 21.9 21.9 24.6 24.6 24.6
DD Front Casing to Steam Nozzle 17.25 17.25 25.25 25.25 30.75 30.75 37.375 37.375 45.25
Steam Nozzle to Safety Valve 15# 8 8 12 12 11.5 11.5 13 13 17
Steam Nozzle to Safety Valve 150# 8 8 12 12 17 17 17 17 17
Wi dths
E Overall 53.25 53.25 53.25 53.25 53.25 53.25 53.25 53.25 53.25
F Center to Water Column 32.4 32.4 32.4 32.4 32.4 32.4 32.4 32.4 32.4
G Center to Opt. Aux. Water Column 26.6 26.6 26.5 26.6 26.6 26.6 26.6 26.6 26.6
H Center to Outside Casing 16.375 16.375 17.375 16.375 16.375 16.375 16.375 16.375 16.375
I Base Frame Inside 20 20 20 20 20 20 20 20 20
J Base Frame Outside 28 28 28 28 28 28 28 28 28
K Soot Washers, Center to Center 21.4 21.4 21.4 21.4 21.4 21.4 21.4 21.4 21.4
L Boiler Centerline to Soot Washer 10.7 10.7 10.7 10.7 10.7 10.7 10.7 10.7 10.7
M Boiler Centerline to Base Centerline 12 12 12 12 12 12 12 12 12
N Boiler Centerline to Soot Drain 5.25 5.25 5.25 5.25 5.25 5.25 5.25 5.25 5.25
Hei ghts
OO Overall [Base to Stack Connection] 78.75 78.75 78.75 78.75 78.75 78.75 78.75 78.75 78.75
O Base to Steam Nozzle 150# 74.75 75.75 74.75 74.75 74.75 74.75 78 78 78
O Base to Steam Nozzle 15# 75 75 75 75 78.25 78.25 78.25 78.25 78.25
O
1
Base to Stack Box. 77.8 77.8 77.8 77.8 77.8 77.8 77.8 77.8 77.8
O
2 Base to Top of Control Panel 83.25 83.25 83.25 83.25 83.25 83.25 83.25 83.25 83.25
P Base to Surface Blowoff 59.25 59.25 59.25 59.25 59.25 59.25 59.25 59.25 59.25
Q Base to Feedwater Inlet 57.25 57.25 57.25 57.25 57.25 57.25 57.25 57.25 57.25
R Base to Soot Washer Lance 55.5 55.5 55.5 55.5 55.5 55.5 55.5 55.5 55.5
S Height of Base 4 4 4 4 4 4 4 4 4
OS Base to Oil Supply Connection 27.75 27.75 27.75 27.75 27.75 27.75 27.75 27.75 27.75
OR Base to Oil Return Connection 25.75 25.75 25.75 25.75 25.75 25.75 25.75 25.75 25.75
Connecti ons
BB. OD Stack - Sleeve Connection 12 12 12 12 12 12 16 16 16
T Bottom Drum Blow Down, 15#[one] 1.25 1.25 1.25 1.25 1.5 1.5 1.5 1.5 1.5
T
1 Bottom Drum Blow Down, 150#[one] 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25
U Steam Nozzle, 15# 4
A
4
A
4
A
4
A
6
B
6
B
6
B
6
B
6
B
V Steam Nozzle, 150# 2.5
A
2.5
A
3
A
3
A
3
A
3
A
4
B
4
B
4
B
W Soot Washer Drains [Two] 2 2 2 2 2 2 2 2 2
X Surface Blow off [One] 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
Y Feedwater Inlet [One] 1 1 1 1 1 1 1 1 1
Z Soot Washer [Two] 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25
GG Oil Supply and Return 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Relief Valve, 15# 2 2 2 2 2 2.5 2.5 2.5 3
Relief Valve, 150# 1 1.25 1.25 1.25 1.5 1.5 1.5 1.5 2
Cl earances
EE Burner/Windbox Swing 33 33 33 33 33 33 33 33 33
FF Tube removal each side 30 30 30 30 30 30 30 30 30
93
155 172 172 187
Boi l er Si ze
Allowance for Burner/Windbox Swing
and 30" Rear Aisle Space.
155
93 93 93 93 93 93 93 93
All Dimensions are in i nches
RF
RD
Allowance for Tube Removal Each
Side and Burner/Windbox Swing.
124
J J
HH
124 140 140
NOTES: 1. The above dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction via certified
prints. For 200 PSIG design pressure and greater, contact Milwaukee Sales for certified prints.
2. Allow sufficient space at rear of boiler for removal of soot washer lance.
3. For access to the furnace, a 13"x 21"access door is provided behind the front door.
4. Control Panel may be larger (up to 4"in height) if certain control options are provided.
A. Connection is a Female Pipe Thread.
B. Connection is a 150# Flange, Flat Face.
B2-11
03-08
Table B2-3. Model 4 Steam Ratings
Table B2-4. Recommended Steam Nozzle Size (to maintain 4000 to 5000 fpm nozzle velocity)
Boil er SIZE 1500 2000 2500 3000 3500 4000 4500 5000 6000
Rated Capacity - Steam (lbs. steam/hr
from & at 212
o
F.)
1,237 1,649 2,062 2,474 2,887 3,299 3,711 4,124 4,949
Rated Steam Capacity [kg/hr from and at
100 C]
461.7 615.5 769.6 923.4 1,077.5 1,231.3 1,385.0 1,539.2 1,847.2
Output Btu/hr [1,000 Btu/h] 1,200 1,600 2,000 2,400 2,800 3,200 3,600 4,000 4,800
Output Kcal/Hr [1,000 Kcal/h] 302 403 504 605 706 806 907 1,007 1,210
Output KW 348 464 580 696 812 928 1,044 1,160 1,392
Natural Gas [ft
3
/hr] - 15#Steam 1,511 1,538 2,500 3,038 3,487 4,025 4,494 5,050 6,052
Natural Gas [ft
3
/hr] - 150#Steam 1,572 2,133 2,597 3,117 3,590 4,155 4,657 5,194 6,233
Natural Gas [m
3
/hr] - 15#Steam 42.8 43.5 70.8 86 98.7 114.0 127.0 143.0 171.4
Natural Gas [m
3
/hr] - 150#Steam 44.5 60.4 73.5 88.3 101.6 117.6 131.8 147.0 176.5
Propane Gas [ft
3
/hr] - 15#Steam 604 615 1,000 1,215 1,395 1,610 1,798 2,020 2,421
Propane Gas [ft
3
/hr] - 150#Steam 629 853 1,039 1,247 1,436 1,662 1,863 2,078 2,493
Propane Gas [m
3
/hr] - 15#Steam 17 17.4 28.3 34.4 39.5 45.6 51 57.2 68.5
Propane Gas [m
3
/hr] - 150#Steam 17.8 24.1 29.4 35.3 40.7 47 52.7 58.8 70.6
No.2 Oil Fuel - 15#Steam, gph 10 14 17 21 24 28 31 35 42
No.2 Oil Fuel - 150#Steam, gph 11 15 18 22 25 28.9 32 36 43
No.2 Oil Fuel - 15#Steam, liters/hour 38 53 64 79 91 106 117 132 159
No.2 Oil Fuel - 150#Steam, liters/hour 41 56 68 82 95 109 121 136 163
Blower Motor HP - Gas Firing 3/4 1 1-1/2 2 2 3 3 3 5
Blower Motor HP - Oil or Combination 1-1/2 1-1/2 2 2 3 5 3 3 5
Oil Pump for Oil or Combination
Blower Motor - Gas Firing Only, 230V 1.53 3.3 4.7 6 6 9 9 9 15
Blower Motor - Gas Firing Only, 460V 0.77 1.7 2.4 3 3 4.5 4.5 4.5 7.5
Blower Motor - Oil or Combination, 230V 4.7 4.7 6 6 9 15 9 9 15
Blower Motor - Oil or Combination, 460V 2.4 2.4 3 3 4.5 7.5 4.5 4.5 7.5
Control Circuit 1.7 1.7 1.7 1.9 1.9 1.9 2.4 2.4 2.4
Operating Weight, lbs. 3,758 3,758 4,566 4,566 5,175 5,175 5,991 5,991 6,900
Operating Weight, kg 1,399 1,399 1,704 1,704 1,932 1,932 2,236 2,236 2,575
Water Content Normal, gallons 79 79 104 104 130 130 156 156 181
Water Content Normal, liters 299 299 394 394 492 492 591 591 685
Water Content Flooded, gallons 109 109 145 145 177 177 213 213 245
Water Content Flooded, liters 413 413 549 549 670 670 806 806 927
Shipping Weight, approximate lbs. 3,100 3,100 3,700 3,700 4,100 4,100 4,700 4,700 5,400
Shipping Weight, approximate kg 1,157 1,157 1,381 1,381 1,530 1,530 1,754 1,754 2,015
Notes:
Rat i ngs [ Not e A]
Belt Driven from the Blower Motor
Approximate Fuel Consumption At Rat ed Capaci t y [ Input - Note B]
Power Requir ements - 3 Phase 60 Hz St andar d [ Not e C]
Mi nimum Ampaci t y
A. Ratings shown for elevation to 1000 Feet. For ratings above 1000 Feet, contact your local Cleaver-Brooks Representative.
B. Input calculated with Nat. Gas @ 1000 Btu/ft
3,
Propane @ 2500 Btu/ft
3,
and Oil @ 140,000Btu/gal.
C. For altitudes above 1000 Feet, contact your local Cleaver-Brooks authorized representative for verification of capacity rating.
Wei ghts
1500 2000 2500 3000 3500 4000 4500 5000 6000
15 4 4 6 6 6 6 8 8 8
20 3 4 4 6 6 6 8 8 8
30 3 4 4 4 4 6 6 6 6
40 2-1/2 3 3 4 4 4 6 6 6
50 2-1/2 3 3 4 4 4 4 4 6
65 2-1/2 2-1/2 3 3 3 4 4 4 4
75 2-1/2 2-1/2 3 3 3 4 4 4 4
95 - 125
A
2-1/2 2-1/2 3 3 3 3 4 4 4
150 1-1/2 2 2 2-1/2 2-1/2 2-1/2 3 3 3
200 1-1/2 1-1/2 1-1/2 2 2 2-1/2 2-1/2 2-1/2 3
250 - 400 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2 2 2-1/2
A. Standard nozzle size for 150 PSIG MAWP Boiler Design
Example 1: Size 3500, 150#boiler to operate @ 30 PSIG requires 4" steam nozzle in lieu of
standard 3" nozzle.
Example 2: Size 3500, 150#boiler to operate @ 200 PSIG requires 2" steam nozzle in lieu of
standard 3" nozzle.
Operating
Pressure
(PSIG)
BOILER SIZE
B2-12
03-08
Figure B2-2. Model 4 Standard Pilot and Main Gas Trains
1
5
6
7
5
7
8
9
5
5
6
5
6
7
8
9
5
2
3
4
5
6
7
8 9
10
5
Pilot
Main
ITEM PART DESCRIPTION
SIZES
INCHES
Sizes 1500 TO 2500
1 Butterfly Valve 1-1/2
2 Pilot Shutoff Cock 1/2
3 Pilot Gas Regulator 1/2
4 Pilot Solenoid Valve 1/2
5 Manual Shutoff Valve 1-1/2
6 Main Gas Regulator 1-1/2
7 Motorized Valve with P.O.C. 1-1/2
Size 3000
5 Manual Shutoff Valve 1-1/2
7 Low Gas Pressure Switch 1/4
8 Motorized Valve with P.O.C. 1-1/2
9 High Gas Pressure Switch 1/4
Sizes 3500 to 5000
1 Butterfly Valve 2
5 Manual Shutoff Valve 2
6 Main Gas Regulator 2
8 Motorized Valve with P.O.C. 2
Size 6000
1 Butterfly Valve 2
5 Manual Shutoff Valve 2
8 Motorized Valve (std) 2
9 Motorized Valve with P.O.C. 2
B2-13
03-08
Table B2-5. Minimum required NATURAL GAS pressure at entrance to STANDARD UL, FM, & XL GAP gas
trains (upstream of gas pressure regulator)
Table B2-6. Minimum required NATURAL GAS pressure at entrance to OVERSIZED UL, FM, & XL GAP gas
1500 1.5 1.5 4.4 28.0
2000
1.5 1.5 8.4 28.0
2500
1.5 1.5 12.9 28.0
3000 1.5 1.5 17.1 28.0
3500 2.0 2.0 11.3 28.0
4000
2.0 2.0 13.6 28.0
4500
2.0 2.0 12.2 28.0
5000 2.0 2.0 16.8 28.0
6000
2.0 2.0 21.5 28.0
Note: For altitude above 1000 feet, contact your local Cleaver-Brooks representative.
Natural Gas @ 1000 Btu/cu-ft, specific gravity @ 0.65
4000
4500
5000
6000
2000
2500
3000
3500
BOILER
SIZE
REQUIRED FUEL
FLOW (SCFH)
1500
INLET PIPE
SIZE
(inches)
HONEYWELL
VALVE SIZE
(inches)
PRESSURE REQUIRED
MIN ("W.C.) MAX ("W.C.)
1500
2.0 2.0 2.3 28.0
2000
2.0 2.0 4.8 28.0
2.0 2.0 6.5
2.5 2.5 5.7
2.0 2.0 9.0
2.5 2.5 6.8
3.0 3.0 6.0
2.5 2.5 9.7
3.0 3.0 7.1
2.5 2.5 11.8
3.0 3.0 8.5
2.5 2.5 9.8
3.0 3.0 5.6
2.5 2.5 12.9
3.0 3.0 7.1
4.0 4.0 5.6
2.5 2.5 17.5
3.0 3.0 10.0
4.0 4.0 7.9
28.0
28.0
4500
5000
6000
28.0
28.0
2500
3000
3500
4500
5000
6000
4000
1500
2000
2500
3000
3500
4000
BOILER
SIZE
INLET PIPE
SIZE
(inches)
HONEYWELL
VALVE SIZE
(inches)
PRESSURE REQUIRED
REQUIRED FUEL
FLOW (SCFH) MIN ("W.C.) MAX ("W.C.)
B2-14
03-08
Table B2-7. Minimum required PROPANE GAS pressure at entrance to STANDARD UL, FM, & XL GAP gas
Table B2-8. Minimum required PROPANE GAS pressure at entrance to OVERSIZED UL, FM, & XL GAP gas
1500
1.5 1.5 6.7 28.0
2000
1.5 1.5 10.5 28.0
2500 1.5 1.5 13.3 28.0
3000 1.5 1.5 17.0 28.0
3500
2.0 2.0 14.3 28.0
4000
2.0 2.0 16.5 28.0
4500 2.0 2.0 14.8 28.0
5000 2.0 2.0 16.4 28.0
6000
2.0 2.0 19.6 28.0
1800
2000
2400
Propane @ 2500 Btu/cu-ft, specific gravity @ 1.6
1000
1200
1400
1600
800
BOILER
SIZE
INLET PIPE
SIZE
(inches)
HONEYWELL
VALVE SIZE
(inches)
PRESSURE REQUIRED
REQUIRED FUEL
FLOW (SCFH)
600
1500 2.0 2.0 5.9 28.0
2000
2.0 2.0 9.0 28.0
2.0 2.0 10.8
2.5 2.5 10.5
2.0 2.0 13.8
2.5 2.5 12.9
3.0 3.0 12.6
2.5 2.5 13.6
3.0 3.0 12.6
2.5 2.5 15.8
3.0 3.0 14.5
2.5 2.5 13.8
3.0 3.0 12.1
2.5 2.5 14.8
3.0 3.0 12.5
4.0 4.0 12.0
2.5 2.5 18.0
3.0 3.0 15.0
4.0 4.0 14.1
5000 28.0 2000
6000 28.0 2400
4000 1600
4500 1800
3000 28.0 1200
3500 1400
800
2500 28.0 1000
REQUIRED FUEL
FLOW (SCFH)
600
BOILER
SIZE
INLET PIPE
SIZE
(inches)
HONEYWELL
VALVE SIZE
(inches)
PRESSURE REQUIRED
B2-15
03-08
Table B2-9. Safety valve outlet size
PERFORMANCE DATA
Efficiency Efficiency data provided in Table B2-10 is based on low pressure steam operation.
For high pressure steam operation contact your local Cleaver-Brooks authorized
representative for expected efficiency data.
Table B2-10. Predicted efficiency, 10 psig operating (includes radiation and convection losses)
1500 1 2 3161 lbs/hr 1 1 1651 lbs/hr
2000 1 2 3161 lbs/hr 1 1-1/4 2585 lbs/hr
2500 1 2 3161 lbs/hr 1 1-1/4 2585 lbs/hr
3000 1 2 3161 lbs/hr 1 1-1/4 2585 lbs/hr
3500 1 2 3161 lbs/hr 1 1-1/2 4240 lbs/hr
4000 1 2-1/2 4676 lbs/hr 1 1-1/2 4240 lbs/hr
4500 1 2-1/2 4676 lbs/hr 1 1-1/2 4240 lbs/hr
5000 1 2-1/2 4676 lbs/hr 1 1-1/2 4240 lbs/hr
6000 1 3 6942 lbs/hr 1 2 6596 lbs/hr
** Female Pipe Thread Connection [FPT]
OUTLET SIZE
(IN.)**
VALVE
CAPACITY
15 PSIG STEAM 150 PSIG STEAM
VALVE
CAPACITY
VALVES
REQ'D
Boiler Size
OUTLET SIZE
(IN.)**
VALVES
REQ'D
SAFETY VALVE SETTING
Low Fire High Fire Low Fire High Fire
1500 81.6 81.9 84.1 84.4
2000
81.1 80.0 83.6 82.5
2500 81.6 81.5 84.1 84.0
3000 81.3 80.3 83.8 82.8
3500 81.6 81.5 84.1 84.0
4000 81.3 80.7 83.8 83.0
4500 81.1 80.9 83.6 83.4
5000 81.3 80.0 83.8 82.5
6000 81.6 79.8 84.1 82.4
Boiler Size Firing Rate
Gas Fuel Oil Fuel
Firing Rate
B2-16
03-08
Emissions The following tables give typical emission levels for Nature Gas and No. 2 Oil.
Please contact your local Cleaver-Brooks authorized representative if an emission
guarantee is required.
ENGINEERING DATA
The following engineering information is provided for the Model 4 steam boiler.
Additional information may be obtained from your local Cleaver-Brooks authorized
representative.
Feedwater Steam boilers require make-up water for steam production. This make-up can be a
combination of condensate return and raw make-up, 100% condensate return or
100% raw make-up. Proper treatment of make-up water and boiler water is
essential to the longevity and performance of the boiler. Table B2-13 shows the rate
of make-up required and Table B2-14 shows the recommended water quality
guidelines.
As a minimum, raw make-up should be piped into a water softener and then to a
feed tank, which also can be the container that receives the system condensate
returns. Chemical feed is recommended to be fed via a quill into the water make-
up line feeding the boiler.
Table B2-11. Model 4 emission
data - Natural Gas
POLLUTANT UNCONTROLLED
CO
ppm xx200
lb/MMBtu 0.15
NOx
ppm 100
lb/MMBtu 0.12
SOx
ppm 1
lb/MMBtu 0.001
HC/
VOCs
ppm 40
lb/MMBtu 0.016
PM
ppm
lb/MMBtu 0.01
Table B2-12. Model 4 emission
data - No. 2 Oil
CO
ppm 90
lb/MMBtu 0.07
NOx
ppm 187
lb/MMBtu 0.248
SOx
ppm 270
lb/MMBtu 0.515
HC/
VOCs
ppm 50
lb/MMBtu 0.025
PM
ppm
lb/MMBtu 0.025
NOTES:
Based on fuel oil constituent levels:
Fuel bound nitrogen =0.05% (max) by weight.
Sulfur =0.5% (max) by weight.
Ash =0.01% (max) by weight.
B2-17
03-08
Blowdown As steam is produced, unwanted solids are left behind in the boiler water and
become concentrated within the vessel. If these constituents are allowed to adhere
to the heat transfer surfaces, they will impede the flow of energy into the water.
Their removal requires proper blowdown that will include bottom and possibly
surface blowoff. For proper TDS control, surface blowoff with a TDS monitoring
device is recommended. Local codes will dictate the manner of treating the
blowdown affluent.
Boiler Stacks General - The Model 4 boiler operates with a positive vent pressure and a vent gas
temperature that is non-condensing. Therefore, the stack must be a positive
pressure design.
Proper design and installation of the flue gas venting is critical to efficient and safe
operation of the burner. The vent should be designed with proper supports and
clearances from combustible materials. Use insulated vent pipe spacers where the
vent passes through walls and roofs.
stack connection. Although constant pressure at the flue gas outlet is not required,
it is necessary to size the breeching and stack to limit flue gas pressure variations.
Consideration of the draft must be given where lengthy runs of breeching or
unusually high stacks are employed. Please note: the allowable pressure range for
design of the stack and breeching is negative 0.25" w.c. (-62 Pa) to a positive 0.25"
w.c. (+62 Pa) for proper light offs and combustion. NOTE: This pressure range does
not pertain to the boiler room; that is, the boiler room must be neutral or slightly
positive, never negative when using air from the boiler room for combustion.
When two or more Model 4 boilers are connected to a common breeching/stack,
one should evaluate the affects of pressure variations that may occur during boiler
sequencing while boilers are firing. It may be determined that some type of
mechanical draft system be employed to ensure proper draft at each boiler is
maintained.
Combustion Air - The burner for each boiler must be supplied with adequate volume
of uncontaminated air to support proper combustion and equipment ventilation. Air
shall be free of chlorides, halogens, fluorocarbons, construction dust or other
contaminants that are detrimental to the burner or boiler heating surfaces.
Combustion air can be supplied by means of conventional venting, that is, with
combustion air drawn from the area immediately surrounding the boiler (boiler room
Boiler Size Gallons/Minute
1500 2.5
2000 3.3
2500 4.1
3000 5
3500 5.8
4000 6.6
4500 7.5
5000 8.3
6000 9.9
Parameter Boiler Water Limit
pH 8.3 - 10.5
Iron 0.1 ppm
Oxygen 0.1 mg/liter
Specific Conductivity 2000 mho/cm
Suspended Solids 300 ppm
Total Hardness 0 ppm as CaCO
3
Table B2-13. Feedwater makeup rates Table B2-14. Water quality parameters
B2-18
03-08
is neutral or slightly positive pressure), or with a direct vent to outside the boiler
room where air is drawn directly from the exterior of the building. Regardless of the
method, all installations must comply with NFPA 54 (National Fuel Gas Code -
NFGC) for U.S. installations and CAN/CSA B149/.1 and B149.2 for Canadian
installations.
Engineered Design - When determining boiler room air requirements for the boiler,
the "Engineered Design" method may be used. Following this method, consideration
must be given to the size of the boiler room, airflow, and air velocity as follows:
A. Two permanent air supply openings in the outer walls of the boiler room are
of 7 feet. This allows air to sweep the length of the boiler. Refer to Figure B2-3.
B. Air supply openings can be louvered for weather protection, but they should not
be covered with a fine mesh wire, as this type of covering has poor air flow qualities
and is subject to clogging with dirt and dust.
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 unsafe burner performance.
D. It is forbidden to have the total area of the air supply openings at less than one
square foot.
E. Size the openings by using the formula (Area in ft
2
= cfm
a
/fpm
a
), where cfm
a
=
cubic feet per minute of air; fpm
a
= feet per minute of air.
F. Amount of air required (cfm):
1. Combustion Air = Maximum boiler horsepower (bhp) times 8 cfm.
2. Ventilation Air = Maximum boiler horsepower (bhp) times 2 cfm.
3. Total Air = 10 cfm per bhp (up to 1000 feet elevation, add 3% more per 1000
feet of added elevation).
G. Acceptable air velocity in the boiler room (fpm):
1. From floor to 7 feet high = 250 fpm.
2. Above 7 feet from boiler room floor = 500 fpm.
Example of required air openings (Engineered Method):
Determine the area of the boiler room air supply openings for [2] size 4500 Model
4 boilers at 750 feet elevation; each have a rating of 107 boiler horsepower. The
air openings will be 5 feet above the floor level.
The total boiler horsepower (bhp): 107 x 2 = 214 bhp.
From F.3 above, total air required = 214 bhp x 10 = 2140 cfm.
Air Velocity: From G.1 above = 250 fpm.
Area required: From the formula in E above, 2140 cfm/250 fpm = 8.56 square
feet total.
Area opening: 8.56 divided by 2 = 4.28 ft
2
per opening (2 required).
Notice
See Table B2-15 for combustion air and flue gas flow.
B2-19
03-08
Table B2-15. Model 4 fuel, combustion air, and flue gas flow rates
Figure B2-3. Boiler room air supply - Engineered Design
1500 2000 2500 3000 3500 4000 4500 5000 6000
Gas cfh 1500 1500 2500 3000 3500 4000 4500 5000 6000
Oil gph 10.72 14.29 17.86 21.43 25.00 28.57 32.14 35.71 42.85
scfh 15,480 20,640 25,800 30,960 36,120 41,280 46,440 51,600 61,920
lb/hr 1207 1609 2012 2414 2817 3219 3621 4024 4828
scfh 17,049 22,733 28,414 34,098 39,782 45,463 51,147 56,831 68,196
lb/hr 1269 1692 2115 2538 2961 3384 3808 4231 5077
scfh 17,520 23,360 29,200 35,040 40,880 46,720 52,560 58,400 70,080
lb/hr 1,278 1,704 2,130 2,556 2,983 3,409 3,835 4,261 5,113
scfh 17,914 23,886 29,855 35,827 41,799 47,769 53,741 59,713 71,655
lb/hr 1,357 1,809 2,261 2,714 3,166 3,618 4,070 4,523 5,427
Notes: A. Gas consumption, expressed in cubic feet per hour, is based on 1,000 Btu/cu.ft gas value.
B. Oil consumption,expressed in pounds per hour, is based on 140,000 Btu/gal oil value.
C. Oil supply lines must be sized for 125 gph pumping rate. Oil pump suction pressure to be -10" Hg to 3 psig.
Fuel Consumpion
Combustion Air
Flue Gas
Boiler Size
Gas
Oil
Gas
Oil
GAS
VENT
EXTERIOR WALL
FRESH AIR OPENING
EXTERIOR WALL
FRESH AIR OPENING
B2-20
03-08
Oil Piping General - Oil operation of the Model 4 boiler requires proper oil to the standard
burner mounted oil pump. As the combustion of oil utilizes mechanical pressure
atomization, line sizing to the pump must be sufficient to provide 125 gph of oil to
the suction side of the pump.
Oil Train Components - Oil flow to the burner is controlled by four solenoid valves.
The oil flows through a primary or safety shutoff valve into a manifold block. This
valve and the low fire valve are energized simultaneously by the flame safeguard
control and when opened, allow flow of oil to the low fire nozzle.
As the damper motor moves to high fire position, the damper motor end switches
close to energize in sequence, the intermediate and then high fire oil valve. The
purpose of the intermediate valve is to smooth the transition from low to high fire by
balancing the oil input with increasing flow of air.
High fire rating of the burner is obtained when all three nozzles are firing, assuming
proper oil pressure and normally sized nozzles.
Gas Piping General - The Model 4 boiler requires appropriate gas supply pressure and volume
for proper operation and long burner life. The gas requirements specified in this
section must be satisfied to ensure efficient and stable combustion. Installation
must follow these guidelines and of the local authorities that have installation
jurisdiction.
Gas Train Components - Model 4 boilers are equipped with a gas train that meets
the requirements of UL as standard. These components also comply with the
recommendations of FM, XL GAP (formerly IRI/GE GAP) and ASME CSD-1. The
gas train and its components have been designed and tested to operate for the
highest combustion efficiency.
Gas Pressure Requirements - For proper and safe operation, each Model 4 boiler
requires a stable gas pressure supply. The pressure requirements are listed in
previous sections for standard gas train size, and oversized trains for reduced
available pressure.
Gas Piping - Model 4 units are standardly equipped with a gas pressure regulator.
If upstream pressure to the standard regulator will be greater than 1 psig, an
additional upstream regulator should be provided with a pressure relief valve.
For buildings or boiler rooms with gas supply pressure exceeding 28" w.c., a "full
lockup" type regulator is recommended along with proper overpressure protection.
In addition to the regulator, a plug type or "butterball" type gas shutoff cock should
be provided upstream of the regulator for use as a service valve. This is also
required to provide positive shutoff and isolate the boiler gas train during gas piping
tests.
Drip legs are required on any vertical piping at the gas supply to each boiler so that
any dirt, weld slag, or debris can deposit in the drip leg rather than into the boiler
gas train. The bottom of the drip leg should be removable without disassembling
any gas piping. The connected piping to the boiler should be supported from pipe
supports and not supported by the boiler gas train or the bottom of the drip leg.
All gas piping and components to the boiler gas train connection must comply with
NFPA 54, local codes, and utility requirements as a minimum. Only gas approved
fittings, valves, or pipe should be used. Standard industry practice for gas piping is
normally Schedule 40 black iron pipe and fittings.
B2-21
03-08
Gas Supply Pipe Sizing - For proper operation of a single unit or multiple units, we
recommend that the gas pipe be sized to allow no more than 0.3" w.c. pressure
drop from the source (gas header or utility meter) to the final unit location. The gas
supplier (utility) should be consulted to confirm that sufficient volume and normal
pressure are provided to the building at the discharge side of the gas meter or
supply pipe (for installations of new boilers into an existing building, gas pressure
should be measured with a manometer to ensure sufficient pressure is available).
A survey of all connected gas using devices should be made. If appliances other
than the boiler are connected to the gas supply line, then a determination should be
made of how much flow volume (cfh = cubic feet per hour) will be demanded at
one time and the pressure drop requirements when all appliances are operating.
The total length of gas piping and all fittings must be considered when sizing the gas
piping. Total equivalent length should be calculated from the utility meter or source
to the final connection. As a minimum guideline, gas piping Tables B2 - 16 through
B2 - 20 should be used. The data in these tables is from the NFPA source book,
2006 edition.
B2-22
03-08
Table B2-16. Gas line capacity - Schedule 40 metallic pipe
Pipe Size
Nominal 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
Actual I.D. 1.049 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"
Length in feet **Maximum Capacity in Cubic Feet of Gas per Hour (cfh)
10 514 1,060 1,580 3,050 4,860 8,580 17,500
20 363 726 1,090 2,090 3,340 5,900 12,000
30 284 583 873 1,680 2,680 4,740 9,660
40 243 499 747 1,440 2,290 4,050 8,290
50 215 442 662 1,280 2,030 3,590 7,330
60 195 400 600 1,160 1,840 3,260 6,640
70 179 368 552 1,060 1,690 3,000 6,110
80 167 343 514 989 1,580 2,790 5,680
90 157 322 482 928 1,480 2,610 5,330
100 148 304 455 877 1,400 2,470 5,040
125 131 269 403 777 1,240 2,190 4,460
150 119 244 366 704 1,120 1,980 4,050
175 109 209 336 648 1,030 1,820 3,720
200 102 185 313 602 960 1,700 3,460
**Fuel: Natural Gas
**Inlet Pressure: Less than 2.0 psi
**Pressure Drop: 0.30" w.c.
**Specific Gravity: 0.60
Pipe Size
Nominal 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
Actual I.D. 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"
10 678 1,390 2,090 4,020 6,400 11,300 23,100
20 466 957 1,430 2,760 4,400 7,780 15,900
30 374 768 1,150 2,220 3,530 6,250 12,700
40 320 657 985 1,900 3,020 5,350 10,900
50 284 583 873 1,680 2,680 4,740 9,600
60 257 528 791 1,520 2,430 4,290 8,760
70 237 486 728 1,400 2,230 3,950 8,050
80 220 452 677 1,300 2,080 3,670 7,490
90 207 424 635 1,220 1,950 3,450 7,030
100 195 400 600 1,160 1,840 3,260 6,640
125 173 355 532 1,020 1,630 2,890 5,890
150 157 322 482 928 1,480 2,610 5,330
175 144 296 443 854 1,360 2,410 4,910
200 134 275 412 794 1,270 2,240 4,560
**Fuel: Natural Gas
B2-23
03-08
Pipe Size
Nominal 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
Actual I.D. 0.622 0.824 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"
Length in
feet
**Maximum Capacity in Cubic Feet of Gas per Hour (cfh)
10
1,510 3,040 5,560 11,400 17,100 32,900 52,500 92,800 189,000
20
1,070 2,150 3,930 8,070 12,100 23,300 57,100 65,600 134,000
30
869 1,760 3,210 6,590 9,880 19,000 30,300 53,600 109,000
40
753 1,520 2,780 5,710 8,550 16,500 26,300 46,400 94,700
50
673 1,360 2,490 5,110 7,650 14,700 23,500 41,500 84,700
60
615 1,240 2,270 4,660 6,980 13,500 21,400 37,900 77,300
70
569 1,150 2,100 4,320 6,470 12,500 19,900 35,100 71,600
80
532 1,080 1,970 4,040 6,050 11,700 18,600 32,800 67,000
90
502 1,010 1,850 3,810 5,700 11,000 17,500 30,900 63,100
100
462 954 1,710 3,510 5,260 10,100 16,100 28,500 58,200
125
414 836 1,530 3,140 4,700 9,060 14,400 25,500 52,100
150
372 751 1,370 2,820 4,220 8,130 13,000 22,900 46,700
175
344 695 1,270 2,601 3,910 7,530 12,000 21,200 43,300
200
318 642 1,170 2,410 3,610 6,960 11,100 19,600 40,000
500
192 401 717 1,470 2,210 4,250 6,770 12,000 24,400
1000
132 275 493 1,010 1,520 2,920 4,650 8,220 16,800
1500
106 221 396 812 1,220 2,340 3,740 6,600 13,500
**Fuel: Natural Gas
**Inlet Pressure: 2.0 psi
**Pressure Drop: 1.0 psi
B2-24
03-08
Pipe Size
Nominal 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
Actual I.D. 0.622 0.824 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"
Length in
feet
10
2,350 4,920 9,270 19,000 28,500 54,900 87,500 155,000 316,000
20
1,620 3,380 6,370 13,100 19,600 37,700 60,100 106,000 217,000
30
1,300 2,720 5,110 10,500 15,700 30,300 48,300 85,400 174,000
40
1,110 2,320 4,380 8,990 13,500 25,900 41,300 75,100 149,000
50
985 2,060 3,880 7,970 11,900 23,000 36,600 64,800 132,000
60
892 1,870 3,520 7,220 10,300 20,300 33,200 58,700 120,000
70
821 1,720 3,230 6,640 9,950 19,200 30,500 54,000 110,000
80
764 1,600 3,010 6,180 9,260 17,800 28,400 50,200 102,000
90
717 1,500 2,820 5,800 8,680 16,700 26,700 47,100 96,100
100
677 1,420 2,670 5,470 8,200 15,800 25,200 44,500 90,300
125
600 1,250 2,360 4,850 7,270 14,000 22,300 39,500 80,500
150
544 1,140 2,140 4,400 6,590 12,700 20,200 35,700 72,900
175
500 1,050 1,970 4,040 6,060 11,700 18,600 32,900 67,100
200
465 973 1,830 3,760 5,640 10,900 17,300 30,600 62,400
500
283 593 1,120 2,290 3,430 6,610 10,300 18,600 38,000
1000
195 407 897 1,380 2,360 4,550 7,240 12,000 26,100
1500
156 327 616 1,270 1,900 3,650 5,820 10,300 21,000
**Fuel: Natural Gas
B2-25
03-08
Pipe Size
Nominal 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
Actual
I.D.
0.622 0.824 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"
Length
in feet
10
3,190 6,430 11,800 24,200 36,200 69,700 111,000 196,000 401,000
20
2,250 4,550 8,320 17,100 25,600 49,300 78,600 139,000 283,000
30
1,840 3,720 6,790 14,000 20,900 40,300 64,200 113,000 231,000
40
1,590 3,220 5,880 12,100 18,100 34,900 55,600 98,200 200,000
50
1,430 2,880 5,260 10,800 16,200 31,200 49,700 87,900 179,000
60
1,300 2,630 4,800 9,860 14,800 28,500 45,400 80,200 164,000
70
1,200 2,430 4,450 9,130 13,700 26,400 42,000 74,300 151,000
80
1,150 2,330 4,260 8,540 12,800 24,700 39,300 69,500 142,000
90
1,060 2,150 3,920 8,050 12,100 23,200 37,000 65,500 134,000
100
979 1,980 3,620 7,430 11,100 21,400 34,200 60,400 123,000
125
876 1,770 3,240 6,640 9,950 19,200 30,600 54,000 110,000
150
786 1,590 2,910 5,960 8,940 17,200 27,400 48,500 98,900
175
728 1,470 2,690 5,520 8,270 15,900 25,400 44,900 91,600
200
673 1,360 2,490 5,100 7,650 14,700 23,500 41,500 84,700
500
384 802 1,510 3,100 4,650 8,950 14,300 25,200 51,500
1000
264 551 1,040 2,130 3,200 6,150 9,810 17,300 35,400
1500
212 443 834 1,710 2,570 4,940 7,880 13,900 28,400
**Fuel: Natural Gas
B2-26
03-08
Figure B2-4. Typical gas header piping
B2-27
03-08
Section B2
Model 4 Boiler
Submittals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-28
Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-28
Guarantees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-28
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-28
Design Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-28
Product Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-29
Burner Management System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-33
Shop Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-34
Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-34
StartUp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-34
Operation and Maintenance Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-35
The following sample specifications are provided by Cleaver-Brooks to assist you in specifying your customers specific
needs and application.
Model 4 Steam Boiler Specifications Section B2
B2-28
03-08
PART 1 GENERAL 1.1 SUBMITTALS
A. The manufacturer shall supply ____copies of a dimensional drawing
indicating all relevant unit dimensions, layout and required
clearances.
B. The manufacturer shall supply ____copies of a ladder type wiring
diagram to include all internal unit wiring, external connections, and
power supply requirements.
C. The manufacturer shall supply a copy of the authorized inspection
report, to the purchaser, upon completion and shipment of the unit.
1.2 CODES
A. The boiler shall be designed, constructed, and hydrostatically tested
in accordance with the ASME Boiler and Pressure Vessel Code.
B. The boiler shall be wired in accordance with the rules of the
National Electric Code.
C. All electrical equipment shall be in conformity with the Underwriters
Laboratories requirements.
D. The complete boilerburner package shall be approved by
Underwriters Laboratories and shall bear a UL label.
E. The boiler shall be built to comply with the following insurances
_______________. (Factory Mutual, XL-GAP, ASME CSD1)
1.3 GUARANTEES
A. The complete boiler package shall be warranted from defects in
materials and/or workmanship for a period of not less than 18
months from shipment or 12 months from unit startup.
PART 2 PRODUCTS 2.1 TYPE
A. The boiler shall be a watertube type steam boiler with all steel
membrane walls.
B. The boiler shall be a three gas pass type boiler mounted on a heavy
duty steel frame.
C. The boiler shall have an integral forced draft burner and burner
controls.
D. The boiler shall be a Cleaver Brooks Model 4, series ________(100
= No. 2 oil, 200 = No. 2 oil and gas, 700 = gas) steam boiler.
2.2 DESIGN CRITERIA
A. The boiler shall be designed in accordance with the ASME Boiler
and Pressure Code Section _____(IV for low pressure, I for high
pressure).
B. The boiler shall be designed for _____psig (15, 150, 250, 350, or
500). The maximum operating pressure will be _____psig.
C. The boiler shall be designed for a maximum output of ________lbs/
hr of steam, or _________bhp. The boiler shall develop ________
lbs/hr of steam when operating at ______psig with a feedwater
temperature of ______F.
D. Electrical power available will be _______volts, _______phase,
______Hz.
Section B2 Model 4 Steam Boiler Specifications
B2-29
03-08
E. The maximum sound level shall not exceed 80 dBA measured 3 feet
in front of the boiler.
2.3 PRODUCT DESIGN
A. Pressure Vessel
1. The upper drum shall have a 20" OD, manufactured from SA
53 Gr. B seamless pipe, with a minimum wall thickness of
0.375".
2. The lower drum shall have an 85/8" OD, manufactured from
SA53 Gr. B seamless pipe, with a minimum wall thickness of
0.322".
3. The generating tubes shall be 2" OD, manufactured from SA
178 Gr. A tubing, with a minimum wall thickness of 0.095".
4. The boiler shall have two downcomers, located at the rear of
the boiler, and be totally insulated from the generating tubes.
These shall be a minimum of 21/2" OD, manufactured from
SA178 Gr. A tubing, with a minimum wall thickness of .105".
5. The upper drum shall have an inspection opening, located at
the rear of the unit, to allow internal inspection, and shall be a
minimum of 4"x6".
6. The lower drum shall have inspection openings, located at the
front and rear of the unit, to allow internal inspection, and shall
be a minimum of 4-7/8" x 5-7/8".
7. The boiler shall have inspection openings in the convection
area.
8. A feedwater tapping and integral feedwater distribution pipe
shall be located in the upper drum. The distribution pipe shall
blend the feedwater with the boiler water.
9. A 3/4" surface blowoff connection shall be located in the rear
head of the upper drum.
10. A _____" bottom blowoff connection shall be located in the
lower drum.
B. Refractory
1. Refractory shall be limited to the furnace floor to insulate the
lower drum, and to the burner throat tile.
2. High temperature insulation shall be installed on the front wall
of the furnace.
C. Insulation and Casing
1. The boiler insulation shall be a minimum of 2" fiberglass, and
shall cover the entire pressure vessel.
2. The insulation shall be covered with a corrugated metal
lagging.
3. The metal lagging and insulation shall be arranged for easy
removal and installation if required.
4. The front head (windbox) shall be attached with a davit arm,
gasket sealed, and bolted. The front head shall swing open to
provide full access to the furnace chamber and burner throat
tile.
B2-30
03-08
5. Observation ports shall be provided at each end of the boiler for
visual inspection of the pilot and main flame conditions.
7. The exhaust gases shall vent at the rear of the boiler, on the top
centerline.
D. Trim
1. The water column shall be located on the left side of the boiler.
It shall be piped with unions for easy removal.
2. A gauge glass set, gauge glass blowdown valve, and water
column blowdown valve shall be provided.
3. The boiler feedwater control switch shall be included as an
integral item of the water column. It shall provide automatic
actuation of a motor driven feedwater pump or valve to
maintain the boiler water level within normal limits.
4. The primary low water cutoff switch shall be an integral part of
the water column. It shall be wired into the burner control
circuit preventing burner operation if the boiler water level falls
below the designated safe level.
5. A steam pressure gauge shall be located at the front end of the
boiler and shall include a cock and test connection.
6. A safety relief valve shall be provided of a size and type to
comply with ASME Code requirements. The safety relief valve
set pressure shall be ______psig.
7. A high limit pressure control shall be provided. It shall be a
manual reset type and shall be wired to prevent burner
operation and lockout if excessive steam pressure occurs.
8. An operating limit control shall be provided. It shall be wired to
provided on off control of the burner at operating set points.
9. A firing rate control shall be provided. It shall control the firing
rate of the burner based on the boiler load.
10. An auxiliary low water cutoff shall be provided (manual reset
type). It shall be wired into the burner control circuit preventing
burner operation if the boiler water level falls below the
designated safe level.
11. A stack thermometer shall be shipped loose for field
installation.
E. Soot Cleaning
1. Soot washer lances shall be provided in the convection area of
the boiler measuring the full length of the pressure vessel.
2. Each lance shall be provided with a shutoff valve and the
assembly shall be capable of rotating 360 degrees. This shall
ensure complete washing of the convection zone while the
boiler is operating in the low fire mode.
3. Soot washer troughs shall be provided at the bottom of the
boiler. These shall be furnished for each convection side and
shall The soot washer troughs shall be provided with 2" drain
connections at the rear of the boiler, and shall have inspection/
cleanout openings at the front of the boiler.
B2-31
03-08
F. Burner Design General
1. The burner shall be integral to the windbox.
2. All air for combustion shall be supplied by a forced draft blower
mounted in the windbox, above the burner, to minimize noise
and vibration level.
3. The blower motor shall be an open drip proof type with a
minimum service factor of 1.15.
4. The impeller shall be an enclosed centrifugal fan type, properly
5. The combustion air damper shall be integral to the windbox
and shall be operated by a single damper motor.
6. The burner shall remain in the low fire position during ignition
and until main flame has been established.
7. A combustion air proving switch shall be provided to ensure
adequate air for pre-purge and combustion.
G. Burner Design Gas
1. The burner shall be the high radiant multiport type approved
for operation with natural gas.
2. The burner shall operate on the _______________(lowhigh
low or full modulation) principle and must return to the low fire
position prior to ignition.
3. Automatic electric ignition of the premix gas pilot shall be
furnished. An electric scanner, of the UV principle, shall
monitor the pilot, preventing the primary fuel valve from
opening until the pilot flame has been established.
4. The single combustion air damper motor shall operate the gas
butterfly valve. The damper motor shall regulate the fire
according to system demand in response to the firing rate
control.
H. Burner Design No. 2 Oil
1. The burner shall be the pressure atomizing type approved for
operation with commercial grade No. 2 oil.
2. The burner shall operate on the lowhighlow principle, and
must return to the low fire position prior to ignition.
and until main flame has been proven. The ignition period
shall be monitored with an electric scanner, of the UV principle,
to confirm the presence of the low fire oil flame.
4. Automatic electric ignition of the low fire oil supply shall be
provided with a minimum 10,000 volt transformer and heavy
duty electrodes.
Notice
Optional insurance compliance may require a premix gas pilot in lieu of direct spark
ignition.
B2-32
03-08
5. [Optional] Automatic electric ignition of the premix gas pilot
shall be furnished. An electric scanner, of the UV principle,
shall confirm the pilot prior to the delivery of the low fire oil
supply.
6. The single combustion air damper motor shall operate the low
and high fire oil valves. The damper motor shall regulate the
fire according to system demand in response to the firing rate
control.
I. Burner Design Gas and No. 2 Oil
1. The burner shall be the high radiant multiport type for gas and
shall be the pressure atomizing for oil. The burner must be
approved for operation with either natural gas or commercial
grade No. 2 oil.
2. The burner shall operate on the lowhighlow principle, and
and until main flame has been proven.
furnished. An electric scanner, of the UV principle, shall
monitor the pilot, preventing the primary fuel valve from
opening until the pilot flame has been established.
5. The single combustion air damper motor shall operate the low
and high fire oil valves and the gas butterfly valve. The damper
motor shall regulate the fire according to system demand in
response to the firing rate control.
J. Main Gas Train
1. The gas burner piping shall include a primary gas shutoff valve.
It shall be controlled by the programming relay to start or stop
the burner and to close automatically in the event of power
failure, flame failure, or a low water condition.
2. A manual shutoff valve shall be located ahead of the primary
gas valve.
3. A plugged leakage test connection and a second manual shutoff
valve shall be provided as a means for a tightness check of the
primary shutoff valve.
4. A gas pressure regulator shall be factory mounted and piped for
pressure regulation to the burner.
5. Gas Train Components
a. [Sizes 15002500] The primary gas shutoff valve shall
be motorized with a proof of closure switch.
b. [Sizes 30005000] The primary gas shutoff valve shall
be motorized with a proof of closure switch. High and low
gas pressure switches shall be provided.
c. [Size 6000] The primary gas shutoff valve shall be
motorized with a proof of closure switch. A second gas
safety shutoff valve and an additional plugged leakage test
cock shall be provided. High and low gas pressure
switches shall be provided.
B2-33
03-08
K. Natural Gas Pilot Train
1. A pilot gas pressure regulator shall be factory mounted and
piped for pressure regulation of the pilot gas to the burner.
2. The pilot gas train shall include a safety shutoff valve. It shall
be controlled by the programming relay to start the burner.
3. A manual shutoff valve shall be located ahead of the pilot gas
pressure regulator.
L. 2.3.12 Oil System
1. An oil pump shall be provided. The oil pump, integral with the
burner, shall include a builtin relief valve and selfcleaning
strainer.
2. The oil pump shall be belt driven from the blower motor.
3. The fuel oil system shall include supply and return tubing to a
terminal block, an oil pressure gauge, shutoff cock, and four
solenoid oil shutoff valves. These items shall be factory
mounted and piped on the front head (windbox).
2.4 BURNER MANAGEMENT SYSTEM
A. Control Panels
1. The control panel shall be a NEMA 1 rated panel and have a
key lock.
2. The control panel shall be mounted on the front head of the
boiler and shall be conveniently located for the boiler operator.
3. The panel shall contain the blower motor starter, control circuit
fuses, control circuit transformer, and control switches. A
damper selector switch shall be provided to permit selection of
automatic or manual selection of low or high firing.
4. A terminal board shall be provided to which all wires entering
or leaving the panel shall be connected.
5. The panel shall include four indicating lights to show operating
conditions of: red = low water; red = flame failure; white =
load demand; and white = fuel valve open. The lights and
switches shall be located on the panel switch ledge.
6. All electrical service connections shall be made to an electrical
entrance box to be mounted on the right hand side of the boiler.
7. All electrical wiring shall be oil, heat, and moisture resistant
and shall be number coded.
B. Combustion Safeguard Control
1. A combustion safeguard control (program relay) shall be
provided to control ignition, starting, and stopping of the
burner. It shall provide precombustion and postcombustion
purge periods and shall stop burner operation in the event of
ignition, pilot, or main flame failure. Trial for ignition shall be
limited to 10 seconds.
2. The boiler shall be provided with a combustion safeguard
controller that provides technology and functions equal to the
Cleaver Brooks Model CB120E.
B2-34
03-08
3. The combustion safeguard control shall be microprocessor
based, with selfdiagnostics, nonvolatile memory, and a
message center with a vocabulary of 42 different messages.
Messages shall scroll across an alphanumeric display and
provide sequence status and flame failure mode information.
4. The combustion safeguard control shall have a fixed operating
sequence incapable of being manually altered. The sequence
shall include start, pre purge, pilot and main fuel ignition run,
and postpurge cycles.
5. The controller shall be the nonrecycle type for maximum
safety that will shut down the burner and indicate as a
minimum the following trip functions: pilot failure, main flame
failure, high and low fire proving switch faults, running
interlocks open, false flame signal, and fuel valve open.
6. The controller shall have a test/run switch. It will allow
interruptions to sequence just after prepurge, during pilot
ignition trial, and during run cycles, for adjustments to firing
rate motor, damper linkages, and pilot flame for turndown
tests.
7. The controller shall also have the following functions: display
history of operating hours and totals of completed onoff
cycles; provide a constant flame signal strength readout; and
have provisions for remote display capability and Modbus
communication.
PART 3 EXECUTION 3.1 SHOP TESTS
A. The pressure vessel shall be hydrostatically tested in accordance
with ASME requirements.
B. The boiler will be test fired by the manufactured, prior to shipment,
to verify proper and safe operation.
3.2 SHIPMENT
A. Painting
1. The entire boiler, base frame, and other components shall be
factory painted, before shipment, using a hard finish enamel.
2. The boiler surface shall be cleaned/prepared for painting using
manufacturer's specifications and standard industrial painting
practices.
B. Preparation
1. All boiler openings shall be plugged/covered prior to shipment.
2. The boiler shall be skid mounted and protected with a weather
resistant covering.
3. All shipped loose components shall wrapped in protective
material and packaged in a separate container(s).
3.3 INSTALLATION
3.4 STARTUP
A. The boiler startup shall be performed by a factory trained
representative and will be done in accordance with the
manufacturer's recommended procedures.
B2-35
03-08
B. The boiler startup shall include boiler operator training and shall
cover boiler operation, water treatment, and maintenance of the
unit.
3.5 OPERATION AND MAINTENANCE MANUALS
Manufacturer shall supply _____copies of the Operating & Maintenance Manual.
B2-36
03-08
Notes
B3-1
06-08
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-4
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-4
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-5
Special Insurance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-7
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-20
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-20
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-20
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-21
Feedwater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-21
Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-21
Boiler Stacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-21
Oil Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-23
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-23
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-31
Section B3
MODEL 5 BOILERS
Model M5 Boilers Commercial Boilers
B3-2
06-08
ILLUSTRATIONS
Model 5 Steam Boiler Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-8
Model 5 Low Water Volume Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-11
Standard Gas Train Model 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-16
Boiler Room Air Flow - Engineered Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-23
TABLES
Model 5 Boiler Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-4
Model 5 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-9
Model 5 connection sizes and clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-10
Model 5 Low Water Volume dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-12
Model 5 Low Water Volume connection sizes and clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-13
Model 5 Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-14
Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity) . . . . . . . . . . . . B3-15
Model 5 Oil Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-15
Model M5 min. req. Natural Gas pressure UL, FM & XL GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-17
Model M5 min. req. Natural Gas pressure UL, FM & XL GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-17
Model M5 min. req. Propane Gas pressure UL, FM & XL GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-18
Model M5 min. req. Propane Gas pressure UL, FM & XL GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-19
Safety Valve Outlet Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-19
Predicted Efficiency, 10 PSIG operating (includes radiation and convection losses) . . . . . . . . . . . . . . B3-20
Model 5 Emission Data, Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-20
Emission Data, No. 2 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-20
Gas line capacity - Schedule 40 metallic pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-25
Sound Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-29
Water Quality Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-29
Feedwater Make-up Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-29
Model 5 Fuel, Combustion Air, and Flue Gas Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-30
The Model 5 Commercial Watertube Boiler product line is used for low and high pressure steam applications. Sizes
range from 1.5 to 8 MMBtu/hr. The Model 5 Boiler is an excellent choice where high outputs are required but space
limitations exist. The model number designation is 1500 through 8000, representing MBtu/hr input (1,500,000 to
8,000,000 Btu/hr).
Fuel series designation is as follows:
Series 100: No. 2 oil firing.
Series 700: Natural gas firing.
Series 200: No. 2 oil/natural gas firing.
Design pressure designation is stated as 15 psig, 150 psig, and 250 psig for steam, and 140 psig for hot water. For
example, a Model M5P-700-2500-150 boiler designates a gas-fired, 2,500,000 Btu/hr, 150 psig, steam boiler.
Commercial Boilers Model M5 Boilers
B3-3
06-08
33" Cased Width:
Boiler fits through most standard doorways.
Direct Driven, Vibration-Free Centrifugal Impeller:
Quiet operation.
Sound levels below 80 dbA.
Ideal for noise critical areas such as hospitals, churches, etc.
Minimum Refractory:
Membrane waterwalls reduce the need for refractory by 95%.
Reduced maintenance costs and refractory repair requirements.
Membrane Waterwalls:
Enhanced heat transfer area in compact design.
Sealed combustion chamber improves heat transfer for high efficiency.
Small Boiler Footprint:
Savings of up to 50% in floor space.
Weighs up to 40% less than Comparable Boilers:
Lower freight and rigging costs.
Reduced structural requirements.
Standard Built-in Soot Washers:
Boiler cleaning without shutdown.
Maintains peak boiler performance.
Packaged Forced Draft Burner:
High pressure drop design.
Improved combustion efficiency.
Low Water Volume Design (optional):
Meets various provincial operating engineer codes and regulations.
Reduced operating costs.
High and low pressure steam.
Steam Design Pressures to 500 psig:
High performance in a compact design.
Proven vessel design for high design pressure applications.
B3-4
06-08
PRODUCT OFFERING
The Model 5 (M5) Boiler is a compact carbon steel, extended fin, watertube boiler.
Heat transfer design is configured in a "3-pass" gas travel across the watertube
surfaces. The pressure vessel is constructed to conform to the A.S.M.E. Code,
either Section IV for low pressure steam @ 15 PSIG MAWP (maximum allowable
working pressure) or Section I for MAWP greater than 15 PSIG.
The vessel (boiler) consists of two rows on each side of the vessel, of formed
seamless tubes with extended fin surfaces and downcomers connected to the steam
drum and lower drum. To reduce standby losses, the vessel is insulated with a
fiberglass blanket and removable steel jacket.
Complete with an integral burner for either No.2 fuel oil or Natural Gas, the
complete burner/boiler package is CSA International Approved, listed, and labeled.
Standard Equipment The standard boiler/burner package is described below. Optional controls, trim, and
devices may be added to meet project requirements, and some of those options are
noted, following this standards list.
1. Boiler
A. Designed, constructed, and hydrostatically tested in accordance with the
A.S.M.E. Boiler and Pressure Vessel Code. The complete vessel is mounted on a
structural steel frame.
B. Steam drum includes a hand hole in the rear head for drum water side
inspection. Connections are included for the following:
Feedwater Makeup w/internal dispersion tube.
MODEL
NO.
INPUT
MBH
HEAT
OUTPUT
MBH
EQUIV
HP
STEAM
OUTPUT
LB/HR
SHIPPING
WEIGHT
LBS
1500 1500 1200 35 1237 3100
2000 2000 1600 47 1649 3100
2500 2500 2000 59 2062 3700
3000 3000 2400 71 2474 3700
3500 3500 2800 83 2887 4100
4000 4000 3200 95 3299 4100
4500 4500 3600 107 3711 4700
5000 5000 4000 119 4124 4700
6000 6000 4800 143 4949 5400
8000 LWV 8000 6320 194 6516 6200
NOTE: Steam output from and at 212 F.
LWV = Low Water Volume.
Table B3-1. Model 5 Boiler Sizes
B3-5
06-08
Surface Blowoff.
Steam Supply.
Safety Relief Valve.
C.Lower Drum includes hand holes at each end for waterside inspection. A drain/
blowoff tapping is provided at the front, bottom centerline.
D.Soot washer lances are provided on each side of the vessel between the two rows
of tubes for fireside cleaning. Soot washer drains are located at the bottom of the
boiler, with connections to drain located on each side of the lower drum at the rear.
E.Refractory is limited to the furnace floor, lower drum, and burner throat tile. High
temperature insulation is installed on the front water wall and furnace access door.
F.Two lifting eyes are provided on the top centerline of the upper drum for ease of
installation.
G.Furnace inspection/access door is provided in the furnace rear wall.
The exhaust gas vent is located at the top rear centerline of the boiler. A stack
thermometer is shipped loose for field installation by the installing contractor into
the stack.
I.The complete vessel is fully insulated (2" fiberglass blanket) under a preformed,
sectional steel jacket.
J.Factory painted using hard-finish enamel.
1. Steam Boiler Control Standard Equipment (15 to 150 psig)
A. ASME safety relief valve(s).
B. Steam pressure gauge.
C. Pressure controls:
High limit control-manual reset.
Operating limit control.
High-low fire control (full modulation for gas firing).
D. D. Low water cutoff with pump control.
E. E. Water column gauge glass set and fittings.
F. F. Auxiliary low water cut-off.
G. G. Combustion air proving switch.
2. Electrical Control Panel
A. Mounted at eye level on the front head of the boiler.
B. NEMA rating 1A with gasket dust seal.
C. Contains electronic program relay and switches.
3. Miscellaneous
A. The boiler is Canadian Standards Association (CSA) approved and bears the
CSA label.
Optional Equipment Optional Equipment
For more detailed information on optional equipment, contact the local Cleaver-
Brooks authorized representative. In summary, options include the following:
1. Boiler
B3-6
06-08
Larger pressure gauges or specific manufacturer type.
Bottom Drain Valves for low pressure applications.
Bottom Blowoff Valves for high pressure applications.
Surface Blowoff Valve with internal collector pipe.
Feedwater Stop and Check Valves.
Steam Stop Valve.
ASME Hydro Test of Valves and Valve Piping.
Design pressures above 150 PSIG.
Full Modulation Firing on Gas.
Lead/Lag Control.
Day-Night Controls.
Low Fire Hold Control.
Elapsed Time Meter.
Alarm with silence switch.
Additional Indicator Lights.
Main Power Disconnect.
Remote Oil Pump.
Optional NEMA Enclosures.
Special Fan Motor requirements (TEFC).
3. Fuel Options
Automatic Fuel Changeover (combination burner).
Propane Fuel Firing.
Special Gas Pressure Regulators.
Dual Pilots (gas and oil).
Gas strainer.
"Guarded Plant" status equipment.
4.Low Water Volume Design Options (LWV)
5.Guarded Plant Requirements
Notice
*Not required for low pressure steam applications.
Special Insurance
Requirements
The boiler package can be equipped to meet various insurance or code
requirements. Some of these insurance/code requirements are:
Factory Mutual (FM)
B3-7
06-08
XL GAP (Formerly GE GAP/IRI).
A.S.M.E. CSD-1.
Factory Mutual (FM Global) - Recommended guidelines as described by FM pertain
to boilers rated at greater than 2.5 MMBtu/hr input on gas and 2.8 MMBtu/hr input
on oil. Boilers that are labeled and tested in accordance with an independent
testing lab such as UL or CSA and are below these inputs are exempt from these
recommendations.
The Model 5 boiler is CSA listed and labeled. In addition to the standard CSA
requirements the following are needed to comply with FM when required.
Alarm Bell with silence switch for low water and safety shutdowns.
Low Oil Pressure Switch if the oil pump is not direct driven from the fan motor.
XL GAP (Formerly GE GAP/IRI) Recommended guidelines as described by XL GAP
pertain to boilers rated at 400,000 Btu/hr input to 12.0 MMBtu/hr input. For these
boilers, the requirements are the same as for A.S.M.E CSD-1 requirements. Above
12.0 MMBtu/hr input, the requirements defer to the NFPA 85 standards for single
burner boilers.
A.S.M.E. CSD-1 - Recommended guidelines as described by this Code pertain to
boilers rated at 400,000 Btu/hr input to 12.0 MMBtu/hr input. Above 12.0
MMBtu/hr input, the requirements defer to the NFPA 85 standards for single burner
boilers. . For the sizes this Code covers, the requirements are as follows, in addition
to the standard CSA package:
Low Oil Pressure Switch for oil firing all sizes.
" Pressure Control Piping
If gas supply is > 5 psig, a relief valve is required after the gas pressure regulator in
the main and pilot gas trains.
Lever Handled shutoff cock for the pilot gas train.
Non-fused disconnect to remove boiler from all sources of power.
For layout purposes, the nominal dimensions and connections for the Model 5
Standard Boiler Packages are shown in Figure B3-1 and Tables B3-1 and B3-2.
Low Water Volume (LWV) Package Boiler Dimensions are shown on Figure B3-2
and Table B3-3 and B3-4. Ratings of each boiler size are noted in Table B3-5.
Additional information is shown in the following figures, tables, and illustrations.
Table B3-6 Recommended steam nozzle sizes for high pressure boilers operating at
lower and higher pressures.
Table B3-7 Model 5 Oil Fuel Requirements.
Figure B3-3 Standard gas train.
Tables B3-8 to B3-11 Gas pressure requirements.
Table B3-12 Safety Valve Outlet Sizes.
B3-8
06-08
Figure B3-1. Model 5 Steam Boiler Dimension Diagram
B3-9
06-08
Table B3-1. Model 5 Dimensions
Note 1 1500 2000 2500 3000 3500 4000 4500 5000 6000
Lengths
A Overall 69.7 69.7 85.8 85.8 104.4 104.4 121.1 121.1 136.7
B Pressure Vessel w/casing 51.25 51.25 67.375 67.375 83 83 99.625 99.625 115.25
C Base Frame 45.5 45.5 61.1 61.1 76.75 76.75 92.4 92.4 108
C
1 Base to Front Head 8 8 8 8 8 8 8 8 8
C
2 Base Frame Anchor Holes 43 43 58.5 58.5 74.5 74.5 90 90 105.5
CC Rear Casing to Stack Connection 17.2 17.2 17.7 17.7 17.7 17.7 21.8 21.8 21.8
D Front Head Extension 13 13 13 13 16 16 16 16 16
DD Front Casing to Steam Nozzle 16.4 16.4 24.4 24.4 30.1 30.1 36.75 36.75 44.6
Steam Nozzle to Safety Valve 15# 7 7 12 12 11.5 11.5 13 13 17
Steam Nozzle to Safety Vavle 150# 8 8 12 12 17 17 17 17 17
Widths
E Overall 57.5 57.5 57.5 57.5 57.5 57.5 57.5 57.5 57.5
F Center to Water Column 33 33 33 33 33 33 33 33 33
G Center to Aux. Water Column 23.5 23.5 23.5 23.5 23.5 23.5 23.5 23.5 23.5
H Center to Outside Casing 16.5 16.5 16.5 16.5 16.5 16.5 16.5 16.5 16.5
I Base Frame Inside 20 20 20 20 20 20 20 20 20
J Base Frame Outside 28 28 28 28 28 28 28 28 28
K Soot Washers, Center to Center 21.5 21.5 21.5 21.5 21.5 21.5 21.5 21.5 21.5
L Boiler Centerline to Soot Washer 10.75 10.75 10.75 10.75 10.75 10.75 10.75 10.75 10.75
M Boiler Centerline to Base Centerline 12 12 12 12 12 12 12 12 12
N Boiler Centerline to Soot Drain 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5

Heights
OO Overall [Base to Stack Connection] 78.25 78.25 78.25 78.25 78.25 78.25 78.25 78.25 78.25
OO
1 Base to Top of Control Panel 84.5 84.5 84.5 84.5 84.5 84.5 84.5 84.5 84.5
O Base to Steam Nozzle 15# 73.5 73.5 73.5 73.5 76.5 76.5 76.5 76.5 76.5
O
1 Base to Steam Nozzle 150# 73.5 73.5 73.5 73.5 73.5 73.5 76.5 76.5 76.5
P Base to Steam Drum Centerline 62.25 62.25 62.25 62.25 62.25 62.25 62.25 62.25 62.25
R Base to Sootwasher Lance 54 54 54 54 54 54 54 54 54
S Height of Base 4 4 4 4 4 4 4 4 4
OS Base to Oil Supply Connection 26.625 26.625 26.625 26.625 26.625 26.625 26.625 26.625 26.625
OR Base to Oil Return Connection 24.625 24.625 24.625 24.625 24.625 24.625 24.625 24.625 24.625
0.5 0.5
0.5 0.5
Drum Centerline To Surface Blowoff;
High Pressure Design Low Water
Volume. [See Note D]
0.5 0.5 0.5
0.5 0.5 0.5
0.5 0.5 0.5 0.5
0.5 0.5 0.5 0.5
Boiler Size
All Dimensions are in Inches
Drum Centerline To Surface Blowoff,
Std. Design & 15# Low Water Volume.
[See Note C]
HH
P
1
P
1
B3-10
06-08
Table B3-2. Model 5 connection sizes and clearances
Connections
BB OD Stack - Sleeve Connection 12 12 12 12 12 12 16 16 16
T Bottom Drum Blow Down, 15# [one] 1.25 1.25 1.25 1.25 1.5 1.5 1.5 1.5 1.5
T
1 Bottom Drum Blow Down, 150# [one] 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25
U Steam Nozzle, 15# 4
A
4
A
4
A
4
A
6
B
6
B
6
B
6
B
6
B
V Steam Nozzle, 150# 2.5
A
2.5
A
3
A
3
A
3
A
3
A
4
B
4
B
4
B
W Soot Washer Drains [Two] 2 2 2 2 2 2 2 2 2
X Surface Blow off [One] 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
Y Feedwater Inlet [One] 1 1 1 1 1 1 1 1 1
Z Soot Washer [Two] 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25
GG Oil Supply and Return 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Relief Valve, 15# 1.5 2 2 2 2.5 2.5 2.5 2.5 3
Relief Valve, 150# 0.75 1 1 1 1.25 1.25 1.25 1.25 1.5
Clearances
EE Front Door Swing 33 33 33 33 33 33 33 33 33
FF Tube removal each side 30 30 30 30 30 30 30 30 30
1.

2.
3. For access to the furnace, a 13" x 21" access door is provided behind the front door.
4. Control Panel may be larger [up to 4" in height] if certain control options are provided.
A. Connection is a Female Pipe Thread.
B. Connection is a 150# Flange, Flat Face.
C. When optional internal collector pipe is requested, tapping will be 4.5" from drum centerline.
D. When optional internal collector pipe is requested, tapping will be 6.8" from drum centerline.
NOTES:
The above dimensions, while sufficiently accurate for layout purposes must be confirmed for construction via certified prints. For
200 PSIG design pressure and greater, contact Milwaukee Sales for certified prints.
Allow sufficient space at rear of boiler for removal of soot washer lance.
94 94 94 94 94 94
Allowance for Tube Removal Each
Side and Front Door Swing.
Allowance for Front Door Swing and
30" Rear Aisle Space.
133 149 149 167 167 184 133 184 200
94 94 94
JJ
RF
RD
B3-11
06-08
Figure B3-2. Model 5 Low Water Volume Dimension Diagram
R
e
a
r

S
i
g
h
t

P
o
r
t
H
a
n
d
h
o
l
e

4

x

6
S
t
e
a
m

P
r
e
s
s
u
r
e

G
a
u
g
e
C
o
n
t
r
o
l

P
a
n
e
l
A
u
x

L
o
w
W
a
t
e
r

C
u
t
o
f
f
2

1
/
2
I
n
s
p
e
c
t
i
o
n
O
p
e
n
i
n
g
O
O
O
P
Q
R
N
M
W
9

1
/
4
Y Z
F
F
2
R
F
B
C
C
B
B
J
J
H
H
V
D
D
C
2
C
A
C
1
T
D
G
G
E
E
E
F
G
H
O
S
O
R
I
J
S
O
O
1
B3-12
06-08
Table B3-3. Model 5 Low Water Volume dimensions
Note 1 7500 8000
Lengths
A Overall 190.1 190.1
B Pressure Vessel w/casing 138.7 138.7
C Base Frame 117.4 129.9
C
1 Base to Front 6 6
C
2 Base Frame Anchor Holes 112.4 127.4
CC Rear Casing to Stack Connection 21.8 21.8
D Burner Extension 56.5 56.5
DD Front Casing to Steam Nozzle 63 63
II Steam Nozzle to Safety Vavle 150# 17 17
Widths
E Overall 57.5 57.5
F Center to Water Column 33 33
G Center to Aux. Water Column 23.5 23.5
H Center to Outside Casing 16.5 16.5
I Base Frame Inside 20 20
J Base Frame Outside 28 28
K Soot Washers, Center to Center 21.5 21.5
L Boiler Centerline to Soot Washer 10.75 10.75
M Boiler Centerline to Base Centerli ne 12 12
N Boiler Centerline to Soot Drain 3.5 3.5
Heights
OO Overall [Base to Stack Connection] 78.25 78.25
OO
1 Base to Top of Control Panel 84.5 84.5
O
1 Base to Steam Nozzle 150# 73.25 73.25
P Base to Surface Blowoff 58.5 58.5
Q Base to Feedwater Inlet 55.75 55.75
R Base to Sootwasher Lance 54 54
S Height of Base 4 4
OS Base to Oil Supply Connection 26.625 26.625
OR Base to Oil Return Connection 24.625 24.625
Boiler Size
All Dimensions are in Inches
NOTES:
1. The above dimensions, while sufficiently accurate for layout purposes, must be
confirmed for construction via certified prints. For 200 PSIG design pressure and
greater, contact Milwaukee Sales for certified prints.
B3-13
06-08
Table B3-4. Model 5 Low Water Volume connection sizes and clearances
Connections
BB. OD Stack - Sleeve Connection 18 18
T
1
Bottom Drum Blow Down, 150# [one] 1.25 1.25
V Steam Nozzle, 150# 6 6
W Soot Washer Drains [Two] 2 2
X Surface Blow off [One] 0.75 0.75
Y Feedwater Inlet [One] 1 1
Z Soot Washer [Two] 0.25 0.25
GG Oil Supply and Return 0.5 0.5
JJ Relief Valve, 150# 2 2

Clearances
EE Clearance from Control Panel 36 36
FF Tube removal each side 30 30
Allowance for Front Burner Removal
and 30" Rear Aisle Space.
220 RF 220
NOTES:
1. The above dimensions, while sufficiently accurate for layout purposes, must be
confirmed for construction via certified prints. For 200 PSIG design pressure and
greater, contact Milwaukee Sales for certified prints.
B3-14
06-08
Notes:
A. Ratings shown for elevation to 1000 Feet. For ratings above 1000 Feet, contact your local Cleaver-Brooks Representative.
B. Input calculated with Nat. Gas @ 1000 Btu/ft
3,
Propane @ 2500 Btu/ft
3,
and Oil @ 140,000Btu/gal.
C. For altitudes above 1000 Feet, contact your local Cleaver-Brooks authorized representative for verification of capacity rating.
Table B3-5. Model 5 Steam Boiler Ratings
Boiler SIZE 1500 2000 2500 3000 3500 4000 4500 5000 6000 7500 LWV 8000 LWV
Rated Capacity - Steam (lbs.
steam/hr from & at 212
o
F.)
1,237 1,649 2,062 2,474 2,887 3,299 3,711 4,124 4,949 6,186 6,600
Rated Steam Capacity [kg/hr from
and at 100 C]
561.0 748.0 935.0 1,122.0 1,309.0 1,496.0 1,683 1,871.0 1,847.2 2,806 2,993.7
Output Btu/hr [1,000 Btu/h] 1,200 1,600 2,000 2,400 2,800 3,200 3,600 4,000 4,800 6,000 6,400
Output Kcal/Hr [1,000 Kcal/h] 302 403 504 605 706 806 907 1,007 1,210 1,512 1,613
Output KW 348 464 580 696 812 928 1,044 1,160 1,392 1,740 1,856
Natural Gas [ft
3
/hr] - 15# Steam 1,465 2,000 2,450 2,952 3,456 3,950 4,444 4,938 5,925 NA NA
Natural Gas [ft
3
/hr] - 150# Steam 1,538 2,077 2,564 3,117 3,590 4,155 4,657 5,194 6,233 7594 8205
Natural Gas [m
3
/hr] - 15# Steam 41.5 56.6 69.4 80.8 97.9 111.9 125.8 139.8 167.7 NA NA
Natural Gas [m
3
/hr] - 150# Steam 43.5 58.8 72.6 88.3 101.6 117.6 131.8 147.0 176.5 215 232.4
Propane Gas [ft
3
/hr] - 15# Steam
586 800 980 1,181 1,382 1,580 1,778 1,975 2,370 NA NA
Propane Gas [ft
3
/hr] - 150# Steam
615 831 1,026 1,247 1,436 1,662 1,863 2,078 2,493 3038 3282
Propane Gas [m
3
/hr] - 15# Steam
16.6 22.6 27.7 33.4 39.1 44.7 50.3 55.9 67.1 NA NA
Propane Gas [m
3
/hr] - 150# Steam 17.4 23.5 29.1 35.3 40.7 47.1 52.7 58.8 70.6 86 92.9
No.2 Oil Fuel - 15# Steam, gph 10 14 17 21 24 28 31 35 42 NA NA
No.2 Oil Fuel - 150# Steam, gph 11 15 18 22 25 28.9 32 36 43 54 59
No.2 Oil Fuel - 15# Steam, lph 38 53 64 79 91 106 117 132 159 NA NA
No.2 Oil Fuel - 150# Steam, lph 41 56 68 82 95 109 121 136 163 204 223
Blower Motor HP - Gas Firing 2 2 2 2 2 3 3 3 5 7.5 7.5
Blower Motor HP - Oi l or Comb. 2 2 2 2 3 5 3 3 5 7.5 7.5
Oil Pump for Oil or Combination
Blower Motor - Gas, 230V 6 6 6 6 6 9 9 9 15 22 22
Blower Motor - Gas, 460 V 3 3 3 3 3 4.5 4.5 4.5 7.5 11 11
Blower Motor - Oil or Comb, 230 V 6 6 6 6 9 15 9 9 15 22 22
Blower Motor - Oil or Comb., 460V 3 3 3 3 4.5 7.5 4.5 4.5 7.5 11 11
Blower Motor - Gas, 575 V 1.6 1.6 1.6 1.6 1.6 2.4 2.4 2.4 4.1 6.1 6.1
Blower Motor - Oil or Comb., 575V 1.6 1.6 1.6 1.6 2.4 4.1 2.4 2.4 4.1 6.1 6.1
Control Circuit 1.7 1.7 1.7 1.9 1.9 1.9 2.4 2.4 2.4 2.5 2.5
Operati ng Weight, lbs. 3,643 3,643 4,445 4,445 5,040 5,040 5,858 5,858 6,753 6,920 6,920
Operati ng Weight, kg 1,652 1,652 2,016 2,016 2,286 2,286 2,657 2,657 3,063 3,139 3,139
Water Content Normal, Imp.gals 54.4 54.4 74.9 74.9 94 94 116.1 116.1 135.7 71.1 71.1
Water Content Normal, liters 248 248 340 340 428 428 528 528 617 324.7 324.7
Water Content Flooded, Imp. gals 79.94 79.94 109.08 109.08 135.7 135.7 166.5 166.5 194.01
Water Content Flooded, liters 363.4 363.4 459.9 459.9 616.9 616.9 756.9 756.9 881.99
Shipping Weight, approximate lbs. 3,100 3,100 3,700 3,700 4,100 4,100 4,700 4,700 5,400 6,200 6,200
Shipping Weight, approximate kg 1,406 1,406 1,678 1,678 1,860 1,860 2,132 2,132 2,449 2,812 2,812
Ratings [Note A]
Belt Driven from the Blower Motor
Approximate Fuel Consumption At Rated Capacity [ Input - Note B]
Power Requirements - 3 Phase 60 Hz Standard [Note C]
Direct Drive from Fan
Motor
Minimum Ampacity
Weights
B3-15
06-08
Table B3-6. Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity)
Table B3-7. Model 5 Oil Fuel Requirements
1500 2000 2500 3000 3500 4000 4500 5000 6000
15 4 4 6 6 6 6 8 8 8
20 3 4 4 6 6 6 8 8 8
30 3 4 4 4 4 6 6 6 6
40 2-1/2 3 3 4 4 4 6 6 6
50 2-1/2 3 3 4 4 4 4 4 6
65 2-1/2 2-1/2 3 3 3 4 4 4 4
75 2-1/2 2-1/2 3 3 3 4 4 4 4
95 - 125
A
2-1/2 2-1/2 3 3 3 3 4 4 4
150 1-1/2 2 2 2-1/2 2-1/2 2-1/2 3 3 3
200 1-1/2 1-1/2 1-1/2 2 2 2-1/2 2-1/2 2-1/2 3
250 - 400 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2 2 2-1/2
A.
Standard nozzle size for 150 PSIG MAWP Boiler Design
Example 1: Size 3500, 150# boiler to operate @ 30 PSIG requires 4" steam nozzle in lieu of
standard 3" nozzle.
Example 2: Size 3500, 150# boiler to operate @ 200 PSIG requires 2" steam nozzle in lieu of
standard 3" nozzle.
Operating
Pressure
(PSIG)
BOILER SIZE
BOILER
MODEL
1500 2000 2500 3000 3500 4000 4500 5000 6000 8000 LWV
OIL
USAGE
A
(GPH)
10.7 14.3 17.9 21.4 25.0 28.6 32.7 35.7 42.8 57.2
NOTES:
1.Oil supply lines to be sized for 125 gph pumping rates.
2.Oil pump suction pressure -10 Hg to 3 psig.
A.Usage Based on #2 Fuel @ 140,000 Btu/gal.
B3-16
06-08
Figure B3-3. Standard Gas Train Model 5
ITEM PART SIZE (IN.)
SIZE 1500 - 3000
1 Gas Inlet 1-1/2
2 Shutoff Cock 1/2
3 Main Regulator 1-1/2
4 Pilot Regulator 1/2
5 Solenoid Valve 1/2
7 Valve (POC) 1-1/2
8 Low Gas Pressure (Switch or Sensor) 1/4
10 Shutoff Valve 1-1/2
SIZES 3500 TO 5000
1 Gas Inlet 2
2 Shutoff Cock 1/2
3 Main Regulator 2
7 Valve (POC) 2
10 Shutoff Valve 2
11 Butterfly Valve 2
SIZE 6000 To 8000
1 Gas Inlet 2
2 Shutoff Cock 1/2
3 Main Regulator 2-1/2
6 Valve (STD) 2
7 Valve (POC) 2
10 Shutoff Valve 2
11 Butterfly Valve 2
PILOT GAS TRAIN
MAIN GAS TRAIN
B3-17
06-08
Table B3-8. Model M5 minimum required Natural Gas pressure at entrance to the standard UL, FM & XL GAP
gas trains (upstream of gas pressure regulator).
Table B3-9. Model M5 minimum required Natural Gas pressure at entrance to the oversized standard UL, FM
& XL GAP gas trains (upstream of gas pressure regulator).
1500 1.5 1.5 4.3 28.0
2000
1.5 1.5 8.4 28.0
2500
1.5 1.5 11.3 28.0
3000 1.5 1.5 14.9 28.0
3500 2.0 2.0 10.0 28.0
4000
2.0 2.0 11.9 28.0
4500
2.0 2.0 11.5 28.0
5000 2.0 2.0 16.0 28.0
6000
2.0 2.0 20.4 28.0
8000 LWV
2.5 19.9 19.9 28.0
INLET PIPE
SIZE
(inches)
HONEYWELL
VALVE SIZE
(inches)
PRESSURE REQUIRED
2500
3000
3500
BOILER
SIZE
REQUIRED FUEL
FLOW (SCFH)
1500
6000
4000
4500
5000
8000
2000
1500
2.0 2.0 2.3 28.0
2000
2.0 2.0 4.8 28.0
2.0 2.0 6.5
2.5 2.5 5.7
2.0 2.0 9.0
2.5 2.5 6.8
3.0 3.0 6.0
2.5 2.5 9.7
3.0 3.0 7.1
2.5 2.5 11.8
3.0 3.0 8.5
2.5 2.5 9.8
3.0 3.0 5.6
2.5 2.5 12.9
3.0 3.0 7.1
4.0 4.0 5.6
2.5 2.5 17.5
3.0 3.0 10.0
4.0 4.0 7.9
3.0 3.0 9.8
4.0 4.0 5.6
REQUIRED FUEL
FLOW (SCFH) MIN ("W.C.) MAX ("W.C.)
BOILER
SIZE
INLET PIPE
SIZE
(inches)
HONEYWELL
VALVE SIZE
(inches)
PRESSURE REQUIRED
1500
2000
2500
3000
3500
4000
2500
3000
3500
4500
5000
6000
4000
4500
5000
6000
28.0
28.0
28.0
28.0
28.0
28.0
28.0
8000 LWV 28.0 8000
B3-18
06-08
Table B3-10. Model M5 minimum required Propane Gas pressure at entrance to the standard UL, FM & XL
GAP gas trains (upstream of gas pressure regulator).
1500
1.5 1.5 6.7 28.0
2000
1.5 1.5 10.5 28.0
2500 1.5 1.5 13.3 28.0
3000 1.5 1.5 17.0 28.0
3500
2.0 2.0 14.3 28.0
4000
2.0 2.0 16.5 28.0
4500 2.0 2.0 14.8 28.0
5000 2.0 2.0 16.4 28.0
6000
2.0 2.0 19.6 28.0
8000 LWV
2.0 2.0 19.6 28.0
REQUIRED FUEL
FLOW (SCFH)
600
BOILER
SIZE
INLET PIPE
SIZE
(inches)
HONEYWELL
VALVE SIZE
(inches)
PRESSURE REQUIRED
800
1000
1200
1400
1600
1800
2000
2400
3200
B3-19
06-08
Table B3-11. Model M5 minimum required Propane Gas pressure at entrance to the oversized standard UL,
FM & XL GAP gas trains (upstream of gas pressure regulator).
Table B3-12. Safety Valve Outlet Sizes
1500 2.0 2.0 5.9 28.0
2000
2.0 2.0 9.0 28.0
2.0 2.0 10.8
2.5 2.5 10.5
2.0 2.0 13.8
2.5 2.5 12.9
3.0 3.0 12.6
2.5 2.5 13.6
3.0 3.0 12.6
2.5 2.5 15.8
3.0 3.0 14.5
2.5 2.5 13.8
3.0 3.0 12.1
2.5 2.5 14.8
3.0 3.0 12.5
4.0 4.0 12.0
2.5 2.5 18.0
3.0 3.0 15.0
4.0 4.0 14.1
2.5 2.5 13.8
3.0 3.0 12.1
BOILER
SIZE
INLET PIPE
SIZE
(inches)
HONEYWELL
VALVE SIZE
(inches)
PRESSURE REQUIRED
REQUIRED FUEL
FLOW (SCFH)
600
800
2500 28.0 1000
1800
3000 28.0 1200
3500 28.0 1400
5000 28.0 2000
6000 28.0 2400
8000 LWV 28.0 3200
4000 28.0 1600
4500 28.0
1500 1 2 3161 lbs/hr 1 1 1651 lbs/hr
2000 1 2 3161 lbs/hr 1 1-1/4 2585 lbs/hr
2500 1 2 3161 lbs/hr 1 1-1/4 2585 lbs/hr
3000 1 2 3161 lbs/hr 1 1-1/4 2585 lbs/hr
3500 1 2 3161 lbs/hr 1 1-1/2 4240 lbs/hr
4000 1 2-1/2 4676 lbs/hr 1 1-1/2 4240 lbs/hr
4500 1 2-1/2 4676 lbs/hr 1 1-1/2 4240 lbs/hr
5000 1 2-1/2 4676 lbs/hr 1 1-1/2 4240 lbs/hr
6000 1 3 6942 lbs/hr 1 2 6596 lbs/hr
8000 LWV NA NA NA 1 2
Boiler Size
OUTLET SIZE
(IN.)**
VALVES
REQ'D
SAFETY VALVE SETTING
** Female Pipe Thread Connection [FPT]
OUTLET SIZE
(IN.)**
VALVE
CAPACITY
VALVE
CAPACITY
VALVES
REQ'D
B3-20
06-08
PERFORMANCE DATA
Efficiency Efficiency data provided in Table B3 - 13 is based on low pressure steam operation.
For high pressure steam operation contact your local Cleaver-Brooks authorized
representative for expected efficiency data.
Table B3-13. Predicted Efficiency, 10 PSIG operating (includes radiation and convection losses)
Emissions The following tables denote typical emission levels for Natural Gas and No. 2 Oil.
Please contact your local Cleaver-Brooks authorized representative if an emission
guarantee is required.
Notice
The data in these tables represent typical emission levels only. Please contact your
local Cleaver-Brooks authorized representative if an emission guarantee is re-
quired, or for emission level information not shown in these tables.
Low Fire High Fire Low Fire High Fire
1500 81.6 81.9 84.1 84.4
2000
81.1 80.0 83.6 82.5
2500 81.6 81.5 84.1 84.0
3000 81.3 80.3 83.8 82.8
3500 81.6 81.5 84.1 84.0
4000 81.3 80.7 83.8 83.0
4500 81.1 80.9 83.6 83.4
5000 81.3 80.0 83.8 82.5
6000 81.6 79.8 84.1 82.4
Boiler Size Firing Rate
Gas Fuel Oil Fuel
Firing Rate
CO
ppm
A
lb/MMBtu
200
0.15
NOx
ppm
A
lb/MMBtu
100
0.12
SOx
ppm
A
lb/MMBtu
1
0.001
HC/VOCs
ppm
A
lb/MMBtu
40
0.016
PM
ppm
A
lb/MMBtu
0.01
2
dry basis.
B
CO
ppm
A
lb/MMBtu
90
0.07
NOx
ppm
A
lb/MMBtu
187
0.248
SOx
ppm
A
lb/MMBtu
278
0.515
HC/VOCs
ppm
A
lb/MMBtu
50
0.025
PM
ppm
A
lb/MMBtu
0.025
NOTES:
2
dry basis.
B. Based on the following fuel oil constituents.
Fuel-bound nitrogen = 0.05% (max) by weight.
Sulfur = 0.5% (max) by weight.
Ash = 0.01% (max) by weight.
Table B3-15. Emission Data, No. 2 Oil
Table B3-14. Model 5 Emission Data, Natural Gas
B3-21
06-08
ENGINEERING DATA
The following engineering information is provided for the Model 5 steam boiler.
Additional information may be obtained from your local Cleaver-Brooks authorized
representative.
combination of condensate return and raw make-up, 100% condensate return or
100% raw make-up. Proper treatment of make-up water and boiler water is
essential to the longevity and performance of the boiler. Table B3-23 depicts the
rate of make-up required and Table B3-22 shows the recommended water quality
guidelines.
As a minimum, raw make-up should be piped into a water softener and then to a
feed tank, which also can be the container that receives the system condensate
returns. Chemical feed is recommended to be fed via a quill into the water make-up
line feeding the boiler.
Blowdown As steam is produced; unwanted solids are left behind in the boiler water and
become concentrated within the vessel. If these constituents are allowed to adhere
to the heat transfer surfaces, they will impede the flow of energy into the water.
Their removal requires proper blowdown that will include bottom and possibly
surface blowoff. For proper TDS control, surface blowoff with a TDS monitoring
device is recommended. Local codes will dictate the manner of treating the
blowdown affluent.
Boiler Stacks General - The Model 5 boiler operates with a positive vent pressure and a vent gas
temperature that is non-condensing. Therefore, the stack must be a positive
pressure design.
operation of the burner. The vent should be designed with proper supports and
vent passes through walls and roofs.
stack connection. Although constant pressure at the flue gas outlet is not required,
it is necessary to size the breeching and stack to limit flue gas pressure variations.
Consideration of the draft must be given where lengthy runs of breeching are
employed or unusually high stacks. Please note: the allowable pressure range for
design of the stack and breeching is negative 0.25" w.c. (-62 Pa) to a positive 0.25"
w.c. (+62 Pa) for proper light offs and combustion. NOTE: This pressure range
does not pertain to the boiler room, that is, the boiler room must be neutral or
slightly positive, never negative when using air from the boiler room for combustion.
When two or more Model 5 boilers are connected to a common breeching/stack,
one should evaluate the affects of pressure variations that may occur during boiler
sequencing while boilers are firing. It may be determined that some type of
mechanical draft system be employed to ensure proper draft at each boiler is
maintained.
Combustion Air - The burner for each boiler must be supplied with adequate volume
of uncontaminated air to support proper combustion and equipment ventilation. Air
B3-22
06-08
combustion air drawn from the area immediately surrounding the boiler (boiler
room is neutral or slightly positive pressure), or with a direct vent to outside the
boiler room where air is drawn directly from the exterior of the building. Regardless
of the method, all installations must comply with NFPA 54 (National Fuel Gas Code
- NFGC) for U.S. installations and CAN/CSA B149/.1 and B149.2 for Canadian
installations.
Engineered Design - When determining boiler room air requirements for the boiler,
the "Engineered Design" method may be used. Following this method,
consideration must be given to the size of the boiler room, airflow, and air velocity
as follows:
Two 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. Refer to Figure
B3 - 4.
Air supply openings can be louvered for weather protection, but they should not be
covered with a fine mesh wire, as this type of covering has poor air flow qualities
and is subject to clogging with dirt and dust.
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 unsafe burner performance.
It is forbidden to have the total area of the air supply openings at less than one
square foot.
Size the openings by using the formula (Area in ft
2
= cfm
a
/fpm
a
), where cfm
a
=
a
Amount of air required (cfm):
Combustion Air = Maximum boiler horsepower (bhp) times 8 cfm.
Ventilation Air = Maximum boiler horsepower (bhp) times 2 cfm.
Total Air = 10 cfm per bhp (up to 1000 feet elevation, add 3% more per 1000 feet
of added elevation).
Acceptable air velocity in the boiler room (fpm):
From floor to 7 feet high = 250 fpm.
Above 7 feet from boiler room floor = 500 fpm.
Determine the area of the boiler room air supply openings for (2) size 4500 Model
5 boilers at 750 feet elevation; each have a rating of 107 boiler horsepower. The
air openings will be 5 feet above the floor level.
The total boiler horsepower (bhp): 107 x 2 = 214 bhp.
From (F.3) above, total air required = 214 bhp x 10 = 2140 cfm.
Air Velocity: From (G.1) above = 250 fpm.
Area required: From the formula in E above, 2140 cfm/250 fpm = 8.56 square
feet total.
B3-23
06-08
Area opening: 8.56 divided by 2 = 4.28 ft
2
Notice
See Table B3-24 for combustion air and flue gas flow.
Figure B3-4. Boiler Room Air Flow - Engineered Design
Oil Piping General - Oil operation of the Model 5 boiler requires proper oil to the standard
burner mounted oil pump. As the combustion of oil utilizes mechanical pressure
atomization, line sizing to the pump must be sufficient to provide 125 gph of oil to
the suction side of the pump.
Oil Train Components - Oil flow to the burner is controlled by four solenoid valves.
The oil flows through a primary or safety shutoff valve into a manifold block. This
valve and the low fire valve are energized simultaneously by the flame safeguard
control and when opened, allow flow of oil to the low fire nozzle.
As the damper motor moves to high fire position, the damper motor end switches
close to energize in sequence, the intermediate and then high fire oil valve. The
purpose of the intermediate valve is to smooth the transition from low to high fire by
balancing the oil input with increasing flow of air.
High fire rating of the burner is obtained when all three nozzles are firing, assuming
proper oil pressure and normally sized nozzles.
Gas Piping General - The Model 5 boiler requires appropriate gas supply pressure and volume
for proper operation and long burner life. The gas requirements specified in this
section must be satisfied to ensure efficient and stable combustion. Installation
GAS
VENT
EXTERIOR WALL
FRESH AIR OPENING
EXTERIOR WALL
FRESH AIR OPENING
B3-24
06-08
must follow these guidelines and of the local authorities that have installation
jurisdiction.
Gas Train Components - Model 5 boilers are equipped with a gas train that meets
the requirements of UL as standard. These components also comply with the
recommendations of FM, XL GAP (formerly IRI/GE GAP) and ASME CSD-1. The
gas train and its components have been designed and tested to operate for the
highest combustion efficiency.
Gas Pressure Requirements - For proper and safe operation, each Model 5 boiler
requires a stable gas pressure supply. The pressure requirements are listed in
previous sections for standard gas train size, and oversized trains for reduced
available pressure.
Gas Piping - Model 5 units are standardly equipped with a gas pressure regulator.
If upstream pressure to the standard regulator will be greater than 1 psig, an
additional upstream regulator should be provided with a pressure relief valve.
For buildings or boiler rooms with gas supply pressure exceeding 28" w.c., a "full
lockup" type regulator is recommended along with proper overpressure protection.
In addition to the regulator, a plug type or "butterball" type gas shutoff cock should
be provided upstream of the regulator for use as a service valve. This is also
required to provide positive shutoff and isolate the boiler gas train during gas piping
tests.
any dirt, weld slag, or debris can deposit in the drip leg rather than into the boiler
gas train. The bottom of the drip leg should be removable without disassembling
any gas piping. The connected piping to the boiler should be supported from pipe
supports and not supported by the boiler gas train or the bottom of the drip leg.
normally Schedule 40 block iron pipe and fittings.
Gas Supply Pipe Sizing - For proper operation of a single unit or multiple units, we
recommend that the gas pipe be sized to allow no more than 0.3" w.c. pressure
drop from the source (gas header or utility meter) to the final unit location. The gas
supplier (utility) should be consulted to confirm that sufficient volume and normal
pressure are provided to the building at the discharge side of the gas meter or
supply pipe. (For installations of new boilers into an existing building, gas pressure
should be measured with a manometer to ensure sufficient pressure is available).
A survey of all connected gas using devices should be made. If appliances other
than the boiler are connected to the gas supply line, then a determination should be
made of how much flow volume (cfh = cubic feet per hour) will be demanded at
one time and the pressure drop requirements when all appliances are operating.
The total length of gas piping and all fittings must be considered when sizing the
gas piping. Total equivalent length should be calculated from the utility meter or
source to the final connection. As a minimum guideline, gas piping Tables B3 - 16
through B3 - 20 should be used. The data in these tables is from the NFPA source
book, 2006 edition.
B3-25
06-08
Pipe Size
Nominal 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
Actual I.D. 1.049 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"
10 514 1,060 1,580 3,050 4,860 8,580 17,500
20 363 726 1,090 2,090 3,340 5,900 12,000
30 284 583 873 1,680 2,680 4,740 9,660
40 243 499 747 1,440 2,290 4,050 8,290
50 215 442 662 1,280 2,030 3,590 7,330
60 195 400 600 1,160 1,840 3,260 6,640
70 179 368 552 1,060 1,690 3,000 6,110
80 167 343 514 989 1,580 2,790 5,680
90 157 322 482 928 1,480 2,610 5,330
100 148 304 455 877 1,400 2,470 5,040
125 131 269 403 777 1,240 2,190 4,460
150 119 244 366 704 1,120 1,980 4,050
175 109 209 336 648 1,030 1,820 3,720
200 102 185 313 602 960 1,700 3,460
**Fuel: Natural Gas
Pipe Size
Nominal 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
Actual I.D. 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"
10 678 1,390 2,090 4,020 6,400 11,300 23,100
20 466 957 1,430 2,760 4,400 7,780 15,900
30 374 768 1,150 2,220 3,530 6,250 12,700
40 320 657 985 1,900 3,020 5,350 10,900
50 284 583 873 1,680 2,680 4,740 9,600
60 257 528 791 1,520 2,430 4,290 8,760
70 237 486 728 1,400 2,230 3,950 8,050
80 220 452 677 1,300 2,080 3,670 7,490
90 207 424 635 1,220 1,950 3,450 7,030
100 195 400 600 1,160 1,840 3,260 6,640
125 173 355 532 1,020 1,630 2,890 5,890
150 157 322 482 928 1,480 2,610 5,330
175 144 296 443 854 1,360 2,410 4,910
200 134 275 412 794 1,270 2,240 4,560
**Fuel: Natural Gas
B3-26
06-08
Pipe Size
Nominal 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
Actual I.D. 0.622 0.824 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"
Length in
feet
10
1,510 3,040 5,560 11,400 17,100 32,900 52,500 92,800 189,000
20
1,070 2,150 3,930 8,070 12,100 23,300 57,100 65,600 134,000
30
869 1,760 3,210 6,590 9,880 19,000 30,300 53,600 109,000
40
753 1,520 2,780 5,710 8,550 16,500 26,300 46,400 94,700
50
673 1,360 2,490 5,110 7,650 14,700 23,500 41,500 84,700
60
615 1,240 2,270 4,660 6,980 13,500 21,400 37,900 77,300
70
569 1,150 2,100 4,320 6,470 12,500 19,900 35,100 71,600
80
532 1,080 1,970 4,040 6,050 11,700 18,600 32,800 67,000
90
502 1,010 1,850 3,810 5,700 11,000 17,500 30,900 63,100
100
462 954 1,710 3,510 5,260 10,100 16,100 28,500 58,200
125
414 836 1,530 3,140 4,700 9,060 14,400 25,500 52,100
150
372 751 1,370 2,820 4,220 8,130 13,000 22,900 46,700
175
344 695 1,270 2,601 3,910 7,530 12,000 21,200 43,300
200
318 642 1,170 2,410 3,610 6,960 11,100 19,600 40,000
500
192 401 717 1,470 2,210 4,250 6,770 12,000 24,400
1000
132 275 493 1,010 1,520 2,920 4,650 8,220 16,800
1500
106 221 396 812 1,220 2,340 3,740 6,600 13,500
**Fuel: Natural Gas
B3-27
06-08
Pipe Size
Nominal 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
Actual I.D. 0.622 0.824 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"
Length in
feet
10
2,350 4,920 9,270 19,000 28,500 54,900 87,500 155,000 316,000
20
1,620 3,380 6,370 13,100 19,600 37,700 60,100 106,000 217,000
30
1,300 2,720 5,110 10,500 15,700 30,300 48,300 85,400 174,000
40
1,110 2,320 4,380 8,990 13,500 25,900 41,300 75,100 149,000
50
985 2,060 3,880 7,970 11,900 23,000 36,600 64,800 132,000
60
892 1,870 3,520 7,220 10,300 20,300 33,200 58,700 120,000
70
821 1,720 3,230 6,640 9,950 19,200 30,500 54,000 110,000
80
764 1,600 3,010 6,180 9,260 17,800 28,400 50,200 102,000
90
717 1,500 2,820 5,800 8,680 16,700 26,700 47,100 96,100
100
677 1,420 2,670 5,470 8,200 15,800 25,200 44,500 90,300
125
600 1,250 2,360 4,850 7,270 14,000 22,300 39,500 80,500
150
544 1,140 2,140 4,400 6,590 12,700 20,200 35,700 72,900
175
500 1,050 1,970 4,040 6,060 11,700 18,600 32,900 67,100
200
465 973 1,830 3,760 5,640 10,900 17,300 30,600 62,400
500
283 593 1,120 2,290 3,430 6,610 10,300 18,600 38,000
1000
195 407 897 1,380 2,360 4,550 7,240 12,000 26,100
1500
156 327 616 1,270 1,900 3,650 5,820 10,300 21,000
**Fuel: Natural Gas
B3-28
06-08
Pipe Size
Nominal 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
Actual
I.D.
0.622 0.824 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"
Length
in feet
10
3,190 6,430 11,800 24,200 36,200 69,700 111,000 196,000 401,000
20
2,250 4,550 8,320 17,100 25,600 49,300 78,600 139,000 283,000
30
1,840 3,720 6,790 14,000 20,900 40,300 64,200 113,000 231,000
40
1,590 3,220 5,880 12,100 18,100 34,900 55,600 98,200 200,000
50
1,430 2,880 5,260 10,800 16,200 31,200 49,700 87,900 179,000
60
1,300 2,630 4,800 9,860 14,800 28,500 45,400 80,200 164,000
70
1,200 2,430 4,450 9,130 13,700 26,400 42,000 74,300 151,000
80
1,150 2,330 4,260 8,540 12,800 24,700 39,300 69,500 142,000
90
1,060 2,150 3,920 8,050 12,100 23,200 37,000 65,500 134,000
100
979 1,980 3,620 7,430 11,100 21,400 34,200 60,400 123,000
125
876 1,770 3,240 6,640 9,950 19,200 30,600 54,000 110,000
150
786 1,590 2,910 5,960 8,940 17,200 27,400 48,500 98,900
175
728 1,470 2,690 5,520 8,270 15,900 25,400 44,900 91,600
200
673 1,360 2,490 5,100 7,650 14,700 23,500 41,500 84,700
500
384 802 1,510 3,100 4,650 8,950 14,300 25,200 51,500
1000
264 551 1,040 2,130 3,200 6,150 9,810 17,300 35,400
1500
212 443 834 1,710 2,570 4,940 7,880 13,900 28,400
**Fuel: Natural Gas
B3-29
06-08
Table B3-21. Sound Levels
Table B3-22. Water Quality Requirements
Table B3-23. Feedwater Make-up Rates
SOUND LEVEL /
FIRING RATE
BOILER SIZE (BHP)
1500
(35)
2000
(47)
2500
(59)
3000
(71)
3500
(83)
4000
(95)
4500
(107)
5000
(119)
6000
(143)
8000
LFG (dBA) 70 70 71 71 72 72 74 75 76
HFG (dBA) 70 70 72 74 74 76 77 78 79
LFO (dBA) 69 69 70 71 72 73 74 75 76
HFO (dBA) 71 71 72 73 74 76 76 77 78
NOTES:
1. Abbreviations: LF=Low Fire, HF=High Fire, O=Oil, G=GAS
2. Measurement: Three (3) feet from front center of boiler and 3-1/2 feet above boiler base. Measurements are
decibel ratings on the A-Weighted scale, and were registered without the addition of sound attenuators, mufflers,
or silencers.
3. N/A to 8000 LWV.
pH 8.3 - 10.5
Iron 0.1 ppm
Oxygen 0.1 mg/liter
Specific Conductivity 2000 mho/cm
3
Boiler Size Gallons/Minute
1500 2.5
2000 3.3
2500 4.1
3000 5
3500 5.8
4000 6.6
4500 7.5
5000 8.3
6000 9.9
8000 13.2
B3-30
06-08
Table B3-24. Model 5 Fuel, Combustion Air, and Flue Gas Flow Rates
1500 2000 2500 3000 3500 4000 4500 5000 6000 8000 LWV
Gas cfh 1500 1500 2500 3000 3500 4000 4500 5000 6000 8000
Oil gph 10.72 14.29 17.86 21.43 25.00 28.57 32.14 35.71 42.85
scfh 15,480 20,640 25,800 30,960 36,120 41,280 46,440 51,600 61,920
lb/hr 1,207 1,609 2,012 2,414 2,817 3,219 3,621 4,024 4,828
scfh 17,049 22,733 28,414 34,098 39,782 45,463 51,147 56,831 68,196
lb/hr 1,269 1,692 2,115 2,538 2,961 3,384 3,808 4,231 5,077
scfh 17,520 23,360 29,200 35,040 40,880 46,720 52,560 58,400 70,080
lb/hr 1,278 1,704 2,130 2,556 2,983 3,409 3,835 4,261 5,113
scfh 17,914 23,886 29,855 35,827 41,799 47,769 53,741 59,713 71,655
lb/hr 1,357 1,809 2,261 2,714 3,166 3,618 4,070 4,523 5,427
Notes: A. Gas consumption, expressed in cubic feet per hour, is based on 1,000 Btu/cu.ft gas value.
B. Oil consumption,expressed in pounds per hour, is based on 140,000 Btu/gal oil value.
C. Oil supply l ines must be sized for 125 gph pumping rate. Oil pump suction pressure to be -10" Hg to 3 psig.
Flue Gas
Boiler Size
Gas
Oil
Gas
Oil
Fuel Consumption
Combustion Air
B3-31
03-08
Section B3
Model 5 Boilers
Boiler Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-32
Boiler Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-32
Soot Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-33
Boiler Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-33
Boiler Trim/Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-33
Low Water Volume Design (LWV), 150 Psig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-34
Low Water Volume Design (LWV), 15 Psig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-34
Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-34
Gas Fired Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-35
Oil Fired Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-36
Gas-Oil Fired Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-37
Burner and Flame Failure Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-38
Burner Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-38
B3-32
05-03
A. The steam boiler shall be a Cleaver-Brooks Model 5, Series (100,
200, 700) rated at _________ lbs/hr or _____ boiler horsepower
designed for (15, 150, 250, 350 or 500) psig steam. The
maximum boiler operating pressure will be ______ psig. (Series
100 is a No.2 oil fired burner; Series 200 is a gas or No.2 oil fired
burner; Series 700 is a straight gas burner).
B. The boiler shall have a maximum output of ________ Btu/hr or
______ boiler horsepower when fired with (No.2 oil) or (natural gas
@ __________ Btu/cu-ft). The boiler shall develop ________ lbs/hr
when operating at ______ psig with feedwater temperature at
_______
o
F. The boiler safety relief valve(s) shall be set at _____
psig.
C. Electrical power to the boiler shall be ______ volts, ______ phase,
____ Hz. All electrical service connections shall be made to an
electrical entrance box mounted on the right hand side of the boiler.
PART 2 PRODUCTS 2.1 BOILER DESCRIPTION
A. The boiler shall be an all steel membrane wall watertube design
with 3-pass gas travel. It shall be mounted on a heavy duty steel
frame with an integral forced draft burner and burner controls. The
complete package, boiler-burner unit, shall be certified, tested, and
labeled by CSA (Canadian Standard Association). The package
shall be completely assembled and receive a factory fire test prior to
shipment.
B. The boiler shell must be constructed and hydrostatically tested in
accordance with the A.S.M.E. Boiler and Pressure Vessel Code
Section I or IV and receive an authorized boiler inspection. A copy
of the inspection report shall be furnished to the purchaser.
C. Two downcomers shall be located at the rear of the boiler and totally
insulated from the generating tubes. The downcomers shall be 2-1/
2" OD for 35 and 47 hp; 3" OD for 59 to 83 hp, and 4" OD for 95
hp and greater. Material shall be SA-178A. The 2-1/2" and 3"
downcomers shall have 0.105" wall while the 4" downcomers shall
have 0.135" wall. The generating tubes shall be 2" OD, SA-178
Grade A with 0.095" wall thickness.
D. The upper drum shall be 20" OD Schedule 20, SA-53-B seamless
pipe with 0.375" wall. The lower drum shall be 6" nominal pipe
size, SA-53-B seamless pipe with 0.312" wall up through 150 psig
design.
E. Two lifting eyes shall be located on the top centerline of the upper
drum.
F. Refractory shall be limited to the furnace floor, lower drum, burner
throat tile, and the formed rear furnace access door. High
temperature insulation shall be installed on the front water wall of
the furnace.
G. Observation ports shall be provided at each end of the boiler for
B3-33
03-08
H. The exhaust gas vent shall be located at the top rear centerline of
the boiler. A stack thermometer shall be shipped loose for field
installation by the installing contractor into the stack.
I. Inspection openings shall be provided in the convection area.
J. The lower drum shall include capped plugs in the front and rear
drum heads, and a handhole shall be provided in the rear upper
drum head for waterside inspection
K. The vessel shall be insulated with a minimum of 2" fiber glass
blanket. This insulation shall be covered with a sheet metal jacket.
The jacket and insulation shall be arranged for easy removal and
reinstallation if required.
L. The entire boiler jacket, base frame, and other components shall be
factory painted using hard finish enamel.
2.2 SOOT CLEANING
A. Soot washer lances shall be provided in the upper convection area of
the boiler, measuring the full length of the pressure vessel. Each
lance assembly shall be capable of rotating 360 degrees. This shall
ensure complete washing of the convection zone while the boiler is
operating in the low fire mode.
B. Soot washer drain troughs shall be provided at the bottom of the
boiler. These shall be furnished for each convection side running the
full length of the boiler with 2" drain connections at the bottom rear.
Inspection/cleanout openings for each trough shall be located at the
front of the boiler.
2.3 BOILER CONNECTIONS
A. The steam nozzle shall be located on the top centerline of the upper
drum and sized for steam velocity not to exceed 5000 fpm.
B. A feedwater tapping and an integral feedwater distribution pipe shall
be located in the upper drum. This distribution pipe shall blend the
feedwater with the boiler water.
C. A " surface blowoff tapping shall be provided in the rear head of
the upper drum.
D. For blowdown or boiler drain, a tapping shall be provided in the
bottom of the lower drum near the front of the boiler.
2.4 BOILER TRIM/CONTROLS
A. The primary water column shall be located on the left side of the
boiler when facing the burner. It shall be piped with union
connections for easy removal and include a full size column
blowdown valve. A gauge glass with gauge glass valves shall be
mounted to the water column.
B. A primary low water cutoff switch shall be an integral part of the
water column and shall be wired into the burner control circuit to
prevent burner operation in the event of an unsafe water level
condition.
C. To maintain proper and safe water level within the boiler, an integral
feed pump control switch shall be included within the primary water
column. This switch may be wired to a control relay for pump on/off
operation or wired to control a solenoid water make-up valve.
B3-34
05-03
D. A secondary low water cutoff control of the manual reset type shall
be provided on the right hand side of the boiler, when facing the
burner. This control shall include a switch wired into the burner
circuit to prevent burner operation in the event that the primary low
water control did not function properly during an unsafe water level
condition. A control blowdown valve shall be included for
maintenance and periodic testing of the level device.
E. For visual indication of the internal boiler pressure, a steam pressure
gauge shall be mounted near the water column and shall include an
inspector's test cock and test connection point.
F. For burner operation, a minimum of three controls shall be
provided: one auto reset type for burner start and stop control, one
for burner firing rate (modulation on gas or low high low on oil), and
one manual reset type for burner shutdown in the event of excessive
steam pressure within the boiler.
G. In compliance with the A.S.M.E. Code, a Code rated safety relief
valve(s) shall be provided. This valve(s) may be shipped loose to
prevent any damage during shipment.
2.5 LOW WATER VOLUME DESIGN (LWV), 150 PSIG
For applications requiring the use of a low water volume vessel, the following trim,
controls and design shall be provided:
A. The primary water column shall be located on the left side of the
boiler when facing the burner, and shall be a McDonnell-Miller
#193-7 or approved equal. It shall be piped with union
connections for easy removal and include a full size column
blowdown valve. A gauge glass with gauge glass valves shall be
mounted to the water column.
B. The primary water level control and water level cut-off settings shall
be installed at a level that limits the total water content within the
boiler to 75 U.S. Gallons (283.9 liters) or less at full operating
capacity.
C. Feedwater into the boiler shall be controlled by means of an electric
proportional feedwater valve, Worchester or approved equal,
complete with stop valve, check valve, and 3-valve by-pass.
D. Controls shall be provided to comply with "Guarded Plant" status
requirements.
E. The upper and lower drums shall be properly insulated to prevent
heat transfer onto these surfaces during combustion.
2.6 LOW WATER VOLUME DESIGN (LWV), 15 PSIG
For applications requiring the use of a low water volume vessel, the following trim,
controls and design shall be provided:
A. Controls shall be provided to comply with "Guarded Plant" status
requirements.
B. The upper and lower drums shall be properly insulated to prevent
heat transfer onto these surfaces during combustion.
2.7 BURNER
A. Models 1500 - 6000; all air for combustion shall be supplied by a
B3-35
03-08
forced draft blower mounted in the front head (wind box) above the
burner, to minimize vibration and reduce noise emissions. The
impeller shall be an enclosed centrifugal fan type, properly balanced
and direct connected to the motor shaft. Sound level shall not
exceed 80 dBA measured 3 feet in front of the burner.
B. Models 7500 - 8000; all air for combustion shall be supplied by a
forced draft blower mounted within the fan housing of the externally
mounted burner. The burner shall be a CB Profire Series V. The fan
shall be a squirrel cage design, properly balanced and direct
connected to the motor. Sound level shall not exceed 85 dBA
measured 3 feet in front of the burner.
C. When firing gas, the burner shall operate on the full modulation
mode and shall be positioned at the low position for the ignition
sequence, and shall remain in the low fire position during ignition
D. For oil operation, the burner shall operate on the low-high-low
principle and shall be positioned at the low position for the ignition
sequence, and shall remain in the low fire position during ignition
2.8 GAS FIRED BURNER
A. The burner shall be a high radiant multi-port type approved for
operation on natural gas.
B. Automatic electric ignition of the premix gas pilot shall be furnished.
An ultra violet (UV) flame detector shall monitor the pilot, preventing
the primary fuel valve from opening until the pilot flame has been
established. The gas pilot assembly shall include a pilot solenoid
shutoff valve, pilot regulator, and manual shutoff cock.
C. A single damper motor shall control the combustion air inlet damper
and the fuel input control valve (butterfly type) via linkage
connections. The damper motor shall modulate the burner in
accordance with system demand, responding to the boiler mounted
modulating pressure control.
D. Gas burner piping shall include a primary safety shutoff valve,
controlled by the burner flame safeguard control to start or stop the
burner. The valve shall close automatically in the event of a power
failure, excess steam pressure, low or high gas pressure, or a low
water condition.
E. A main gas pressure regulator shall be piped in the gas train to
regulate the incoming pressure for proper burner operating pressure
including an upstream manual shutoff valve.
F. For tightness checking of the primary shutoff valve, a plugged
leakage test connection and a lubricated plug cock shall be
provided.
G. The primary shutoff valve shall be of the motorized type.
H. For sizes 6000 - 8000, a second motorized gas valve shall be
provided and piped in series with the primary shutoff valve.
I. Low and High gas pressure switches of the manual reset type shall
be mounted and wired to prevent burner operation if gas pressure is
above or below the settings of these switches.
B3-36
05-03
J. To prove proper air is available for pre purge and combustion, a
combustion air proving switch shall be provided.
2.9 OIL FIRED BURNER
A. The burner shall be a pressure atomizing type approved for
operation with commercial grade No. 2 fuel oil.
B. For 1500 through 6000 units,
1. Automatic electric spark ignition for the low fire oil supply shall
be provided with a 10,000 volt ignition transformer and heavy
duty electrodes. The ignition period shall be monitored with
an electronic scanner of the UV principle to confirm the
presence of the low fire oil flame.
2. A single damper motor shall control the combustion air inlet
damper and the fuel input control valves via linkage
connections. The damper motor shall operate the burner in
accordance with system demand, responding to the boiler
mounted low high low pressure control.
3. For fuel input control, 4 solenoid type fuel oil valves shall be
piped and wired onto the front head of the boiler. Two valves
shall be used for low fire ignition and the other two for high fire
operation.
4. The fuel oil system shall include supply and return tubing to an
oil terminal block, oil pressure gauge, and shutoff cock.
5. An oil pump shall be provided and shall be integral with the
burner. The pump shall include a built-in pressure relief valve
and self cleaning strainer. Operation of the pump shall be via
belt connection to the fan motor.
C. For 7500 - 8000 units, automatic electric ignition of the premix gas
pilot shall be furnished. An ultra violet (UV) flame detector shall
monitor the pilot, preventing the primary fuel valve from opening
until the pilot flame has been established. The gas pilot assembly
shall include a pilot solenoid shutoff valve, pilot regulator, and
manual shutoff cock.
damper and the fuel input control valve via linkage
connections. The damper motor shall modulate the burner in
mounted modulating pressure control.
2. For fuel input control, metering type fuel oil valve shall be
piped and onto the burner housing. Two solenoid valves shall
be used for safety shutoff.
3. The fuel oil system shall include supply and return tubing to an
oil terminal block, oil pressure gauge, low oil pressure
interlock, and shutoff cock.
4. An oil pump shall be provided and shall be shipped loose with
the burner. The pump shall include a built-in pressure relief
valve and self cleaning strainer. Operation of the pump shall
be via oil pump starter mounted and wired in the burner
control panel.
B3-37
03-08
2.10 GAS-OIL FIRED BURNER
A. A. General
1. The burner shall be a high radiant multi-port type approved for
operation on natural gas and shall be a pressure atomizing type
approved for operation with commercial grade No. 2 fuel oil.
furnished. An ultra violet (UV) flame detector shall monitor the
pilot, preventing the primary fuel valve from opening until the
pilot flame has been established. The gas pilot assembly shall
include a pilot solenoid shutoff valve, pilot regulator, and
manual shutoff cock.
damper and the fuel input control valve via linkage
connections. The damper motor shall regulate the burner in
mounted pressure control.
4. To prove proper air is available for pre purge and combustion, a
combustion air proving switch shall be provided.
B. Gas System
1. Gas burner piping shall include a primary safety shutoff valve,
controlled by the burner flame safeguard control to start or stop
the burner. The valve shall close automatically in the event of a
power failure, excess steam pressure, low or high gas pressure,
or a low water condition.
2. A main gas pressure regulator shall be piped in the gas train to
regulate the incoming pressure for proper burner operating
pressure including an upstream manual shutoff valve.
3. For tightness checking of the primary shutoff valve, a plugged
leakage test connection and a lubricated plug cock shall be
provided.
4. The primary shutoff valve shall be of the motorized type.
5. For sizes 6000 - 8000, a second motorized gas valve shall be
provided and piped in series with the primary shutoff valve.
6. Low and High gas pressure switches of the manual reset type
shall be mounted and wired to prevent burner operation if gas
pressure is above or below the settings of these switches.
C. Oil System
1. For 1500 through 6000 units,
a. For fuel input control, 4 solenoid type fuel oil valves shall
be piped and wired onto the front head of the boiler. Two
valves shall be used for low fire ignition and the other two
for high fire operation.
b. The fuel oil system shall include supply and return tubing
to an oil terminal block, oil pressure gauge, and shutoff
cock.
c. An oil pump shall be provided and shall be integral with
the burner. The pump shall include a built-in pressure
relief valve and self cleaning strainer. Operation of the
pump shall be via belt connection to the fan motor.
B3-38
05-03
2. For 7500 - 8000 units,
a. For fuel input control, metering type fuel oil valve shall be
piped and onto the burner housing. Two solenoid valves
shall be used for safety shutoff.
b. The fuel oil system shall include supply and return tubing
to an oil terminal block, oil pressure gauge, low oil
pressure interlock, and shutoff cock.
c. An oil pump shall be provided and shall be shipped loose
with the burner. The pump shall include a built-in
pressure relief valve and self cleaning strainer. Operation
of the pump shall be via oil pump starter mounted and
wired in the burner control panel.
2.11 BURNER AND FLAME FAILURE CONTROLLER
A third party listed and approved safeguard control shall be provided to control
ignition, starting and stopping the burner, and provide pre-combustion and post
combustion air purge. The control shall stop and prevent burner operation in the
event of ignition, pilot, or main flame failures. Trial for ignition shall be limited to
10 seconds.
A. The flame safeguard control shall be a microprocessor based burner
management control system, designed to provide proper burner
sequencing, ignition, and flame monitoring protection.
B. Through SMART LED's, the control shall provide current operating
status and lockout information in the event of a safety shutdown.
C. A separate preconfigured program module shall plug in to the
microprocessor control.
D. For trouble shooting and retrieving history, a VFD format display
shall be mounted onto the control. This alpha numeric display shall
provide 2 lines by 16 characters per line display of operating
conditions, fault conditions, flame signal strength, and burner run
history.
E. In addition to the VFD display, LED Indicator Lights shall be
provided integral with the control for Fan, Open Damper, Close
Damper, Auto Operation, and Ignition.
F. The control shall be a CB120E or equal.
2.12 BURNER CONTROL PANEL
A. The control panel shall be mounted at the front of the boiler on the
burner fan housing (windbox) and conveniently located for the
operator. It shall be mounted within a NEMA 1A type enclosure and
include a key lock.
B. Factory mounted and wired components and controls shall include
the following:
1. Fan Motor Starter
2. Fan Motor Fuses
3. Control Circuit Transformer with fuses
4. Oil Pump Starter (size 7500 - 8000 units) firing oil.
5. Terminals for wiring connections
B3-39
03-08
6. Flame Safeguard Control
7. Burner On/Off Switch
8. Manual Damper Positioning Switch
9. Indicating lights for low water, flame failure, load demand, and
fuel valve on.
C. All electrical equipment shall be in conformity with CSA. Oil, heat,
and moisture resistant wire shall be used and number coded relative
to the wiring diagram.
B3-40
05-03
B3-41
03-08
Section B3
Model 5 Boilers
(Hot Water Boiler Specifications)
Boiler Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-42
Boiler Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-42
Soot Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-43
Boiler Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-43
Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-43
Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-29
Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-44
No.2 Oil and Gas Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-45
Burner and Flame Failure Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-45
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-46
packages.
Section B3 Model 5 Hot Water BoilerSpecifications
B3-42
03-08
A. The hot water boiler shall be Cleaver-Brooks Model 5, Series ______
(100, 200, 700), _______ bhp, designed for 140 psig hot water.
The maximum supply temperature will be ______ F, and the
minimum return water temperature will be _______ F. The
minimum operating temperature of the boiler shall be 170 F. (Series
100 - No. 2 oil; 200 - No. 2 oil and gas; 700 - gas.)
B. The boiler shall have a maximum output of ______ Btu/hr, or _____
hp, when fired with No.2 oil and/or natural gas _______ Btu/cu-ft.
Safety relief valves shall be set at _______ psig.
C. Electrical power available will be ______ volts, _______ phase,
_______ Hz. All electrical service connections shall be made to an
electrical entrance box mounted on the right hand side of the boiler.
PART 2 PRODUCTS 2.1 BOILER DESCRIPTION
A. The boiler shall be an all steel membrane wall watertube boiler with
3-pass gas travel. It shall be mounted on a heavy duty steel frame
with integral forced draft burner and burner controls. The complete
packaged boiler-burner unit shall be approved by Canadian Standard
Association and shall have the CSA label affixed to the front head.
The boiler shall be completely assembled and fire tested at the
factory.
B. The boiler shell must be constructed and hydrostatically tested in
accordance with the ASME Boiler and Pressure Vessel Code. It must
receive authorized boiler inspection prior to shipment. A copy of the
C. Two lifting eyes shall be located on top of the boiler.
D. Two downcomers shall be located at the rear of the boiler and totally
insulated from the generating tubes. The generating tubes shall be
2" OD SA-178 Grade A with.095 wall thickness. The downcomers
shall be 2-1/2 OD for 35 and 47 hp; 3" OD for 59 to 83 hp and 4"
OD for 95 to 143 hp. Material shall be SA-178-A and the 2-1/2
and 3" downcomers shall have a 0.105" wall. The 4" downcomers
shall have a 0.135" wall.
E. The upper drum shall be 20" OD schedule 20, SA-53-B seamless
pipe with.375 wall. The lower drum shall be 6" nominal pipe size,
SA-53-B seamless pipe with.312 wall.
F. Refractory shall be limited to the furnace floor, insulating the lower
drum, the burner throat tile, and to the formed rear access door
which unbolts for ease of entry and/or inspection. High-temperature
insulation shall be installed on the front wall of the furnace.
G. Observation ports shall be provided at each end of the boiler for
H. The exhaust gas vent shall be located at the rear of the boiler on the
top centerline. A stack thermometer shall be shipped loose for field
installation.
I. Inspection openings shall be provided in the convection area.
Model 5 Hot Water BoilerSpecifications Section B3
B3-43
03-08
J. The boiler insulation shall be a minimum of 2" fiber glass blanket.
This insulation shall be covered with a corrugated sheet metal
lagging. The lagging and insulation shall be arranged for easy
removal and reinstallation if required. The entire boiler, base frame,
and other components shall be factory painted before shipment
using a hard finish enamel.
2.2 SOOT CLEANING
A. Soot washer lances shall be provided in the convection area of the
boiler measuring full length of the pressure vessel. Each lance shall
be provided with a shutoff valve and the assembly shall be capable
of rotating 360 F. This shall ensure complete washing of the
convection zone while the boiler is operating in the low fire mode.
B. Soot washer troughs shall be provided at the bottom of the boiler.
These shall be furnished for each convection side running the full
length of the boiler with 2" drain connections at the boiler rear.
Inspection/cleanout openings for each trough shall be located at the
front of the boiler.
2.3 BOILER CONNECTIONS
A. The hot water outlet connection shall be located on the top
centerline of the boiler and the return connection shall be located at
the rear of the lower drum. The design of the boiler shall provide jet
induced circulation, which shall mix the return water with the hot
water within the boiler.
B. A dip tube shall be included as an integral part of the hot water
outlet. An air vent tapping shall be located on the top centerline of
the boiler for connection to an expansion tank.
C. Handholes shall be provided at the end of the lower drum and in the
rear of the upper drum for inspection of the water side surfaces.
2.4 BOILER TRIM
A. The low water cutoff switch shall be a probe type, mounted in the
top center-line of the boiler. It shall be wired into the burner control
circuit to prevent burner operation if the boiler water falls below a
proper level.
B. A minimum of three controls shall be provided: one auto reset type
for burner on-off control, one for burner firing rate, and one manual
reset type for burner cutout on excessive water temperature. The
sensing elements shall be located adjacent to the outlet connection.
C. A hot water circulating pump shall be mounted between the supply
and return water connections (standard on ASME Section IV heating
boilers only). This pump will blend the supply and the system return
water. It will ensure a minimum continuous circulation at all times
to a level of 10 boiler water changes per hour.
D. A combination pressure-temperature gauge shall be located on the
boiler.
E. Water relief valves shall be provided of a type and size to comply
with ASME Code requirements.
B3-44
03-08
2.5 BURNER
A. Burner Description
1. All air for combustion shall be supplied by a forced draft blower
mounted in the front head (windbox), above the burner, to
minimize vibration and noise level.
2. The impeller shall be an enclosed centrifugal fan type, properly
balanced and directly connected to the blower motor shaft.
3. The maximum sound level shall not exceed 80 dBA measured
3 feet in front of the boiler.
4. The oil burner shall operate on the low-high-low principle and
5. The gas burner shall operate on the full modulation system and
B. Gas Fired Burner
1. The burner shall be integral with the front head of the boiler
and shall be the high radiant multi-port type approved for
operation with natural, manufactured, or mixed gas.
furnished. A UV flame detector shall monitor the pilot,
preventing the primary fuel valve from opening until the pilot
flame has been established.
3. A single damper motor shall control the combustion air damper
and the butterfly gas valve. The damper motor shall regulate
the fire according to system demand in response to the boiler
mounted temperature/pressure control.
4. The gas burner piping system on the unit shall include a
primary gas shutoff valve. It shall be controlled by the
programming relay to start or stop the burner and to close
automatically in the event of power failure, flame failure,
excessive pressure or temperature, high or low gas pressure, or
a low water condition. A lubricated shutoff cock shall be
located ahead of the primary valve for manual shutoff.
5. A plugged leakage test connection and a lubricated plug cock
are provided as a means for a tightness check of the primary
shutoff valve.
6. A gas pressure regulator shall be factory mounted and piped for
proper pressure regulation to the burner.
7. Gas Train Components
8. The primary shutoff valve shall be a motorized type. High and
low gas pressure switches shall be provided.
C. No. 2 Oil Fired Burner
1. The burner shall be integral with the front head of the boiler. It
shall be the pressure atomizing type approved for operation
with commercial grade No.2 oil.
2. The burner shall operate on the low-high-low principle, and
must return to the low-fire position prior to ignition.
B3-45
03-08
3. The burner shall remain in the low-fire position during ignition,
and until low fire and main flames have been proven.
4. Automatic electric ignition of the low-fire oil supply shall be
provided with a 10,000 volt transformer and heavy duty
electrodes. The ignition period shall be monitored with an
electric scanner of the UV principle to confirm the presence of
the low fire oil flame.
Notice
Optional insurance compliance may require a premix gas pilot in lieu of electric
ignition.
5. The combustion air damper, low-fire, and high-fire oil valves
shall be operated by a single damper control motor. This motor
shall regulate the fire according to system demand in response
to the boiler mounted high-low fire temperature/pressure
control.
2.6 OIL SYSTEM
A. An oil pump shall be provided. The oil pump, integral with the
burner, shall include a built-in relief valve and self- cleaning strainer.
The pump shall be belt driven from the blower motor.
B. The fuel oil system shall include supply and return tubing to a
terminal block, oil pressure gauge, shutoff cock, and four solenoid oil
shutoff valves. These items shall be factory mounted on the front
head.
2.7 NO.2 OIL AND GAS BURNER
A. General
1. The burner shall be integral with the front head of the boiler. It
shall be the pressure atomizing type for oil and high radiant
multi-port type for gas. The burner must be approved for
operation with either commercial grade No.2 oil or natural gas.
2. The oil burner shall operate on the low-high-low principle, and
must return to the low-fire position prior to ignition.
3. The gas burner shall operate on the full modulation system and
4. The burner shall remain in the low-fire position during ignition
provided. A UV flame detector shall monitor the pilot to prevent
the primary fuel valve from opening until the pilot flame has
been established.
6. A single damper motor shall control the combustion air
damper, high and low fire oil valves, and the butterfly gas
valve. The damper motor shall regulate the fire according to
system demand in response to the boiler mounted high-low fire
temperature/pressure control.
B. Oil System
1. An oil pump shall be included. The oil pump, integral with the
burner, shall include a built-in relief valve and self-cleaning
strainer. The pump shall be belt-driven from the blower motor.
B3-46
03-08
2. The fuel oil system shall include supply and return tubing to a
terminal block, oil pressure gauge, shutoff cock, and four
solenoid oil shutoff valves. These items shall be factory
mounted on the front head.
C. Gas System
1. The gas burner piping system on the unit shall include a
primary gas shutoff valve. It shall be controlled by the
programming relay to start or stop the burner and to close
automatically in the event of power failure, flame failure,
excessive pressure or temperature, high or low gas pressure, or
a low water condition. A lubricated shutoff cock shall be
located ahead of the primary valve for manual shutoff.
2. A plugged leakage test connection and a lubricated plug cock
are provided as a means for a tightness check of the primary
shutoff valve.
3. A gas pressure regulator shall be factory-mounted and piped
for proper pressure regulation to the burner.
D. Gas Train Components
1. The primary shutoff valve shall be a motorized type. High and
low gas pressure switches shall be provided.
2.8 BURNER AND FLAME FAILURE CONTROLLER
A combustion safeguard control shall be provided to control ignition, starting and stopping the
burner and provide precombustion and postcombustion purge periods. It shall stop burner opera-
tion in the event of ignition, pilot or main flame failure. Trial for ignition shall be limited to 10
seconds.
2.9 CONTROL PANEL
A. The control panel shall be mounted on the front head of the boiler
and shall be conveniently located for the operator. It shall be a
NEMA 1A rated enclosure and have a Yale key lock.
B. Each boiler shall be factory-equipped with a flame safeguard
controller that provides technology and functions equal to the
Cleaver-Brooks Model CB100.
C. Flame safeguard controller shall be microprocessor based, with self-
diagnostics, non-volatile memory, and a message center with a
vocabulary of 42 different messages. Messages shall scroll across
an alpha-numeric display and provide sequence status and failure
mode information. The controller shall have a fixed operating
sequence incapable of being manually altered. The sequence will
include start, pre-purge, pilot and main fuel ignition run and post-
purge cycles.
D. Controller shall be the non-recycle type for maximum safety that will
functions: pilot and main flame failure, high and low fire proving
switch faults, running interlocks open, false flame signal and fuel
valve open.
B3-47
03-08
E. The controller shall have a run/test switch. It will allow interruptions
to sequence just after pre-purge, during pilot ignition trial, and
during run cycles for adjustments to firing rate motor, damper
linkages and pilot flame for turndown tests.
F. In addition to the above functions, the controller shall:
1. Display history of operating hours and totals of completed on-
off cycles.
2. Provide a constant flame signal strength read-out.
3. Have provisions for a remote display capability.
G. The panel shall contain the blower motor starter, control circuit
fuses, control circuit transformer, and control switches. A damper
positioning switch shall be provided to permit selection of automatic
firing or manual selection of low or high fire.
1. A terminal board shall be provided to which all wires entering
or leaving the panel shall be connected.
2. All electrical equipment shall be in conformity with the
Canadian Standard Association requirements. Oil, heat and
moisture resistant wire shall be used and shall be number
coded.
3. A low fire hold timer shall be mounted in the panel and wired
to hold the boiler in a low firing mode, for a minimum of 10
minutes, each time the boiler cycles on. This low fire hold timer
ensures gradual boiler warm up.
B3-48
03-08
Notes
B4-1
07-08
CONTENTS
Standard Equipment - Steam Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4
Standard Equipment - Water Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-27
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-27
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-35
Section B4
Electric Resistance Boilers
Steam or Hot Water
Section B4 Electric Boilers
B4-2
07-08
ILLUSTRATIONS
Figure B4-1. Model CWB Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-10
Figure B4-2. Model S Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-11
Figure B4-3. Model CR Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-12
Figure B4-4. Model CSB Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-13
Figure B4-5. Model IWH Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-14
TABLES
Table B4-1 Standard Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-9
Table B4-2 Model CWB Ratings 208V, 240V Suppplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-15
Table B4-3 Model CWB Ratings (480V, 600V Supplies) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-16
Table B4-4 Model S/CR Ratings (208/240V Supplies) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-18
Table B4-5 Model S/CR Ratings (480V Supplies) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-19
Table B4-6 Model S/CR Ratings (600V Supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-21
Table B4-7 Model CSB Ratings (480V Supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-23
Table B4-8 Model CSB Ratings (600V Supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-25
Table B4-9 Model IWH Ratings (208V/240V Supplies) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-26
Table B4-10 Model IWH Ratings (480V/600V Supplies) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-26
Table B4-11 Model CWB Max Flow Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-28
Table B4-12 Model CWB Minimum Over Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . B4-30
Table B4-13 kW per pound of steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-31
Table B4-14 Electric Boilers Required Water Quality Parameters . . . . . . . . . . . . . . . . . . . . . . . . B4-32
Table B4-15 Power Supply Wire Lug Sizing Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-33
This section contains information on the complete line of Cleaver-Brooks electric boilers with kilowatt output rat-
ings from 9 to 3,375 kW. Electric boilers are typically utilized for applications where stringent environmental
regulations and boiler space requirements are critical.
Electric Boilers Section B4
B4-3
07-08
In applications where electric power is more economically available than fossil fuels,
or where fossil fuel combustion and the handling of combustion by-products are
unacceptable, electric boilers offer a viable alternative.
Compact Design Electric boilers are typically one-quarter to one-half the size of fuel fired boilers with
similar BTU per hour output. The smaller footprint reduces the overall boiler room
space.
No Stack
Requirements
With no products of combustion to contend with, installation costs are reduced by
the elimination of stack requirements. This means the unit can be located anywhere
in the building and the exterior of the building is not compromised with an unsightly
stack, particularly helpful in tall or high rise buildings.
Emissions Because there is no combustion, electric boilers are 100% emission free. This is
beneficial in meeting total emissions of the project site or in areas where fuel
combustion emissions are not tolerated.
Quiet Operation Elimination of combustion noise and minimal moving parts results in extremely
quiet operation, virtually no noise emissions. Very beneficial in applications such as
hospitals, nursing homes, schools, and the like.
High Efficiency With minimum radiation losses and not having the losses associated with
combustion equipment the electric boiler will provide nearly 100% efficiency at all
operating points.
Ease of Maintenance The absence of high maintenance combustion equipment and the use of solid state
control devices reduce the complexity and number of moving parts.
Electric elements are easily accessible and replaceable either individually or in
flange mounted groups.
Pressure vessel components are not subjected to thermal stresses induced by high
temperature differentials and cycling encountered with fossil fuel combustion.
Quality Construction ISO 9001:2001 certified manufacturing process ensures the highest degree of
manufacturing standards are always followed.
ASME Code construction ensures high quality design, safety, third party inspection,
and reliability, and stamped accordingly.
Each unit is tested and certified in accordance with UL or cUL and the Label is
affixed attesting to meeting the latest UL requirements for packaged electric boilers.
Progressive
Sequencing
Modulation
By individually controlling the heating the heating elements with solid state digital
step controllers, only the amount of heat required in response to the system demand
is achievable. Virtually unlimited input control is available with optional solid
B4-4
07-08
state analog current controllers, which reduces on/off cycling, excellent load
tracking, and reduced operating costs.
Designed For
Heating
Applications
Electric boilers are able to withstand virtually any return water temperature. With
combustion by-products and high temperature differentials eliminated,
condensation and thermal shock do not limit return water temperatures.
Because of the design characteristics, the electric boiler is well suited for
applications utilizing indoor/outdoor reset controls, radiant floor heating, snow melt
systems, and ground source heat pump systems
For potable water applications, the IWH can be used with the optional epoxy lining
or with the optional stainless steel vessel and stainless steel trim.
PRODUCT OFFERING
Information in this section applies to electric resistance steam or hot water boiler
sizes ranging from 12 kW through 3375 kW for operation on 208, 240, 380, 480,
575 or 600 volts, thee phase power supplies. Installation is for indoor use only.
The complete package has been tested and certified in accordance with U.L.and is
approved, listed, and bears the U.L label (U.S.A. and Canada) for electric
resistance boilers. For Canada, each vessel is registered in each Province and the
relative CRN number is attached to the boiler.
Dimensions, ratings, and product information may change to meet current market
requirements and product improvements. Therefore, use this information as a
guide.
Refer to Table B4-1 as a quick reference guide to the boiler models and sizes
provided.
Standard Equipment
- Steam Boilers
Equipment described below is for the standard steam electric boilers offering:
A. Model CR and S Boiler
1. Each boiler is designed and constructed in accordance with the
A.S.M.E. Code; UL listed, and are mounted on an integral steel
frame. Fiberglass insulation (4" thickness) is covered with a
preformed, sectional steel painted jacket, factory installed.
2. Trim and Controls:
a. Manual Reset High Pressure Cutoff.
b. Probe Aux. Low Water Cutoff, MR.
c. Aux. Auto High Pressure Cutoff.
d. For S/CR-120 through 161:
e. 1-Step (1) on/off pressure switch.
f. 2-Step (2) on/off pressure switch.
g. For Models S/CR above 161:
B4-5
07-08
h. Solid state electronic proportional pressure control with
progressive step control with adjustable span and inter-
stage time delay.
i. Primary Low Water Cutoff and On/Off Pump Controller.
j. Bottom and Water Column Blowdown Valves.
k. Feedwater Stop and Check Valves.
l. A.S.M.E Pressure Relief Valve(s).
m. Steam Pressure Gauge w/test cock.
n. Sight Gauge with drain and guards.
3. Model CR Boilers include an integral Feedwater Tank and
Feedwater Pump Assembly piped and wired.
4. Electric Equipment
a. Main Control Panel with panel door key lock.
b. Lugs for the primary power supply, top of panel ingress as
standard.
c. Fuses for each contactor, 200,000 Amps interrupting
capacity (AIC).
d. Contactors duty rated @ 500,000 cycles.
e. Pilot lights for "Control Power On", "High Pressure", "Low
Water", and "Steps".
f. 67 watts per square inch (WSI) Incoloy 800 heating
elements.
g. Control Circuit Step-down Transformer with primary and
secondary fuses and secondary control power switch.
h. Terminal strip for control wiring and external customer
connections.
5. Vessel Inspection Openings:
S/CR120 to S/CR: Element Flange.
S/CR200 to S/CR302: 3: Half Coupling.
S361 and larger: 12" x 16" Manway.
B. Model CSB Boiler
1. Each boiler is designed and constructed in accordance with the
A.S.M.E. Code; UL listed, and are mounted on an integral steel
frame. Fiberglass insulation (4" thickness) is covered with a
preformed, sectional steel painted jacket, factory installed.
a. Manual Reset High Pressure Cutoff.
b. Probe Aux. Low Water Cutoff, MR.
c. Aux. Auto High Pressure Cutoff.
d. Solid state electronic proportional pressure control with
progressive step control with adjustable span and inter-
stage time delay.
e. Primary Low Water Cutoff and On/Off Pump Controller.
f. Bottom and Water Column Blowdown Valves.
g. Feedwater Stop and Check Valves.
B4-6
07-08
h. A.S.M.E Pressure Relief Valve(s).
i. Steam Pressure Gauge w/test cock.
j. Sight Gauge with drain and guards.
standard.
capacity (AIC).
e. Pilot lights for "Control Power On", "High Pressure", "Low
Water", and "Steps".
f. 75 watts per square inch (WSI) "Incoloy- 800" heating
elements.
connections.
CSB-301 to CSB-302: 3" Half Coupling.
CSB-361 and larger: 12" x 16" Manway.
Standard Equipment
- Water Boilers
Equipment described below is for the standard hot water electric boilers offering:
A. Model CWB Boiler
1. The Model CWB boiler is designed and constructed in
accordance with the A.S.M.E. Code; UL listed, and are
mounted on an integral steel frame. Fiberglass insulation (4"
thickness) is covered with a preformed, sectional steel painted
jacket, factory installed.
a. Manual Reset High Temperature Cutoff.
b. Probe Low Water Cutoff, auto reset.
c. Aux. Auto High Temperature Cutoff.
d. For CWB-120:
e. 1-Step (1) on/off temperature switch.
f. 2-Step (2) on/off temperature switch.
g. 3-Step (1) 3-stage electronic temperature control.
h. 4-Step (1) 4-stage electronic temperature control.
i. For Models CWB 122 and above:
j. Solid state electronic proportional temperature control
with progressive step control with adjustable span and
inter-stage time delay.
k. Bottom drain valve.
B4-7
07-08
l. A.S.M.E Pressure Relief Valve(s).
m. CWB120: Separate Pressure and temperature gauge.
n. CWB-121 and above: Separate Pressure Gauge and
Digital Temperature Readout.
standard.
capacity (AIC).
e. Pilot lights for "Control Power On", "High Temperature",
"Low Water", and "Steps".
elements.
connections.
CWB-120 to CWB-200: Element Flange.
CWB-201 to CWB-243: 3: Half Coupling.
CWB361 and larger: 12" x 16" Manway.
B. Model IWH Heater
1. The Model IWH water heater is designed and constructed in
accordance with the A.S.M.E. Code; UL listed, and are
mounted on an integral steel frame. Fiberglass insulation (4"
thickness) is covered with a preformed, sectional steel painted
jacket, factory installed.
a. Manual Reset High Temperature Cutoff.
b. Water Flow Switch - shipped loose.
c. Aux. Auto High Temperature Cutoff.
d. Stage Controls for 15 - 240 kW:
1-Step (1) on/off temperature switch.
2-Step (2) on/off temperature switch.
3-Step (1) 3-stage electronic temperature control.
4-Step (1) 4-stage electronic temperature control.
1) For 270 kW and greater:
Solid state electronic proportional temperature control
with progressive step control with adjustable span and
inter-stage time delay.
e. Bottom drain valve.
f. A.S.M.E Pressure Relief Valve(s).
B4-8
07-08
g. Combination Pressure and Temperature gauge - shipped
loose.
b. 2. Lugs for the primary power supply, top of panel
ingress as standard.
capacity (AIC).
e. Pilot lights for "Control Power On", "High Temperature",
"Low Water", and "Steps".
elements.
connections.
Element Flange.
Optional Equipment For option details, contact the local authorized Cleaver-Brooks representative. In
summary, here are the options that can be provided with the boiler:
Output step enable/disable toggle switches.
Additional Pilot Lights.
Alarm relays for remote annunciation.
Alarm Horn with silence switch.
Safety Door Interlock.
Outdoor reset control.
Time Clock.
Ammeter.
Voltmeter.
Kilowatt hour meter.
Ground Fault Detection.
Pneumatic control interface (3-15 or 6 - 30 psig to 0 - 145 ohms.)
Load limiting module.
Auxiliary Low Water Cutoff.
Preheat Switch for elements.
Manual Disconnect Switches.
Shunt Trip for disconnect switches.
Main Power Door Interlock (standard with switchgear below 600 AMPS).
B4-9
07-08
Blowdown Separators.
Water Softener.
Chemical Feed Systems.
For layout purposes, the overall dimensions for the Electric Boilers are shown in
Figures B4-1 through B4-5 including the various pipe connections sizes for supply
and return water, drain, and steam supply.
Specific ratings of each model are noted in Tables B4-2 through B4-10. These
tables provide the ampacity at the various supply voltages, element ratings, and
contactors employed in the standard models.
Altitude Because the electric boiler does not require combustion air, installation of the boiler
at any elevation is possible without derating or providing special devices for altitude
correction normally associated with fuel combustion. Thus the ratings shown are for
all elevations.
1.
2.
A.
B. Water content not applicable. Flow rate in GPM is listed.
TABLE B4-1 Standard Product Offering
Model CR identical to Model S but has integral condensate return
tank and pump.
Notes:
Some boiler combinations that have vessel sizes above 20" or 42", or above 600
gallons, will have additional design pressure limitations. Contact your Cleaver-
Brooks authorized representative for final design pressure and model selection.
135 - 360
B
150 15 - 360
67
75
1
Heating elements are of Incoloy-800 construction.
16 - 115 15 or 125 1,2
180 - 790 15 or 125 1
12 - 480
540 - 3375
75
CR
CSB
Steam Boilers
Instantaneous
Water
Heaters
IWH
16 - 500 160 1
S 12 - 1944 67 16 - 595 15 or 125 1
Product
Type
Element
Density
[w/sq.in]
Hot Water
Boilers
CWB 12 - 3360 75
Water Content
[Gallons]
Design
Pressure
[PSIG]
A
Notes
Boiler
Model
Output
[kW]
B4-10
07-08
Figure B4-1. Model CWB Dimensions
MODEL NO
CONNECTION SIZE (NPT)
DIMENSIONS (IN.) CLEARANCES
APPROIXMATE
WEIGHTS (LBS.)
WIDTH DEPTH HEIGHT INLET TOP SIDES REAR
SHIPPING OPERATING
SUPPLY RETURN DRAIN A B C D E F G
CWB-120 2 2 3/4 28 28 39 8 12 15 12 450 580
CWB-121 3 3 3/4 28 28 39 8 12 15 12 500 630
CWB-122 3 3 3/4 28 28 54 8 12 15 12 800 1005
CWB-201 4 * 4 * 1-1/4 46 36 66 14 18 18 18 1400 2040
CWB-202 4 * 4 * 1-1/4 46 36 66 14 18 18 18 1500 2140
CWB-241 6 * 6 * 1-1/2 50 42 72 18 18 21 18 2200 3200
CWB-242 6 * 6 * 1-1/2 50 42 72 18 18 21 18 2400 3400
CWB-243 6 * 6 * 1-1/2 50 42 80 18 18 21 18 2800 3980
CWB-361 6 * 6 * 1-1/2 62 54 72 20 24 24 24 3300 5260
CWB-362 8 * 8 * 1-1/2 62 54 88 23 24 24 24 3600 6220
CWB-363 8 * 8 * 2 62 54 100 23 24 24 36 4200 7280
CWB-421
A
10 * 10 * 2 68 72 86 24 24 30 36 5800 9300
CWB-422
A
10 * 10 * 2 68 72 100 24 24 30 36 6500 10500
NOTES:
Dimensional heights are for the boiler only. Control panel size varies based
on the number of steps and optional equipment.
A.These models normally supplied with 2 control cabinets for 2 power supplies.
*These are flange connections; 150# ANSI.
B4-11
07-08
Figure B4-2. Model S Dimensions
MODELS S-120 THRU S-200 MODELS S-241 THRU S-480
MODEL
NO
CONNECTION SIZE (NPT) DIMENSIONS (IN.) CLEARANCES
APPROIXMATE
WEIGHTS (LBS.)
BLOWDOWN STEAM OUTLET*
FEED-
WATER
WIDTH DEPTH HEIGHT LWCO TOP SIDES
SHIPPING OPERATING
15 PSIG 150 PSIG 15 PSIG 150 PSIG A B C D E F
S-120 3/4 3/4 1-1/2 1-1/4 1/2 28 38 38 20 12 18 600 675
S-161 3/4 3/4 2 1-1/4 1/2 32 32 54 34 12 18 750 880
S-162 3/4 3/4 2 2 1/2 32 32 54 34 12 18 800 930
S-200 1 1 3 flg 2 3/4 36 36 66 41 12 18 1150 1480
S-241 1-1/4 1 4 flg 2 3/4 50 42 72 41 12 18 1400 1900
S-242 1-1/4 1 4 flg 2 3/4 50 42 72 41 12 18 1600 2000
S-301 1-1/2 1 6 flg 3 flg 3/4 56 48 72 40 15 21 2100 3000
S-302 1-1/2 1 6 flg 3 flg 3/4 56 48 88 50 15 21 2200 3300
S-361 1-1/2 1 8 flg 4 flg 3/4 62 54 72 42 18 24 2900 4000
S-362 1-1/2 1 8 flg 4 flg 3/4 62 54 86 52 18 24 3200 4800
S-421 1-1/2 1 8 flg 4 flg 1 68 60 72 41 18 27 4150 5800
S-422 1-1/2 1 8 flg 4 flg 1 68 60 88 51 18 27 4500 6700
S-480 2 1-1/4 10 flg 6 flg 1 74 66 92 53 18 27 5450 8000
NOTES:
Dimensional heights are for the boiler only. Control Panel size varies based on the number of steps and optional equipment.
* Steam Outlet is MPT connection unless otherwise noted.
B4-12
07-08
Figure B4-3. Model CR Dimensions
MODEL
NO
CONNECTION SIZE (NPT) DIMENSIONS (IN.)
APPROIXMATE WEIGHTS
(LBS.)
COND.
RETURN
OVER-
FLOW
WIDTH DEPTH HEIGHT LWCO
SHIPPING OPERATING
15 PSIG 150 PSIG 15 PSIG 150 PSIG A B C D
CR-120 3/4 3/4 1-1/2 1-1/4 3/4 3/4 28 38 38 20 850 950
CR-161 3/4 3/4 2 1-1/4 1 1 32 42 54 28 1050 1200
CR-162 3/4 3/4 2 2 1 1 32 42 54 34 1150 1280
CR-200 1 1 3 flg 2 1-1/4 1-1/4 36 48 66 41 1650 2030
CR-241 1-1/4 1 4 flg 2 1-1/2 1-1/2 50 52 72 41 2000 2600
CR-242 1-1/4 1 4 flg 2 1-1/2 1-1/2 50 52 72 41 2200 2700

* Steam Nozzle connection is MPT unless noted otherwise
B4-13
07-08
Figure B4-4. Model CSB Dimensions
MODEL
NO
CONNECTION SIZE (NPT) DIMENSIONS (IN.) CLEARANCES
APPROIXMATE
WEIGHTS (LBS.)
FEED-
WATER
WIDTH DEPTH HEIGHT LWCO TOP SIDES
SHIPPING OPERATING
15 PSIG 150 PSIG 15 PSIG 150 PSIG A B C D E F
CSB-301 1-1/2 1 6 3 3/4 56 48 72 40 15 21 2400 3200
CSB-361 1-1/2 1 8 4 3/4 62 54 72 42 18 24 2900 4000
CSB-362 1-1/2 1 8 4 3/4 62 54 88 52 18 24 3300 4800
CSB-421 1-1/2 1 8 4 1 68 60 72 41 18 27 4250 5800
CSB-422 1-1/2 1 8 4 1 68 60 88 51 18 27 4600 6700
CSB-423 2 1-1/2 10 4 1 116 68 62 34 24 36 5700 8000
CSB-424 2 1-1/2 10 6 1 132 68 62 34 24 36 6400 9300
CSB-425 2 1-1/2 10 6 1 148 68 62 34 24 36 7100 10600
NOTES:
Dimensional heights are for the boiler only. Control Panel size varies based on the number of steps and optional equipment.
* Steam Outlet is 150# ANSI Flange connection unless otherwise noted.
B4-14
07-08
Figure B4-5. Model IWH Dimensions
MODEL NO
CONNECTION SIZE (NPT)
DIMENSIONS (IN.) CLEARANCES
APPROIXMATE
WEIGHTS (LBS.)
WIDTH DEPTH HEIGHT INLET INLET LEFT RIGHT
FRONT SHIPPING OPERATING
SUPPLY RETURN DRAIN A B C D E RL RR
IWH-611 2 2 3/4 30 20 18 8-1/2 6 20 12 36 250 295
IWH-811 3 3 3/4 50 22 22 9-1/2 6 36 36 36 450 525
IWH-812 3 3 3/4 50 22 22 9-1/2 6 36 36 36 450 525
IWH-822 3 3 3/4 82 22 22 9-1/2 8 36 36 36 500 630
IWH-022 3 * 3 * 3/4 82 26 30 10 9 36 36 36 600 810
NOTES:
Dimensional heights are for the boiler only. Control panel size varies based on the
number of steps and optional equipment.

*For flow rates above 240 gpm, specify 4" flanged connections.
B4-15
07-08
Table B4-2. Model CWB Ratings 208V, 240V Suppplies
MODEL #
Vessel
Capacity
(gallons)
Rated kW MBTU/HR
ELEMENTS
# of
CONTACTORS
NUMBER and kW oF
STEPS
3-PHASE AMPERES
Qty kW 208/240V 208-240V 208V 240V
CWB-120 16 12 41 3 4 1 1@12 34 30
18 61 3 6 1 1@18 51 44
24 82 6 4 2 1@24 68 59
30 102 6 5 2 1@30 84 73
36 123 6 6 2 1@36 101 87
45 154 9 5 3 1@30,1@15 126 109
54 184 9 6 3 1@36,1@18 151 131
60 205 12 5 4 2@30 167 145
72 246 12 6 4 2@36 201 174
CWB-121 16 90 307 15 6 5 2@36,1@18 251 217
108 368 18 6 6 3@36 301 261
126 430 21 6 7 3@36,1@18 351 304
144 491 24 6 8 4@36 401 347
CWB-122 25 162 553 27 6 9 4@36,1@18 451 391
180 614 30 6 10 5@36 501 434
198 676 33 6 11 5@36,1@18 551 477
216 737 36 6 12 6@36 601 521
234 798 39 6 13 6@36,1@18 651 564
252 860 42 6 14 7@36 701 607
270 921 45 6 15 7@36,1@18 751 651
288 983 48 6 16 8@36 801 694
CWB-201 78 324 1105 54 6 18 6@54 901 781
360 1228 60 6 20 4@54,4@36 1001 868
396 1350 66 6 22 6@54,2@36 1101 954
432 1474 72 6 24 8@54 1201 1041
B4-16
07-08
Table B4-3. Model CWB Ratings (480V, 600V Supplies) Sheet 1 of 2
Model #
Vessel
Capacity
(gallons)
Rated kW MBTU/HR
ELEMENTS
# of
CONTACTORS
NUMBER and kW of
STEPS
3-PHASE AMPERES
Qty kW 480/600V 480/600V 480V 600V
CWB-120 16
12 41 3 4 1 1 @ 12 15 13
18 61 3 6 1 1 @ 18 22 18
24 82 6 4 1 1 @ 24 30 24
30 102 6 5 1 1 @ 30 37 29
36 123 6 6 1 1 @ 36 44 35
45 154 9 5 2 1 @ 45 55 44
54 184 9 6 2 1 @ 54 66 53
60 205 12 5 2 2 @ 30 73 58
72 246 12 6 2 2 @ 36 87 70
CWB-121 16
90 307 15 6 3 2 @ 36, 1 @18 109 87
108 368 18 6 3 3 @ 36 131 105
126 430 21 6 4 3 @36, 1 @18 152 122
144 491 24 6 4 4 @ 36 174 139
CWB-122 25
162 553 27 6 5 3 @36, 1 @54 196 157
180 614 30 6 5 5 @ 36 212 174
198 676 33 6 6 5 @36, 1@18 239 191
216 737 36 6 6 6 @ 36 261 209
234 798 39 6 7 6 @36, 1 @18 282 226
252 860 42 6 7 7 @ 36 304 243
270 921 45 6 8 7 @36, 1 @18 326 261
288 983 48 6 8 8 @ 36 347 278
CWB-201 78
324 1105 54 6 9 3 @72, 3 @36 391 313
360 1228 60 6 10 2 @72, 6 @36 434 347
396 1350 66 6 11 3 @72, 5 @36 477 382
432 1474 72 6 12 4 @72, 4 @36 521 417
CWB-202 78
468 1597 78 6 13 5 @72, 3 @36 564 451
504 1720 84 6 14 6 @72, 2 @36 607 486
540 1842 90 6 15 7 @72, 1 @36 651 521
576 1965 96 6 16 8 @72 694 555
CWB-241 122
600 2047 60 10 20 10 @ 60 723 579
630 2150 63 10 21 1 @90, 9 @60 759 607
660 2252 66 10 22 2 @90, 8 @60 795 636
690 2354 69 10 23 3 @90, 7 @60 831 665
720 2457 72 10 24 4 @90, 6 @60 868 694
750 2559 75 10 25 5 @90, 5 @60 904 723
CWB-242 122
780 2661 78 10 26 6 @90, 4 @60 940 752
810 2764 81 10 27 7 @90, 3 @60 976 781
840 2866 84 10 28 8 @90, 2 @60 1012 810
870 2968 87 10 29 9 @90, 1 @60 1048 838
900 3071 90 10 30 10 @ 90 1084 868
930 3173 93 10 31 7 @90, 5 @60 1120 896
960 3276 96 10 32 8 @90, 4 @60 1157 925
CWB-243 142
990 3378 99 10
33 9 @90, 3 @60
1193 954
1020 3480 102 10
34 10 @90, 2 @60
1229 983
1050 3583 105 10
35 11 @90, 1 @60
1265 1012
1080 3685 108 10
36 12 @ 90
1301 1041
1110 3787 111 10
37 9 @90, 5 @60
1337 1070
CWB-243 142
1140 3890 114 10
38 10 @90, 4 @60
1373 1099
1170 3992 117 10
39 11 @90, 3 @60
1409 1128
1200 4094 120 10
40 12 @90, 2 @60
1446 1157
CWB-361 235
1224 4176 102 12
34 10 @108, 2 @72
1474 1180
1260 4299 105 12
35 11 @108, 1 @72
1518 1214
1296 4422 108 12
36 12 @ 108
1561 1249
B4-17
07-08
Table B4-3. Model CWB Ratings (480V, 600V Supplies) Sheet 2 of 2
Model #
Vessel
Capacity
(gallons)
Rated kW MBTU/HR
ELEMENTS
# of
CONTACTORS
NUMBER and kW of
STEPS
3-PHASE AMPERES
Qty kW 480/600V 480/600V 480V 600V
CWB-362 315
1332 4545 111 12
37 9 @108, 5 @72
1605 1284
1368 4668 114 12
38 10 @108, 4 @72
1648 1318
1404 4790 117 12
39 11 @108, 3 @72
1691 1353
1440 4913 120 12
40 12 @108, 2 @72
1735 1388
1476 5036 123 12
41 13 @108, 1 @72
1778 1422
1512 5159 126 12
42 14 @ 108
1821 1457
1548 5282 129 12
43 11 @108, 5 @72
1865 1492
1584 5405 132 12
44 12 @108, 4 @72
1908 1527
1620 5527 135 12
45 13 @108, 3 @72
1951 1561
1656 5650 138 12
46 14 @108, 2 @72
1995 1596
1692 5773 141 12
47 15 @108, 1 @72
2038 1631
1728 5896 144 12
48 16 @ 108
2081 1665
CWB-363 370
1764 6019 147 12
49 13 @108, 5 @ 72
2125 1700
1800 6142 150 12
50 14 @108, 4 @ 72
2168 1735
1836 6264 153 12
51 15 @108, 3 @ 72
2211 1769
1872 6387 156 12
52 16 @108, 2 @ 72
2255 1804
1908 6510 159 12
53 17 @108, 1 @ 72
2298 1839
1944 6633 162 12
54 18 @ 108
2342 1873
1980 6756 165 12
55 15 @108, 5 @ 72
2385 1908
2016 6879 168 12
56 16 @108, 4 @ 72
2428 1943
2052 7001 171 12
57 17 @108, 3 @ 72
2472 1977
2088 7124 174 12
58 18 @108, 2 @ 72
2515 2012
2160 7370 180 12
60 20 @ 108
2602 2081
CWB-421 425
2240 7643 168 13.3
56 16 @120, 4 @ 80
2698 2158
2320 7916 174 13.3
58 18 @ 120, 2 @ 80
2794 2236
2400 8189 180 13.3
60 20 @ 120
2891 2313
2480 8462 183 13.3
62 2 @160, 18 @120
2987 2390
2560 8735 192 13.3
64 4 @160, 16 @120
3083 2467
2640 9008 198 13.3
66 6 @160, 14 @120
3180 2544
CWB-422 500
2720 9281 204 13.3
68 8 @160, 12 @120
3276 2621
2800 9554 210 13.3
70 10 @160, 10 @120
3372 2698
2880 9827 216 13.3
72 12 @160, 8 @120
3469 2775
3000 10236 225 13.3
75 15 @160, 5 @120
3613 2891
3040 10372 228 13.3
76 16 @160, 4 @120
3661 2929
3120 10509 234 13.3
78 18 @160, 2 @120
3758 3006
3200 10645 240 13.3
80 20 @ 160
3854 3083
3280 11191 246 13.3
82 10 @160, 14 @120
3950 3160
3360 11464 252 13.3
84 12 @160, 12 @120
4047 3237
B4-18
07-08
Table B4-4. Model S/CR Ratings (208/240V Supplies)
Model #
Vessel
Capacity
(gallons)
Steam
Space
(gallons)
Rated kW
ASME
(Steam lbs/
hr)
ELEMENTS
# of
CONTACTORS
NUMBER and kW of
STEPS
3-PHASE AMPERES
Qty kW 208/240V 208/240V 208V 240V
S-120 or
CR-120
9 7
12 42 3 4 1 1 @ 12 34 30
24 84 6 4 2 1 @ 24 68 59
36 126 9 4 3 1 @ 36 101 88
48 168 12 4 4 2 @ 24 134 116
S-161 or
CR-161
23 16
60 210 9 6.7 3 1 @40, 1 @20 168 145
80 280 12 6.7 4 2 @ 40 223 193
S-162 or
CR-162
23 16
100 350 15 6.7 5 2 @40, 1 @20 279 242
120 420 18 6.7 6 3 @ 40 334 290
140 490 21 6.7 7 3 @ 40, 1 @ 20 390 338
S-200 or
CR-200
48 26
160 560 24 6.7 8 4 @ 40 445 386
180 630 27 6.7 9 4 @40, 1 @20 501 434
200 700 30 6.7 10 5 @ 40 556 482
220 770 33 6.7 11 5 @40, 1 @ 20 612 530
240 840 36 6.7 12 6 @ 40 667 578
S-241 or
CR-241
62 53
260 910 39 6.7 13 6 @40, 1 @ 20 723 626
280 980 42 6.7 14 7 @ 40 778 675
300 1050 45 6.7 15 7 @ 40, 1 @ 20 834 723
320 1120 48 6.7 16 8 @ 40 889 771
S-242 or
CR-242
62 53
340 1190 51 6.7 17 8 @ 40, 1 @ 20 945 819
360 1260 54 6.7 18 2 @ 60, 6 @ 40 1000 867
380 1330 57 6.7 19 3 @ 60, 5 @ 40 1056 915
400 1400 60 6.7 20 4 @ 60, 4 @ 40 1111 963
B4-19
07-08
Table B4-5. Model S/CR Ratings (480V Supplies) Sheet 1 of 2
Model #
Vessel
Capacity
(gallons)
Steam
Space
(gallons)
Rated kW
ASME
(Steam lbs/
hr)
ELEMENTS # of Contactors
NUMBER and kW of
STEPS
3-PHASE
AMPERES
Qty kW 480V 480V 480V
S-120 or
CR-120
9 7
12 42 3 4
1 1 @ 12 15
24 84 6 4
1 1 @ 24 29
36 126 9 4
1 1 @ 36 44
48 168 12 4
2 2 @ 24 58
S-161 or
CR-161
23 16
60 210 9 6.7
2 1 @40, 1 @20 73
80 280 12 6.7
2 2 @ 40 97
S-162 or
CR-162
23 16
100 350 15 6.7
3 2 @40, 1 @20 121
120 420 18 6.7
3 3 @ 40 145
140 490 21 6.7
4 3 @40, 1 @20 169
S-200 or
CR-200
48 26
160 560 24 6.7
4 4 @ 40 193
180 630 27 6.7
5 4 @40, 1 @20 217
200 700 30 6.7
5 5 @ 40 241
220 770 33 6.7
6 5 @40, 1 @20 265
240 840 36 6.7
6 6 @ 40 289
S-241 or
CR-241
62 53
260 910 39 6.7
7 6 @40, 1 @20
314
280 980 42 6.7
7 7 @ 40
338
300 1050 45 6.7
8 7 @40, 1 @20
362
320 1120 48 6.7
8 8 @ 40
386
S-242 or
CR-242
62 53
340 1190 51 6.7
9 8 @40, 1 @20
410
360 1260 54 6.7
9 1 @80, 7 @40
434
380 1330 57 6.7
10 1@80,6@40,1@60
458
400 1400 60 6.7
10 2 @80, 6 @40
482
420 1470 63 6.7
10 2@80,5@40,1@60
506
S-301 110 70
440 1540 66 6.7
11 3 @80, 5 @40
530
460 1610 69 6.7
11 3@80,4@40,1@60
554
480 1680 72 6.7
12 4 @80, 4 @40
578
S-302 140 90
500 1750 75 6.7
13 4 @80, 3 @40, 1@60
603
520 1820 78 6.7
13 5 @80, 3 @40
627
540 1890 81 6.7
13 5 @80, 2 @40, 1@60
651
560 1960 84 6.7
14 6 @80, 2 @40
675
580 2030 87 6.7
14 6 @80, 1 @40, 1@60
699
600 2100 90 6.7
15 7 @80, 1 @40
723
620 2170 93 6.7
15 7 @80, 1 @60
747
640 2240 96 6.7
16 8 @ 80
771
660 2310 99 6.7
16 6 @80, 3 @40, 1@60
795
680 2380 102 6.7
17 7 @80, 3 @40
819
700 2450 105 6.7
17 7 @80, 2 @40, 1@60
843
720 2520 108 6.7
18 8 @ 80, 2 @40
867
S-361 150 100
756 2646 63 12
21 9 @72, 3 @36
911
792 2772 66 12
22 10 @72, 2 @36
954
828 2898 69 12
23 11 @72, 1 @36
998
864 3024 72 12
24 12 @ 72
1041
B4-20
07-08
Table B4-5. Model S/CR Ratings (480V Supplies) Sheet 2 of 2
Model #
Vessel
Capacity
(gallons)
Steam
Space
(gallons)
Rated kW
ASME
(Steam lbs/
hr)
ELEMENTS # of Contactors
NUMBER and kW of
STEPS
3-PHASE
AMPERES
Qty kW 480V 480V 480V
S-362 200 130
900 3276 75 12
25 12 @72, 1 @36
1084
936 3402 78 12
26 13 @ 72
1128
972 3528 81 12
27 13 @72, 1 @36
1171
1008 3780 84 12
28 14 @ 72
1214
S-421 210 140
1044 3654 87 12
29 14 @72, 1 @36
1258
1080 3780 90 12
30 15 @ 72
1301
1116 3906 93 12
31 15 @72, 1 @36
1344
1152 4032 96 12
32 16 @ 72
1388
1188 4158 99 12
33 16 @72, 1 @36
1431
1224 4284 102 12
34 17 @ 72
1474
1260 4410 105 12
35 17 @72, 1 @36
1518
1296 4536 108 12
36 18 2 72
1560
S-422 270 180
1332 4662 111 12
37 18 @ 72, 1 @36
1605
1368 4788 114 12
38 19 @ 72
1648
1404 4914 117 12
39 19 @ 72, 1 @36
1691
S-480 360 235
1440 5040 120 12
40 20 @ 72
1735
1476 5166 123 12
41 9 @108, 7 @72
1778
1512 5290 126 12
42 10 @108, 6 @72
1821
1548 5418 129 12
43 11 @108, 5 @72
1864
1584 5540 132 12
44 12 @108, 4 @72
1908
1620 5670 135 12
45 13 @108, 3 @72
1951
1656 5790 138 12
46 14 @108, 2 @72
1995
1692 5922 141 12
47 15 @108, 1 @72
2038
1728 6050 144 12
48 16 @ 108
2081
1764 6174 147 12
49 13 @108, 5 @72
2125
1800 6300 150 12
50 14 @108, 4 @72
2168
1836 6426 153 12
51 15 @108, 3 @72
2211
1872* 6550 156 12
52 16 @108, 2 @72
2255
1908* 6678 159 12
53 17 @108, 1 @72
2298
1944* 6800 162 12
54 18 @ 108
2342
* High Pressure Only
B4-21
07-08
Table B4-6. Model S/CR Ratings (600V Supply) Sheet 1 of 2
Model #
Vessel
Capacity
(gallons)
Steam
Space
(gallons)
Rated kW
ASME
(Steam lbs/
hr)
ELEMENTS
# of
CONTACTORS
NUMBER and kW of
STEPS
3-PHASE
AMPERES
Qty kW 600 V 600 V 600 V
S-120 9 7
19 66 3 6.3
1 1 @ 19 19
38 131 6 6.3
1 1 @ 37 37
S-161 23 16
56 197 9 6.3
2 1 @37, 1 @19 54
70 246 9 7.8
2 1 @47, 1 @23 68
75 263 12 6.3
2 2 @ 37 73
94 328 12 7.8
2 2 @ 47 91
S-162 23 16
117 410 15 7.8
3 2 @47, 1 @23 113
141 492 18 7.8
3 3 @ 47 136
S-200 48 26
164 574 21 7.8
4 3 @47, 1 @23 158
188 656 24 7.8
4 4 @ 47 182
211 738 27 7.8
5 4 @47, 1 @23 204
234 820 30 7.8
5 5 @ 47 226
258 902 33 7.8
6 5 @47, 1 @23 249
281 984 36 7.8
6 6 @ 47 271
S-241 62 53
305 1066 39 7.8
7 6 @47, 1 @23 294
328 1148 42 7.8
7 7 @ 47 316
352 1230 45 7.8
8 7 @47, 1 @23 340
375 1313 48 7.8
8 8 @ 47 362
S-242 62 53
398 1395 51 7.8
9 7 @47, 1 @70 384
422 1477 54 7.8
9 1 @94, 7 @47 407
445 1559 57 7.8
10 1 @94, 6 @47, 1@60 429
S-301 110 70
469 1641 60 7.8
10 2 @94, 6 @47 452
492 1724 63 7.8
10 2 @94, 5 @47, 1@60 474
516 1805 66 7.8
11 3 @94, 5 @47 498
539 1889 69 7.8
11 3 @94, 4 @47, 1@60 520
563 1969 72 7.8
12 4 @94, 4 @47 543
S-302 140 90
586 2054 75 7.8
12 4 @94, 3 @47, 1@60 565
609 2133 78 7.8
13 5 @94, 3 @47 587
633 2218 81 7.8
13 5 @94, 2 @47, 1@60 610
656 2297 84 7.8
14 6 @94, 2 @47 632
672 2355 87 7.8
14 6 @94, 1 @47, 1@60 648
703 2461 90 7.8
15 4 @94, 4 @47 678
S-361 150 100
750 2625 48 15.6
16 6 @94, 4 @47 723
797 2789 51 15.6
17 7 @94, 3 @47 768
844 2953 54 15.6
18 8 @94, 2 @47 814
891 3117 57 15.6
19 9 @94, 1 @47 859
938 3281 60 15.6
20 10 @ 94 904
984 3445 63 15.6
21 9 @94 3 @47 948
1031 3609 66 15.6
22 10 @94, 2 @47 994
B4-22
07-08
Table B4-6. Model S/CR Ratings (600V Supply) Sheet 2 of 2
Model #
Vessel
Capacity
(gallons)
Steam
Space
(gallons)
Rated kW
ASME
(Steam lbs/
hr)
ELEMENTS
# of
CONTACTORS
NUMBER and kW of
STEPS
3-PHASE
AMPERES
Qty kW 600 V 600 V 600 V
S-421 210 140
1078 3773 69 15.6
23 11 @94, 1 @47 1039
1125 3938 72 15.6
24 12 @ 94 1084
1172 4102 75 15.6
25 12 @94, 1 @47 1129
1219 4266 78 15.6
26 13 @ 94 1175
1266 4430 81 15.6
27 13 @94, 1 @47 1220
1313 4594 84 15.6
28 14 @ 94 1265
1359 4758 87 15.6
29 14 @94, 1 @47 1310
1406 4922 90 15.6
30 15 @ 94 1355
1453* 5086 93 15.6
31 15 @94, 1 @47 1400
1500* 5250 96 15.6
32 16 @ 94 1445
1547* 5414 99 15.6
33 16 @94, 1 @47 1491
1594* 5578 102 15.6
34 17 @ 94 1536
1641* 5742 105 15.6
35 17 @94, 1 @47 1581
1688* 5906 108 15.6
36 18 @ 94 1627
S-480 360 235
1734 6070 111 15.6
N/A 17 @94, 3 @47 1671
1781 6234 114 15.6
58 18 @94, 2 @47 1716
1828 6398 117 15.6
60 19 @94, 1 @47 1761
1875 6563 120 15.6
62 20 @ 94 1807
1922* 6727 123 15.6
64 9 @ 141, 7 @94 1852
1969* 6891 126 15.6
66 10 @141, 7 @94 1897
2016* 7055 129 15.6
68 11 @141, 5 @94 1943
2063* 7219 132 15.6
70 12 @141, 4 @94 1988
2109* 7383 135 15.6
72 13 @141, 3 @94 2032
2156* 7547 138 15.6
75 14 @141, 2 @94 2077
2203* 7711 141 15.6
76 15 @141, 1 @94 2123
2250* 7875 144 15.6
84 16 @ 141 2168
* High Pressure Only
B4-23
07-08
Table B4-7. Model CSB Ratings (480V Supply) Sheet 1 of 2
Model #
Vessel
Capacity
(gallons)
Steam Space
(gallons)
Rated kW
ASME
(Steam lbs/
hr)
ELEMENTS
# of
CONTACTORS
NUMBER and kW of
STEPS
3-PHASE
AMPERES
Qty kW 480 V 480 V 480 V
CSB-301 110 70
540 1890 54 10 18 8 @60, 2 @30 651
570 1995 57 10 19 9 @60, 1 @30 687
600 2100 60 10 20 10 @ 60 723
630 2205 63 10 21 5 @90, 3 @60 759
660 2310 66 10 22 6 @90, 2 @60 795
690 2415 69 10 23 7 @90, 1 @60 831
720 2520 72 10 24 8 @ 90 868
CSB-361 150 100
760 2660 57 13.3 19 9 @80, 1 @40 916
800 2800 60 13.3 20 10 @ 80 964
840 2940 63 13.3 21 9 @80, 3 @40 1012
880 3080 66 13.3 22 10 @80, 2 @40 1060
920 3220 69 13.3 23 11 @80, 1 @40 1108
960 3360 72 13.3 24 12 @ 80 1157
CSB-362 200 130
1000 3500 75 13.3 25 12 @80, 1 @40 1205
1040 3640 78 13.3 26 13 @ 80 1253
1080 3780 81 13.3 27 13 @80, 1 @40 1301
1120 3920 84 13.3 28 14 @ 80 1349
1160 4060 87 13.3 29 14 @80, 1 @40 1397
1200 4200 90 13.3 30 15 @ 80 1446
CSB-421 210 140
1240 4340 93 13.3 31 15 @80, 1 @40 1494
1280 4480 96 13.3 32 16 @ 80 1542
1320 4620 99 13.3 33 1 @120, 15 @80 1590
1360 4760 102 13.3 34 2 @120, 14 @80 1638
1400 4900 105 13.3 35 3 @120, 13 @80 1686
1440 5040 108 13.3 36 4 @120, 12 @80 1735
CSB-422 270 180
1480 5180 111 13.3 37 5 @120, 11 @80 1783
1520 5320 114 13.3 38 6 @120, 10 @80 1831
CSB-423 300 200
1560 5460 117 13.3
39 7 @120, 9 @80 1879
1600 5600 120 13.3
40 8 @120, 8 @80 1927
1640 5740 123 13.3
41 9 @120, 7 @80 1975
1680 5880 126 13.3
42 10 @120, 6 @80 2025
1720 6020 129 13.3
43 11 @120, 5 @80 2072
1760 6160 132 13.3
44 12 @120, 4 @80 2120
1800 6300 135 13.3
45 13 @120, 3 @80 2168
1840 6440 138 13.3
46 14 @120. 2 @80 2216
1880 6580 141 13.3
47 15 @120, 1 @80 2264
1920 6720 144 13.3
48 16 @ 120 2313
B4-24
07-08
Table B4-7. Model CSB Ratings (480V Supply) Sheet 2 of 2
Model #
Vessel
Capacity
(gallons)
Steam Space
(gallons)
Rated kW
ASME
(Steam lbs/
hr)
ELEMENTS
# of
CONTACTORS
NUMBER and kW of
STEPS
3-PHASE
AMPERES
Qty kW 480 V 480 V 480 V
CSB-424 385 260
1960 6860 147 13.3
49 1 @160, 15 @120 2361
2000 7000 150 13.3
50 2 @160. 14 @120 2409
2040 7140 153 13.3
51 3 @160. 13 @120 2457
2080 7280 156 13.3
52 4 @160, 12 @120 2505
2120 7420 159 13.3
53 5 @160, 11 @120 2553
2160 7560 162 13.3
54 6 @160. 10 @120 2602
2200 7700 165 13.3
55 7 @160. 9 @120 2650
2240 7840 168 13.3
56 8 @160, 8 @120 2698
2280 7980 171 13.3
57 9 @160, 7 @120 2746
2320 8120 174 13.3
58 10 @160, 6 @120 2794
2360 8260 177 13.3
59 11 @160, 5 @120 2843
2400 8400 180 13.3
60 12 @160, 4 @120 2891
CSB-425 470 320
2440 8540 183 13.3
61 13 @160, 3 @120 2939
2480 8680 186 13.3
62 14 @160, 2 @120 2987
2520 8820 189 13.3
63 15 @160, 1 @120 3035
2560 8960 192 13.3
64 16 @ 160 3083
2600 9100 195 13.3
65 11 @160, 7 @120 3132
2640 9240 198 13.3
66 12 @160, 6 @120 3180
2680 9380 201 13.3
67 13 @160, 5 @120 3228
2720 9520 204 13.3
68 14 @160, 4 @120 3276
2760 9660 207 13.3
69 15 @160, 3 @120 3324
2800 9800 210 13.3
70 16 @160, 2 @120 3372
2840 9940 213 13.3
71 17 @160, 1 @120 3421
2880 10080 216 13.3
72 18 @ 160 3469
B4-25
07-08
Table B4-8. Model CSB Ratings (600V Supply)
Model #
Vessel
Capacity
(gallons)
Steam
Space
(gallons)
Rated kW
ASME
(Steam lbs/
hr)
ELEMENTS
# of
CONTACTORS
NUMBER and kW
of STEPS
3-PHASE
AMPERES
Qty kW 600 V 600 V 600 V
CSB-423 300 200
1734 6070 111 15.6
37 17 @94, 3 @47 1671
1781 6234 114 15.6
38 18 @94, 2 @47 1716
1828 6398 117 15.6
39 19 @94, 1 @47 1762
1875 6563 120 15.6
40 20 @ 94 1807
1922 6727 123 15.6
41 9 @141, 7 @94 1852
1969 6891 126 15.6
42 10 @141, 6 @94 1897
2016 7055 129 15.6
43 11 @141, 5 @94 1943
2063 7219 132 15.6
44 12 @141, 4 @94 1988
2109 7383 135 15.6
45 13 @141, 3 @94 2032
2156 7547 138 15.6
46 14 @141, 2 @94 2078
2203 7711 141 15.6
47 15 @141, 1 @94 2123
2250 7875 144 15.6
48 16 @ 141 2168
CSB-424 385 260
2297 8039 147 15.6
49 13 @141, 5 @94 2213
2344 8203 150 15.6
50 14 @141, 4 @94 2259
2391 8367 153 15.6
51 15 @141, 3 @94 2304
2438 8531 156 15.6
52 16 @141, 2 @94 2349
2484 8695 159 15.6
53 17 @141, 1 @94 2394
2531 8859 162 15.6
54 18 @ 141 2439
2578 9023 165 15.6
55 15 @141, 5 @94 2484
2625 9188 168 15.6
56 16 @141, 4 @94 2529
2672 9352 171 15.6
57 17 @141, 3 @94 2575
2719 9516 174 15.6
58 18 @141, 2 @94 2620
2766 9680 177 15.6
59 19 @141, 1 @94 2665
2813 9844 180 15.6
60 20 @ 141 2710
CSB-425 470 320
2859 10008 183 15.6
61 17 @141, 5 @94 2755
2906 10172 186 15.6
62 18 @141, 4 @94 2800
2953 10336 189 15.6
63 19 @141, 3 @94 2845
3000 10500 192 15.6
64 20 @141, 2 @94 2891
3047 10664 195 15.6
65 21 @141, 1 @94 2936
3094 10828 198 15.6
66 22 @ 141 2981
3141 10992 201 15.6
67 19 @141, 5 @94 3027
3188 11156 204 15.6
68 20 @141, 4 @94 3072
3234 11320 207 15.6
69 21 @141, 3 @94 3116
3281 11484 210 15.6
70 22 @141, 2 @94 3161
3328 11648 213 15.6
71 23 @141, 1 @94 3207
3375 11813 216 15.6
72 24 @ 141 3252
B4-26
07-08
Table B4-9. Model IWH Ratings (208V/240V Supplies)
Table B4-10. Model IWH Ratings (480V/600V Supplies)
Model #
Maximum
Flow (GPM) *
MBTU/Hr Rated kW
ELEMENTS # of CONTACTORS
NUMBER and kW of
STEPS
3-PHASE AMPERES
Qty. kW 208/240V 208/240V 208V 240V
IWH-611 135
51
15 3 5
1 1 @ 15 42
37
102
30 6 5
2 1 @ 30 84
73
IWH-811 240
154
45 9 5
3 1 @ 45 125
109
205
60 12 5
4 2 @ 30 167
145
256
75 15 5
5 1 @ 30, 1 @ 45 209
181
IWH-812 240
307
90 18 5
6 2 @ 45 251
217
358
105 21 5
7 1 @ 15, 3 @ 30 292
253
409
120 24 5
8 4 @ 30 334
290
* Maximum flow rate based on a maximum velocity of 1.5 fps (feet per second) through the heater.
Minimum flow rate should not be less than 10% of the maximum flow rate listed.
Model #
Maximum
Flow (GPM) *
MBTU/Hr Rated kW
ELEMENTS # of CONTACTORS
NUMBER and kW of
STEPS
3-PHASE AMPERES
Qty. kW 208/240V 208/240V 208V 240V
IWH-611 135
51
15 3 5
1 1 @ 15 19
15
102
30 6 5
1 1 @ 30 37
29
IWH-811 240
154
45 9 5
2 1 @ 45 55
44
205
60 12 5
2 2 @ 30 73
58
IWH-812 240
256 75 15 5
3 1 @ 30, 1 @ 45
91 73
307 90 18 5
3 3 @ 30
109 87
358 105 21 5
4 2 @ 30, 1 @ 45
127 102
409 120 24 5
4 4 @ 30
145 116
IWH-822 240
512 150 15 10
5 3 @ 30, 1 @ 60
181 145
614 180 18 10
6 2 @ 30, 2 @ 60
217 174
IWH-022 360
717 210 21 10
7
1 @ 30, 3 @ 60
253 203
819 240 24 10
8 4 @ 60
290 232
921 270 27 10
9 3 @ 30, 3 @ 60
325 261
1024 300 30 10
10 2 @ 30, 4 @ 60
362 290
1126 330 33 10
11 1 @ 30, 5 @ 60
398 318
1228 360 36 19
12 60 @ 60
434 347
* Maximum flow rate based on a maximum velocity of 1.5 fps (feet per second) through the heater.
Minimum flow rate should not be less than 10% of the maximum flow rate listed.
B4-27
07-08
PERFORMANCE DATA
Efficiency Electric boilers are void of losses normally associated with fuel fired equipment such
as stack loss, combustion loss, excess air loss, etc. Therefore electric boilers are
nearly 100% efficient at all operating points. For hot water boilers, the only loss
from 100% is the radiation loss from the vessel which is %. For steam units, in
addition to the radiation loss, blowdown losses should be factored in.
Emissions Since electric boilers are void of fuel combustion, no emissions occur. Therefore,
electric boilers are well suited for installations that must meet stringent emissions
requirements.
Noise Level With not moving parts, the electric boiler is nearly noiseless and thus, is well suited
for installations sensitive to noise emissions from mechanical equipment.
Installations such as hospitals, nursing homes, schools, research laboratories, and
the like are ideal for an electric boiler application.
Regardless of output from minimum to maximum, noise emissions are almost
undetectable.
ENGINEERING DATA
Boiler Information -
Hot Water
Cleaver-Brooks electric hot water boilers are designed for service in any closed
hydronic system and can be used to augment any hot water system. They can be
put into operation as a single stand-alone unit with high turndown or in multiple
units for larger turndown and capacity.
C-B electric hot water boilers may be utilized in water heating systems with
temperatures from 40
0
F (4.4 C) to 245
0
F (118.3 C); ideal for ground water source
heat pump applications, etc. Because the CWB is an electric boiler, low water
temperature (below the dewpoint) restrictions do not apply.
Variable temperature differentials can be designed to make use of changing outdoor
conditions and thus, the CWB is not restrictive to a nominal 20
0
F (10 C)
differential. The boiler is designed to withstand thermal stresses with supply and
return temperature differences of 100
0
F (55 C) and greater. However, when the
elements are on, water flow through the boiler must be ensured and a flow switch to
prove water flow is established is recommended.
Flow Rates and
Pressure Drops
To maintain rated capacity of the boiler, recommended flow rates should not be
exceeded as the flow will remove the heat beyond the capacity of the boiler. Table
B4-11 can be used to determine the full boiler output relative to system
temperature drop and the maximum recommended system pump flow.
The pressure drop through the boiler is < 1 psig.
B4-28
07-08
Table B4-11. Model CWB Max Flow Ratings Sheet 1 of 2
Model # Rated kW
System Temperature Drop
0
F
10 20 30 40 50 60 70 80
Maximum Flow Rate in GPM
CWB-120
12 8.2 4.5 3 2 1.75 1.5 1.25 1
18 12.4 6.5 4.5 3.2 2.6 2 1.75 1.6
24 16.5 8 5.5 4.1 3.2 2.75 2.3 2.1
30 20.5 10.3 6.75 5.1 4.1 3.4 3 2.6
36 24.5 12.25 8.2 6.2 4.9 4.1 3.5 3.1
45 30.9 15.7 10.3 7.7 6.3 5.1 4.4 3.9
54 37 18.4 12.3 9.2 7.4 6.1 5.3 4.6
60 41 20.5 13.5 10.3 8.2 6.8 5.8 5.1
72 49.5 24.2 16.5 12.3 9.8 8.2 7 6.1
CWB-121
90 61.5 30.5 20.5 15.4 12.3 10.3 8.8 7.7
108 73.6 37 24.7 18.5 14.8 12.3 10.6 9.2
126 86 43 28.7 21.6 17.3 14.4 12.3 10.8
144 98 49.2 32.9 24.6 19.7 16.5 14.1 12.3
CWB-122
162 110.5 55.5 37 27.7 22.2 18.5 15.9 13.7
180 122.6 61.5 41 30.8 24.6 20.5 17.6 15.4
198 135.5 67.5 45 33.9 27.1 22.6 19.4 16.9
216 148 74 49.3 37 29.6 24.6 21.1 18.5
234 160 80 53.4 40 32 26.7 22.9 20
252 172 86 57.5 43.1 34.5 28.8 24.6 21.6
270 184.3 92.4 61.6 46.2 37 30.8 26.4 23.2
288 196 98.5 65.7 49.3 39.5 32.9 28.2 24.6
CWB-201
324 222 111 74 55.5 44.4 37 31.7 27.7
360 246.5 123 82.2 61.6 49.3 41.1 35.2 30.8
396 271 135.5 90.4 67.8 54.2 45.2 38.7 33.9
432 296 148 98.6 74 59.2 49.3 42.3 37
CWB-202
468 320 160.3 106.8 80.1 64.1 53.4 45.8 40
504 345 172.5 115 86.3 69 57.5 49.3 43.2
540 370 185 123.3 92.5 74 61.6 52.8 46.2
576 394 197 131.5 98.6 79 65.7 56.4 49.3
CWB-241
600 411 205.5 137 102.7 82.2 68.5 58.7 51.4
630 431 215.5 143.8 107.9 86.3 71.9 61.6 53.9
660 452 226 150.7 113 90.4 75.3 64.6 56.5
690 472 236 157.5 118.2 94.5 78.8 67.5 59.1
720 493 246.4 164.4 123.3 98.6 82.2 70.5 61.6
CWB-242
750 514 257 171.2 128.4 102.7 85.6 73.4 64.2
780 534 267 178.1 133.6 106.8 89 76.3 66.8
810 555 277.5 185 138.7 110.9 92.5 79.2 69.3
840 575 287.5 191.8 143.8 115.1 95.9 82.2 71.9
870 596 298 198.6 150 119.2 99.3 85.1 74.5
900 615 308 205.5 154.1 123.3 102.7 88.1 77
930 637 318.5 212.3 159.2 127.4 106.2 91 79.6
960 657 328.5 219.2 164.4 131.5 109.6 93.9 82.2
B4-29
07-08
Table B4-11. Model CWB Max Flow Ratings Sheet 2 of 2
Model # Rated kW
0
F
10 20 30 40 50 60 70 80
Maximum Flow Rate in GPM
CWB-243
990 678 339 226 169.5 135.6 113 96.9 84.8
1020 698 349 232.9 174.6 139.7 116.4 99.8 87.3
1050 719 359.5 239.7 179.8 143.8 119.9 102.7 89.9
1080 740 370 246.6 184.9 150 123.3 105.7 92.5
1110 760 380 253.4 190 152.1 126.7 108.6 95
1140 781 390.5 260.3 195.2 156.2 130.1 111.5 97.6
1170 801 400.5 267.1 200.3 160.3 133.6 114.5 100.2
1200 822 411 274 205.5 164.4 137 117.4 102.7
CWB-361
1224 838 419 279.5 209.6 167.7 139.7 119.8 104.8
1260 863 431.5 287.7 215.7 172.6 143.8 123.3 107.9
1296 888 444 296 221.9 177.5 147.9 126.8 110.9
CWB-362
1332 912 456 304.1 228.1 182.5 150.9 130.3 114
1368 937 468.5 312.3 234.2 187.4 156.2 133.8 117.1
1404 962 481 320.5 240.4 192.3 160.3 137.4 120.2
1440 986 493 328.8 246.6 197.3 164.4 140.9 123.3
1476 1011 505.5 337 252.7 202.2 168.5 144.4 126.4
1512 1035 517.5 322.4 258.9 207.1 172.6 147.9 129.5
1548 1060 530 353.4 265.1 212.1 176.7 151.5 132.5
1584 1085 542.5 361.6 271.2 217 180.8 155 135.6
1620 1109 554.5 370 277.4 221.9 184.9 158.5 138.7
1656 1134 567 378 283.6 226.8 189 162 141.8
1692 1159 579.5 386.3 289.7 231.8 193.1 165.5 144.9
1728 1183 591.5 394.5 295.9 236.7 197.3 169.1 147.9
CWB-363
1764 1208 604 402.7 302.2 241.6 201.4 172.6 151
1800 1233 616.5 411 308.2 246.6 205.5 176.1 154.1
1836 1257 628.5 419.2 314.4 251.5 209.6 179.6 157.2
1872 1282 641 427.4 320.5 256.4 213.7 183.2 160.3
1908 1307 653.5 435.6 326.7 261.4 217.8 186.7 163.4
1944 1332 665.5 443.8 332.9 266.3 221.9 190.2 166.4
1980 1356 678 452 339 271.2 226 193.7 169.5
2016 1381 690.5 460.3 345.2 276.2 230.1 197.3 172.6
2052 1405 702.5 468.5 240.6 281.1 234.2 200.8 175.7
2088 1430 715 476.7 357.5 286 238.4 204.3 178.8
2160 1480 740 493.2 369.9 295.9 246.6 211.3 184.9
CWB-421
2240 1534 767 511.4 383.6 306.8 255.7 219.2 191.8
2320 1589 794.5 529.7 397.3 317.8 264.8 227 198.6
2400 1644 822 548 411 328.8 274 234.8 205.5
2480 1699 849.5 566.2 424.6 339.7 283.1 242.7 212.3
2560 1754 877 584.5 438.3 350.7 292.2 250.5 219.2
2640 1808 904 602.7 452.1 361.6 301.4 258.3 226
CWB-422
2720 1863 931.5 621 465.7 372.6 310.5 266.1 232.9
2800 1918 959 639.3 479.5 383.6 319.6 274 239.7
2880 1973 98.5 657.5 493.1 394.5 328.8 281.8 246.6
3000 2055 1027.5 685 513.7 411 342.5 293.5 256.8
3040 2082 1041 694 520.5 416.4 347 297.5 260.3
3120 2137 1068.5 712.3 534.2 427.4 356.2 305.2 267.1
3200 2192 1096 730.5 547.9 438.4 365.3 313.1 274
3280 2247 1123 748.8 561.6 449.3 374.4 320.9 280.8
3360 2302 1151 767.1 575.3 460.3 383.6 328.8 287.7
B4-30
07-08
System Operating
Parameters
To prevent water flashing to steam within the boiler or system, hot water boilers
must operate with proper over pressure. System over pressure requirements are
shown in Table B4 12.
While proper overpressure is required, a means to relieve excess pressure at or
beyond the design pressure of the boiler must be provided. As boiler water is
heated, expansion occurs. And this expansion must be accounted for either with an
expansion tank (air filled) or with a bladder type tank. These devices permit the
water pressure to expand outside of the boiler and not impact the pressure vessel or
pressure relieving device. But, in accordance with Code, each boiler is equipped
with an ASME approved safety relieving device should pressure build-up occur.
Table B4-12. Model CWB Minimum Over Pressure Requirements
Rule of Thumb
Calculations
The following formula can be used to size a hot water boiler:
kW = gph (gallons per hour) x delta T (as expressed in
0
F) divided by 410
Or
kW = 1 lph (liter per hour) x delta T (as expressed in
0
C) divided by 862.
Where:
kW is the boiler output rating.
l ph or gph (liters per hour ) or (gallons per hour) is the hot water flow rate.
"delta T" is the temperature rise of water.
As an example:
kw = gph x delta T/410
kw = 5000 x 20/410
kw = 100000/410
kw = 244
Outlet Water Temperature
0
F (C) Minimum System Pressure PSIG (Bar)
80 - 180 ( 27 - 82) 12 (0.83)
181 - 185 ( 83 - 85) 15 (1.03)
186 - 195 ( 86 - 91) 18 (1.24)
B4-31
07-08
Boiler Information -
Steam
Models CR, S, and CSB are designed for steam service and are built in accordance
with the ASME Code for either low pressure steam applications (less than 15 psig
operation) or for high pressure steam applications (above 15 psig).
For approximate conversion of pounds of steam to kW, the following can be used:
10 kW = 34 lbs. steam/hr = 1.02 boiler horsepower from and at 212 F.
It is important to know what the operating pressure will be and the feedwater
makeup temperature, to properly size the steam boiler. From Table B4-11, one can
obtain the pound of steam value for the operating pressure and corresponding
feedwater makeup temperature. Based on this, the proper assumption can be made
as to the required kW size of the electric boiler.
For example: Steam load required of 2000 pounds per hour of steam at an
operating pressure of 100 psig and feedwater temperature of 170 degrees F.
Referring to Table B4-13, we find the value of 0.3077 kW per pound of steam. We
multiply the required pounds of steam by this value (2000 x 0.3077) and obtain
615. The required boiler would be 615 kW or the Model S-301-620, 150#
design.
Table B4-13. kW per pound of steam
Water Treatment Even though hot water systems are closed some amount of make-up water (up to
10%) will be introduced. This more often than not results from pump seal leaks or
other minimal leaks from valves etc., that go unnoticed. Therefore, proper water
chemistry of a hot water boiler is necessary for good operation and longevity,
particularly to ensure that free oxygen is removed to prevent waterside corrosion.
For steam boilers, proper blowdown (surface and bottom) is a required maintenance
procedure. This water loss and associated steam use or loss must be made up. Any
make-up water should be properly treated prior to introduction into the boiler via
water softener, chemical feed, etc. Proper water chemistry in a steam boiler is
mandatory for effective operation and longevity.
See Table B4-14 for water quality requirements.
Feedwater
Temperature [
0
F]
Boiler Operating Pressure [PSIG]
0 15 50 100 150
50 0.3318 0.3359 0.3401 0.3429 0.3441
70 0.3259 0.3300 0.3343 0.3370 0.3382
100 0.3171 0.3212 0.3255 0.3283 0.3294
120 0.3112 0.3154 0.3196 0.3224 0.3236
150 0.3025 0.3066 0.3108 0.3136 0.3148
170 0.2966 0.3001 0.3050 0.3077 0.3089
200 0.2878 0.2919 0.2962 0.2978 0.3001
212 0.2857 0.2898 0.2941 0.2957 0.2980
227 0.2836 0.2877 0.2920 0.2936 0.2967
B4-32
07-08
Table B4-14. Electric Boilers Required Water Quality Parameters
Boiler Room
Information
The boiler must be installed on a level non-combustible surface. If the surface is not
level, piers or a raised pad (slightly larger than the length and width of the boiler
base dimensions) will make boiler leveling possible. Installing the boiler on a raised
pad or piers will make boiler drain connections more accessible and will keep water
from splashing onto the boiler when the boiler room floor is washed. NOTE: The
pad or piers must be of sufficient load bearing strength to safely support the
operating weight of the boiler and any additional equipment installed with it.
Approximate operating weights are shown in Dimensions and Ratings.
Clearances The boiler must be installed so that all components remain accessible, especially be
free of side mounted piping so the element flanges may be opened. Refer to
Dimension Sheets Figure B4 1 through B4 - 5.
Hot Water Piping Primary/Secondary Pumps are not necessary with the electric hot water boilers,
although they can be used. As its design is such that thermal shock is not a
concern, some flow is required whenever the boiler elements are on. Therefore,
whether primary/secondary or system pump, an interlock such as a flow switch
should be employed to ensure that water flow is established before the boiler
elements are allowed on.
Electrical Voltage requirements for the electric boilers are as noted in the ratings sheets
including the relative ampacity. Lug sizes through 1400 kW are listed in Table B4
-15. Incoming power supplies for larger kW units must be reviewed by Cleaver-
Brooks for lug selection.
Switchgear above 600 amps will not be furnished by Cleaver-Brooks due to the
pH 8.3 - 10.5
Iron 0.1 ppm
Alkalinity <300 ppm
Chlorides 30 mg/liter
Oxyen 0.1 mg/liter
Specific Conductivity 4500 umho/cm
Total Hardness
0 ppm as C
a
CO
3
B4-33
07-08
overall size of the equipment and NEC Code requirement for switchgear wiring. The
larger switchgear wiring requirements exceed the UL certification of the package
boiler.
Table B4-15. Power Supply Wire Lug Sizing Guide
MAX KW
Supply Wire LUG
Qty/PH/Size
GROUND LUG
SIZE
208V, 240V/3/60 Hz
18 1 @ SLU70 SLU35
90 1 @ SLU350 SLU70
105 1 @ SLU500 SLU70
180 2 @ TA500 SLU125
420 4 @ TA500 SLU225
540 6 @ TA500 SLU300
480V/3/60 Hz
36 1 @ SLU70 SLU35
105 1 @ SLU350 SLU70
180 1 @ SLU500 SLU70
360 2 @ TA500 SLU125
1000 4 @ TA500 SLU225
1480 6 @ TA500 SLU300
B4-34
07-08
B4-27
Section B4
Electric Boiler Specifications
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-28
Storage Tank Heater Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-28
Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-28
Heating Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-28
Trim and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-29
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-29
The following sample specifications are provided by Cleaver-Brooks to assist you in meeting your customers
Electric Boiler Specifications Section B4
B4-28
PART 1 GENERAL 1.1 CAPACITIES
A. Boiler Capacity - Hot Water
1. The ____ gallon _____ capacity hot water boiler shall be
Cleaver-Brooks Model ___________ rated ____ kW at ____ V,
____ ph, 60 Hz, ____ MBtu/hr. Unit shall be suitable to
operate under the following conditions: system flow rate ____
gpm; outlet water temperature ____ F; return water
temperature ____F; system operating pressure ____ psig.
B. Boiler Capacity - Steam
1. The _____ gallon ______ capacity steam boiler shall be
Cleaver-Brooks Model ______________ rated _____ kW at
____ V, _____ ph, 60 Hz. Unit shall produce ______ lbs steam/
hr (from and at 212 F) at a nominal pressure of ____ psig.
C. Water Heater Capacity - Instantaneous
D. The horizontal circulation water heater shall be Cleaver-Brooks
Model IWH ___________ rated _____ kW at ____ V, ____ ph,
60 Hz.
1.2 STORAGE TANK HEATER CAPACITY
The _____ gallon capacity (horizontal or vertical) shall be Cleaver-Brooks Model
___________ rated kW at _____ V, _____ ph,
60 Hz, and shall recover ____ gpm at 100 F rise.
PART 2 PRODUCTS 2.1 BOILER
A. The vessel shall be constructed in accordance with ASME Boiler
Code.
B. The vessel shall be designed for ____ psig.
C. The relief valve shall be per ASME Code, set at ____ psig.
D. The vessel shall be insulated with a double wrap of 2-inch fiber
blanket insulation having 1-1/2 PCF density.
E. The boiler shall be UL listed, and bear the Underwriters
Laboratories label.
F. The boiler shall be of the packaged type, factory assembled, wired,
and tested.
G. The boiler shall be mounted on a full size structural steel base.
H. The boiler enclosure shall be 16-gauge steel.
I. The entire enclosure shall be finished in light blue enamel paint.
J. The overall dimensions of the boiler shall be _____ inches long,
______ inches wide, and _____ inches high.
K. For CR Models, the boiler shall include built-in condensate receiver
and feed pump, with make-up valve mounted on common base with
boiler, factory wired and piped, and enclosed in boiler casing.
2.2 HEATING ELEMENTS
A. The heating elements shall be individually mounted, rod type, and
field replaceable with standard tools.
B. The heating watt density shall not exceed _______ (50 or 75) W/
sq-in.
Section B4 Electric Boiler Specifications
B4-29
C. The heating elements shall be _________ (copper or Incoloy)
sheathed.
2.3 TRIM AND CONTROLS
A. The units shall be complete with the following:
1. Main lugs for supply circuits.
2. Supplemental internal branch circuit fuses, current limiting,
rated at 200,000 amps interrupting capacity.
3. Fused 120 V control circuit transformer.
4. Magnetic contactors rated at 500,000 cycles.
5. Integral high temperature limit (hot water boilers).
6. High pressure limit (steam boilers).
7. Low water cutoff (float-type with gauge glass for steam) on all
models except IWH which is supplied with a flow switch.
8. Pressure-temperature gauge (hot water boilers).
9. Pressure gauge (steam boilers).
10. Pilot switch.
11. Pilot lights for power on, low water, high temperature or
pressure.
12. Relief valve.
13. Drain valve (hot water boilers).
14. Bottom and water column blowdown valves (steam boilers).
15. Feedwater stop and check valves (steam boilers).
16. All models except IWH shall be supplied with modulating step
controls to gradually apply the load in ____ steps.
17. All models except IWH shall be supplied with proportioning
temperature (hot water units) or pressure (steam units) control
to balance power input to match system demand.
18. Temperature control on IWH is one of the following methods
(select a. or b. or c. below).
a. Thermostats - The heating elements shall be staged by
control thermostats. (Standard for one and two step
heaters).
b. Sequencer - The heating elements shall be staged by a
time delay sequencer, to energize heating elements in
____ stages with an adjustable 1 to 15 second time delay
between stages. (Standard for 3 or 4 step heaters.)
c. Modulating Step Control - (Standard for heaters above 4
steps).
A. The Cleaver-Brooks unit shall be warranted against defective
workmanship and materials for a period of one year from the date of
start- up or 18 months from shipment.
Electric Boiler Specifications Section B4
B4-30
Notes
B5-1
03-08
Table of Contents
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-5
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-8
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-8
ENGINEERING DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-19
STACK/BREECHING SIZE CRITERIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-54
CB FALCON CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-63
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-67
List of Figures
AluFer Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-3
Fireside access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-3
Premix Burner Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-4
Model CFC Heat Flow and Component Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-5
Clearfire Control Panel and Wiring (MCBA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-7
Model CFC Dimensional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-9
Competitive Condensation Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-13
Emissions Data Clearfire Model CFC 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-16
Emissions Data Clearfire Model CFC 750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-16
Emissions Data Clearfire Model CFC 1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-17
Pressure Drop Curve ClearFire Boiler Size 500, U.S. Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-22
Pressure Drop Curve ClearFire Boiler Size 500, Metric Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-22
Pressure Drop Curve ClearFire Boiler Size 750, U.S. Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-23
Pressure Drop Curve ClearFire Boiler Size 750, Metric Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-23
Pressure Drop Curve ClearFire Boiler Size 1000, U.S. Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-24
Pressure Drop Curve ClearFire Boiler Size 1000, Metric Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-24
Pressure Drop Curve ClearFire Boiler Size 1500, Metric Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-25
Pressure Drop Curve ClearFire Boiler Size 1800, Metric Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-26
Standard Condensate Piping Direct to Drain, No Condensate Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-29
Condensate Piping Direct To Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-30
Section B5
Model CFC ClearFire Condensing Boiler
Commercial Boilers Model CFC
B5-2
03-08
Optional Condensate Treatment Assembly - Single Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-30
Condensate Piping for Multiple Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-31
Condensate Treatment Tank for Multiple Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-31
Gas Piping Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-32
Gas Header Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-33
Model CFC Minimum Room Clearance Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-35
No primary loop with domestic water and 2-way divert valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-36
2-Pipe system, typical (reverse return). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-37
Zoning with zone valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-38
Two Boilers and Three Variable Temperature Zones (no primary loop). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-39
Two-Pipe Primary/Secondary Piping with Domestic Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-40
Two-Pipe Primary/Secondary Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-41
No Primary Loop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-42
Domestic Water Heating, No Primary Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-43
Domestic Water with On/Off and 3-Way Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-44
Piping Hybrid Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-45
Hybrid Boilers with Domestic Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-46
Domestic Water with 2 Boilers and 2 Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-47
Two Opening Outside Wall Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-49
Two Opening Ducted Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-50
One Opening Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-51
Two Opening Engineered Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-52
Direct Vent Combustion Piping Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-53
Optional Direct Vent Combustion Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-53
Horizontal Through the wall venting using inside air for combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-56
Horizontal Flue through- wall with direct vent combustion intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-57
Inside Air - Vertical Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-60
Vertical Stack with Direct Vent Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-61
Electrical Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-62
CFC Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-62
CB Falcon Display/Operator Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-65
CB Falcon Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-66
List of Tables
U.S. Standard Dimensions Model CFC Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-10
Metric Dimensions Model CFC Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-11
Model CFC Boiler Ratings (Sea Level to 2000 Feet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-12
Altitude Correction for Input Capacity at Various Altitude Levels (Natural Gas) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-13
CFC 500 ClearFire Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-14
CFC 750 ClearFire Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-14
CFC 1000 ClearFire Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-14
Noise Level (dBA) measured 3 feet in front of boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-19
Maximum Flow Rate Through ClearFire Boilers (US Flow Rates) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-21
Maximum Flow Rate Through ClearFire Boilers (Metric Flow Rates) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-21
Model CFC Minimum Over Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-28
Model CFC Boiler Safety Valve Information @ 60 PSIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-28
Model CFC Boiler Safety Valve Information @ 30 PSIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-28
Model CFC Water Chemistry Requirements in accordance with ABMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-29
Model CFC Maximum Condensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-30
Model CFC Minimum and Maximum Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-34
Model CFC Minimum Required Gas Pressure Altitude Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-34
Stack design single boiler using room air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-58
Stack sizing using outside air for combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-59
Operating Conditions - Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-63
Operating Conditions - Display/Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-63
CB Falcon Burner Sequence (central heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-64
Model CFC Commercial Boilers
B5-3
03-08
MODEL CFC FEATURES AND BENEFITS
Compact Firetube
Design
The Model CFC boiler is a single pass, vertical down fired durable firetube boiler.
The internal extended-heating surface tubes provide very high levels of performance
in a compact space, offering over 10 square feet of heating surface per boiler
horsepower, providing many years of trouble free performance.
Figure B5-1. AluFer Inserts
Advanced
Technology
Construction from ASME steel, 316Ti stainless steel tube sheets and 2.3" OD 316Ti
stainless steel tubes with AluFer tube inserts provides optimal heat transfer (see
Figure B5-1).
Advanced
Construction
The extended heating surface design provides the ideal solution for the demands of
a condensing boiler and helps to recover virtually all the latent heat of the flue gas.
Each tube consists of an outer stainless steel tube (waterside) and the AluFer
extended surface profile on the flue gas side.
High Efficiency With the extended heating surface tubes the CFC boiler will provide fuel to water
efficiency of up to 99% at low fire and 97% at high fire with 80 degrees F return
water temperature.
Ease of Maintenance The powder coated steel casing is designed for easy removal and re-assembly. As
shown in Figure B5-2, the burner is hinged and is provided with hydraulic pistons
for simple opening for service of the spark electrode, inspection of the burner
cylinder, tubes and tube sheet on Models CFC1000 and larger. (On the CFC500 and
750, the burner is hinged only). A front mounted service platform is provided for
easy access to the burner components and controls.
Figure B5-2. Fireside Access
Quality Construction ISO 9001:2001 certified manufacturing process ensures the highest degree of
manufacturing standards are always followed.
ASME Code construction ensures high quality design, safety, third party inspection,
B5-4
03-08
and reliability, and is stamped accordingly.
Each unit is tested and certified in accordance with CSA International and the CSA
Label is affixed attesting to meeting the latest CSA requirements for packaged
heating boilers.
Premix Technology The burner utilizes "Premix" technology to mix both gas fuel and combustion air prior
to entering the burner canister, with air "leading" during burner firing transitions.
Combined with a variable speed fan, this technology provides very low emission
levels, exceptionally safe operation, and nearly 100% combustion efficiency.
Full Modulation To provide only the amount of heat required to the burner, the variable speed fan
provides modulated firing to reduce on/off cycling, excellent load tracking, and
reduced operating costs. The burner does not require mechanical linkage
connections between the fuel input valve and air control. Instead, the
microprocessor control positions the fan speed in accordance with system demand,
and this determines the fuel input without mechanical device positioning, that is,
linkage-less fuel/air ratio control. This eliminates linkage slippage, minimizes
burner maintenance, and provides control repeatability. This is shown schematically
in Figure B5-3.
Figure B5-3. Premix Burner Technology
Designed For
Heating
Applications
The pressure vessel is designed for 60 psig MAWP (Max. Allowable Working
Pressure) and is constructed of durable ASTM Grade Steel and Stainless Steel
materials. Figure B5-4 shows the counter flow heat exchanger design that gives
optimal heat transfer. The design also prevents hot spots, does not require a
minimum flow for thermal shock protection, and does not require a minimum return
water temperature. In fact, the design carries a 20-year "Thermal Shock" warranty.
Because of the design characteristics, the Model CFC is well suited for applications
utilizing indoor/outdoor reset controls, radiant floor heating, snow melt systems,
ground source heat pump systems and systems that utilize variable speed
circulating pumps. It may also be employed in standard hot water systems that
require higher heated water at colder outdoor temperatures but then require
minimum temperatures during warmer heating days, realizing fuel efficiency savings
over traditional hot water boilers.
While the design does not lend itself to the direct supply of potable water, a separate
storage tank with an internal heat exchanger can be employed as the
microprocessor control permits domestic water programming. Therefore, the Model
B5-5
03-08
CFC can service both hydronic heating and domestic water source heating.
Figure B5-4. Model CFC Heat Flow and Component Orientation
MODEL CFC PRODUCT OFFERING
Information in this section applies to condensing hot water boiler sizes ranging from
500,000 Btu input through 2,500,000 Btu input for operation on Natural Gas or
LP Gas only. Installation is for indoor use only.
The complete package has been tested and certified in accordance with CSA 4.9b
and ANSI Standard Z21.13b 2003 and is approved, listed, and bears the CSA label
(U.S.A. and Canada) for condensing hot water boilers on gas only.
Dimensions, ratings, and product information may change to meet current market
requirements and product improvements. Therefore, use this information as a guide.
Combustion Fan and
Premix Gas Valve
Assembly
Burner
Head
Control
Panel
Finned High
Efficiency AluFer
Tubes
ASME Code
Pressure Vessel
Flue Gas
Outlet
Cold Water
Return
Hot Water
Outlet
Safety Relief Valve
Condensate Drain
Cleaning Cover
Filling and Draining Connection
Insulation Mat
Electrode
Ignition and
Flame Rod
Burner
Canister
B5-6
03-08
Standard Equipment Equipment described below is for the standard boiler offering:
1. The Boiler
A. Each boiler size is designed for a Maximum Allowable Working Pressure
(MAWP) of 60 psig (4.1 Bar), constructed in accordance with the ASME
Code Section IV and bear the "H" stamp.
B. The insulated boiler is mounted on a base and powder coated steel casing
provided.
C. A drain valve connection is provided at the front bottom for field piping of a
boiler drain valve, which can be furnished as an option.
D. For waterside inspection, a rear inspection opening (closed with a 150#
blind flange) is provided. Additionally, a capped opening is provided at the
front near the bottom of the vessel for filling and draining.
2. Boiler Trim and Controls
The following items are furnished:
Probe Type Low Water Cutoff control, manual reset.
Excess Water Temperature Cutoff, manual reset.
NTC (negative temp. coefficient) sensor for hot water supply temperature.
NTC sensor for hot water return temperature.
ASME Safety Relief Valve set @ 60 psig. (4.1 Bar)
Combination Temperature/Pressure Gauge.
3. Burner Control
A. The CB Falcon is an integrated burner management and modulation control
with a touch-screen display/operator interface. Its functions include the
following:
Two (2) heating loops with PID load control
Electronic Ignition.
Flame Supervision.
Safety Shutdown with time-stamped display of lockout condition.
Variable speed control of the combustion fan.
Supervision of low and high gas pressure, air proving, stack back pressure, high limit, and
low water.
Real-time data trending.
Modbus communication capability
B5-7
03-08
Figure B5-5. ClearFire Control Panel
4. Forced Draft Burner
A. The burner is a "Pre-mix" design consisting of a unitized venturi, single body
dual safety gas valve, blower, and burner head.
B. Full modulation is accomplished with a variable speed fan for 5:1 turndown
ratio.
C. For near flameless combustion, the burner utilizes a Fecralloy-metal fiber
head.
D. Noise level at maximum firing is less than 70 dBA regardless of boiler size.
E. Operating on Natural Gas, NOx emissions will be less than 20 PPM
regardless of boiler size and the boiler is certified for California and Texas for
Low NOx emissions.
F. As an option, the burner is capable of direct vent combustion.
G. Ignition of the main flame is via direct spark, utilizing high voltage electrodes
and a separate electrode for flame supervision.
H. To ensure adequate combustion air is present prior to ignition, and to ensure
the fan is operating, a combustion air proving switch is furnished.
I. A High Air Pressure Switch is provided to ensure burner lockout if excessive
back pressure due to a blocked stack occurs.
J. For ease of maintenance and inspection, the burner is furnished with
hydraulic rods and easy opening lockdown nuts, which permit the burner to
swing up (except 500 and 750, which are hinged only). This provides full
access to the burner and electrodes, as well, to the tube sheet and tubes.
5. Burner Gas Train
The standard gas train is equipped in accordance with CSA/ANSI Standards, ASME
CSD-1, GE-GAP (Formerly IRI), and FM. Each burner gas train includes:
Low Gas Pressure Interlock, manual reset.
Falcon Display/Interface
Demand Switch
Control Circuit
On/Off
Falcon Controller
Transformer
LWCO
Ignition Transformer
Power Supply
Terminal Blocks
Fuses
B5-8
03-08
High Gas Pressure Interlock, manual reset.
ASME CSD-1 Test Cocks.
Downstream manual ball type shutoff cock.
Single body dual safety shutoff gas valve.
summary, here are some of the options that can be provided with the boiler:
Auxiliary Low Water Cutoff, probe type shipped loose for installation in the
system piping.
Condensate Treatment Assembly.
Condensate water trap with make-up connection.
Direct Vent Combustion Kit.
Safety Valve set @ 30 psig. (2 Bar)
Outdoor reset control.
Alarm Horn.
Relay for remote boiler on signal.
Interface terminals for remote lead lag control, control by others.
Controller option for communication device to computer interface for service/set-
up.
For layout purposes, the overall dimensions for the Model CFC are shown in Table
B5-1 (US Dimensions) and Table B5-2 (Metric Dimensions) including the various
pipe connection sizes for supply and return water, drain, and vent. The performance
ratings for the boiler are shown in Table B5-3.
Altitude Relative to the ratings shown, installation of the boiler above 2000 feet elevation
will result in input capacity reduction. Please refer to Table B5-4 for input ratings of
the boiler at various elevations.
PERFORMANCE DATA
Efficiency The Model CFC is a "full condensing" boiler realizing efficiency gain at variable
operating conditions. It is designed to extract the latent heat of condensation over a
greater range than other designs. This can be seen in Figure B5-7, which depicts
nominal stack temperatures of the boiler versus other designs. The nominal point of
condensation is approximately 132 F (55.5 C) and thus, with the Clearfire's lower
stack temperature, due to its more efficient heat transfer design, it captures the
latent heat of condensation over a broader range.
Fuel-to-Water efficiency is relative to specific operating conditions. Operating
efficiency will be greater when performance is in the "condensing" mode of operation
as noted above, yet, with its inherently greater heat transfer surfaces and superior
pre-mix burner, efficiency at "traditional" hot water conditions is outstanding. Table
B5-6 through Table B5-9 show the guaranteed efficiencies at various operating
conditions and firing rates for Natural Gas. It should be noted that the efficiency is
exceptional at high fire and low fire versus other designs where high efficiency is
realized only when in low fire or minimal firing rates and low temperature returns.
B5-9
03-08
Figure B5-6. Model CFC Dimensional Views
Y
B5-10
03-08
Table B5-1. U.S. Standard Dimensions Model CFC Boiler
BOILER SIZE
ITEM DIMENSIONS 500 750 1000 1500 1800 2500
A OVERALL HEIGHT 71.9" 71.9" 75.4" 81.5" 81.5" 81.9"
B OVERALL WIDTH 32.3" 32.3" 36.6" 43.7" 43.7" 50.8"
C OVERALL DEPTH 48.9" 48.9" 64.0" 65.6" 65.6" 72.3"
D WIDTH LESS CASING 26.8" 26.8" 31.1" 38.2" 38.2" 45.3"
E GAS CONNECTION TO TOP OF CASING 7.8" 7.8" 9.2" 9.5" 9.5" 9.4"
F GAS CONNECTION TO BASE 64.1" 64.1" 66.2" 72.0" 72.0" 72.5"
G SIDE OF CASING TO GAS CONNECTION 2.5" 2.5" 3.8" 4.9" 4.3" 5.2"
H
BOILER CENTERLINE TO AIR INLET
CENTERLINE 4.3" 4.3" 3.9" 7.0" 7.0" 7.0"
J BASE TO TOP OF STACK CONNECTION 18.6" 18.6" 18.1" 19.1" 19.1" 20.9"
K
CENTERLINE TO CENTERLINE OF STACK
STUB 15.4" 15.4" 16.9" 21.0" 21.0" 28.1"
L
REAR OF BOILER TO CENTERLINE OF STACK
STUB 5.4" 5.4" 7.5" 8.1" 8.1" 8.6"
M FRONT OF BOILER TO REAR OF CASING 38.8" 38.8" 49.6" 49.4" 49.4" 56.5"
N CONTROL PANEL PROJECTION 4.1" 4.1" 4.1" 4.1" 4.1" 4.1"
O CASING HEIGHT 56.2" 56.2" 60.0" 65.4" 65.4" 65.4"
P
AIR VENT LINE PROJECTION FROM REAR OF
CASING 7.8" 7.8" 7.3" 8.1" 8.1" 8.7"
Q
BASE TO CENTERLINE OF RETURN
CONNECTION 19.3" 19.3" 19.3" 20.3" 21.1" 21.9"
S
BASE TO CENTERLINE OF SUPPLY
CONNECTION 54.3" 54.3" 55.9" 56.7" 56.0" 56.8"
T BASE TO CENTERLINE OF AIR VENT 59.9" 59.9" 62.0" 62.9" 62.9" 64.8"
AA BOILER ADJUSTMENT (MAX.) 2.5" 2.5" 2.5" 2.5" 2.5" 2.5"
CONNECTIONS
U
WATER SUPPLY AND RETURN, 150# RF
FLANGE 2-1/2" 2-1/2" 2-1/2" 3" 4" 5"
V BOILER AIR VENTING, NPT 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2"
W
ELECTRICAL CONDUIT RUN, LEFT OR RIGHT
SIDE (DIA.) 1.6" 1.6" 1.6" 1.6" 1.6" 1.6"
X BOILER DRAIN, NPT 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2"
Y
FLUE GAS, LEFT OR RIGHT SIDE OPTION
(NOMINAL) 6" 6" 8" 10" 12" 12"
Z
AIR INLET FOR SEALED COMBUSTION
OPTION 4" 4"OR 6" 6" 6" 6" 6"OR 8"
BB
GAS-CONNECTION FROM REAR OF BOILER,
NPT 1" 1" 1" 1-1/4" 1-1/4" 1-1/2"
CC CONDENSATE, NPT 3/4" 3/4" 3/4" 3/4" 3/4" 1"
DD
WATERSIDE INSPECTION, 150# BLIND
FLANGE 3" 3" 3" 3" 3" 3"
EE RELIEF VALVE, 60# SETPOINT, NPT 1" 1" 1" 1" 1-1/4" 1-1/4"
B5-11
03-08
Table B5-2. Metric Dimensions Model CFC Boiler
BOILER SIZE
ITEM DIMENSIONS (mm) 500 750 1000 1500 1800 2500
A OVERALL HEIGHT 1826 1826 1915 2070 2070 2080
B OVERALL WIDTH 820 820 930 1110 1110 1290
C OVERALL DEPTH 1242 1242 1626 1666 1666 1836
D WIDTH LESS CASING 681 681 790 970 970 1151
E GAS CONNECTION TO TOP OF CASING 198 198 234 241 241 239
F GAS CONNECTION TO BASE 1628 1628 1681 1829 1829 1842
G SIDE OF CASING TO GAS CONNECTION 64 64 97 124 109 132
H
BOILER CENTERLINE TO AIR INLET
CENTERLINE 109 109 99 178 178 178
J BASE TO TOP OF STACK CONNECTION 472 472 460 485 485 531
K
CENTERLINE TO CENTERLINE OF STACK
STUB 391 391 429 533 533 714
L
REAR OF BOILER TO CENTERLINE OF STACK
STUB 137 137 191 206 206 218
M FRONT OF BOILER TO REAR OF CASING 986 986 1260 1255 1255 1435
N CONTROL PANEL PROJECTION 104 104 104 104 104 104
O CASING HEIGHT 1427 1427 1524 1661 1661 1661
P
AIR VENT LINE PROJECTION FROM REAR OF
CASING 198 198 185 206 206 218
Q
BASE TO CENTERLINE OF RETURN
CONNECTION 490 490 490 516 536 556
S
BASE TO CENTERLINE OF SUPPLY
CONNECTION 1379 1379 1420 1440 1422 1443
T BASE TO CENTERLINE OF AIR VENT 1521 1521 1575 1598 1598 1646
AA BOILER ADJUSTMENT (MAX.) 64 64 64 64 64 64
CONNECTIONS (INCHES NPT)
U
WATER SUPPLY AND RETURN, 150# RF
FLANGE 2-1/2" 2-1/2" 2-1/2" 3" 4" 5"
V BOILER AIR VENTING, NPT 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2"
W
ELECTRICAL CONDUIT RUN, LEFT OR RIGHT
SIDE (DIA.) 1.6" 1.6" 1.6" 1.6" 1.6" 1.6"
X BOILER DRAIN, NPT 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2"
Y
FLUE GAS, LEFT OR RIGHT SIDE OPTION
(NOMINAL) 6" 6" 8" 10" 12" 12"
Z
AIR INLET FOR SEALED COMBUSTION
OPTION 4" 4"OR 6" 6" 6" 6" 6"OR 8"
BB
GAS-CONNECTION FROM REAR OF BOILER,
NPT 1" 1" 1" 1-1/4" 1-1/4" 1-1/2"
CC CONDENSATE, NPT 3/4" 3/4" 3/4" 3/4" 3/4" 1"
DD
WATERSIDE INSPECTION, 150# BLIND
FLANGE 3" 3" 3" 3" 3" 3"
EE RELIEF VALVE, 60# SETPOINT, NPT 1" 1" 1" 1" 1-1/4" 1-1/4"
B5-12
03-08
Table B5-3. Model CFC Boiler Ratings (Sea Level to 2000 Feet)
Boiler Size
Description Value
500 750 1000 1500 1800 2500
Input Max. BTU/Hr. 500,000 750,000 1,000,000 1,500,000 1,800,000 2,500,000
KCAL/Hr. 120,998 189,000 252,000 378,000 453,600 629,989
Natural Gas FT
3
/Hr 500 750 1000 1500 1800 2500
Propane FT
3
/Hr 200 300 400 600 720 880
Natural Gas M
3
/Hr 14.16 21 28 42 51 70.7
Propane M
3
/Hr 5.66 8.5 11 17 20 24.9
Output at BTU/Hr. 480,000 720,000 960,000 1,440,000 1,728,000 2,400,000
104/86 F (40/30 C) KCAL/Hr. 120,958 181,440 241,920 362,880 435,456 604,790
100% Firing BHP 14.3 21.5 28.7 43 51.6 71.7
KW 140 211 281 422 506 703
Output at BTU/Hr. 435,000 652,500 870,000 1,305,000 1,566,000 2,175,000
176/140 F (80/60 C) KCAL/Hr. 109,618 164,430 219,240 328,860 394,632 548,091
100% Firing BHP 13 19.5 26 39 47 65
KW 127 191 255 382 458 637
MAWP PSI 60 60 60 60 60 60
BAR 4.1 4.1 4.1 4.1 4.1 4.1
Operating Temp., Max.
o
F 194 194 194 194 194 194
o
C 90 90 90 90 90 90
Water Content Gallons 52 52 87 108 105 126
Liters 196.8 196.8 329.3 408.8 397.5 477.0
Weight w/o Water Pounds 1,010 1,010 1,554 1,940 2,061 3,500
Kg 458 458 705 880 935 1588
Standby Heat Loss BTU/Hr 1,206 1,810 1,912 2,390 2,459 3,415
Watts 353 530 560 700 720 1,000
Fan Motor Size Watts 335 335 335 750 1200 1200
Operating Voltage, Fan Volts/Ph/Hz 120/1/60 120/1/60 120/1/60 120/1/60 120/1/60 120/1/60
Control Circuit Volts/Ph/Hz 120/1/60 120/1/60 120/1/60 120/1/60 120/1/60 120/1/60
Current Draw, Fan Amperes 4 4 4 8.5 12 12
Current Draw Cont. Ckt. Amperes 1.5 1.5 1.5 1.5 2 2
Condensate Quantity
Firing Nat. Gas &
operating @ 104/86 F.
Gal/Hr. 4 4.7 5.8 7 8.1 12
l/Hr. 15.14 17.8 22 26.5 30.9 45
Condensate Value PH 5 - 5.5 5 - 5.5 5 - 5.5 5 - 5.5 5 - 5.5 5 - 5.5
Flue Gas Mass Flow @
100% Firing
lb/hr 557 835 1,113 1,670 2,004 2,783
kg/h 253 378 505 757 909 1262
Flue Gas Temp. Oper.
o
F 155 180 160 170 170 160
176/140 F (80/60 C)
o
C

68 82 71 74 77 71
Flue Gas Temp. Oper.
o
F 105 125 106 108 108 110
104/86 F (40/30 C)
o
C 41 52 41 42 42 43
B5-13
03-08
Table B5-4. Altitude Correction for Input Capacity at Various Altitude Levels (Natural Gas)
Figure B5-7. Competitive Condensation Analysis
700' ASL 2000' 4500' 6000' 8000' 10000'
CFC 2500 2500 2500 2250 2025 1925 1730
CFC 1800 1800 1779 1530 1472 1413 1356
CFC 1500 1500 1500 1350 1296 1244 1194
CFC 1000 1000 1000 900 864 829 783
CFC 750 750 750 700 675 645 620
CFC 500 500 500 450 425 425 400
** Ratings assume 35% excess air, 80F combustion air.
Blower speed adjustments should be made to match performance accordingly.
Gas pressure corrections for altitude should be made per Boiler Book Table B5-19.
Competitor 1
Competitor 2
Clearfire
B5-14
03-08
ClearFire
Efficiencies
The Tables below depict the operating efficiencies of each size Model CFC boiler,
including radiation losses. As the Model CFC is a fully condensing boiler, maximum
efficiency is obtained when operating within the condensing mode, utilizing the latent
heat of condensation.
Table B5-5. CFC 500 ClearFire Efficiency

%
Return Water Temperature F
0
(C)
Firing Rate
68 80 100 120 130 140 160
(20) (27) (38) (49) (55) (60) (72)
20 99 98.4 97 96.5 95 93 87.5
50 98.25 98.1 96 92.5 93 89 87.5
75 98 97 94 87.5 88 87.5 86.5
100 97.2 96 90.5 87.25 87 87 86

%
0
(C)
Firing Rate
68 80 100 120 130 140 160
(20) (27) (38) (49) (55) (60) (72)
20 99 98.4 97 96.5 95 93 87.5
50 98.25 98.1 96 92.5 93 89 87.5
75 98 97 94 87.5 88 87.5 86.5
100 97.2 96 90.5 87.25 87 87 86
Firing Rate
%
0
(C)
68 80 105 120 130 140 160
(20) (27) (38) (49) (55) (60) (72)
20 99 99 98.5 97 95.5 94.5 88.5
50 99 99 97.5 93.5 92 90.5 87.9
75 98 97 93 89 88 87.5 86.5
100 97.2 97 91.5 88.50 87.5 87 86.50
B5-15
03-08
Emissions The Model CFC Boiler has been tested by an independent testing lab for Low NOx
certification in California under the requirements of South Coast Air Quality
Management District (SCAQMD) Rule 1146. Meeting the requirements of SCAQMD
also qualifies the boiler for meeting the NOx requirements in the state of Texas.
By means of the Pre-mix burner, the Clearfire boiler provides environmentally
friendly emissions when firing natural gas; emission data are shown in Figure B5-8
through Figure B5-13.
Firing Rate
%
0
(C)
68 80 105 120 130 140 160
(20) (27) (38) (49) (55) (60) (72)
20 99 99 98 97 96.5 94 88
50 98.25 99 97 93 91.5 89.5 87
75 98 97 93 89 88 87.5 86.5
100 97.2 97 91 88 87.5 87 86.25
Firing Rate
%
0
(C)
68 80 105 120 130 140 160
(20) (27) (38) (49) (55) (60) (72)
20 99 99 98 97 95.5 93.7 88
50 98.25 99 97 93 91.5 89.5 87.5
75 98 97 93 89 88 87.5 86.5
100 97.2 96.5 91 88.25 87.5 87 86.25
Firing Rate
%
0
(C)
68 80 105 120 130 140 160
(20) (27) (38) (49) (55) (60) (72)
20 99 99 98 97 95.5 93.7 88
50 98.25 99 97 93 91.5 89.5 87.5
75 98 97 93 89 88 87.5 86.5
100 97.2 96.5 91 88.25 87.5 87 86.25
B5-16
03-08
Figure B5-8. Emissions Data Clearfire Model CFC 500
Emi ssi ons CFC 500
* PM i s l ess t han 1
*S0x r el ati ve to Sul phur i n fuel
Compl i ant to SCAQMD Rul e 1146.2
4
5
6
7
1 1 1 1
15
17 17
19
0
2
4
6
8
10
12
14
16
18
20
20 50 75 100
Fi r i n g Rat e %
P
P
M
CO
*PM
NOx
Em i ssi o n s CFC 750
* PM i s l e ss t h a n 1
*S0x r e l a t i ve t o Su l p h u r i n f u e l
Co m p l i a n t t o SCAQMD Ru l e 1146. 2
4
5
6
7
1 1 1 1
15
17 17
19
0
2
4
6
8
10
12
14
16
18
20
20 50 75 100
Fi r i n g Rat e %
P
P
M
CO
*PM
NOx
B5-17
03-08
Emi ssi ons CFC1000
* PM i s l ess than 1
*S0x rel ati ve to Sul phur i n fuel
4
5
6
7
1 1 1 1
15
17 17
19
0
2
4
6
8
10
12
14
16
18
20
20 50 75 100
Fir ing Rat e %
P
P
M
CO
*PM
NOx
Emi ssi ons CFC 1500
8
6
5
4
1 1 1 1
19
17
13
9
0
2
4
6
8
10
12
14
16
18
20
20 50 75 100
Fir i ng Rat e %
P
P
M
CO
*PM
NOx
B5-18
03-08
4 4
6 6
1 1 1 1
14 14
13 13
0
2
4
6
8
10
12
14
16
20 50 75 100
Fi r i ng Rat e %
P
P
M
CO
*PM
NOx
4 4
6 6
1 1 1 1
14 14
13 13
0
2
4
6
8
10
12
14
16
20 50 75 100
Fir ing Rat e %
P
P
M
CO
*PM
NOx
B5-19
03-08
Noise Level The Model CFC is extremely quiet at all operating levels, does not require any sound
level modifications to provide ultra low noise levels, and is virtually vibration free.
Thus, it is very suitable in applications that demand very low noise emissions.
Table B5-11 shows the noise levels of the Clearfire at various firing rates.
Table B5-11. Noise Level (dBA) measured 3 feet in front of boiler
ENGINEERING DATA
Boiler Information The Model CFC boiler is designed for service in any closed hydronic system and can
be used to augment any hot water system. It can be put into operation as a single
stand-alone unit with 5:1 turndown or in multiple units for larger turndown and
capacity.
Clearfire boilers may be utilized in water heating systems with temperatures from
40 F (4.4 C) to 195 F (90.5 C); ideal for ground water source heat pump
applications, etc. Because the Clearfire is a full condensing boiler, low water
temperature (below the dewpoint) restrictions do not apply. In fact, the lower the
return the better the fuel savings.
Variable temperature differentials can be designed to make use of changing outdoor
conditions and thus, the Clearfire is not restricted to a nominal 20 F (10 C)
differential. The boiler is designed to withstand thermal stresses with supply and
return temperature differences up to 100 F (55 C), without the use of a boiler-
circulating pump, blend pump or minimum water flow.
Note: The Clearfire does not require a minimum flow or continuous flow through it during operation.
However, the load imposed on the boiler must be considered when sizing the system flow so that
the flow does not exceed the capacity of the boiler or the demand.
Flow Rates and
Pressure Drops
To maintain rated capacity of the boiler, recommended flow rates should not be
exceeded as the flow will remove the heat beyond the capacity of the boiler. Table
B5-12 through Table B5-13 can be used to determine the full boiler output relative
to system temperature drop and the maximum recommended system pump flow.
Knowing the flow rate, the pressure drop through the boiler can be found in Figure
B5-14 through Figure B5-24.
System Operating
Parameters
To prevent water flashing to steam within the boiler or system, hot water boilers
must operate with proper over-pressure. System over-pressure requirements are
shown in Table B5-14.
Note: The ASME Code Section IV limits the maximum setting of the excess temperature control to
210 F (98.9 C) for boilers constructed with stainless steel. This is to ensure that water
temperature will not reach the boiling point (steaming) and therefore, so as not to exceed the
maximum limit of this control and in compliance with the Code, the operating limit of 195 F
(90.5 C) is set for normal boiler operation.
20% Firing 60% Firing 100% Firing
CFC 500 39 48 60
CFC 750 41 51 62
CFC 1000 43 57 66
CFC 1500 40 50 64
CFC 1800 45 56 66
CFC 2500 45 57 68
B5-20
03-08
While proper overpressure is required, a means to relieve excess pressure at or
beyond the design pressure of the boiler must be provided. As boiler water is
heated, expansion occurs. And this expansion must be accounted for either with an
expansion tank (air filled) or with a bladder type tank. These devices permit the
water pressure to expand outside of the boiler and not impact the pressure vessel or
pressure relieving device. But, in accordance with Code, each boiler is equipped
with an ASME approved safety relieving device should pressure build-up occur (See
Table B5-15 and Table B5-16).
Air Venting The elimination of entrained air is required. It is recommended that each unit be
piped to an expansion tank. If this is not possible, then an auto air vent should be
provided on the vent connection of the boiler. The caveat in using an auto vent is
that free oxygen can be introduced to the vesel as the boiler cools, or in some
instances the vent can become plugged.
B5-21
03-08
Table B5-12. Maximum Flow Rate Through ClearFire Boilers (US Flow Rates)
Table B5-13. Maximum Flow Rate Through ClearFire Boilers (Metric Flow Rates)
0
F
10 20 30 40 50 60 70 80 90 100 110 120
Boiler
Size
Flow Rate GPM
500 95 48 33 24 19 16 12 11 10.5 9 8 7
750 131 66 44 33 26 22 19 16 15 13 12 11
1000 176 88 59 44 35 29 25 22 20 18 16 15
1500 260 130 87 65 52 43 37 33 29 26 24 23
1800 351 176 117 88 70 59 50 44 39 35 32 30
2500 470 235 157 118 95 79 67 59 52 48 43 39
Recommended flow rates relative to temperature drop so as not to exceed boiler output.
0
C
5 11 17 22 27 33 38 45 50 55 61 64
Boiler
Size
Flow Rate m
3
/hr.
500 21.6 10.9 7.5 5.4 4.3 3.6 2.7 2.5 2.3 2 1.8 1.6
750 29.75 15 10 7.5 6 5 4.3 3.6 3.4 2.9 2.7 2.5
1000 40 20 14 10 8 7 6 5 4.5 4 3.6 3.4
1500 59 29.5 20 15 12 10 8.4 7.5 6.6 6 5.4 5.2
1800 80 40 27 20 16 13 11.3 10 9 8 7.3 6.8
2500 106.7 53.4 36.7 26.8 21.6 17.9 15.2 13.4 11.8 10.9 9.8 8.8
Recommended flow rates relative to temperature drop so as not to exceed boiler output.
B5-22
03-08
Figure B5-14. Pressure Drop Curve ClearFire Boiler Size 500, U.S. Flow Rates.
Figure B5-15. Pressure Drop Curve ClearFire Boiler Size 500, Metric Flow Rates.
Hydr aul i c Resi st ance CFC 500
0
0.2
0.4
0.6
0.8
1
1.2
1.4
0
8
.
8
1
3
.
2
1
7
.
6
2
2
2
6
.
4
3
0
.
8
3
5
.
2
3
9
.
6
4
4
4
8
.
4
5
2
.
8
5
7
.
2
6
1
.
6
6
6
7
0
.
4
1
3
1
Flow - GPM
Pr es s ur e PSI
Hyd r a u l i c Re s i s t a n c e CFC 5 0 0
Me t r i c
0
5
10
15
20
25
30
0 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Fl o w m 3/h
Pr e s s u r e m b ar
B5-23
03-08

Hydraulic Resistance CFC 750
0
0.2
0.4
0.6
0.8
1
1.2
1.4
0
1
3
.
2
2
2
.
0
1
3
0
.
8
3
9
.
6
4
8
.
4
5
7
.
2
6
6
1
3
1
Fl ow - GPM
Pressure PSI
Metric
0
5
10
15
20
25
30
0 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Flow m3/h
Pressure mbar
B5-24
03-08
Hydr aulic Res is t anc e CFC 1000
0
0.2
0.4
0.6
0.8
1
1.2
0 8.8 22 44 66 88 110 132 154 176
Fl ow - GPM
Pr es s ur e - PSI
Hy d r a u l i c Re s i s t a n c e CFC 1 0 0 0
0
10
20
30
40
50
60
70
80
0 2 5 10 15 20 25 30 35 40
Fl o w m 3 /h
P r e s s u r e m b a r
B5-25
03-08
Figure B5-21. Pressure Drop Curve ClearFire Boiler Size 1500, Metric Flow Rate.
Hydr aul i c Resi st ance CFC 1500
U.S. St andar ds
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
2
0 8.8 22 44 66 88 110 132 154 176 198 220 242 264
Fl ow - GPM
Pr essur e- PSI
Metric
0
20
40
60
80
100
120
140
0 2 5 10 15 20 25 30 35 40 45 50 55 60
Flow m3/h
Pressure mbar
B5-26
03-08
U.S. Standards
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
0
8
.
8
2
2
4
4
6
6
8
8
1
1
0
1
3
2
1
5
4
1
7
6
1
9
8
2
2
0
2
4
2
2
6
4
2
8
6
3
0
8
3
3
0
3
5
2
Flow - GPM
Pressure - PSI
Hydr aul ic Resi stance CFC 1800
Metr i c
0
20
40
60
80
100
120
0 2 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80
Flow m3/h
Pressure mbar
B5-27
03-08
Hydr aul i c Res i s t ance CFC 2500
U.S. St andar ds
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
0 44 66 88 118 132 154 176 198 220 242 264 286 308 330 352 375 395 420 474
Fl ow - GPM
Pr es s ur e - PSI
B5-28
03-08
Table B5-14. Model CFC Minimum Over Pressure Requirements
Table B5-15. Model CFC Boiler Safety Valve Information @ 60 PSIG
Table B5-16. Model CFC Boiler Safety Valve Information @ 30 PSIG
Outllet Water Temperature
0
F (C) Minimum System Pressure PSIG (Bar)
80 - 180 (27 - 82) 12 (0.83)
181 - 185 (83 - 85) 15 (1.03)
186 - 195 (86 - 91) 18 (1.24)
Boiler Size
Valve Connection
@ Boiler
Valve Setting 60 psig
Relief Valve
Capacity (MBH)
No. Valves Req'd Outlet Size
500 3/4" 1 1" 1784
750 3/4" 1 1" 1784
1000 3/4" 1 1" 1784
1500 3/4" 1 1" 1784
1800 1" 1 1-1/4" 2788
2500 1" 1 1-1/4" 2788
Boiler Size
Valve Connection
@ Boiler
Valve Setting 30 psig
Relief Valve
Capacity (MBH)
No. Valves Req'd Outlet Size
500 3/4" 1 1" 1054
750 3/4" 1 1" 1054
1000 3/4" 1 1" 1054
1500 1" 1 1-1/4" 1648
1800 1-1/2" 1 2" 3495
2500 1-1/2" 1 2" 3495
B5-29
03-08
Water Treatment Even though hot water systems are "closed", some amount of make-up water (up to
10%) will be introduced. This more often than not happens from seal leaks of
pumps, or other minimal leaks from valves etc., that go unnoticed. Therefore,
proper water chemistry of a hot water boiler is necessary for good operation and
longevity, particularly to ensure that free oxygen is removed to prevent waterside
corrosion (see Table B5-17).
Table B5-17. Model CFC Water Chemistry Requirements in accordance with ABMA
Condensation As the Model CFC boiler is a full condensing boiler, condensation will develop during
startup of a cold boiler or at any time when the return water temperature is below
the dew point or approximately 132 F (55.5 C).
The condensation collects in the lower portion of the boiler from the tube surfaces
and from the stack, and must be discharged to a drain. A Condensate trap must be
piped on the boiler and this must be field piped to either a drain or to the optional
Condensate treatment kit (see Figure B5-25). Table B5-18 provides the amount of
condensation that will form when the boiler operates in the full condensing mode.
Figure B5-25. Standard Condensate Piping Direct to Drain, No Condensate Treatment
Parameter Limit
Glycol 40%
pH 8.0 - 9.5
Chloride 30 mg/liter
Oxyen 0.1 mg/liter
Specific Conductivity 3500 umho/cm
Total Hardness
0 ppm as C
a
CO
3
6
Return Water In
Stack
Clearfire
Base
B5-30
03-08
Table B5-18. Model CFC Maximum Condensation
Relative to local codes, this condensate may be discharged directly to the drain or
treated, using an optional treatment assembly. Figure B5-26 depicts piping without
the treatment assembly and Figure B5-27 depicts the optional treatment assembly.
Note: One treatment kit may be used for up to four boilers as shown in Figure B5-
28 and Figure B5-29.
Figure B5-26. Condensate Piping Direct To Drain
Figure B5-27. Optional Condensate Treatment Assembly - Single Boiler
Boiler Size
Gallons Per Hour - GPH
(Liters Per Hour - L/H)
500 3.5 [
750 5 [18.9]
1000 7 [26.5]
1500 9 [34]
1800 12 [45]
2500 17
Boiler Operating @ maximum in full condensing mode.
1
2
3
1. Removabl e front
2. Mi n. 6 water trap
3. Pl asti c drai n pi pe
1
2
3
4
5
1. Removable Front Panel
2. 6 Water Trap
3. Neutralization Material
4. Plastic Drain Pipe
5. Neutralized Condensate reservoir
B5-31
03-08
Notice
If a treatment kit is utilized, clearance at the front of the boiler must be provided for
servicing the assembly and for periodically adding the neutralizing granules.
Figure B5-28. Condensate Piping for Multiple Boilers
Figure B5-29. Condensate Treatment Tank for Multiple Boilers
Note: The boiler may be installed without the legs as long as provisions are made for a 6 P trap
using a 5 or 5 1/2 housekeeping pad or trench.
To Drain
Slope Towards Neutralization Tank
" ODC Make-up Water Supply
Condensate Drain Tank
Neutralization Tank
To Drain
Condensate Drain Tank
Slope Towards Neutralization Tank
1" NPT. Minimum Header Size
(Use PVC Pipe or other Nonferrous Material)
Model ClearFire Boiler
Neutralization Tank
12" Minimum
B5-32
03-08
Gas Fuel
Connections
The local Gas Company should be consulted for the requirements 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 must be arranged so that all components
are accessible for inspection, cleaning, and maintenance.
A drip leg should be installed in the supply line before the connection to the boiler.
The drip leg should be at least as large as the gas piping connection on the boiler.
See Figure B5-30, and Figure B5-31 for piping suggestions.
Figure B5-30. Gas Piping Schematic
Consideration of volume and pressure requirements must be given when selecting
gas supply piping.
Connections to the burner gas train must include a union so that the burner may be
opened for inspection and maintenance.
B5-33
03-08
A. Gas supply connection is at the rear of the boiler near the top. To permit
burner opening, gas piping must not traverse the top of the boiler.
B. Table B5-19 shows the gas pressure required at the inlet of the gas line.
Note: a pressure regulator is not furnished and if gas pressure exceeds 14"
W.C. a pressure regulator is recommended.
C. Table B5-20 shows the correction factors for gas pressure at elevations at
2000 feet and higher above sea level.
Figure B5-31. Gas Header Piping
B5-34
03-08
Table B5-19. Model CFC Minimum and Maximum Gas Pressure
Table B5-20. Model CFC Minimum Required Gas Pressure Altitude Correction
Boiler Room
Information
The boiler must be installed on a level non-combustible surface. If the surface is not
level, piers or a raised pad, slightly larger than the length and width of the boiler
base dimensions, will make boiler leveling possible. Installing the boiler on a raised
pad or piers will make boiler drain connections more accessible and will keep water
from splashing onto the boiler whenever the boiler room floor is washed.
Note: The pad or piers must be of sufficient load bearing strength to safely support the operating
weight of the boiler and any additional equipment installed with it. Approximate operating
weights are shown in Dimensions and Ratings.
Leveling Once the boiler is placed, it must be leveled side to side and front to back using the
supply and return nozzles for horizontal and vertical positions. If shims are required
to level the boiler, the weight of the boiler must be evenly distributed at all points of
support. The legs may also be used for leveling.
Clearances The boiler must be installed so that all components remain accessible; ensure no
overhead obstructions so the burner may be opened. Refer to Figure B5-32.
Boiler Size
Low Fire High Fire Maximum Pressure
Inches W.C. Inches W.C. Inches W.C.
500-1000 7 5
14
1500 10 7
1800 7 5
2500 9.5 8
Note: Pressure is measured at entrance to burner gas train or discharge of regulator.
A gas pressure regulator is not furnished as standard.
Altitude in Feet Correction Factor Altitude in Feet Correction Factor
1000 1.04 6000 1.25
2000 1.07 7000 1.3
3000 1.11 8000 1.35
4000 1.16 9000 1.4
5000 1.21

To obtain minimum required inlet pressure, select altitude of installation and multiply the pressure shown
in Table B5-19 by the correction factor corresponding to the altitude listed above.
B5-35
03-08
Figure B5-32. Model CFC Minimum Room Clearance Dimensions
Hot Water Piping Primary/secondary pumps are not necessary with the Model CFC boiler. As its
design is such that no minimum flow is required, variable speed or on/off pumps
may be employed in the piping scheme.
Typical piping arrangements are shown in figures B5-34 through B5-46.
Note: These diagrams are typical and are not intended for use in a specific design without
consultation with your local Cleaver-Brooks sales representative
DIM Inches
Top Clearance A 12
Side Clearance B 20
Backway C 8
Front D 36
Between Boilers E 3
C
B
D
B
E
C
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B
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M
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C
F
C
B
5
-
3
6
0
3
-
0
8
Figure B5-34. No primary Loop with Domestic Water and 2-Way Divert Valve
M
o
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C
F
C
C
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B
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B
5
-
3
7
0
3
-
0
8
Figure B5-35. 2 Pipe System, Typical (reverse-return)
C
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m
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B
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M
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C
F
C
B
5
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3
8
0
3
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0
8
Figure B5-36. Zoning with Zone Valves
M
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C
F
C
C
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B
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s
B
5
-
3
9
0
3
-
0
8
Figure B5-37. Two Boilers and Three Variable Temperature Zones (No Primary Loop)
C
o
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m
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B
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M
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C
F
C
B
5
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4
0
0
3
-
0
8
Figure B5-38. Two-Pipe Primary/Secondary Piping with Domestic Hot Water
M
o
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C
F
C
C
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B
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s
B
5
-
4
1
0
3
-
0
8
Figure B5-39. Two-Pipe Primary/Secondary Piping
C
o
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m
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B
o
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s

M
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C
F
C
B
5
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4
2
0
3
-
0
8
Figure B5-40. No Primary Loop
M
o
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C
F
C
C
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B
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B
5
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4
3
0
3
-
0
8
Figure B5-41. Domestic Water Heating, No Primary Loop
C
o
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m
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c
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B
o
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M
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C
F
C
B
5
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4
4
0
3
-
0
8
Figure B5-42. Domestic Water with On/Off and 3-Way Valves
C
o
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m
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c
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B
o
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s

M
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C
F
C
B
5
-
4
5
0
3
-
0
8
Figure B5-44. Piping Hybrid Boilers
M
o
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C
F
C
C
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B
o
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B
5
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4
6
0
3
-
0
8
Figure B5-45. Hybrid Boilers with Domestic Water
C
o
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c
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B
o
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M
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C
F
C
B
5
-
4
7
0
3
-
0
8
Figure B5-46. Domestic Water with 2 Boilers and 2 Coils
B5-48
03-08
Boiler Room
Combustion and
Ventilation Air
The boiler(s) must be supplied with adequate quantities of uncontaminated air to
support proper combustion and equipment ventilation. Air shall be free of chlorides,
halogens, fluorocarbons, construction dust or other contaminants that are
detrimental to the burner/boiler. If these contaminants are present, we recommend
the use of direct vent combustion provided the outside air source is
uncontaminated.
Combustion air can be supplied by means of conventional venting, where
combustion air is drawn from the area immediately surrounding the boiler (boiler
room must be positive pressure), or with direct vent (direct vent combustion) where
air is drawn directly from the outside. All installations must comply with local
Codes and with NFPA 54 (the National Fuel Gas Code - NFGC) for the U.S. and for
Canada, CAN/CGA B 149.1 and B 149.2.
Note: A boiler room exhaust fan is not recommended as this type of device can cause a negative
pressure in the boiler room if using conventional air intake.
In accordance with NFPA54, the required volume of indoor air shall be determined
in accordance with the "Standard Method" or "Known Air Infiltration Rate Method.
Where the air infiltration rate is known to be less than 0.40 Air Changes per Hour,
the Known Air Infiltration Rate Method shall be use. (See Section 8.3 in the
NFPA54 Handbook for additional information.)
Combustion Air
Supply - Unconfined
Spaces (For U.S.
Installations Only)
A. All Air From Inside the Building - If additional combustion air is drawn from
inside the building (the mechanical equipment room does not receive air
from outside via louvers or vent openings and the boiler is not equipped with
direct vent combustion) and the boiler is located in a unconfined space, use
the following guidelines:
1. The mechanical equipment room must be provided with two permanent
openings linked directly with additional room (s) of sufficient volume so
that the combined volume of all spaces meet the criteria for an
unconfined space. Note: An "unconfined space" is defined as a space
whose volume is more than 50 cubic feet per 1,000 Btu per hour of
aggregate input rating of all appliances installed in that space.
2. Each opening must have a minimum free area of one square inch per
1,000 Btu per hour of the total input rating of all gas utilizing equipment
in the mechanical room.
3. One opening must terminate within twelve inches of the top, and one
opening must terminate within twelve inches of the bottom of the room.
4. Refer to the NFGC, Section 8.3 for additional information and Figure B5-
47.
B5-49
03-08
Figure B5-47. Two Opening Outside Wall Method
B. All Air From Outdoors - If all combustion air will be received from outside the building (the mechanical
room equipment is linked with the outdoors), the following methods can be used:
1. Two Opening Method (Figure B5-48) - The mechanical equipment room
must be provided with two permanent openings, one terminating within
twelve inches from the top, and one opening terminating within twelve
inches of the bottom of the room.
2. The openings must be linked directly or by ducts with the outdoors.
3. Each opening must have a minimum free area of one square inch per
4,000 Btu per hour of total input rating of all equipment in the room,
when the opening is directly linked to the outdoors or through vertical
ducts.
4. The minimum free area required for horizontal ducts is one square inch
per 2,000 Btu per hour of total input rating of all the equipment in the
room.
GAS
VENT
CLEARFIRE
BOILER
WATER
HEATER
GAS
VENT
INTERIOR WALL
FRESH AIR OPENING
FRESH AIR OPENING
12"MINIMUM
12"MINIMUM
B5-50
03-08
Figure B5-48. Two Opening Ducted Method
C. One Opening Method (Figure B5-49) - One permanent opening,
commencing within 12 inches of the top of the enclosure, shall be provided.
1. The equipment shall have clearances of at least 1 inch from the sides and
back and 6 inches from the front of the appliance.
2. The opening shall directly communicate with the outdoors and shall have
a minimum free area of 1 square inch per 3000 BTU's per hour of the
total input rating of all equipment located in the enclosure, and not less
than the sum of the areas of all vent connectors in the confined space.
3. Refer to the NFGC, Section 8.3 for additional information.
GAS
VENT
CLEARFIRE
BOILER
WATER
HEATER
GAS
VENT
EXTERIOR WALL
INTERIOR WALL
FRESH AIR
INLET DUCT
OUTLET AIR DUCT
12"MINIMUM
12"MINIMUM
B5-51
03-08
Figure B5-49. One Opening Method
Unconfined Space/
Engineered Design
When determining boiler room air requirements for unconfined space, the size of the
room, airflow, and velocity of air must be reviewed as follows:
1. Size (area) and location of air supply openings in the boiler room.
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. See
Figure B5-50.
qualities and is subject to clogging with dirt and dust.
combustion air. This can result in unsafe burner performance.
D. Under no condition should the total area of the air supply openings be less
than one square foot.
GAS
VENT
CLEARFIRE
BOILER
WATER
HEATER
GAS
VENT
EXTERIOR WALL
FRESH AIR OPENING
12"MINIMUM
B5-52
03-08
Figure B5-50. Two Opening Engineered Method
Area in square feet = cfm/fpm
Where cfm = cubic feet per minute of air
Where fpm = feet per minute of air
2. Amount of Air Required (cfm).
A. Combustion Air = Rated bhp x 8 cfm.
B. Ventilation Air = Maximum bhp x 2 cfm.
C. Total air = 10 cfm per bhp (boiler horsepower up to 1000 feet elevation.
Add 3% more per 1000 feet of added elevation.
3. Acceptable air velocity in the Boiler Room (fpm).
A. From floor to 7 feet high = 250 fpm.
B. Above 7 feet above floor = 500 fpm.
Example: Determine the area of the boiler room air supply openings for (2) Clearfire
1800 boilers at 750 feet elevation. The air openings to be 5 feet above floor level.
(Size 1800 boiler is equivalent to 52 horsepower at full condensing)
Air required: 52 x 2 = 104 bhp. From 2C above, 104 x 10 = 1,040 cfm.
Air Velocity: Up to 7 feet = 250 fpm from 3 above.
Area required: Area = cfm/fpm = 1,040/250 = 4.16 square feet total.
Area/Opening: 4.16/2 = 2.08 sq-ft/opening (2 required).
GAS
VENT
CLEARFIRE
BOILER
WATER
HEATER
GAS
VENT
EXTERIOR WALL
FRESH AIR OPENING
EXTERIOR WALL
FRESH AIR OPENING
B5-53
03-08
Notice
Direct Vent
Combustion
If combustion air will be drawn directly from the outside by means of a duct
connected to the burner air intake, use the following as a guide:
1. Install combustion air vent (direct vent combustion) in accordance with the
boiler's Operating and Maintenance manual.
2. Provide for adequate ventilation of the boiler room or mechanical equipment
room.
3. In cold climates, and to mitigate potential freeze-up of the intake pipe, it is
highly recommended that a motorized sealed damper be used to prevent the
circulation of cold air through the boiler during non-operating hours.
4. Refer to Figure B5-51 for suggested piping of direct vent combustion
installations. Figure B5-52 shows the optional direct vent combustion kit
providing easy adaptation of the contractor supplied air duct to boiler
connection. Refer to Table B5-22 for sizing the direct vent combustion air pipe.
Figure B5-51. Direct Vent Combustion Piping Options.
Figure B5-52. Optional Direct Vent Combustion Kit
Clearfire Boiler
Flue Gas Vent (w/Screen)
Air Intake (w/Screen)
36" Minimum
24" Minimum
12"Minimum
FAN/BLOWER
VENTURI
AIR SUPPLY LINE
B5-54
03-08
STACK/BREECHING SIZE CRITERIA
General The Model CFC is a Category IV Boiler, according to ANSI Z21.13. This Code
defines a Category IV boiler as one that operates with a positive vent pressure and a
vent gas temperature that may produce condensation in the breeching and stack,
depending upon operating conditions. Consequently, the vent material must
conform to this category boiler rating. UL 17-38 certified material must be used.
Under certain conditions, PVC and CPVC may be utilized.
If PVC or CPVC is considered, the maximum outlet temperature of the water supply
from the boiler shall not exceed 120 F. Also, the primary consideration of PVC or
CPVC shall be the temperature limits of the material and local codes.
Proper installation of flue gas exhaust venting is critical to efficient and safe
operation of the Clearfire Boiler. The vent should be supported to maintain proper
vent passes through combustible roofs and walls.
flue gas connection; proper draft is critical to burner performance.
size the breeching and stack to limit flue gas pressure variation. Consideration of
the draft must be given whenever direct vent combustion is utilized and lengthy runs
of breeching are employed. Please note: The allowable pressure range for design of
the stack, breeching and if used, direct vent combustion pipe, is negative 0.25"
W.C. (- 62 Pa) to positive 0.25" W.C. (+62 Pa) for proper combustion and light offs.
Whenever two or more boilers are connected to a common breeching/stack, a draft
control system may be required to ensure proper draft.
Vent Termination To avoid the possibility of property damage or personal injury, special attention to
the location of the vent termination must be considered.
1. Combustion gases can form a white vapor plume in the winter. The plume could
obstruct a window view if the termination is installed in close proximity to
windows.
2. Prevailing winds could cause freezing of Condensate and water/ice buildup on
building, plants, or roof.
3. The bottom of the vent termination and the air intake shall be located at least
12 inches above grade, including the normal snow line.
4. Non-insulated single-wall metal vent pipe shall not be used outside in cold
climates for venting combustion gases.
5. Through the wall vents for Category II and Category IV appliances shall not
terminate over public walkways or over an area where Condensate or vapor
could create a nuisance or hazard or could be detrimental to the operation of
other equipment.
6. To prevent accidental contact by people or pets, the vent termination shall be
guarded.
7. DO NOT terminate vent in window well, alcove, stairwell or other recessed area,
unless approved by local authority.
8. DO NOT terminate above any door, window, or gravity air intake as Condensate
can freeze causing ice formation.
B5-55
03-08
9. Locate or guard vent to prevent Condensate from damaging exterior finishes.
Use a 2' x 2' rust resistant sheet metal backing plate against brick or masonry
surfaces.
10. Multiple direct stack installations require four feet clearance between the stack
caps, center to center.
U.S. Installations - Refer to the latest edition of the National Fuel Gas Code/NFPA 54. Vent
termination requirements are:
1. Vent must terminate at least four feet below and four feet horizontally or one foot
above any door, window or gravity air inlet to the building.
2. The vent must be at least seven feet above grade when located adjacent to
public walkways.
3. Terminate vent at least three feet above any forced air inlet located within ten
feet.
4. Vent must terminate at least four feet horizontally, and in no case above or below
unless four feet horizontal distance is maintained, from electric meters, gas
meters, regulators, and relief equipment.
5. Terminate vent at least six feet from adjacent walls.
6. DO NOT terminate vent closer than five feet below roof overhang.
Canadian
Installations -
Refer to the latest edition of CAN/CSA-B149.1 and B149.2. Vent shall not
terminate:
1. Directly above a paved sidewalk or driveway which is located between two
single-family dwellings and serves both dwellings.
2. Less than 7 feet (2.31m) above a paved sidewalk or paved driveway located on
public property.
3. Within 6 feet (1.8m) of a mechanical air supply inlet to any building.
4. Above a meter/regulator assembly with 3 feet (900mm) horizontally of the
vertical centerline of the regulator.
5. Within 6 feet (1.8m) of any gas service regulator vent outlet.
6. Less than 1 foot (300mm) above grade level.
7. Within 3 feet (1m) of a window or door which can be opened in any building,
any non-mechanical air supply inlet to any building or to the combustion air inlet
of any other appliance.
8. Underneath a Verandah, porch, or deck unless:
A. The Verandah, porch, or deck is fully open on a minimum of two sides
beneath the floor.
B. The distance between the top of the vent termination and the underside of
the Verandah, porch, or deck is greater than one foot (300mm).
B5-56
03-08
Horizontal Through
the Wall Venting
Venting configurations using inside air for combustion (See Figure B5-53)
These installations utilize the boiler-mounted blower to vent the combustion
products to the outside. Combustion air is obtained from inside the room and the
exhaust vent is installed horizontally through the wall to the exterior of the building.
Adequate combustion and ventilation air must be supplied to the boiler room in
accordance with the NFGC/NFPA 54 for the U.S. and in Canada, the latest edition
of CAN/CSA-B149.1 and.2 Installation Code for Gas Burning Appliances and
Equipment.
Figure B5-53. Horizontal Through the wall venting using inside air for combustion
The vent must be installed to prevent the potential accumulation of stack
condensate in the horizontal run of vent pipe. Therefore, it is recommended that:
1. The vent shall be installed with a slight downward slope of not more than 1/4"
per foot of horizontal run to the vent termination.
2. The vent must be insulated through the length of the horizontal run.
Note: For installations in cold/freezing climates, it is recommended that:
1. The vent shall be installed with a slight upward slope of not more than 1/4" per
foot of horizontal run to the vent termination. In this case, an approved
Condensate trap must be installed per applicable codes.
2. The vent must be insulated through the length of horizontal run.
The stack vent cap MUST be mounted on the exterior of the building. The stack
vent cap cannot be installed in a well or below grade. The stack vent cap must be
installed at least two feet above ground level and above normal snow levels.
Notice
The stainless steel direct vent cap must be furnished in accordance with AGA/CGA
requirements.
Refer to Table B5-21 for the recommended sizes of horizontal vent pipe.
12" Minimum +any
Flue Gas Vent
Inside Air
Combustion
Intake
(w/Screen)
Snow Load
B5-57
03-08
Horizontal Through
the Wall Stack
Venting
Direct Vent Combustion. See Figure B5-54.
Figure B5-54. Horizontal Flue through-wall with direct vent combustion intake
These installations utilize the boiler-mounted blower to take combustion air from the
outside and vent combustion by-products to the outside.
The direct vent combustion air vent cap is not considered in the overall length of the
venting system.
The stack vent must be installed to prevent the potential accumulation of
Condensate in the stack pipes. It is recommended that:
1. The vent shall be installed with a slight downward slope of not more than 1/4"
per foot of horizontal run to the stack termination.
2. The stack vent is to be insulated through the length of the horizontal run.
Note: For installations in freezing climates, it is recommended that:
1. The stack vent shall be installed with a slight upward slope of not more than 1/
4" per foot of horizontal run to the vent termination. In this case, an approved
Condensate trap must be installed per applicable codes.
2. The stack vent is to be insulated through the length of the horizontal run.
Note: For Horizontal Stack Vent Termination:
18" Minimum
24" Minimum
24" Minimum
B5-58
03-08
1. The stack vent cap must be mounted on the exterior of the building. The stack
vent cap cannot be installed in a well or below grade. The stack vent cap must
be installed at least one foot above ground level and above normal snow levels.
2. Multiple stack vent caps should be installed in the same horizontal plane with
three feet clearance from side of one stack cap to the side of the adjacent vent
cap.
3. Combustion air supplied from the outside must be free of particulate and
chemical contaminants. To avoid a blocked flue condition, keep all the vent
caps clear of snow, ice, leaves, debris, etc.
Note: Multiple direct stack vent caps must not be installed with one combustion air inlet directly above
a stack vent cap. This vertical spacing would allow the flue products from the stack vent to be
pulled into the combustion air intake installed above. This type of installation can cause non-
warrantable problems with components and poor operation of the unit due to the recirculation of
flue products.
Refer to Table B5-22 for recommended flue vent sizing when using Direct Vent
Combustion.
Table B5-21. STACK DESIGN SINGLE BOILER USING ROOM AIR
Boiler Size
Boiler Stack
Connection
Stack/Vent
Size
Maximum length of breeching or stack
(feet)*
CFC 500
6" Standard 6" 80
4" Option 4" 40
CFC 750 6" Standard 6" 80
CFC 1000
8" Standard 8" 140
6" Option 6" 80
10" Option 10" 220
CFC 1500
10" Standard 10" 140
8" Option 8" 90
12" Option 12" 250
CFC 1800
12" Standard 12" 60
10" Option 10" 40
CFC 2500 12" Standard 12" 110
* Each additional 90 elbow equals 5 equivalent feet of ductwork. Subtract from the
maximum or minimum length accordingly.
Maximum allowable pressure drop in flue vent ducting is 0.25" w.c.
B5-59
03-08
Table B5-22. STACK SIZING USING OUTSIDE AIR FOR COMBUSTION
Boiler
Boiler Stack
Connection
Boiler Air
Intake Duct &
Connection
Boiler Vent/
Stack Size
Maximum length of
Flue Gas Vent in
Feet*
Maximum length of
Air Intake Duct in
Feet**
CFC 500
6" Standard 4" 6" 75 75
4" Option 4" 4" 40 40
CFC750 6" Standard 4" 6" 40 40
CFC1000
8" Standard 6" 8" 60 60
6" Option 6" 6" 40 40
10" Option 6" 10" 70 70
CFC1500
10" Standard 6" 10" 40 40
8" Option 6" 8" 30 30
12" Option 6" 12" 45 45
CFC1800
12" Standard 6" 12" 30 30
10" Option 6" 10" 25 25
CFC 2500 12" Standard 8" 12" 100 100
* Each additional 90 elbow equals 5 equivalent feet of ductwork. Subtract from the maximum or
minimum length accordingly.
** Increasing the diameter of the air intake will reduce the pressure drop and thereby allow longer total
vent lengths.
Maximum allowable pressure drop in combustion air intake duct is - 0.25" w.c.
B5-60
03-08
Vertical Venting
Inside Combustion
Air
See Figure B5-55.
Figure B5-55. Inside Air - Vertical Vent
As noted in Paragraph A above, these installations use air from within the boiler
room for combustion. The same recommendations apply as noted in Paragraph A
above and also, the recommendations on flue vent sizing according to Table B5-21.
ClearFire Boiler
24"
Minimum
10'-0"or Less
24"
Minimum
B5-61
03-08
Vertical Venting
Direct Vent
Combustion
See Figure B5-56.
Figure B5-56. Vertical Stack with Direct Vent Combustion Air
As noted in Paragraph B above, these installations use air from outside the building
for combustion. The same recommendations apply as noted in B and also, the
recommendations on flue vent sizing according to Table B5-22.
ELECTRICAL Voltage requirements for the Fan Motor are 208 - 240/1/60 (sizes 700-1800) and
120/1/60 (Sizes 500 and 2500). Control Circuit voltage is 120/1/60 for all boiler
sizes. Refer to Table B5-3 "Ratings" for ampacity requirements.
Refer to Figure B5-57 and Figure B5-58 for wiring connections and control
locations.
ClearFire Boiler
36"Minimum
24"
Minimum
12"
Minimum
B5-62
03-08
Figure B5-57. Electrical Connection Diagram
Figure B5-58. CFC Connections
Air Inlet
Extension
Location
Flue Gas Vent
Connection
Alt. Flue
Gas
Connection
Gas
Connection
Hot
Water
Out
Return
Water
Inlet
Electrical
High
Voltage
Electrical
Low
Voltage (sensors)
B5-63
03-08
CB FALCON CONTROLLER
1. Control Description - The CB Falcon hydronic control is an integrated burner
management and modulation control with a touch-screen display/operator
interface.
2. Functionality - The controller is capable of the following functions:
Two (2) heating loops with PID load control.
Burner sequencing with safe start check, pre-purge, direct spark ignition,
and post purge.
Electronic ignition.
Flame Supervision.
Safety shutdown with time-stamped display of lockout condition.
Variable speed control of the combustion fan.
Supervision of low and high gas pressure, air proving, stack back pressure,
high limit, and low water.
Alarm output
Remote reset
First-out annunciator.
Real-time data trending.
(3) pump/auxiliary relay outputs.
Modbus communication capability.
Outdoor temperature reset.
Anti-short-cycling mode
Frost protection
Time-of-day (night setback) operation
Three levels of access to control configuration:
End-user
Installer/Service Engineer (password protected)
OEM Manufacturer (password protected)
Table B5-23. Operating Conditions - Controller
Temperature Range
Operating -4 F to 150 F (-20 C to 66 C)
Storage -40 F to 150 F (-40 C to 66 C)
Humidity 85% max. relative humidity, non-condensing
Table B5-24. Operating Conditions - Display/Interface
Temperature Range
Operating 32 F to 122 F (0 C to 50 C)
Humidity 85% max. relative humidity
B5-64
03-08
3. Main Voltage Connection - 115V/single phase/60Hz
4. Local/Remote demand switch
5. Combustion Air Proving Switch - This input is used for proving airflow sufficient
for proper combustion throughout the burner run sequence.
6. High Air Pressure Switch - prevents boiler operation in the event of high stack
back pressure (blocked flue or condensate drain).
7. Gas Pressure Switch - Gas pressure switches for low gas pressure and high gas
pressure prevent the burner from being activated if either is open. Each switch
is a physical manual reset device, requiring physical depression of the reset
button if either switch is not closed prior to burner start or during burner
operation.
8. NTC (Negative Temperature Coefficient) Thermistor Inputs (10k @ 25
o
C)
A. Flow Temperature (Outlet water temperature)
B. Return Temperature (Inlet water temperature)
C. Optional Domestic Water Temperature
D. Optional Outdoor Temperature
E. Optional Stack Temperature
F. Optional Header Temperature
9. System Configuration - CB Falcon configuration is grouped into the following
functional groups:
Table B5-25. CB Falcon burner sequence (Central Heat)
1. Heat request detected (CH demand)
2. CH pump switched on
3. Safe Start Check, dynamic ILK input test (if enabled), blower switched on
4. If ILK input and CAPS switch closed and purge rate fan speed achieved, begin 15
second prepurge
5. When purge complete, blower RPM changed to lightoff speed
6. Trial for Ignition - 4 seconds
7. Ignition and gas valve switched on
8. Ignition turned off at the end of direct ignition period; 5 sec. stabilization time
9. Release to modulation (Run)
10. At the end of CH heat request, burner is switched off and blower stays on for 15
sec. post purge period. Boiler enters standby mode.
System Identification and Access
Central Heat Configuration
Outdoor Reset Configuration
DHW - Domestic Hot Water Configuration
Modulation Configuration
Pump Configuration
Statistics Configuration
High Limits
Stack Limit
Other Limits
Anti-condensation Configuration
Frost Protection Configuration
Annunciation Configuration
Burner Control Interlocks
Burner Control Timings & Rates
Burner Control Ignition
Burner Control Flame Failure
System Configuration
Fan Configuration
Lead Lag Configuration
B5-65
03-08
10. CB Falcon Access - There are three levels of access to the CB Falcon controller:
End User Level - read or view parameters; change setpoints. No password
required.
Installer/Service Level - read all parameters; enables changing of most
parameters. This access level is used to configure the CB Falcon for a
particular installation, and is password-protected.
OEM Level - read/change all parameters; for factory configuration of boiler-
specific parameters. Password-protected and restricted to CB or factory
authorized service personnel.
For additional information regarding service and setup of the burner controller, refer
to CB manual part no. 750-263.
Figure B5-59. CB Falcon Display/Operator Interface
B5-66
03-08
Figure B5-60. CB Falcon pinout
3
1
4
2
F
L
A
M
E
S
T
R
E
N
G
T
H
LOCAL
MODBUS
A B C
GLOBAL
MODBUS
A B C
POWER
FLAME
ALARM
RESET
PIM
1
2
3
4
5
6
CB FALCON
HYDRONIC
CONTROL
J1
J2 J1
J3
ENVIRACOM
D R C
L1
L2 FOR 120VAC OR
24VAC RETURN (OPTOS)
EGND
EX. IGNITION
ALARM
MAIN VALVE
ANNUN 1/IAS
ANNUN 2
ANNUN 3
ANNUN 4
ANNUN 5
ANNUN 6
INTERLOCK
P
P
P
LCI
PUMP A
{
{
{
PUMP B
PUMP C
24 VAC
24 VAC RTN
INLET TEMP
INLET TEMP RTN
HEADER TEMP
HEADER TEMP RTN
OUTLET TEMP A
OUTLET TEMP RTN
OUTLET TEMP B
OUTDOOR TEMP
OUTDOOR TEMP RTN
DHWTEMP A
DHWTEMP RTN
DHWTEMP B
STACK TEMP A
STACK TEMP RTN
STACK TEMP B
TOD
REMOTE RESET
AUX. (REMOTE) INPUT
0 - 10 VDC
MA /VDC RTN
4 TO 20 MA
V
I
BUILDING
AUTOMATION
SYSTEM
TACHOMETER
PWM OUT
FAN POWER (25 VDC)
FAN GND
MULTIPLE
APPLIANCE
CONTROLLER
GLOBALMODBUS
LOCALMODBUS
+
+
FUTURE
LOCAL DISPLAY
SYSTEM DISPLAY
J4
J5
J6
J7
J9
J8
J10
J11
12
11
10
9
8
7
6
5
4
3
2
1
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
7
6
5
4
3
2
1
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
B5-67
03-08
Section B5
ClearFire Model CFC
SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-68
REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-68
QUALITY ASSURANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-69
SUBMITTALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-69
SUBSTITUTIONS/MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-70
CERTIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-70
DELIVERY, STORAGE, AND HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-71
MANUFACTURERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-71
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-71
PERFORMANCE: BOILER SIZE AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-71
BOILER DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-73
BURNER DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-74
BOILER TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-75
BOILER CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-75
BOILER FLUE VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-76
MANUFACTURER'S FIELD SERVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-76
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-78
FIELD TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-78
START-UP, INSTRUCTION AND WARRANTY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-78
Section B5 Commercial Boilers
B5-68
03-08
PART 1 GENERAL Cleaver Brooks Condensing Boiler Line
1.01 SCOPE
A. The work to be performed consists of providing all labor, equipment,
materials, etc. to furnish and install new factory assembled, low-
pressure full condensing hot water boilers as described in the
1. Division 15 Section "Chemical Water Treatment" for feedwater
treatment.
2. Division 15 Section, "Breechings, Chimneys, and Stacks" for
connections to chimneys, and stacks.
3. Division 15 Sections for control wiring for automatic
temperature control.
1.02 REFERENCES
A. Product Data: Include rated capacities; shipping, installed, and
operating weights; furnished specialties; and accessories for each
model indicated.
B. Shop Drawings: Detail equipment assemblies and indicate
dimensions, required clearances, and method of field assembly,
components, and location and size of each field connection.
C. Wiring Diagrams: Detail wiring for power, signal, and control
systems and differentiate between manufacturer-installed and field-
installed wiring.
D. Source Quality Control Tests and Inspection Reports: Indicate and
interpret test results for compliance with performance requirements
before shipping.
E. Field Test Reports: Indicate and interpret test results for compliance
with performance requirements.
F. Maintenance Data: Include in the maintenance manuals specified in
Division 1. Include parts list, maintenance guide, and wiring
diagrams for each boiler.
G. Other:
1. ASME Section IV - Heating Boilers
2. ANSI Z21.13 - Gas Fired Low Pressure Boilers
3. NFPA 54/ANSI Z221.3 - National Fuel Code
4. FM - Factory Mutual
5. ASME CSD-1 - Controls and Safety Devices
6. XL-GAP (Formerly GE-GAP/IRI)
7. UL or CSA Standards for Gas Fired Boilers
8. UBC - Uniform Building Code
Commercial Boilers Section B5
B5-69
03-08
9. UMC - Uniform Mechanical Code
10. NEC - National Electrical Code
A. The equipment shall, as a minimum, be in strict compliance with
the requirements of this specification and shall be the
manufacturer's standard commercial product unless specified
otherwise. Additional equipment features, details, accessories,
appurtenances, etc. which are not specifically identified but which
are a part of the manufacturer's standard commercial product, shall
be included in the equipment being furnished.
B. The equipment shall be of the type, design, and size that the
manufacturer currently offers for commercial sale and appears in the
manufacturer's current catalogue. The equipment shall be new and
fabricated from new materials and shall be free from defects in
materials and workmanship
C. The equipment must fit within the allocated space, leaving ample
allowance for maintenance and cleaning, and must leave suitable
space for easy removal of all equipment appurtenances.
D. All units of the same classification shall be identical to the extent
necessary to ensure interchangeability of parts, assemblies,
accessories, and spare parts wherever possible.
E. To accept unit responsibility for the specified capacities, efficiencies,
and performance, the boiler manufacturer shall certify in writing that
the equipment being submitted shall perform as specified. The
boiler manufacturer shall be responsible for guarantying that the
boiler provides the performance as specified herein.
1.04 SUBMITTALS
A. The contractor shall submit, in a timely manner, all submittals for
approval by the engineer. Under no circumstances shall the
contractor install any materials until the engineer has made final
approval on the submittals.
B. The engineer shall review and stamp submittals. Work may proceed
and equipment released for fabrication after contractor receives
returned submittals stamped with "NO EXCEPTIONS TAKEN" or
"MAKE CORRECTIONS NOTED".
C. Shop Drawings - Shop drawings shall be submitted to the engineer
for approval and shall consist of:
1. General assembly drawing of the boiler including product
description, model number, dimensions, clearances, weights,
service sizes, etc.
3. Schematic wiring diagram of boiler control system of the
ladder-type showing all components, interlocks, etc.
Schematic wiring diagram shall clearly identify factory wiring
and field wiring by others.
4. Manufacturer's Warranties: Manufacturer's printed warranties,
as specified hereinafter, shall be submitted prior to final
acceptance by the engineer.
B5-70
03-08
5. Manufacturer's Field Service: Manufacturer's printed field
service procedures and reports, as specified hereinafter, shall
be submitted prior to final acceptance by the engineer. Report
forms shall contain all information as required to do start-up
and testing as specified in the product section.
1.05 SUBSTITUTIONS/MODIFICATIONS
A. The bidder must submit in writing to the engineer any request for a
proposed deviation, omission, modification, or substitution to this
specification for evaluation no later than ten (10) days prior to the
bid date.
B. Technical data, drawings, product samples, and complete data
substantiating compliance of proposed substitution with these
specifications shall accompany a request for any substitution.
C. No materials shall be deemed acceptable if not in strict and full
compliance with these specifications.
D. All bidders must bid solely on the specified materials unless
acceptance by the engineer of a deviation, omission, modification,
or substitution is granted in writing to all bidders prior to the bid
date.
1.06 CERTIFICATIONS
A. Manufacturer's Certification: The boiler manufacturer shall certify
the following:
1. The products and systems furnished are in strict compliance
with the specifications.
2. The boiler, burner, and other associated mechanical and
electrical equipment have been properly coordinated and
integrated to provide a complete and operable boiler package.
3. ASME Certification.
4. ASME CSD-1 Certification.
5. CSA or UL Certification.
1. The products and systems installed are in strict compliance
with the specifications.
C. Boiler Inspectors' Certification: All boiler inspections during
hydrostatic testing shall be performed by an authorized boiler
inspector who is certified by the National Board of Boiler and
Pressure Vessel Inspectors and shall be submitted in writing prior to
final acceptance by the engineer.
D. Operation and Maintenance Manuals: Manufacturer's printed
operation and maintenance manuals shall be submitted prior to
final acceptance by the engineer. Operation and maintenance
manuals shall contain shop drawings, product data, operating
instructions, cleaning procedures, replacement parts list,
maintenance and repair data, complete parts list, etc.
B5-71
03-08
A. The contractor shall be responsible for the timely delivery of the
equipment to the jobsite. The contractor shall be responsible for
unloading and rigging of the equipment. The contractor shall be
responsible for protecting the equipment from the weather, humidity
and temperature conditions, dirt, dust, other contaminants, as well
as jobsite conditions during construction.
B. Equipment shall be unloaded, handled, and stored in accordance
with the manufacturer's handling and storage instructions.
C. Responsibility of making freight claims to be performed by
contractor or owner personnel.
PART 2 PRODUCTS 2.01 MANUFACTURERS
A. Contractor shall furnish and install Cleaver Brooks Model MCF 700-
______-60 natural gas (LP Gas) fired hot water boiler(s) with input
as scheduled on the drawings.
B. Alternate manufacturers complying with plans and specifications
must be submitted and approved by the engineer within 10 days
prior to bid date (Approval of alternate manufacturer does not imply
that performance, including warranties, efficiencies, etc. are waved,
only that alternate manufacters are acceptable).
A. Each unit shall be a Down-fired Firetube type complete with boiler
fittings and automatic controls. The boiler, with all piping and
wiring, shall be factory packaged. Each boiler shall be neatly
finished, thoroughly tested and properly packaged for shipping.
Boiler design and construction shall be in accordance with Section
IV of the ASME Code for hot water heating boilers with a maximum
working pressure of 60 PSIG. The boiler shall be CSA (formerly AGA/
CGA) certified as an indirect or direct vent boiler and comply with
ASME CSD-1 Code requirements.
A. The capacity of each unit shall be indicated on the drawing
schedule.
B. Exit flue gas temperature of the boiler shall not exceed ______F
gross at maximum rated input and a hot water supply temperature
of ______F and return temperature of _____F. The boiler net
input shall not exceed ____________BTU/Hr and the output not less
than _________BTU/Hr with an overall fuel-to-water efficiency of
_______% at high fire and ________% at low fire at above operating
temperatures.
C. Performance Criteria:
B5-72
03-08
Model: CFC____________
Horsepower: _____________HP
Output: _____________MBTU
Gas Input: _____________MBTU
Design Pressure: _____________PSIG
Operating Pressure: _____________PSIG
Heating Surface (minimum): _____________Sq. Ft. Fireside
Burner Turndown Ratio 5:1
Overall Efficiency (With a hot
water supply
_____________% at low fire
_____________% at low fir ___________% at High Fire
Temperature of ______F and
return
Temperature of _____F.
NOX Emission (maximum) 20 PPM (corrected to 3% O2)
CO Emissions (maximum) 10 PPM (corrected to 3% O2)
Electrical: 220V /60H /1P
Fan Motor: _____HP Max
Noise level 70 dBA Max
Available Gas Supply Pressure _____PSIG
Weight
Dry:_____ Flooded:_____
Seismic Zone:_____ Altitude:_____? ASL
Code Requirements: ASME /NATIONAL BOARD
CSD-1
CSA
STATE OF _____
FACTORY MUTUAL (FM)
XL-GAP - Formerly GE-GAP (IRI)
B5-73
03-08
A. Noise Sound Levels: Based on ABMA test code for packaged boilers
measured @ 4 1/2 feet vertically above the bottom of the base and
3'0" horizontally in front of the end of the burner or front surface of
control cabinet. Sound levels dBA on the scale in reference to
0.0002 microbars.
2.04 BOILER DESIGN
A. Boiler shall be a compact, single-pass, vertical down-fired Firetube
type, with stainless steel tubes and tube sheets. The boiler pressure
vessel shall be completely insulated with a minimum of 2" of
insulation and shall be encased in an 18 gauge metal cabinet with
powder coated finish. To prevent installation damage, the casing
shall be packaged separately and shall ship loose for field
installation by the manufacturer's service representative.
B. The tubes shall be 316Ti Stainless Steel and shall be fitted with
Aluminum internal heat transfer fins creating no less than 10 square
feet of fireside heating surface per boiler horsepower.
C. The Vessel shall be mounted on a structural steel stand with exhaust
gasses collected in a polymer drain collection box complete with
drain fitting for draining condensation from the products of
combustion. As an option, a condensate neutralizing box complete
with limestone granules shall be shipped loose for field installation
by contractor. Note: A condensate trap assembly shall be furnished
if a condensate collection tray is not provided due to operating
conditions.
D. The top tubesheet shall be fully accessible by lifting the burner
assembly which shall come complete with lifting hinges and
pneumatic lifters. The boiler shall have a built in hinged platform
allowing the operator to access the tubesheet, burner, ignition
assembly and flame rod without the use of a ladder.
E. The vessel shall be fully insulated with a minimum of 2" of
insulation, guaranteeing external convection and radiation heat
losses to the boiler room from the boiler shall be less than 0.5% of
the rated input.
F. The condensing capability shall allow the boiler to be operated
without the use of a 3-way valve for the boiler supply water
temperature reset. No minimum boiler return water temperature or
secondary pump or minimum flow rate shall be required.
G. Boiler shall be built to seismic zone ___requirements and
manufacturer shall provide seismic calculations showing tie-down
requirements for bolt diameters. Bolts and tie-down shall be by
contractor.
H. Each boiler shall be constructed in accordance with the A.S.M.E.
Section IV Code and bear the "H" stamp and shall be manufactured
within an ISO 9001 Certified facility to ensure high quality
standards.
B5-74
03-08
I. The boiler shall be designed for top rear water outlet and bottom
rear water inlet; the water inlet [return] shall be equipped with
internal baffling. Inlet connection size shall be _______flanged.
Outlet connection size shall be _______flanged. The maximum
pressure drop through the boiler shall not exceed 0.45 psi with a
20-degree differential and less than 0.05 psi with a 60-degree
differential.
J. A threaded air vent connection shall be furnished at the top rear of
the boiler for field piping to an expansion tank or for the addition of
an auto-vent valve when a bladder type expansion tank is utilized.
K. To drain the boiler, a bottom-threaded connection shall be provided
at the front of the boiler and field piped by the installing contractor
with a manual full size shutoff valve to drain.
2.05 BURNER DESIGN
A. General: Forced draft burner mounted in and integral with the boiler
hinged top door so when the door is opened the burner head,
furnace, tubesheet, and tubes are exposed. The burner door shall
utilize easy removable threaded handles, and the burner shall swing
upward on hydraulic piston arms, one on each side to provide open
support of the burner assembly.
B. A drop down hinged service platform shall be furnished to provide
service personnel an easy means of accessing the burner and
controls for service and maintenance. When out of use, this
platform shall fold up beneath the front service boiler panel.
C. The burner shall be of the Unitized Venturi, Gas Valve, Blower, and
burner head design. This pre-mix design shall utilize a variable
speed fan connected to a venturi to simultaneously modulate fuel
and air for a minimum a 5:1 turndown ratio. The venturi design
shall also act as a method for compensating for changes in
barometric pressure, temperature and humidity so the excess air
levels are not adversely affected by changes in atmospheric
conditions. External linkages, damper motor drives and single
speed fans shall not be acceptable.
D. Burner head shall be constructed of a Fecralloy-metal fiber for solid
body radiation of the burner flame. Combustion shall take place on
the surface of the burner mantle, which shall be constructed of a
woven fecralloy material creating a 360 degree low temperature
radiant flame.
E. Emissions: The boiler(s) burner shall be guaranteed to limit NOx
emissions to 20 PPM or less, as certified by an independent testing
lab. NOx emissions shall be at full operating conditions. Proof of
such certification shall be made available to the engineer and
purchaser. External flue gas recirculation shall not be accepted for
emission control.
F. Gas Train - As a minimum, the gas train shall meet the
requirements of CSA and ASME CSD-1 and shall include:
1. Low Gas Pressure Interlock, manual reset.
2. High Gas Pressure Interlock, manual reset.
3. Upstream and downstream manual test cocks.
B5-75
03-08
4. Ball Type manual shutoff valve upstream of the main gas valve.
5. Unibody double safety gas valve assembly.
6. Gas Pressure Regulator
7. Union connection to permit burner servicing.
G. Combustion Air Proving Switch shall be furnished to ensure
sufficient combustion airflow is present for burner firing.
H. To ensure that proper draft is not blocked in the stack, the burner
shall include a High Air Pressure Switch sensing the outlet pressure
connection relative to stack back draft.
2.06 BOILER TRIM
A. Safety valve(s) shall be ASME Section IV approved side outlet type
mounted on the boiler water outlet. Size shall be in accordance with
code requirements and set to open at 60 psig.
B. Temperature and pressure gauge shall be mounted on the water
outlet.
C. Solid State Low water cut-off probe with manual reset and test
switch.
D. Outlet water supply sensing probe for operating water limit setpoint.
E. Return water-sensing probe for operating water limit setpoint.
A. The Boiler shall include a Computerized Boiler Burner control which
shall be an integrated, solid state digital micro-processing
modulating device, complete with sequence indication, fault reset,
mode selection, and parameter set-point switches. It shall be
mounted at the front of the boiler panel for easy access and viewing.
B. Controller shall provide for both flame safeguard and boiler control
and shall perform the following functions:
1. Burner sequencing with safe start check, pre-purge, Electronic
direct spark ignition, and post purge. Flame rod to prove
combustion.
2. Flame Supervision - the control shall provide pre-purge and
post-purge and shall maintain a running history of operating
hours, number of cycles, and the most recent faults. The
control shall be connected to a touchscreen display module
that will retrieve this information.
3. Safety Shutdown with display of error.
4. Modulating control of the variable speed fan for fuel/air input
relative to load requirements.
5. High Limit temperature control.
6. Gas pressure supervision, high and low.
7. Combustion Air Proving Supervision.
8. High Air Pressure (back draft too high) Supervision.
9. Display of supply temperature and set-point temperature shall
be accessible via touchscreen. Output shall be continuous PID
via 4 -20 mA current.
B5-76
03-08
10. Controller shall have an option for communication device to a
laptop computer interface service and troubleshooting.
11. Include the programming of system circulating pump and
provide the programming of 2 heating loops.
C. All parameter input control set-points shall be factory downloaded
with jobsite conditions programmed at the time of initial jobsite
operation.
D. All controls to be panel mounted and so located on the boiler as to
provide ease of servicing the boiler without disturbing the controls
and also located to prevent possible damage by water according to
CSA requirements.
E. Electrical power supply shall be 220 volts, 60 Hertz, single phase
for the fan motor and 120 volts, 60 Hertz, single phase for the
control circuit.
F. When multiple boilers are utilized for a single installation, the boiler
manufacturer or its authorized representative shall provide a UL
listed sequencing control for up to 4 boilers. The control shall
include automatic rotation of lead boiler, and adjustable outdoor
reset schedule, 4-20 mA output to the boilers, digital display of
settings, and interface capabilities to an Energy Management
System. The control shall be provided with a NEMA 1 enclosure.
2.08 BOILER FLUE VENTING
A. The Boiler shall be CSA certified as an indirect or direct vent boiler.
Venting shall be accomplished with a catagory IV vent piping
installed in accordance with applicable national and local codes.
B. For direct venting, the boiler shall have the combustion air intake
supply ducted with PVC pipe from the outside. Vibration isolation
components are not required.
2.09 MANUFACTURER'S FIELD SERVICES
A. General: The boiler supplier's factory authorized service
organization shall be responsible for performance of inspections,
start up and testing of the package boiler, and accessory equipment
and materials furnished under this Section. A detailed written
record of the start up performance, including burner setting data
over the entire load range shall be furnished to the engineer before
final acceptance. All labor, equipment, and test apparatus shall be
furnished by the authorized service organization. All equipment
defects discovered by the tests shall be rectified either by the
service organization or boiler manufacturer.
B. Equipment inspection: Boiler representative to provide ___hours of
jobsite assistance to inspect boilers and other equipment upon
arrival, verifying completeness of equipment supplied and potential
damages. All shipped loose components, such as casing, to be
mounted on boiler by boiler provider after contractor has set boiler
in building.
C. Pre start-up walk through: Boiler representative shall spend ___
hours at jobsite reviewing installation with mechanical contractor to
be conducted approximately 1 week prior to startup.
B5-77
03-08
D. Start-up shall be conducted by experienced and factory authorized
technician in the regular employment of the authorized service
organization, and shall include:
1. Demonstrate that boiler, burner, controls, and accessories
comply with requirements of this Section as proposed by the
boiler and accessories supplier. Pre-test all items prior to
scheduling the final testing that will be witnessed by the test
engineer.
2. Readings at different firing rates (20, 50, 75 and 100%) of
load for the modulating burner shall be taken with a written
report of the tests submitted to the engineer. The reports shall
include readings for each firing rate tested and include stack
temperatures, O2, CO, NOx, and overall boiler efficiency.
3. Auxiliary Equipment and Accessories: Observe and check all
valves, draft fans, electric motors and other accessories and
appurtenant equipment during the operational and capacity
tests for leakage, malfunctioning, defects, and non compliance
with referenced standards or overloading as applicable.
b. Set up fuel train and combustion air system
c. Set up operating set points
d. Check all safeties, including Flame safeguard, LWCO,
Airflow, Fuel pressures, High limits.
e. Set up and verify efficiencies at 20%, 50%, 75%, and
100%
f. Set up and verify burner turndown.
E. Training to include all safety procedures, maintenance procedures,
control operations, and diagnostic procedures. Training to be
provided in a single ____hour continuous session to accommodate
operator's availability on site.
A. Provide two (2) Operating and Maintenance manuals including cut-
away views of boiler and burner, schematics including fuel trains,
general instructions for maintenance and inspections, complete
spare parts lists and trouble shooting procedures.
B. A wiring diagram corresponding to the boiler shall be affixed to the
boiler near the electrical panel.
2.11 WARRANTY DATA
A. The pressure vessel shall be guaranteed against thermal shock for
20 years when utilized in a closed loop hydronic heating system
with a temperature differential of 170 F or less. The boiler pressure
vessel shall be guaranteed accordingly without a minimum flow rate
or return water temperature requirement. The boiler shall not
require the use of flow switches or other devices to ensure minimum
flow.
B5-78
03-08
B. The pressure vessel, tubes and tube sheets (heat exchanger) shall
be guaranteed against flue gas corrosion and materials/
workmanship for a period of 10 years. The condensate collection
box shall be guaranteed for 20 years.
C. All parts not covered by the above warranties shall carry a 1 year
warranty from startup, or 18 months from shipment, whichever
occurs first. This shall include all electrical components and burner
components.
PART 3 EXECUTION 3.01 GENERAL
Installation shall be provided by the contractor in accordance with the requirements
of the codes specified hereinbefore. All of the contractor's work shall be performed
by experienced personnel previously engaged in boiler plant construction and shall
be under the supervision of a qualified installation supervisor.
3.02 INSTALLATION
A. Install equipment in strict compliance with manufacturer's
B. Install equipment in strict compliance with state and local codes
and applicable NFPA standards.
C. Maintain manufacturer's recommended clearances around sides and
over top of equipment.
D. Install components that were removed from equipment for shipping
purposes.
E. Install components that were furnished loose with equipment for
field installation.
3.03 FIELD TESTING
A. The manufacturer's representative shall test all boiler and burner
interlocks, actuators, valves, controllers, gauges, thermometers,
pilot lights, switches, etc. Any malfunctioning component shall be
replaced.
B. All adjustments to boiler, burner, and boiler control system shall be
performed by the manufacturer's representative.
A. The manufacturer's representative shall provide start-up and
instruction of each new boiler, including burner and boiler control
system as specified herein. Start-up and instruction shall cover all
components assembled and furnished by the manufacturer whether
or not of his own manufacture.
B6-1
03/08
Section B6
CLEARFIRE MODEL CFH BOILERS
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6-5
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6-9
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6-16
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6-18
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6-33
LIST OF FIGURES
Figure B6-1 Tube Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6-3
Figure B6-2 AluFerTubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6-3
Figure B6-3 Premix Burner Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6-4
Figure B6-4 Burner maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6-4
Figure B6-5 ClearFire-H Steam Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6-5
Figure B6-6 CB90 Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6-7
Figure B6-7 ClearFire-H Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6-7
Figure B6-8 Burner Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6-8
B6-2
Clearfire-H Boilers Section B6
03/08
Figure B6-9 ClearFire-H burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-8
Figure B6-10 Gas Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-8
Figure B6-11 ClearFire-H electrical panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-9
Figure B6-12 Model CFH Steam Boiler Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-10
Figure B6-13 Boiler Room Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-14
Figure B6-14 Model CFH Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-15
Figure B6-15 Model CFH Lifting Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-15
Figure B6-16 Inside Air - Two Opening Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-20
Figure B6-17 Two Opening Ducted Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-21
Figure B6-18 One Opening Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-22
Figure B6-19 Engineered Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-22
Figure B6-20 Direct Vent Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-24
Figure B6-21 Air Inlet Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-25
Figure B6-22 Typical gas header piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-30
LIST OF TABLES
Table B6-1 Model CFH Steam Boiler Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-11
Table B6-2 Model CFH Steam Boiler Metric Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-12
Table B6-3 Model CFH Steam Boiler Connection Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-13
Table B6-4 Model CFH Steam Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-13
Table B6-5 Model CFH Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-13
Table B6-6 Model CFH Gas Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-14
Table B6-7 Model CFH Steam Boiler Safety Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . B6-14
Table B6-8 Boiler Room Width (Typical Layout) Model CFH . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-14
Table B6-9 Model CFH Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-15
Table B6-10 Model CFH Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-15
Table B6-11 Model CFH Boilers: Predicted Fuel-to-Steam Efficiencies-Natural Gas . . . . . . . . . . . . B6-16
Table B6-12 Model CFH Radiation and Convection Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-17
Table B6-13 Model CFH Boilers: Natural Gas, Estimated Emission Levels . . . . . . . . . . . . . . . . . . B6-17
Table B6-14 Model CFH Boilers: Predicted sound levels at high fire . . . . . . . . . . . . . . . . . . . . . . B6-17
Table B6-15 Model CFH Boiler Feedwater Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-18
Table B6-16 Model CFH Boilers Required Water Quality Parameters . . . . . . . . . . . . . . . . . . . . . B6-18
Table B6-17 Model CFH Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-19
Table B6-18 Model CFH Minimum Gas Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . B6-25
Tables B6-19 B6-23 Gas line capacity - Schedule 40 metallic pipe . . . . . . . . . . . . . . . . . . . . B6-27
Tables B6-24 B6-31 Pipe sizing for multiple unit manifolds . . . . . . . . . . . . . . . . . . . . . . . . . B6-32
Section B6 Clearfire-H Boilers
B6-3
03/08
General The ClearFire Model CFH is a single pass, horizontally fired durable firetube steam boiler.
Extended heating surface tubes provide a very high level of performance in a compact
package. An integral premix burner is provided for natural gas operation. As standard, the
Model CFH burner provides low emissions of <20 PPM NOx. Propane fuel is also available.
Advanced Technology Heat is transferred through 3 OD carbon steel tubes with patented AluFerextended heating
surfaces. The AluFertube design provides for optimum heat transfer and eliminates laminar
gas flow during minimum firing, providing optimized efficiency throughout the firing range
(see Figure B6-1 and Figure B6-2).
High Efficiency With the AluFerextended heating surface tubes, the Model CFH steam boiler will provide
fuel-to-steam efficiency of up to 83% operating at 125 psig or 85% at 10 psig (85%
efficiency for high-pressure steam is available with an optional flue gas economizer package).
Quality Construction ISO 9001-2001 certification ensures the highest manufacturing standards.
ASME code construction ensures high quality design, safety, and reliability. Units are third-
party inspected and are stamped to assure compliance.
Certification Each unit is tested and certified in accordance with UL/cUL standards and the UL/cUL label is
affixed attesting to equipment meeting the latest UL requirements for packaged steam boilers.
Premix Technology The ClearFire CFH burner utilizes Premix technology to mix both gas fuel and combustion air
prior to entering the burner canister, with fuel flow governed by the air flow during firing
transitions. Combined with a variable speed fan, this technology provides very low emission
levels, exceptionally safe operation, and nearly 100% combustion efficiency. An inlet air filter
is provided as standard to prevent airborne dust from entering the combustion canister.
Full Modulation The variable speed fan modulates to provide only the amount of heat required to the boiler.
Full modulation reduces on/off cycling and provides excellent load tracking with reduced
operating costs. The burner does not require mechanical linkage connections between the fuel
input valve and air control. Instead, the microprocessor control adjusts the fan speed in
accordance with system demand, determining fuel input without mechanical device
Figure B6-2. Tube Cross Section
Figure B6-1. AluFer Tubes
B6-4
03/08
positioning. This method of controlling the fuel-air ratio eliminates slippage due to linkages,
minimizes burner maintenance, and provides control repeatability. See Figure B6-3.
Ease of Maintenance The burner is hinged and swings out to allow inspection or service of the burner canister,
tubes, and tube sheets (see Figure B6-4). A union connection provides easy disconnect from
the fuel train. All burner components are easily accessed for inspection and maintenance.
Figure B6-4. Burner maintenance
B6-5
03/08
Designed for commercial
steam applications
Whether for heating or for steam process, the CFH packaged boiler is designed for 15 psig or
150 psig MAWP (Maximum Allowable Working Pressure) and is constructed of durable ASTM
grade steel materials. Figure B6-5 shows the component and connection locations.
Figure B6-5. ClearFire-H Steam Boiler
PRODUCT OFFERING
Information in this section applies to steam boiler sizes ranging from 10 horsepower
through 60 horsepower for operation on natural gas or LP gas only. Fuel oil operation
is not available for the model CFH. Standard installation is for indoor use with an
optional engineering design for outdoor applications.
The complete package has been tested and certified in accordance with UL/cUL.
Package is approved and listed and bears the appropriate UL/cUL package boiler
label.
Dimensions, ratings, and product information may change due to market
requirements or product enhancements. The information contained herein is a guide
for general purposes only.
Stack Outlet
Feedwater
Chem. Feed
(Optional Direct Vent)
Steam Outlet
Blowdown
Gas Train
Combustion Air
Safety Relief Valve
Low Water Cut-Off
Aux. Low Water Cut-Off
Operating Limit Control
High Limit Control
Modulating Controller
Flame Safety Display
(optional)
B6-6
03/08
Standard Equipment The equipment listed below applies to the standard boiler package offering. Optional
items are available to meet specific projects when required.
1. The Boiler
A. Each boiler (pressure vessel) size is designed and built for a Maximum Allowable
Working Pressure (MAWP) of 15 psig in accordance with ASME Section IV
(bearing the H stamp) or 150 psig in accordance with ASME Section I (bearing
the S stamp).
B.The vessel is insulated with a 2 thick blanket and mounted on a base frame. A
powder-coated 18 gauge steel casing covers the insulation.
C. Vessel connections are furnished for:
Steam outlet
Bottom drain or blowoff
Surface blowoff
Chemical feed
Feedwater makeup
High water level overflow
D.For waterside inspection, handholes are provided.
E. Two lifting lugs are provided on the top of the boiler for rigging purposes.
F. The combustion exhaust is located at the top rear.
2. Boiler trim and controls
Water column with primary low water cutoff and pump control (probe type).
Water column gauge glass and gauge glass drain valve.
Water column drain valve.
Auxiliary low water cutoff (probe type), manual reset.
Operating limit pressure control, auto reset.
Excess steam pressure control, manual reset.
Pressure transmitter for burner on/off and modulation.
Steam pressure gauge.
ASME safety relief valve.
3. Burner/boiler control and flame safeguard
The Model CFH incorporates the following primary controllers:
A. RWF40 modulating pressure controller, located externally on the right side of the
control panel. Utilizing a steam pressure transmitter, PID control drives the
variable speed forced draft blower for optimum firing rate. Controller display
shows the setpoint and actual value and can be configured for various options
such as dual set point, remote set point and outdoor reset. Optional Modbus
communications version is available.
B.CB90 Flame Safety Control for burner sequencing and flame monitoring. Safe
start check, pre-purge, ignition, release to modulation, safety shutdown, and
B6-7
03/08
post purge are controlled by the CB90. Optional Modbus communications
available with ED510 display.
4. Forced draft burner
A. The burner is a "Pre-mix" design consisting of a unitized venturi, single body dual
safety gas valve, blower, and burner head (canister).
B.Full modulation is accomplished with a variable speed fan for up to 5:1
turndown ratio on 40 horsepower boilers and larger (4:1 turndown on 30
horsepower and less).
C. For near flameless combustion, the burner utilizes a Fecralloy metal fiber head
(canister).
D.Noise level at maximum firing is less than 70 dBA regardless of boiler size.
E. When boiler is operating on natural gas, NOx emissions will be less than 20
PPM regardless of boiler size; certified for California and Texas low emissions
requirements.
F. As an option, the burner can utilize direct vent combustion air.
G.Ignition of the main flame is via direct spark, utilizing high voltage electrodes
H.To ensure adequate combustion air is present prior to ignition, and to ensure the
fan is operating, a combustion air proving switch is provided.
I. For ease of inspection and maintenance, the burner is hinged for easy swing
away from the boiler permitting full inspection of the burner components, front
tube sheet and furnace.
J. A flame observation port is located in the burner door.
Figure B6-7. CB90 Unit
Figure B6-6. ClearFire-H Controls
Modulating
Controller
Flame Safety
display (optional)
B6-8
03/08
5. Burner Gas Train
The standard gas train is equipped in accordance with UL 795, ASME, CSD-1, GE-
GAP (formerly IRI), and FM. Each burner gas train includes:
Low gas pressure interlock, manual reset
High gas pressure interlock, manual reset
ASME CSD-1 test cocks
Downstream manual ball type shutoff cock
Single body dual safety shutoff gas valve
Gas pressure regulator for maximum of 1 psig inlet pressure
Figure B6-10. Gas Train
Figure B6-9. Burner Components
Figure B6-8. ClearFire-H burner
B6-9
03/08
6. Boiler control panel
A standard NEMA 1A type panel enclosure is located at the front top of the boiler.
This panel encloses the Flame Safeguard control, water level circuit boards, fan
speed interface board, terminals, burner on/off switch, and the RWF burner operating
control. 115/1/60 terminals are provided for contractor connections.
Figure B6-11. ClearFire-H electrical panel
summary, here are some of the options that can be provided with the boiler package:
Bottom blowdown valves, shipped loose or mounted and piped
Surface blowoff valve, shipped loose or mounted and piped
Feedwater stop and check valves, shipped loose or mounted and piped
Surface blowoff skimmer tube
Steam stop valve
ASME hydro test of boiler piping
Integral economizer package (150 psig boiler only) complete with vertical
feedwater tank and make-up pump
Modbus communications
Alarm light package
Direct vent combustion air provision
For layout purposes, the overall dimensions for the Model CFH are shown in Figure
B6-12 and Tables B6-1 (U.S. dimensions) and B6-2 (metric). Connection sizes are
given in Table B6-3 and ratings of each boiler size are noted in Table B6-4. Additional
information is shown in the following tables and illustrations:
Table B6-5 Recommended steam nozzle sizes
Table B6-6 Minimum required gas pressure
Table B6-7 Safety valve outlet sizes
Table B6-8, Figure B6-13 Boiler room width
Table B6-9, Figure B6-14 Lifting lug locations
Table B6-10, Figure B6-15 Boiler mounting piers
Incoming electrical
connections
Low water and pump controls
CB90
Flame
Safety
Control
Power and control wiring
B6-10
03/08
Figure B6-12. Model CFH Steam Boiler Dimensions
(4)1/2 Holes
MM/NN
LL
CC
F
JJ
KK
D
GG
L
X
E B
AA
DD
1
Z
J H
C
A
G
EE BB
V
HH
Y
W
AA
1
DD
4
M
N P
T
Q
R
S
FF
K
B6-11
03/08
Table B6-1. Model CFH Steam Boiler Dimensions
Boiler Horsepower
Dimension 10 15 20 25 30 40 50 60
LENGTHS inches
Overall A 86 86 87 87 91.5 104 110 110
Shell B 54 54 56 56 58 66 68 68
Base Channel C 56 56 58 58 60 68 70 70
Front Lagging Extension D 18 18 18 18 18 23.5 23.5 23.5
Rear Lagging Extension E 14 14 13 13 15.5 14.5 18.5 18.5
Front Tubesheet to Steam Outlet F 30 30 38 38 34 40 38 38
Front Tubesheet to Stack Outlet G 61 61 62.5 62.5 66 74 77.5 77.5
Base End to Bolt Hole H 4 4 4 4 4 4 4 4
Hole to Hole J 48 48 50 50 52 60 62 62
Rear Base to Gas Train Inlet K 34.25 34.25 35.5 35.5 34 44 43.25 43.25
Front Tubesheet to Combustion Air Inlet L 9 9 9 9 10 13 14 14
WIDTHS inches
Overall M 43.5 43.5 47 47 56 56 60 60
Center to Lagging N 17.5 17.5 19.5 19.5 23.5 23.5 26.5 26.5
Center to Water Column P 26 26 27.5 27.5 32.5 32.5 33.5 33.5
Base, Inside of Channel Q 30.5 30.5 34 34 42 42 48 48
Base Bolt Hole to Bolt Hole R 33 33 36.5 36.5 44.5 44.5 50.5 50.5
Base, Outside of Channel S 35 35 38.5 38.5 46.5 46.5 52.5 52.5
Boiler I.D. T 30.5 30.5 34 34 42 42 48 48
HEIGHTS inches
Overall V 54 54 57 57 65.5 65.5 69 69
Base to 150# Steam Outlet W 47 47 50 50 58 58.5 64.5 64.5
Base to 15# Steam Outlet X 47.5 47.5 50.5 50.5 58.5 59 65 65
Base to Stack Outlet Y 49 49 52 52 60.5 60.5 66.5 66.5
Base to Combustion Air Inlet Z 19 19 19 19 22 19.5 21.5 21.5
CLEARANCES inches
Front Door Swing
A
JJ 31 31 32 32 39 39 46 46
Tube Removal, Rear LL 41 41 41 41 41 49 49 49
MINIMUM BOILER ROOM LENGTH (INCHES) ALLOWING FOR DOOR SWING AND TUBE REMOVAL FROM:
Rear of Boiler MM 126 126 129 129 138 154 163 163
Front of Boiler NN 123 123 125 125 136.5 143.5 156.5 156.5
WEIGHTS - LBS
Water Weight (150# Normal Level) 1010 1010 1250 1250 1850 2150 2700 2700
Water Weight (15# Normal Level) 920 920 1150 1150 1710 1980 2510 2510
Approx. Dry Weight (150#) 2020 2020 2410 2410 3160 3700 5600 5600
Approx. Dry Weight (15#) 2000 2000 2330 2330 2870 3400 5400 5400
A. Front Door Swing clearance sufficient for front tube removal.
B6-12
03/08
Table B6-2. Model CFH Steam Boiler Metric Dimensions
Boiler Horsepower
Dimension 10 15 20 25 30 40 50 60
LENGTHS mm
Overall A 2184.4 2184.4 2209.8 2209.8 2324.1 2641.6 2794 2794
Shell B 1371.6 1371.6 1422.4 1422.4 1473.2 1676.4 1727.2 1727.2
Base Channel C 1422.4 1422.4 1473.2 1473.2 1524 1727.2 1778 1778
Front Lagging Extension D 457.2 457.2 457.2 457.2 457.2 596.9 596.9 596.9
Rear Lagging Extension E 355.6 355.6 330.2 330.2 393.7 368.3 469.9 469.9
Front Tubesheet to Steam Outlet F 762 762 965.2 965.2 863.6 1016 965.2 965.2
Front Tubesheet to Stack Outlet G 1549.4 1549.4 1587.5 1587.5 1676.4 1879.6 1968.5 1968.5
Base End to Bolt Hole H 101.6 101.6 101.6 101.6 101.6 101.6 101.6 101.6
Hole to Hole J 1219.2 1219.2 1270 1270 1320.8 1524 1574.8 1574.8
Rear Base to Gas Train Inlet K 869.95 869.95 901.7 901.7 863.6 1117.6 1098.55 1098.55
Front Tubesheet to Combustion Air Inlet L 228.6 228.6 228.6 228.6 254 330.2 355.6 355.6
WIDTHS mm
Overall M 1104.9 1104.9 1193.8 1193.8 1422.4 1422.4 1524 1524
Center to Lagging N 444.5 444.5 495.3 495.3 596.9 596.9 673.1 673.1
Center to Water Column P 660.4 660.4 698.5 698.5 825.5 825.5 850.9 850.9
Base, Inside of Channel Q 774.7 774.7 863.6 863.6 1066.8 1066.8 1219.2 1219.2
Base Bolt Hole to Bolt Hole R 838.2 838.2 927.1 927.1 1130.3 1130.3 1282.7 1282.7
Base, Outside of Channel S 889 889 977.9 977.9 1181.1 1181.1 1333.5 1333.5
Boiler I.D. T 774.7 774.7 863.6 863.6 1066.8 1066.8 1219.2 1219.2
HEIGHTS mm
Overall V 1371.6 1371.6 1447.8 1447.8 1663.7 1663.7 1752.6 1752.6
Base to 150# Steam Outlet W 1193.8 1193.8 1270 1270 1473.2 1485.9 1638.3 1638.3
Base to 15# Steam Outlet X 1206.5 1206.5 1282.7 1282.7 1485.9 1498.6 1651 1651
Base to Stack Outlet Y 1244.6 1244.6 1320.8 1320.8 1536.7 1536.7 1689.1 1689.1
Base to Combustion Air Inlet Z 482.6 482.6 482.6 482.6 558.8 495.3 546.1 546.1
CLEARANCES mm
Front Door Swing
A
JJ 787.4 787.4 812.8 812.8 990.6 990.6 1168.4 1168.4
Tube Removal, Rear LL 1041.4 1041.4 1041.4 1041.4 1041.4 1244.6 1244.6 1244.6
MINIMUM BOILER ROOM LENGTH (mm) ALLOWING FOR DOOR SWING AND TUBE REMOVAL FROM:
Rear of Boiler MM 3200.4 3200.4 3276.6 3276.6 3505.2 3911.6 4140.2 4140.2
Front of Boiler NN 3124.2 3124.2 3175 3175 3467.1 3644.9 3975.1 3975.1
WEIGHTS - kg
Water Weight (150# Normal Level) 458.13 458.13 566.99 566.99 839.15 975.22 1224.7 1224.7
Water Weight (15# Normal Level) 417.31 417.31 521.63 521.63 775.64 898.11 1138.5 1138.5
Approx. Dry Weight (150#) 916.26 916.26 1093.2 1093.2 1433.4 1678.3 2540.1 2540.1
Approx. Dry Weight (15#) 907.19 907.19 1056.9 1056.9 1301.8 1542.2 2449.4 2449.4
A. Front Door Swing clearance sufficient for front tube removal.
B6-13
03/08
Table B6-3. Model CFH Steam Boiler Connection Sizes
Table B6-4. Model CFH Steam Ratings
Table B6-5. Model CFH Recommended Steam Nozzle Size
BOILER CONNECTIONS inches
Feedwater, Both Sides AA 1 1 1 1 1 1 1-1/4 1-1/4
Steam Outlet (150# Only) BB 1-1/2 1-1/2 2 2 2 2 3 3
Steam Outlet (15# Only)
A
CC 4 4 4 4 4 6 6 6
Drain /Blowdown (Front) DD 1 1 1 1 1 1 1-1/4 1-1/4
Surface Blowoff EE 1 1 1 1 1 1 1 1
Stack O.D. FF 6 6 6 6 8 8 10 10
Combustion Air Inlet GG 4 4 4 4 6 6 6 6
Chemical Feed HH 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2
Gas Train 1 1 1 1 1-1/4 1-1/4 1-1/2 1-1/2
A. Connections are 150# F.F. Flanged
OPERATING PRESSURE
BOILER HP
PSIG
10 15 20 25 30 40 50 60
15 4 4 4 4 4 6 6 6
30 2 2 2 2.5 2.5 3 4 4
40 2 2 2 2.5 2.5 3 3 4
50 1.5 1.5 2 2 2.5 2.5 3 3
75 1.5 1.5 2 2 2 2.5 3 3
100 1.5 1.5 1.5 2 2 2 3 3
125 1.5 1.5 1.5 2 2 2 3 3
NOTES:
Boiler H.P. 10 15 20 25 30 40 50 60
Rated Capacity - Steam (lbs. steam/hr
from & at 212
o
F.)
345 518 690 863 1,035 1,380 1,725 2,070
Rated Steam Capacity [kg/hr from and at
100 C]
156.5 234.5 313 391 469.5 626 782 939
Output Btu/hr 334,750 502,125 669,500 836,875 1,004,250 1,339,000 1,673,750 2,008,500
Output Kcal/Hr 84,168 126,535 168,714 210,892 253,071 337428 421,785 506,142
Output KW 97 145 194 243 291 388 485 582
Natural Gas [ft
3
/hr] - 15#Steam
A
394 591 788 985 1,181 1,575 1,969 2,363
Natural Gas [m
3
/hr] - 15#Steam
A
11.1 16.7 22.3 27.9 33.4 44.6 55.7 66.9
Natural Gas [ft
3
/hr] - 150#Steam
B
408 612 816 1,020 1,225 1,633 2,041 2,449
Natural Gas [m
3
/hr] - 150#Steam
B
11.5 17.3 23.1 28.9 34.7 46.2 57.8 69.3
Propane Gas [ft
3
/hr] - 15#Steam
A
157 236 315 394 473 630 788 945
Propane Gas [m
3
/hr] - 15#Steam
A
4.4 6.7 8.9 11.1 13.4 17.8 22.3 26.8
Propane Gas [ft
3
/hr] - 150#Steam
B
163 245 327 408 490 653 817 980
Propane Gas [m
3
/hr] - 150#Steam
B
4.6 6.9 9.3 11.5 13.9 18.5 23.1 27.8
Blower Motor Size (Watts)
C,D
255 335 335 335 335 750 1,200 1,200
Blower Motor 3.3 4 4 4 4 8.5 13.5 13.5
Blower Motor Fuse 4.5 6 6 6 6 12 15 15
Control Circuit 1.7 1.7 1.7 1.9 1.9 1.9 2.4 2.4
Notes:
D. Fan motor is variable speed, DC Brushless Type.
A. Input calculated at nominal 85% efficiency with Nat. Gas @ 1000 Btu/ft
3
and Propane @ 2500 Btu/ft
3
.
B. Input calculated at nominal 82% efficiency with Nat. Gas @ 1000 Btu/ft
3
and Propane @ 2500 Btu/ft
3
.
C. For altitudes above 1000 Feet, contact your local Cleaver-Brooks authorized representative for capacity rating.
Approximate Fuel Consumption At Rated Capacity [ Input]
Power Requirements - 60 Hz (Single Phase, 115 VAC)
Minimum Ampacity
Ratings
B6-14
03/08
Table B6-6. Model CFH Gas Pressure Requirements
BOILER INLET PIPE HONEYWELL PRESSURE REQUIRED
HP SIZE VALVE SIZE MIN MAX
(Inches) (Inches) ("WC) ("WC)
10 1 0.5 7.2 28
15 1 0.75 7.3 28
20 1 0.75 7.5 28
25 1 1 7.7 28
30 1.25 1 8.8 28
40 1.25 1.25 11.0 28
50 1.5 1.25 9.5 28
60 1.5 1.25 10.0 28
Note: For altitudes above 700 feet, contact your local Cleaver-Brooks
representative.
Table B6-7. Model CFH Steam Boiler Safety Valve Outlet Size
VALVE SETTING
BOILER HP
NO. OF VALVES
REQ'D
OUTLET SIZE
(IN.)
NO. OF VALVES
REQ'D
OUTLET SIZE
(IN.)
10 1 1-1/2 1 3/4
15 1 1-1/2 1 3/4
20 1 1-1/2 1 3/4
25 1 2 1 1
30 1 2 1 1
40 1 2-1/2 1 1
50 1 2-1/2 1 1-1/4
60 1 2 1 1-1/4
NOTE: Valve manufacturers are Kunkle, Consolidated or Conbraco, depending on
availability.
NOTES:
1. Recommended minimum distance between boiler and
wall. Dimension A allows for a clear 36 inch 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
36 inches. If space permits, this aisle should be widened.
Figure B6-13. Boiler Room Width
Table B6-8. Boiler Room Width (Typical Layout)
Model CFH
BOILER HP 10-15 20-25 30-40 50-60
DIM. "A"
1
62 64 69 70
DIM. "B"
2
80 83 92 96
A B
B6-15
03/08
Figure B6-15. Model CFH Mounting Piers
Table B6-9. Model CFH Boilers
Lifting Lug Location
BOILER
HP
A B C D
10 44.0 4 45.5 6
15 44.0 4 45.5 6
20 47.5 4 48.5 6
25 47.5 4 48.5 6
30 55.5 5 48.0 6
40 55.5 5 56.0 6
50 61.5 5 57.5 6
60 61.5 5 57.5 6
NOTE: A, B, and C dimensions may vary
by 1 inch.
Table B6-10. Model CFH Boiler Mounting Piers
HP A B C D E F G
10-15 4 6 26.75 38.75 2.25 30.5 56
20-25 4 6 30.25 42.25 2.25 34 58
30 4 6 38.25 50.25 2.25 42 60
40 4 6 38.25 50.25 2.25 42 68
50-60 4 6 44.25 56.25 2.25 48 70
NOTE:
4"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 B6-14. Model CFH Lifting Lugs
B6-16
03/08
PERFORMANCE DATA
Table B6-11 shows predicted fuel-to-steam efficiencies for the Model CFH.
Cleaver-Brooks offers an industry leading fuel-to-steam efficiency guarantee for Model
CFH boilers. The guarantee is based on the numbers shown in the tables and on the
conditions listed below (the efficiency percent number is only meaningful if the
specific conditions of the efficiency calculations are clearly stated in the
specification).
Cleaver-Brooks will guarantee that, at the time of initial start-up, the boiler will
achieve fuel-to-steam efficiency as shown for 25%, 50%, 75% and 100% firing. If
the boiler fails to achieve the corresponding efficiency guarantee as published,
Cleaver-Brooks will rebate, to the final owner, five thousand dollars ($5,000.00) for
every full efficiency point (1.0%) that the actual efficiency is below the guaranteed
level. The specified boiler efficiency is based on the following conditions:
Natural Gas
Carbon, % by weight = 69.98
Hydrogen, % by weight = 22.31
Sulfur, % by weight = 0.0
Heating Value, Btu/lb = 21,830
Efficiencies are based on ambient air temperature of 80
o
F (27 C), relative
humidity of 30%, and 15% excess air in the exhaust gas stream.
Efficiencies are based on the manufacturer's published radiation and convection
losses; see Table B6-12.
Nominal feedwater temperature of 190
0
F (88 C) or greater.
Table B6-11. Model CFH Boilers: Predicted Fuel-to-Steam Efficiencies-Natural Gas
BHP
% OF LOAD % OF LOAD
25% 50% 75% 100% 25% 50% 75% 100%
10 84.8 85.5 85.4 85.2 82.0 82.8 82.9 83.0
15 84.6 85.0 84.7 84.3 81.8 82.3 82.2 82.1
20 84.7 85.2 85.0 84.7 81.9 82.5 82.5 82.4
25 84.6 85.0 84.6 84.2 81.8 82.3 82.2 82.0
30 84.8 85.3 85.2 85.0 82.0 82.6 82.7 82.7
40 84.7 85.3 85.1 84.8 81.9 82.6 82.6 82.6
50 84.8 85.5 85.4 85.2 82.0 82.8 82.9 83.0
60 84.8 85.3 85.2 84.9 82.0 82.6 82.7 82.6
B6-17
03/08
Table B6-12. Model CFH Radiation and Convection Losses
The emission data included in Table B6-13 consists of typical controlled emission
levels of the Model CFH boiler. Because of the premix burner technology, the standard
burner provided with the CFH package provides low emissions as standard without
the need for external or special devices.
Table B6-14 shows predicted sound levels at high fire.
BHP
10# Operating Pressure 125# Operating Pressure
25% 50% 75% 100% 25% 50% 75% 100%
10 1.6 0.7 0.5 0.4 1.9 1.0 0.7 0.5
15 1.6 0.7 0.5 0.4 1.9 1.0 0.7 0.5
20 1.6 0.7 0.5 0.4 1.9 1.0 0.7 0.5
25 1.6 0.7 0.5 0.4 1.9 1.0 0.7 0.5
30 1.6 0.7 0.5 0.4 1.9 1.0 0.7 0.5
40 1.6 0.7 0.5 0.4 1.9 1.0 0.7 0.5
50 1.6 0.7 0.5 0.4 1.9 1.0 0.7 0.5
60 1.6 0.7 0.5 0.4 1.9 1.0 0.7 0.5
Table B6-13. Model CFH Boilers: Natural Gas, Estimated
Emission Levels
POLLUTANT UNITS
CO
ppm* 50
lb/MMBtu 0.04
NOx
ppm* 20
lb/MMBtu 0.024
SOx
ppm* 1
lb/MMBtu 0.001
HC/VOC
ppm* 10
lb/MMBtu 0.004
PM
ppm* -
lb/MMBtu 0.01
* ppm levels are given on a dry volume basis and corrected to 3% oxygen
(15% excess air)
Table B6-14. Model CFH Boilers: Predicted
sound levels at high fire
BHP Sound Level - dBA*
10 60
15 65
20 60
25 66
30 62
40 68
50 67
60 69
*At 1 m from front of boiler and 4.5 ft height
B6-18
03/08
ENGINEERING DATA
The following engineering information is provided for the Model CFH steam boiler.
Additional information may be obtained from your local Cleaver-Brooks
representative.
combination of condensate return and raw make-up or in some instances, 100% raw
make-up. Proper treatment of make-up water is essential to the longevity and
performance of the boiler. Table B6-15 shows the rate of make-up required and Table
B6-16 shows the water quality guidelines.
Blowdown As steam is produced, unwanted solids are left behind in the water and become
concentrated within the vessel. If these constituents are allowed to adhere to the heat
transfer surfaces they will impede the flow of energy. Their removal requires proper
blowdown - either bottom, surface, or both. Table B6-15 shows the recommended
blowdown tank requirements for bottom blowdown. The surface blowdown
requirement is relative to the water quality and to the level of TDS control desired by
the water treatment specialist. Local codes will dictate the manner of treating
blowdown affluent.
recommendations of the National Board of Boiler and Pressure Vessel Inspectors. The
National Board's recommendations base the size of the blowdown tank on the
Table B6-15. Model CFH Boiler Feedwater Flow Rates
BHP Gallons/Hour
10 41
15 62
20 83
25 103
30 124
40 165
50 207
60 248
Table B6-16. Model CFH Boilers Required Water Quality Parameters
pH 8.3 - 10.5
Iron 0.1 ppm
Oxyen 0.1 mg/liter
Specific Conductivity 2000 mmho/cm
3
B6-19
03/08
Stack/Breeching
Criteria
General - The ClearFire Model CFH is a Category III Boiler according to ANSI Z21.13.
This code defines a Category III boiler as one that operates with a positive vent
pressure and a vent gas temperature that is non-condensing. Therefore the stack
must be a positive pressure design.
operation of the boiler. The vent should be designed with proper supports and
stack connection as proper draft is critical to safe and efficient burner performance.
size the breeching and stack to limit flue gas pressure variations. Consideration of the
draft must be given whenever direct combustion air ducting is utilized and lengthy
runs of breeching are employed. Please note: The allowable pressure range for design
of the stack and breeching is negative 0.25" w.c. (-62 Pa) to a positive 0.25" w.c.
(+62 Pa) for proper light offs and combustion. NOTE: This pressure range does not
pertain to the boiler room; that is, the boiler room must be neutral or slightly positive,
never negative when using air from the boiler room for combustion.
Whenever two or more CFH boilers are connected to a common breeching/stack, a
mechanical draft control system may be required to ensure proper draft at all times.
Cleaver-Brooks recommends individual stacks for multiple boiler installations.
Combustion Air - The burner must be supplied with adequate volume of
uncontaminated air to support proper combustion and equipment ventilation. Air
Table B6-17. Model CFH Blowdown Tank Sizing Information
10 11
15 11
20 13
25 13
30 16
40 19
50 22
60 22
NOTE: Quantity of water removed from boiler by lowering normal
water line 2".
B6-20
03/08
method, all installations must comply with NFPA54 (the National Fuel Gas Code -
NFGC) for U.S. installations and CAN/CSA B149.1 and B149.2 for Canadian
installations.
Note: A boiler room exhaust fan is not recommended as this type of device can cause
a negative pressure in the boiler room if using conventional air intake.
In accordance with NFPA 54, the required volume of indoor air shall be determined
in accordance with the "Standard Method" or "Known Air Infiltration Rate Method".
Where air infiltration rate is known to be less than 0.40 Air Changes per Hour, the
Known Air Infiltration Rate Method shall be used. (See the NFPA Handbook for
additional information).
Unconfined Spaces
All Air From Inside the Building - If combustion air is drawn from inside the building
(the mechanical equipment room does not receive air from outside via louvers or vent
openings and the boiler is not equipped with direct vent) and the boiler is located in
an unconfined space, use the following guidelines:
The mechanical equipment room must be provided with two permanent openings
linked directly with additional room(s) of sufficient volume so that the combined
volume of all spaces meets the criteria for an unconfined space. Note: An "unconfined
space" is defined as a space whose volume is more than 50 cubic feet per 1,000 Btu
per hour of aggregate input rating of all appliances installed in that space.
Each opening must have a minimum free area of one square inch per 1,000 Btu per
hour of the total input rating of all gas utilizing equipment in the mechanical room.
One opening must terminate within twelve inches of the top, and one opening must
terminate within twelve inches from the bottom of the room.
See Figure B6-16; refer to the NFGC for additional information.
Figure B6-16. Inside Air - Two Opening Method
GAS
VENT
CLEARFIRE
BOILER
INTERIOR WALL
FRESH AIR OPENING
FRESH AIR OPENING
12"MINIMUM
12"MINIMUM
B6-21
03/08
All Air From Outdoors - If all combustion air will be received from outside the
building (the mechanical room is linked with the outdoors), the following methods
can be used:
Two Opening Method (Figure B6-17) - The mechanical equipment room must be
provided with two permanent openings, one terminating within twelve inches from
the top, and one opening terminating within twelve inches from the bottom of the
room.
A. The opening must be linked directly or by ducts with the outdoors.
B. Each opening must have a minimum free area of one square inch per 4,000 Btu
per hour of total input rating of all equipment in the room, when the opening is
directly linked to the outdoors or through vertical ducts.
C. The minimum free area required for horizontal ducts is one square inch per 2,000
Btu per hour of total input rating of all the equipment in the room.
One Opening Method (Figure B6-18) - One permanent opening, commencing within
12 inches of the top of the room shall be provided.
A. The equipment shall have clearances of at least 1 inch from the sides and back
and 6 inches from the front of the appliance.
B. The opening shall directly communicate with the outdoors and shall have a
minimum free area of 1 square inch per 3000 Btu's per hour of the total input rating
of all equipment located in the enclosure, and not less than the sum of the areas of
all vent connectors in the unconfined space.
C. Refer to the NFGC for additional information.
GAS
VENT
CLEARFIRE
BOILER
EXTERIOR WALL
INTERIOR WALL
FRESH AIR
INLET DUCT
OUTLET AIR DUCT
12"MINIMUM
12"MINIMUM
B6-22
03/08
Unconfined Spaces
Engineered Design - When determining boiler room air requirements for an
unconfined space the "Engineered Design" method may be used. Following this
method, consideration must be given to the size of the room, airflow and velocity of
air as follows:
of 7 feet. This allows air to sweep the length of the boiler (see Figure B6-19).
Figure B6-19. Engineered Method
GAS
VENT
CLEARFIRE
BOILER
EXTERIOR WALL
FRESH AIR OPENING
12"MINIMUM
EXTERIOR WALL
FRESH AIR OPENING
EXTERIOR WALL
FRESH AIR OPENING
CLEARFIRE
BOILER
GAS
VENT
B6-23
03/08
subject to clogging with dirt and dust.
square foot.
2
= cfm
a
/fpm
a
), where cfm
a
=
a
Determine the area of the boiler room air supply openings for (2) 60 horsepower
Model CFH boilers at 750 feet elevation. The air openings will be 5 feet above the
floor level.
Total boiler horsepower (bhp): 60 x 2 = 120 bhp
Area required: From the formula in E above, 1200cfm/250fpm = 4.8 square feet
total.
Area/Opening: 4.8 divided by 2 = 2.4 ft
2
Notice
Direct Combustion Air - If combustion air will be drawn directly from the outside
(sometimes referred to as "sealed combustion") by means of a duct connected directly
to the burner air intake, use the following guidelines:
1. Install combustion air duct in accordance with local codes and the boiler
operating and maintenance manual.
room.
3. Duct material can be PVC or metallic vent material. It should be air tight to
prevent in leakage of air during operation.
B6-24
03/08
4. Maximum pressure drop for the duct shall not exceed 0.25" w.c. negative. If this
pressure drop is exceeded a larger size duct is recommended.
5. Multiple boilers may be connected to a single duct with take-offs to each boiler.
6. If the duct will run horizontally to an outside wall, it is recommended that the
duct have a slight downward slope away from the burner intake to prevent
collected moisture from draining into the burner connection.
7. If the outside air is dust-laden or the installation is near a heavily traveled
roadway, it is recommended that an air filter be installed to prevent intake of
contaminants that could accumulate on the burner canister.
Figure B6-20. Direct Vent Combustion
B6-25
03/08
Gas Piping General - The ClearFire Model CFH gas fired steam boilers are full modulating input
units that require appropriate gas supply pressure and volume for proper operation
and long burner life. The gas requirements specified in this section must be satisfied
to ensure efficient and stable combustion. Installation must follow these guidelines
and of the local authorities that have installation jurisdiction.
Gas Train Components - CFH boilers are equipped with a gas train that meets the
requirements of UL/cUL and ASME CSD-1, and also the requirements of FM and GE-
GAP (formerly IRI). The gas train and its components have been designed and tested
to operate for the highest combustion efficiency for the CFH units. Major components
are as noted in the current product specifications and O & M manual.
Gas Pressure Requirements - For proper and safe operation, each Model CFH boiler
requires a stable gas pressure input. The pressure requirements are listed in the O &
M and current specifications and added here for reference purposes.
The minimum inlet supply pressure must be as noted in Table B6-18 when firing the
boiler at low fire and high fire. Actual gas pressure should be measured when the
burner is firing using a manometer at the upstream test port connection on the main
gas valve. For a multiple unit installation, gas pressure should be set for a single unit
first, then the remaining units should be staged on to ensure that gas pressure droop
is not more than 1" w.c. and never below the required pressure. Fluctuating gas
pressure readings could be indicative of a faulty supply regulator or improper gas train
size to the boiler.
Table B6-18. Model CFH Minimum Gas Pressure Requirements
Figure B6-21. Air Inlet Extension kit for Direct Vent combustion
Fan/Blower
Venturi
Direct Vent Connection
Casing Support
Attachment
Flexible Connection
Adapter Flange
Gasket
Boiler
Size
Pressure required at gas
train connection
Low Fire High Fire
10 7.0" w.c. 5.2" w.c.
15 7.0" w.c. 5.3" w.c.
20 7.0" w.c. 5.5" w.c.
25 7.0" w.c. 5.7" w.c.
30 8.5" w.c. 6.8" w.c.
40 10.5" w.c. 8.0" w.c.
50 9.5" w.c. 7.0" w.c.
60 10.0" w.c. 8.0" w.c.
B6-26
03/08
Gas Piping - CFH units are standardly equipped with a gas pressure regulator. If
upstream pressure exceeds 1 psig, an additional upstream regulator must be installed
along with a pressure relief valve. Note: Gas connection is at the left side of the boiler,
left hand side as you face the front of the boiler.
For buildings or boiler rooms with gas supply pressure exceeding 28" w.c. a "full lock-
up" type regulator is recommended along with proper overpressure protection (e.g.
relief valve). In addition to the regulator, a plug type or "butterball type" gas shutoff
cock should be installed upstream of the regulator for use as a service valve. This is
also required to provide positive shutoff and isolate the unit during gas piping tests.
any dirt, weld slag, or debris can deposit in the drip leg rather than into the boiler gas
train. The bottom of the drip leg should removable without disassembling any gas
piping. The connected piping to the boiler should be supported from pipe supports
and not supported by the boiler gas train or the bottom of the drip leg.
Before starting the unit(s) all piping must be cleaned of all debris to prevent its'
entrance into the boiler gas train. Piping should be tested as noted in NFPA 54 and
the boiler must be isolated during any tests.
After initial startup, the inlet screen to the gas valve should be checked and cleaned
for any debris buildup
Gas Supply Pipe Sizing - For proper operation of a single unit or a multiple unit
installation, we recommend that the gas pipe sizing be sized to allow no more than
0.3" w.c. pressure drop from the source (gas header or utility meter) to the final unit
location. The gas supplier (utility) should be consulted to confirm that sufficient
volume and normal pressure are provided to the building at the discharge side of the
gas meter or supply pipe.
For installations of new boilers into an existing building, gas pressure should be
measured with a manometer to ensure sufficient pressure is available. A survey of all
connected "gas using devices" should be made. If appliances other than the boiler or
boilers are connected to the gas supply line, then a determination must be made of
how much flow volume (cfh = cubic feet per hour) will be demanded at one time and
the pressure drop requirement when all appliances are firing.
piping. Total equivalent length should be calculated from the utility meter or source to
the final unit connection. As a minimum guideline, gas piping Tables B6-19 through
B6-23 should be used. The data in these tables is from the NFPA 54 source book,
2006 edition.
To verify the input of each device that is connected to the gas piping, obtain the btu/
hr input and divide this input by the calorific value of the gas that will be utilized. For
instance, a 40 HP unit with 1,613,253 btu/hr input divided by a gas calorific value
of 1060 will result in a cfh flow of 1,522. The single boiler is approximately 20 feet
from the gas supply header source. And with a measured gas supply pressure of 10"
w.c. we find from Table 1 that a supply pipe size of 2" should be used as a minimum.
B6-27
03/08
Pipe Size
Nominal 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
Actual I.D. 1.049 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"
10 514 1,060 1,580 3,050 4,860 8,580 17,500
20 363 726 1,090 2,090 3,340 5,900 12,000
30 284 583 873 1,680 2,680 4,740 9,660
40 243 499 747 1,440 2,290 4,050 8,290
50 215 442 662 1,280 2,030 3,590 7,330
60 195 400 600 1,160 1,840 3,260 6,640
70 179 368 552 1,060 1,690 3,000 6,110
80 167 343 514 989 1,580 2,790 5,680
90 157 322 482 928 1,480 2,610 5,330
100 148 304 455 877 1,400 2,470 5,040
125 131 269 403 777 1,240 2,190 4,460
150 119 244 366 704 1,120 1,980 4,050
175 109 209 336 648 1,030 1,820 3,720
200 102 185 313 602 960 1,700 3,460
**Fuel: Natural Gas
Pipe Size
Nominal 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
Actual I.D. 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"
10 678 1,390 2,090 4,020 6,400 11,300 23,100
20 466 957 1,430 2,760 4,400 7,780 15,900
30 374 768 1,150 2,220 3,530 6,250 12,700
40 320 657 985 1,900 3,020 5,350 10,900
50 284 583 873 1,680 2,680 4,740 9,600
60 257 528 791 1,520 2,430 4,290 8,760
70 237 486 728 1,400 2,230 3,950 8,050
80 220 452 677 1,300 2,080 3,670 7,490
90 207 424 635 1,220 1,950 3,450 7,030
100 195 400 600 1,160 1,840 3,260 6,640
125 173 355 532 1,020 1,630 2,890 5,890
150 157 322 482 928 1,480 2,610 5,330
175 144 296 443 854 1,360 2,410 4,910
200 134 275 412 794 1,270 2,240 4,560
**Fuel: Natural Gas
B6-28
03/08
Pipe Size
Nominal 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
Actual I.D. 0.622 0.824 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"
Length in
feet
10
1,510 3,040 5,560 11,400 17,100 32,900 52,500 92,800 189,000
20
1,070 2,150 3,930 8,070 12,100 23,300 57,100 65,600 134,000
30
869 1,760 3,210 6,590 9,880 19,000 30,300 53,600 109,000
40
753 1,520 2,780 5,710 8,550 16,500 26,300 46,400 94,700
50
673 1,360 2,490 5,110 7,650 14,700 23,500 41,500 84,700
60
615 1,240 2,270 4,660 6,980 13,500 21,400 37,900 77,300
70
569 1,150 2,100 4,320 6,470 12,500 19,900 35,100 71,600
80
532 1,080 1,970 4,040 6,050 11,700 18,600 32,800 67,000
90
502 1,010 1,850 3,810 5,700 11,000 17,500 30,900 63,100
100
462 954 1,710 3,510 5,260 10,100 16,100 28,500 58,200
125
414 836 1,530 3,140 4,700 9,060 14,400 25,500 52,100
150
372 751 1,370 2,820 4,220 8,130 13,000 22,900 46,700
175
344 695 1,270 2,601 3,910 7,530 12,000 21,200 43,300
200
318 642 1,170 2,410 3,610 6,960 11,100 19,600 40,000
500
192 401 717 1,470 2,210 4,250 6,770 12,000 24,400
1000
132 275 493 1,010 1,520 2,920 4,650 8,220 16,800
1500
106 221 396 812 1,220 2,340 3,740 6,600 13,500
**Fuel: Natural Gas
B6-29
03/08
Pipe Size
Nominal 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
Actual I.D. 0.622 0.824 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"
Length in
feet
10
2,350 4,920 9,270 19,000 28,500 54,900 87,500 155,000 316,000
20
1,620 3,380 6,370 13,100 19,600 37,700 60,100 106,000 217,000
30
1,300 2,720 5,110 10,500 15,700 30,300 48,300 85,400 174,000
40
1,110 2,320 4,380 8,990 13,500 25,900 41,300 75,100 149,000
50
985 2,060 3,880 7,970 11,900 23,000 36,600 64,800 132,000
60
892 1,870 3,520 7,220 10,300 20,300 33,200 58,700 120,000
70
821 1,720 3,230 6,640 9,950 19,200 30,500 54,000 110,000
80
764 1,600 3,010 6,180 9,260 17,800 28,400 50,200 102,000
90
717 1,500 2,820 5,800 8,680 16,700 26,700 47,100 96,100
100
677 1,420 2,670 5,470 8,200 15,800 25,200 44,500 90,300
125
600 1,250 2,360 4,850 7,270 14,000 22,300 39,500 80,500
150
544 1,140 2,140 4,400 6,590 12,700 20,200 35,700 72,900
175
500 1,050 1,970 4,040 6,060 11,700 18,600 32,900 67,100
200
465 973 1,830 3,760 5,640 10,900 17,300 30,600 62,400
500
283 593 1,120 2,290 3,430 6,610 10,300 18,600 38,000
1000
195 407 897 1,380 2,360 4,550 7,240 12,000 26,100
1500
156 327 616 1,270 1,900 3,650 5,820 10,300 21,000
**Fuel: Natural Gas
B6-30
03/08
B6-31
03/08
Pipe Size
Nominal 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
Actual
I.D.
0.622 0.824 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"
Length
in feet
10
3,190 6,430 11,800 24,200 36,200 69,700 111,000 196,000 401,000
20
2,250 4,550 8,320 17,100 25,600 49,300 78,600 139,000 283,000
30
1,840 3,720 6,790 14,000 20,900 40,300 64,200 113,000 231,000
40
1,590 3,220 5,880 12,100 18,100 34,900 55,600 98,200 200,000
50
1,430 2,880 5,260 10,800 16,200 31,200 49,700 87,900 179,000
60
1,300 2,630 4,800 9,860 14,800 28,500 45,400 80,200 164,000
70
1,200 2,430 4,450 9,130 13,700 26,400 42,000 74,300 151,000
80
1,150 2,330 4,260 8,540 12,800 24,700 39,300 69,500 142,000
90
1,060 2,150 3,920 8,050 12,100 23,200 37,000 65,500 134,000
100
979 1,980 3,620 7,430 11,100 21,400 34,200 60,400 123,000
125
876 1,770 3,240 6,640 9,950 19,200 30,600 54,000 110,000
150
786 1,590 2,910 5,960 8,940 17,200 27,400 48,500 98,900
175
728 1,470 2,690 5,520 8,270 15,900 25,400 44,900 91,600
200
673 1,360 2,490 5,100 7,650 14,700 23,500 41,500 84,700
500
384 802 1,510 3,100 4,650 8,950 14,300 25,200 51,500
1000
264 551 1,040 2,130 3,200 6,150 9,810 17,300 35,400
1500
212 443 834 1,710 2,570 4,940 7,880 13,900 28,400
**Fuel: Natural Gas
B6-32
03/08
Gas Header - Design of a single common gas header with individual takeoffs for a
multiple unit installation is recommended (See Figure B6-16). Boiler gas manifold
piping should be sized based on the volume requirements and lengths between
boilers and the fuel main header. Tables B6-24 through B6-25 indicate the proper
sizing for multiple units of equal size, placed on the factory standard center with the
noted take off size. For installations with a mixed sized use, determine the flow of
each unit and total the input. With the total input, determine length of run from the
source and determine what size header will be needed for the flow of all units firing.
Pipe sizes are based on Table B6-19 with boiler gas line take-off at 20 feet from the
header. If pipe runs are greater or if gas pressure is different, refer to the Tables for
pipe sizing.
Table B6-24. CFH 10 HP Boilers
# of
Units
1 2 3 4
Pipe Size
To Boiler
1-1/4" 1-1/4" 1-1/4" 1-1/4"
Header
Pipe Size
1-1/4" 1-1/4" 2" 2"
# of
Units
1 2 3 4
Pipe Size
To Boiler
1-1/2" 1-1/2" 1-1/2" 1-1/2"
Header
Pipe Size
1-1/2" 2" 2-1/2" 2-1/2"
# of
Units
1 2 3 4
Pipe Size
To Boiler
2" 2" 2" 2"
Header
Pipe Size
2" 2-1/2" 3" 3"
# of
Units
1 2 3 4
Pipe Size
To Boiler
2" 2" 2" 2"
Header
Pipe Size
2" 3" 3" 4"
# of
Units
1 2 3 4
Pipe Size
To Boiler
1-1/4" 1-1/4" 1-1/4" 1-1/4"
Header
Pipe Size
1-1/4" 2" 2" 2-1/2"
# of
Units
1 2 3 4
Pipe Size
To Boiler
1-1/2" 1-1/2" 1-1/2" 1-1/2"
Header
Pipe Size
1-1/2" 2" 2-1/2" 3"
# of
Units
1 2 3 4
Pipe Size
To Boiler
2" 2" 2" 2"
Header
Pipe Size
2" 2-1/2" 3" 4"
# of
Units
1 2 3 4
Pipe Size
To Boiler
2-1/2" 2-1/2" 2-1/2" 2-1/2"
Header
Pipe Size
2-1/2" 3" 4" 4"
Pipe sizing for multiple unit manifolds
B6-33
03/08
SPECIFICATIONS
MODEL CFH PRODUCT SPECIFICATIONS
A. The boiler shall be a Cleaver-Brooks Model CFH 700, single pass horizontal
commercial Firetube design or approved equal. It shall be mounted on a heavy-
duty steel frame with premix forced draft burner and burner controls as a complete
package from one manufacturer.
B. Approvals - The complete package including the burner shall be Underwriters
Laboratories, Inc. listed and the official UL/cUL label shall be affixed to the
package attesting to its certification.
C. As a preassembled package, the standard boiler shall be factory fire tested.
D. The complete package as shipped, shall be ready for connections to water, fuel,
blowdown, and exhaust venting. Certain items may be shipped loose to prevent
their damage such as the safety valves and gauges.
E. The specified boiler shall have an output rating of _____horsepower when fired
with Natural Gas [LP Gas] with a gas supply pressure of ____" w.c. Power supply
to the boiler shall be 115/1/60. Design pressure shall be [15#] [150#] steam.
Operating characteristics shall be [___] psig steam. Steam boilers shall be
supplied with ____degrees F make-up water @ ____%.
F. Performance: Shall be as specified in Paragraph 5.
1.1 BOILER SHELL
A. The boiler shell must be constructed in accordance with the ASME Code, either
Section I for high-pressure steam or Section IV for low-pressure steam. The vessel
must be subjected to the required inspections of the Code conducted by an
independent third party inspector. A signed inspection sheet shall be provided to
the purchaser and the appropriate ASME symbol shall be affixed or stamped onto
the boiler.
1. Two lifting eyes shall be furnished and located on the top centerline of the vessel
for lifting or rigging purposes.
2. Furnace and front furnace tube sheet access/inspection shall be provided via a
swing away burner housing attached to the front head on a right hand hinge
assembly.
3. Rear tube sheet access shall be available via a removable exhaust outlet
assembly.
4. Each carbon steel boiler tube shall utilize the AluFer heat transfer design
technology for high efficiency and reduction in overall size of the vessel and shall
be a minimum of 0.105 tube wall thickness.
5. To facilitate waterside inspection, 3 hand holes shall be provided.
6. An observation port for flame inspection shall be provided in the front burner
door.
B6-34
03/08
7. Boiler insulation shall consist of 2-inch fiberglass blanket, which shall be
covered with a powder coated sheet metal jacket. This jacket and insulation
design shall permit field removal and reattachment if necessary for inspection,
etc.
8. The entire boiler and base frame shall be factory painted.
9. Tube cleaning and inspection shall be provided from either end.
10.Exhaust vent shall be located at the rear of the boiler and shall be a slip
connection. Stack support shall be by means other than the boiler connection.
1.2 BOILER SHELL TAPPINGS/OPENINGS
A. The following boiler vessel tappings/openings shall be furnished:
1. Steam supply, to be located on the top centerline, NPT connection for high-
pressure steam and flanged connection for low-pressure steam with 3" and
greater connection.
2. Bottom blowdown at the front bottom of the boiler.
3. Feedwater Make-up - located on the right hand side and left hand of the shell
when facing the front of the boiler.
4. Surface blowoff on the top centerline of the boiler including a collector tube.
5. Chemical Feed.
6. High Water Level Overflow Drain to discharge water in the boiler if water level
reaches an unacceptable level.
2.0 STEAM BOILER TRIM (All piping and devices per ASME CSD-1)
A. Water Column
1. A water column shall be piped on the right hand side of the boiler [when facing
the burner] complete with gauge glass and water column blowdown valve.
a. Feedwater Pump control - shall be integral with the water column via probe control
device and electronics for on/off pump operation.
b. Low Water cutoff - shall be integral with the water column via probe control device
and solid state electronics mounted and wired in the control panel.
B. An Auxiliary Low Water Cutoff shall be provided. It shall be located on the top
centerline of the boiler using an internal probe and of the manual reset design.
C. For safety steam pressure lockout a high limit pressure control, manual reset shall
be provided. The device shall be mercury free.
D. For normal operation an operating limit pressure control, auto reset shall be
provided to start and stop the burner on demand requirements and demand
satisfied. The device shall be mercury free.
E. To provide steam demand tracking a steam pressure transmitter shall be provide
that provides an input signal for burner positioning in accordance to steam
demand.
B6-35
03/08
F. A 3" Steam Pressure Gauge shall be piped onto the trim piping, including an
inspectors test cock.
G. In accordance with the A.S.M.E. Code an approved A.S.M.E. rated and stamped
safety valve shall be provided and set at [15#] or [150#].
3.0 BURNER AND BURNER CONTROLS
A. Mode of Operation - To minimize short cycling and provide highest efficiency the
burner for the specified boiler shall be of the electronic modulation with a
turndown ratio of 5:1 for Natural Gas for sizes of 30 horsepower and greater, and
4:1 for sizes below 30 horsepower. On/off or low/high burner operation shall not
be accepted.
B. The burner shall be enclosed in a NEMA 1 type enclosure. A lift off panel shall be
provided to gain access to the burner and controls.
C. Design - The burner design shall be of the linkage-less premix technology wherein
the fuel and air are mixed in the fan housing assembly prior to entering the burner
canister. Separately driven linkage or servo motor driven fuel and air valves shall
not be permitted.
1. Fan housing shall utilize non-sparking material and shall be approved for premix
operation.
2. The fan shall be driven by a variable speed motor which shall react to output
demand requirements via the demand control Motor shall be a high efficiency
DC Brushless type. Continuous speed synchronous motors will not be
acceptable.
D. Ignition of the fuel shall be of the direct spark design; separate pilot gas train is
not required. Dual ignition electrodes shall used for the spark generated from the
panel mounted ignition transformer.
E. Combustion shall take place on the surface of the burner canister. The canister
shall be constructed of Fecralloy material and stainless steel and shall be
warranted for five years against failure from defects or poor workmanship.
F. Air Filter - shall be fitted to the intake air venturi to filter the incoming air supply
when using boiler room air. The air filter shall be designed to be easily cleaned
and re-used.
G. Fuel - The burner shall be designed for operation with natural gas or LP gas. Gas
Train, shall be located at the front of the burner and along the left side of the boiler.
In accordance with UL/cUL and ASME CSD-1, the following components shall be
furnished:
1. Single body dual solenoid safety shutoff valve and incorporate the following:
a. The valve shall be a 1:1 ratio valve with an integral trim regulator and operate in
relation to the fan speed. An air sensing line shall be connected from the air inlet venturi
[mounted to the fan motor] and to the gas valve for control of gas input.
b. As fan speed increases a negative pressure will be applied to the valve, allowing the
valve to open further, permitting more fuel to flow into the venturi for mixing. As fan
speed is reduced, fuel input shall be reduced accordingly. Air shall always lead fuel from
low to high or high to low.
B6-36
03/08
2. Manual fuel shutoff valve - shall be located downstream of the gas valve and
used for CSD-1 leak testing.
3. Gas Pressure Interlocks - one shall be provided for sensing high gas pressure and
one provided to sense low gas pressure. Each control shall be of the manual
reset type.
4. Gas Pressure Regulator - shall be provided upstream of the gas valve to provide
regulated pressure to the gas train from the gas supply. This regulator shall be
suitable for a maximum of 1 psig gas pressure. If gas pressure exceeds 1 psig,
a gas pressure relief valve shall be furnished and upstream pressure regulator
that is of the full lockup type.
5. Manual Shutoff Valves - shall be provided upstream of the gas regulator to
manually close off the gas supply when servicing the gas train or isolating the
boiler. A shutoff valve shall be provided at the burner for tightness checking of
the gas valve.
6. Combustion Air Proving Switch shall be provided to prove, prior to modulation
that the fan is operating properly.
7. A High Air Pressure Switch [Blocked Flue] shall be mounted and wired to
prevent burner operation if excessive back pressure in the flue is sensed. This
switch shall require a manual reset.
H. Flame Safety
1. Flame sensing shall be accomplished with a flame rod and mounted in the
burner mounting plate, designed for easy removal for inspection or replacement.
2. The Combustion flame safeguard control shall be a CB90 Micro M control
mounted and wired in the Boiler Control Panel. [Option: Provide a remote digital
display of operating and fault conditions on the exterior of the Control Panel.]
4.0 CONTROL PANEL
A NEMA 1A type enclosure is furnished and located at the front of the boiler above
the burner to house the following components. Surface mounted devices are located
on the right hand side of the panel.
A. Combustion Flame Safeguard Control - CB90 Micro M for sequence operation,
flame supervision and safety shutdown and interfaced to work with the RWF40
Boiler Control.
B. A Siemens Model RWF40 Control shall be mounted and wired for boiler operating
control and burner firing rate sequencing. The device shall be field programmable
for site conditions and shall provide settings for fan and fuel input control.
C. Mount and wire a Burner On/Off Switch.
D. Provide terminals for control interface wiring, customer connections, and
connections for incoming power.
E. Install solid state circuit boards for water level controls.
F. Selectable Options:
B6-37
03/08
_____Alarm Light Package to provide indication of Low Water, Flame Failure,
Load Demand, Fuel Valve On, including a horn with silence switch for alarm
conditions.
_____Remote Display of Flame Safeguard Control.
_____ModBus Communication Interface.
5.0 PERFORMANCE
The proposed Boiler shall provide the following operating performance targets for
Natural Gas:
A. Efficiency - Fuel to Steam Efficiency shall be guaranteed at 85% for 15# Steam
Design. For 150# steam operating at 125#, the guaranteed Fuel to Steam
Efficiency shall be 83% and 85% with an optional flue gas economizer. Efficiency
rating shall account for radiation and convection losses.
B. Emissions - NOx emissions shall be less than 20 PPM corrected to 3% O2 and
less than 10 PPM CO over the operating range of the burner turndown. If
emissions exceed this level, the boiler manufacturer shall correct at their expense
until this level is achieved on a repeatable basis.
C. Noise - Sound level shall not exceed 70 dBA at high fire when measured 3 feet in
front of the burner.
D. Radiation losses shall be less than 0.5% of the rated input at maximum firing.
E. Steam quality shall be 99.5% at maximum firing regardless of operating pressure.
6.0 WARRANTY
The package boiler shall be warranted for a period of one year from date of start-up or
18 months from shipment whichever shall occur first.
7.0 OPTIONAL ECONOMIZER PACKAGE
For application with 150# Design Model CFH, an economizer package shall be
factory installed and piped to increase operating efficiency to 85%. The factory
installed package shall include an economizer coil located in the rear of the boiler,
integral to the stack outlet with integral make-up water supply and outlet piping. A
vertical stainless steel feedwater tank complete with a continuous running pump shall
be provided with integral piping. This piping shall include the feedwater make-up
stop valve, check valve, and on/off electric make up valve. The make-up valve shall
be factory wired to the on/off pump control. Feedwater piping shall include by-pass
piping so that water circulates through the economizer at all times.
B6-38
03/08
B7-1
01/09
Section B7
CLEARFIRE MODEL CFV BOILERS
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-6
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-13
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-36
LIST OF FIGURES
Tube Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-3
AluFer Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-3
Premix Burner Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-4
Burner maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-4
CFV connections and controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-5
CB Falcon Display/Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-9
CB Falcon pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-10
CFV Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-11
B7-2
Model CFV Boilers Section B7
01/09
Gas Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-12
CFV electrical panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-12
Model CFV Steam Boiler Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-14
Inside Air - Two Opening Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-23
Two Opening Ducted Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-24
One Opening Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-24
Engineered Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-25
Direct Vent Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-27
Direct Vent Combustion kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-27
Typical gas header piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-30
Example gas piping <1 psig supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-30
LIST OF TABLES
Operating Conditions - CB Falcon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-7
CB Falcon burner sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-8
Model CFV Steam Boiler Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-15
Model CFV Steam Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-16
Model CFV Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-16
Model CFV Gas Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-16
Model CFV Steam Boiler Safety Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-17
Boiler Room Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-17
Predicted Fuel-to-Steam Efficiencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-18
Radiation and Convection Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-19
Model CFV Boilers: Natural Gas, Estimated Emission Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-20
Predicted sound levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-20
Feedwater flow rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-21
Model CFV Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-21
Model CFV Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-22
Model CFV Minimum Gas Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-28
Gas line capacity - Schedule 40 metallic pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-31
Pipe sizing for multiple unit manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-35
Section B7 Model CFV Boilers
B7-3
01/09
General The ClearFire Model CFV is a single pass, horizontally fired durable firetube steam boiler.
Extended heating surface tubes provide a very high level of performance in a compact
package. An integral premix burner is provided for natural gas operation. As standard, the
Model CFV burner provides low emissions of <20 PPM NOx. Propane fuel is also available.
Advanced Technology Heat is transferred through 3 OD carbon steel tubes with patented AluFer extended heating
surfaces. The AluFer tube design provides for optimum heat transfer and eliminates laminar
gas flow during minimum firing, providing optimized efficiency throughout the firing range
(see Figure B7-1 and Figure B7-2).
High Efficiency With the AluFer extended heating surface tubes, the Model CFV steam boiler will provide
fuel-to-steam efficiency of up to 81% operating at 125 psig.
Quality Construction ISO 9001-2001 certification ensures the highest manufacturing standards.
ASME code construction ensures high quality design, safety, and reliability. Units are third-
party inspected and are stamped to assure compliance.
Certification Each unit is tested and certified in accordance with UL/cUL standards and the UL/cUL label is
affixed attesting to equipment meeting the latest UL requirements for packaged steam boilers.
Premix Technology The ClearFire CFV burner utilizes Premix technology to mix both gas fuel and combustion air
prior to entering the burner canister, with fuel flow governed by the air flow during firing
transitions. Combined with a variable speed fan, this technology provides very low emission
levels, exceptionally safe operation, and nearly 100% combustion efficiency. An inlet air filter
is provided as standard to prevent airborne dust from entering the combustion canister.
Full Modulation The variable speed fan modulates to provide only the amount of heat required to the boiler.
Full modulation reduces on/off cycling and provides excellent load tracking with reduced
operating costs. The burner does not require mechanical linkage connections between the fuel
input valve and air control. Instead, the microprocessor control adjusts the fan speed in
accordance with system demand, determining fuel input without mechanical device
positioning. This method of controlling the fuel-air ratio eliminates slippage due to linkages,
Figure B7-2. Tube Cross Section
Figure B7-1. AluFer Tubes
B7-4
01/09
minimizes burner maintenance, and provides control repeatability. See Figure B7-3.
Ease of Maintenance The blower is easily removed to allow inspection or service of the burner canister, tubes, and
tube sheets (see Figure B7-4). A union connection provides easy disconnect from the fuel
train. All burner components are easily accessed for inspection and maintenance.
Figure B7-4. Burner maintenance
B7-5
01/09
Designed for commercial
steam applications
The CFV packaged boiler is designed for 150 psig MAWP (Maximum Allowable Working
Pressure) and is constructed of durable ASTM grade steel materials. Figure B7-5 shows the
component and connection locations.
Figure B7-5. CFV connections and controls
B7-6
01/09
PRODUCT OFFERING
Information in this section applies to steam boiler sizes ranging from 10 horsepower
through 60 horsepower for operation on natural gas or LP gas only. Fuel oil operation
is not available for the model CFV. Standard installation is for indoor use with an
optional engineering design for outdoor applications.
The complete package has been tested and certified in accordance with UL/cUL.
Package is approved and listed and bears the appropriate UL/cUL package boiler
label.
Dimensions, ratings, and product information may change due to market
requirements or product enhancements. The information contained herein is a guide
for general purposes only.
Standard Equipment The equipment listed below applies to the standard boiler package offering. Optional
items are available to meet specific projects when required.
1. The Boiler
A.Each boiler (pressure vessel) size is designed and built for a Maximum Allowable
Working Pressure (MAWP) of 150 psig in accordance with ASME Section I
(bearing the S stamp).
B.The vessel is insulated with a 2 thick blanket and mounted on a base frame. A
powder-coated 18 gauge steel casing covers the insulation.
C.Vessel connections are furnished for:
Steam outlet
Bottom drain or blowoff
Surface blowoff
Chemical feed
Feedwater makeup
High water level overflow
D.For waterside inspection, handholes are provided.
E. Two lifting lugs are provided on the top of the boiler for rigging purposes.
F. The combustion exhaust is located at the top rear.
2. Boiler trim and controls
Water column with primary low water cutoff and pump control (probe type).
Water column gauge glass and gauge glass drain valve.
Water column drain valve.
Auxiliary low water cutoff (probe type), manual reset.
Operating limit pressure control, auto reset.
Excess steam pressure control, manual reset.
Pressure transmitter for burner on/off and modulation.
ASME safety relief valve.
B7-7
01/09
3. CB Falcon Control System
A.Control Description - The CB Falcon control is an integrated burner management
and modulation control with a touch-screen display/operator interface.
B.Functionality - The controller incorporates the following functions:
PID load control.
Burner sequencing with safe start check, pre-purge, direct spark ignition, and
post purge.
Electronic ignition.
Flame Supervision.
Safety shutdown with time-stamped display of lockout condition - last 15
lockouts stored in memory.
Variable speed control of the combustion air fan.
Supervision of low and high gas pressure, air proving, stack back pressure,
and low water.
Alarm output
Remote enable & remote modulation or set point.
First-out annunciator.
Diagnostics.
Real-time data trending (w/System Display).
(3) pump/auxiliary relay outputs.
Modbus communication.
Outdoor temperature reset.
Anti-short-cycling mode
Time-of-day (night setback) operation
Three levels of access to control configuration:
End-user
Installer/Service Engineer (password protected)
OEM Manufacturer (password protected)
Table B7-1. Operating Conditions - CB Falcon
Temperature Range
Operating 32 F to 122 F (0 C to 50 C)
Humidity 85% max. relative humidity
B7-8
01/09
C.Main Electrical Connection - 115V/single phase/60Hz
D.Demand switch - Local/Remote/Off.
E. Combustion Air Proving Switch
F. Gas Pressure Switch - Gas pressure switches for low gas pressure and high gas
pressure prevent the burner from being activated if either is open. Each switch
is a physical manual reset device, requiring physical depression of the reset
button if either switch is not closed prior to burner start or during burner
operation. Monitored in Interlock (ILK) Circuit.
G.System Configuration - CB Falcon configuration is grouped into the following
functional groups:
H.CB Falcon Control Access - There are three levels of access to the CB Falcon
controller:
End User Level - read or view parameters; change setpoints. No password
required.
Installer/Service Level - read all parameters; enables changing of most
parameters. This access level is used to configure the CB Falcon for a
particular installation, and is password-protected.
OEM Level - read/change all parameters; for factory configuration of boiler-
Table B7-2. CB Falcon burner sequence
1. Heat request detected (Setpoint minus On Hysteresis); LCI limits and steam
demand detected (terminals J6 3 and J8 3).
2. The CH pump is switched on (relay contact closes).
3. After a system Safe Start Check, the Blower (combustion air fan) is started
4. After the ILK input is energized - 10 sec. allowed for IAS input (combustion air
proving) to energize - and the purge rate proving fan RPM is achieved, prepurge
time is started.
5. When 30 sec. purge time is complete, the fan RPM is changed to the lightoff
speed.
6. Trial for Ignition (4 sec).
7. The ignitor and the gas valve are energized.
8. The ignitor is turned off at the end of the direct burner ignition period.
9. The fan is kept at the lightoff rate during the stabilization time.
10.Release to modulation (Run).
11.At the end of the CH-heat request the burner is switched off and the fan stays on
until post purge is complete (15 sec.). Boiler enters standby mode.
System Identification and Access
Central Heat Configuration
Outdoor Reset Configuration
DHW - Domestic Hot Water Configuration
Modulation Configuration
Pump Configuration
Statistics Configuration
High Limits
Stack Limit
Other Limits
Anti-condensation Configuration
Frost Protection Configuration
Annunciation Configuration
Burner Control Interlocks
Burner Control Timings & Rates
Burner Control Ignition
Burner Control Flame Failure
System Configuration
Fan Configuration
Lead Lag Configuration
B7-9
01/09
specific parameters. Password-protected and restricted to CB or factory
authorized service personnel.
For additional information regarding service and setup of the burner controller, refer to
CB manual part no. 750-269.
Figure B7-6. CB Falcon Display/Operator Interface
B7-10
01/09
Figure B7-7. CB Falcon pinout
4. Forced draft burner
A.The burner is a "Pre-mix" design consisting of a unitized venturi, single body dual
safety gas valve, blower, and burner head (canister).
3
1
4
2
F
L
A
M
E
S
T
R
E
N
G
T
H
LOCAL
MODBUS
A B C
GLOBAL
MODBUS
A B C
POWER
FLAME
ALARM
RESET
PIM
1
2
3
4
5
6
STEAM
CONTROL
J1
J2
J3
ECOM
D R C
L1
L2 FOR 120VAC OR
24VAC RETURN (OPTOS)
EGND
BLOWER/HSI
EX. IGNITION
ALARM
MAIN VALVE
PILOT VALVE
ANNUN 1/IAS
ANNUN 2
ANNUN 3
ANNUN 4
ANNUN 5
ANNUN 6
PRE IGN INTLK
INTERLOCK
P
P
P
LCI
PUMP A
{
{
{
{
PUMP B
PUMP C
ANNUN 7 HFS
ANNUN 8 LFS
24 VAC
24 VAC RTNS
STEAM PRESSURE
SENSOR
4-20 mA
STACK TEMP A
STACK TEMP RTN
STACK TEMP B
TOD
REMOTE RESET
0 - 10 VDC
MA /VDC RTN
4 TO 20 MA
V
I
BUILDING
AUTOMATION
SYSTEM
FUTURE
System Display
TACHOMETER
PWM OUT
FAN POWER (25 VDC)
FAN GND
MULTIPLE
APPLIANCE
CONTROLLER
GLOBALMODBUS
LOCALMODBUS
+
+
FUTURE
UV
BLUE
WHITE
STAT
+
EXTERNALLY POWERED PRESSURE SENSOR (0-15 PSI OR 0-150 PSI). 1

1
FALCON STEAM CONTROL
PLUG CONNECTORS
J4
J5
J6
J7
J8
J9
J10
J11
12
11
10
9
8
7
6
5
4
3
2
1
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
7
6
5
4
3
2
1
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
Local Display
B7-11
01/09
B.Full modulation is accomplished with a variable speed fan for up to 5:1
turndown ratio on 40 horsepower boilers and larger (4:1 turndown on 30
horsepower and less).
C.For near flameless combustion, the burner utilizes a Fecralloy metal fiber head
(canister).
D.Noise level at maximum firing is less than 70 dBA regardless of boiler size.
E. When boiler is operating on natural gas, NOx emissions will be less than 20
PPM regardless of boiler size; certified for California and Texas low emissions
requirements.
F. As an option, the burner can utilize direct vent combustion air.
G.Ignition of the main flame is via direct spark, utilizing high voltage electrodes
H.To ensure adequate combustion air is present prior to ignition, and to ensure the
fan is operating, a combustion air proving switch is provided.
I. For ease of inspection and maintenance, the blower is hinged for easy swing
away from the boiler permitting full inspection of the burner components, front
tube sheet and furnace.
J. A flame observation port is located at the top of the boiler.
Figure B7-8. CFV Burner
5. Burner Gas Train
The standard gas train is equipped in accordance with UL 795, ASME, CSD-1, GE-
GAP (formerly IRI), and FM. Each burner gas train includes:
Low gas pressure interlock, manual reset
High gas pressure interlock, manual reset
ASME CSD-1 test cocks
Downstream manual ball type shutoff cock
Single body dual safety shutoff gas valve
Gas pressure regulator for maximum of 1 psig inlet pressure
B7-12
01/09
Figure B7-9. Gas Train
6. Boiler control panel
A standard NEMA 1A type panel enclosure is mounted on the side of the boiler. This
panel encloses the CB Falcon control, water level circuit boards, terminals, fuse
blocks, and ignition transformer. 115/1/60 terminals are provided for contractor
connections.
Figure B7-10. CFV electrical panel
summary, here are some of the options that can be provided with the boiler package:
Bottom blowdown valves, shipped loose or mounted and piped
Manual SOV
Manual SOV
LGPS
HGPS
Test Cocks
Regulator
Gas Valve
Optional
Alarm/Annunciation
Fuse Block
Terminal Block
Ignition Transformer
Falcon Display
& Operator Interface
Transformer
Power Supply
Power
On/Off
Demand
Switch
Optional
Aux. Switch
ALWCO
Reset
CB Falcon
Controller
LWCO and
Pump Control
ALWCO
Control
B7-13
01/09
Surface blowoff valve, shipped loose or mounted and piped
Feedwater stop and check valves, shipped loose or mounted and piped
Surface blowoff skimmer tube
Steam stop valve
ASME hydro test of boiler piping
Alarm light package
Direct vent combustion air provision
For layout purposes, the overall dimensions for the Model CFV are shown in Figure
B7-11 and Table B7-3. Connection sizes are given in Table B7-3 and ratings of each
boiler size are noted in Table B7-4. Additional information is shown in the following
Table B7-5 Recommended steam nozzle sizes
Table B7-6 Minimum required gas pressure
Table B7-7 Safety valve outlet sizes
Table B7-8 Boiler room width
Table B7-9, Figure B7-14 Lifting lug locations
Table B7-10, Figure B7-15 Boiler mounting piers
B7-14
01/09
Figure B7-11. Model CFV Steam Boiler Dimensions
B7-15
01/09
Table B7-3. Model CFV Steam Boiler Dimensions
Boiler Horsepower
Dimension 10 15 20 25 30 40 50 60
LENGTHS
Overall A 50 50 55 55 68 68 75 75
Centerline to Boiler Front B 25 25 29 29 35 35 37.5 37.5
Centerline to Boiler Rear C 25 25 26 26 33 33 37.5 37.5
Centerline to Stack Outlet D 22.5 22.5 24.5 24.5 30.5 30.5 34.5 34.5
Centerline to Combustion Air
Inlet
E 4 4 4 4 4 7 7 7
Boiler I.D. F 27 27 34 34 42 42 51 51
WIDTHS
Overall G 32 32 39 39 47 47 56 56
Base, Outside of Channel H 26 26 28 28 36 36 46 46
Base, Inside of Channel J 14 14 16 16 24 24 34 34
Centerline to Gas Inlet K 26 26 26 26 26 33 33 33
HEIGHTS
Overall L 84 90 84 90 86.5 92.5 99 105
Vessel M 73 77 73 79 72 78 81 87
Top of Boiler Clearance N 24 24 24 24 24 36 36 36
Floor to Gas Inlet P 77 83 77 83 78.5 88.5 89.25 95.25
Floor to Air Inlet Q 77 83 77 83 78.5 87.5 88.25 94.25
Floor to Feedwater Inlet R 30 30 27 27 29.5 29.5 34.5 34.5
Floor to Drain/Blowdown S 15.5 15.5 15 15 17 17 20 20
Floor to Stack Outlet T 8.5 8.5 8.5 8.5 9 9 11 11
BOILER CONNECTIONS
Horizontal Centerline to Gas
Inlet
V 5 5 4.25 4.25 4.25 5.25 5.25 5.25
Horizontal Centerline to Steam
Outlet
W 2 2 5 5 6.5 6.5 7.25 7.25
Vertical Centerline to Steam
Outlet
X 11.4 11.5 14 14 17.5 17.5 19.75 19.75
Feedwater AA 1 1 1 1 1 1 1-1/4 1-1/4
Steam Outlet BB 1-1/2 1-1/2 1-1/2 1-1/2 2 2 3 3
Gas Inlet CC 1 1 1 1 1-1/4 1-1/4 1-1/2 1-1/2
Surface Blowoff DD 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4
Drain / Blowdown EE 1 1 1 1 1 1 1-1/4 1-1/4
Stack O.D. FF 6 6 6 6 8 8 10 10
Combustion Air Inlet
A
GG 4 4 4 4 6 6 8 8
WEIGHTS - LBS
Water Weight (Normal) 710 815 1195 1365 1795 2050 2715 3090
Approx. Dry Weight 2000 2120 2540 2780 3690 4030 5280 5740
B7-16
01/09
Table B7-4. Model CFV Steam Ratings
Table B7-5. Model CFV Recommended Steam Nozzle Size
Boiler H.P. 10 15 20 25 30 40 50 60
Ratings
Rated Capacity - Steam
345 518 690 863 1,035 1,380 1,725 2,070
Output (1000 Btu/hr) 335 502 669 837 1,004 1,339 1,674 2,008
Fireside Heating Surface
(sq.ft.)
84 103 128 159 208 258 312 388
Approximate Fuel Consumption At Rated Capacity
Natural Gas Input (cfh) -
150#Steam
A
413 620 826 1,033 1,240 1,653 2,066 2,479
Power Requirements -
60Hz
(Single Phase, 115 VAC)
Blower Motor Size
(Watts)
B
335 335 335 335 335 750 1,200 1,200
Notes:
A. Input calculated at nominal 81% efficiency for 1000 Btu gas content
B. For altitudes above 700 ft, contact your local Cleaver Brooks authorized representative for verification of blower
motor size.
OPERATING PRESSURE
PSIG 10 15 20 25 30 40 50 60
75 1.5 1.5 2 2 2 2.5 3 3
100 1.5 1.5 1.5 2 2 2 3 3
125 1.5 1.5 1.5 2 2 2 3 3
NOTES:
BOILER HP
B7-17
01/09
Table B7-6. Model CFV Gas Pressure Requirements
Table B7-8. Boiler Room Width
BOILER INLET PIPE
HP SIZE MIN. MAX
(Inches) ("WC) ("WC)
10 1 7.2
15 1 7.3
20 1 7.5
25 1 7.7
30 1.25 8.5
40 1.25 11.0
50 1.5 10.0
60 1.5 10.0
Note: For altitudes up to 700 feet.
28
PRESSURE REQUIRED
BOILER HP 10-15 20-25 30-40 50-60
DIM. "A" 40 44 48 52
DIM. "B" 62 63 71 80
NOTES:
1. Recommended Minimum Distance Between Boiler and Wall. Dimension "A" allows for a
clear 24" aisle between the boiler and the wall. If space permits, this aisle
should be widened.
Dimension "B" between boilers allows for a clear aisle of 24".
NOTE: Valve manufacturers are Kunkle,
Consolidated or Conbraco, depending on
availability.
Table B7-7. Model CFV Steam Boiler
Safety Valve Outlet Size
VALVE SETTING
150 PSIG STEAM
BOILER HP
NO. OF
VALVES
REQ'D
OUTLET
SIZE (IN.)
10 1 3/4
15 1 3/4
20 1 3/4
25 1 1
30 1 1
40 1 1
50 1 1-1/4
60 1 1-1/4
B7-18
01/09
PERFORMANCE DATA
Table B7-9 shows predicted fuel-to-steam efficiencies for the Model CFV.
Cleaver-Brooks offers an industry leading fuel-to-steam efficiency guarantee for Model
CFV boilers. The guarantee is based on the numbers shown in the tables and on the
conditions listed below (the efficiency percent number is only meaningful if the
specific conditions of the efficiency calculations are clearly stated in the
specification).
Cleaver-Brooks will guarantee that, at the time of initial start-up, the boiler will
achieve fuel-to-steam efficiency as shown for 25%, 50%, 75% and 100% firing. If
the boiler fails to achieve the corresponding efficiency guarantee as published,
Cleaver-Brooks will rebate, to the final owner, five thousand dollars ($5,000.00) for
every full efficiency point (1.0%) that the actual efficiency is below the guaranteed
level. The specified boiler efficiency is based on the following conditions:
Natural Gas
Carbon, % by weight = 69.98
Hydrogen, % by weight = 22.31
Sulfur, % by weight = 0.0
Heating Value, Btu/lb = 21,830
Efficiencies are based on ambient air temperature of 80
o
F (27 C), relative
humidity of 30%, and 15% excess air in the exhaust gas stream.
Efficiencies are based on the manufacturer's published radiation and convection
losses; see Table B7-10.
Nominal feedwater temperature of 190
0
F (88 C) or greater.
Table B7-9. Predicted Fuel-to-Steam Efficiencies
25% 50% 75% 100%
10 81.8 82.3 82.2 82.1
15 81.7 82.2 82.0 81.8
20 81.5 81.6 81.2 80.7
25 81.6 81.9 81.6 81.2
30 81.8 82.3 82.2 82.0
40 81.8 82.4 82.3 82.2
50 81.4 81.6 81.1 80.6
60 81.6 81.9 81.6 81.3
BHP
OPERATING PRESSURE = 125 psig
% OF LOAD
B7-19
01/09
Table B7-10. Model CFV Radiation and Convection Losses
The emission data included in Table B7-11 consists of typical controlled emission
levels of the Model CFV boiler. Because of the premix burner technology, the standard
burner provided with the CFV package provides low emissions as standard without
the need for external or special devices.
Table B7-12 shows predicted sound levels at high fire.
Table B7-11. Model CFV Boilers: Natural Gas, Estimated Emission Levels
BHP
125# Operating Pressure
25% 50% 75% 100%
10 1.9 1.0 0.7 0.5
15 1.9 1.0 0.7 0.5
20 1.9 1.0 0.7 0.5
25 1.9 1.0 0.7 0.5
30 1.9 1.0 0.7 0.5
40 1.9 1.0 0.7 0.5
50 1.9 1.0 0.7 0.5
60 1.9 1.0 0.7 0.5
POLLUTANT UNITS
ppm
A
50
lb/MMBtu 0.04
ppm
A
20
lb/MMBtu 0.024
ppm
A
1
lb/MMBtu 0.001
ppm
A
10
lb/MMBtu 0.004
ppm
A
-
lb/MMBtu 0.01
A. ppm levels are given on a dry volume basis and corrected to 3% oxygen (15% excess air)
PM
CO
NOx
SOx
HC/VOC
5
B7-20
01/09
Table B7-12. Predicted sound levels
Sound levels are measured 3 feet from the front of the panel at an elevation of 5 feet
from the floor.
ENGINEERING DATA
The following engineering information is provided for the Model CFV steam boiler.
Additional information may be obtained from your local Cleaver-Brooks
representative.
combination of condensate return and raw make-up or in some instances, 100% raw
make-up. Proper treatment of make-up water is essential to the longevity and
performance of the boiler. Table B7-13 shows the rate of make-up required and Table
B7-14 shows the water quality guidelines.
Table B7-13. Feedwater flow rates
Table B7-14. Model CFV Water Quality
BHP Sound Level-dbA
10 60
15 65
20 60
25 66
30 62
40 68
50 67
60 69
BHP Gal lons/Hour
10 41
15 62
20 83
25 103
30 124
40 165
50 207
60 248
Feedwater flow is at maxumin firing rate, 212F steaming capacity
Constit uent Level
Hardness 1.0 ppm max.
Iron 0.1 ppm max.
pH 8.3 - 10.5
Suspended Solids 300 ppm max.
B7-21
01/09
Blowdown As steam is produced, unwanted solids are left behind in the water and become
concentrated within the vessel. If these constituents are allowed to adhere to the heat
transfer surfaces they will impede the flow of energy. Their removal requires proper
blowdown - either bottom, surface, or both. Table B7-15 shows the recommended
blowdown tank requirements for bottom blowdown. The surface blowdown
requirement is relative to the water quality and to the level of TDS control desired by
the water treatment specialist. Local codes will dictate the manner of treating
blowdown affluent.
recommendations of the National Board of Boiler and Pressure Vessel Inspectors. The
National Board's recommendations base the size of the blowdown tank on the
Table B7-15. Model CFV Blowdown Tank Sizing Information
Stack/Breeching
Criteria
General - The ClearFire Model CFV is a Category III Boiler according to ANSI Z21.13.
This code defines a Category III boiler as one that operates with a positive vent
pressure and a vent gas temperature that is non-condensing. Therefore the stack
must be a positive pressure design.
operation of the boiler. The vent should be designed with proper supports and
stack connection as proper draft is critical to safe and efficient burner performance.
size the breeching and stack to limit flue gas pressure variations. Consideration of the
draft must be given whenever direct combustion air ducting is utilized and lengthy
runs of breeching are employed. Please note: The allowable pressure range for design
of the stack and breeching is negative 0.25" w.c. (-62 Pa) to a positive 0.25" w.c.
(+62 Pa) for proper light offs and combustion. NOTE: This pressure range does not
pertain to the boiler room; that is, the boiler room must be neutral or slightly positive,
never negative when using air from the boiler room for combustion.
Whenever two or more CFV boilers are connected to a common breeching/stack, a
10 3
15 3
20 6
25 6
30 8
40 8
50 12
60 12
B7-22
01/09
mechanical draft control system may be required to ensure proper draft at all times.
Cleaver-Brooks recommends individual stacks for multiple boiler installations.
Combustion Air - The burner must be supplied with adequate volume of
uncontaminated air to support proper combustion and equipment ventilation. Air
method, all installations must comply with NFPA54 (the National Fuel Gas Code -
NFGC) for U.S. installations and CAN/CSA B149.1 and B149.2 for Canadian
installations.
Note: A boiler room exhaust fan is not recommended as this type of device can cause
a negative pressure in the boiler room if using conventional air intake.
In accordance with NFPA 54, the required volume of indoor air shall be determined
in accordance with the "Standard Method" or "Known Air Infiltration Rate Method".
Where air infiltration rate is known to be less than 0.40 Air Changes per Hour, the
Known Air Infiltration Rate Method shall be used. (See the NFPA Handbook for
additional information).
Unconfined Spaces
All Air From Inside the Building - If combustion air is drawn from inside the building
(the mechanical equipment room does not receive air from outside via louvers or vent
openings and the boiler is not equipped with direct vent) and the boiler is located in
an unconfined space, use the following guidelines:
The mechanical equipment room must be provided with two permanent openings
linked directly with additional room(s) of sufficient volume so that the combined
volume of all spaces meets the criteria for an unconfined space. Note: An "unconfined
space" is defined as a space whose volume is more than 50 cubic feet per 1,000 Btu
per hour of aggregate input rating of all appliances installed in that space.
Each opening must have a minimum free area of one square inch per 1,000 Btu per
hour of the total input rating of all gas utilizing equipment in the mechanical room.
One opening must terminate within twelve inches of the top, and one opening must
terminate within twelve inches from the bottom of the room.
See Figure B7-12; refer to the NFGC for additional information.
B7-23
01/09
Figure B7-12. Inside Air - Two Opening Method
All Air From Outdoors - If all combustion air will be received from outside the
building (the mechanical room is linked with the outdoors), the following methods
can be used:
Two Opening Method (Figure B7-13) - The mechanical equipment room must be
provided with two permanent openings, one terminating within twelve inches from
the top, and one opening terminating within twelve inches from the bottom of the
room.
A. The opening must be linked directly or by ducts with the outdoors.
B. Each opening must have a minimum free area of one square inch per 4,000 Btu
per hour of total input rating of all equipment in the room, when the opening is
directly linked to the outdoors or through vertical ducts.
C. The minimum free area required for horizontal ducts is one square inch per 2,000
Btu per hour of total input rating of all the equipment in the room.
GAS
VENT
INTERIOR WALL
FRESH AIR OPENING
FRESH AIR OPENING
12" MINIMUM
12" MINIMUM
B7-24
01/09
One Opening Method (Figure B7-14) - One permanent opening, commencing within
12 inches of the top of the room shall be provided.
A. The equipment shall have clearances of at least 1 inch from the sides and back
and 6 inches from the front of the appliance.
B. The opening shall directly communicate with the outdoors and shall have a
minimum free area of 1 square inch per 3000 Btu's per hour of the total input rating
of all equipment located in the enclosure, and not less than the sum of the areas of
all vent connectors in the unconfined space.
C. Refer to the NFGC for additional information.
GAS
VENT
EXTERIOR WALL
INTERIOR WALL
FRESH AIR
INLET DUCT
OUTLET AIR DUCT
12" MINIMUM
12" MINIMUM
GAS
VENT
EXTERIOR WALL
FRESH AIR OPENING
12" MINIMUM
B7-25
01/09
Unconfined Spaces
Engineered Design - When determining boiler room air requirements for an
unconfined space the "Engineered Design" method may be used. Following this
method, consideration must be given to the size of the room, airflow and velocity of
air as follows:
of 7 feet. This allows air to sweep the length of the boiler (see Figure B7-15).
Figure B7-15. Engineered Method
subject to clogging with dirt and dust.
square foot.
2
= cfm
a
/fpm
a
), where cfm
a
=
a
EXTERIOR WALL
FRESH AIR OPENING
EXTERIOR WALL
FRESH AIR OPENING
GAS
VENT
B7-26
01/09
Determine the area of the boiler room air supply openings for (2) 60 horsepower
Model CFV boilers at 750 feet elevation. The air openings will be 5 feet above the
floor level.
Total boiler horsepower (bhp): 60 x 2 = 120 bhp
Area required: From the formula in E above, 1200cfm/250fpm = 4.8 square feet
total.
Area/Opening: 4.8 divided by 2 = 2.4 ft
2
Notice
Direct Combustion Air - If combustion air will be drawn directly from the outside
(direct vent combustion, sometimes called "sealed combustion") by means of a duct
connected directly to the burner air intake, use the following guidelines:
1. Install combustion air duct in accordance with local codes and the boiler
operating and maintenance manual.
room.
3. Duct material can be PVC or metallic vent material. It should be air tight to
prevent in leakage of air during operation.
4. Maximum pressure drop for the duct shall not exceed 0.25" w.c. negative. If this
pressure drop is exceeded a larger size duct is recommended.
5. Multiple boilers may be connected to a single duct with take-offs to each boiler.
6. If the duct will run horizontally to an outside wall, it is recommended that the
duct have a slight downward slope away from the burner intake to prevent
collected moisture from draining into the burner connection.
7. If the outside air is dust-laden or the installation is near a heavily traveled
roadway, it is recommended that an air filter be installed to prevent intake of
contaminants that could accumulate on the burner canister.
B7-27
01/09
Figure B7-16. Direct Vent Combustion
Gas Piping General - The ClearFire Model CFV gas fired steam boilers are full modulating input
units that require appropriate gas supply pressure and volume for proper operation
and long burner life. The gas requirements specified in this section must be satisfied
to ensure efficient and stable combustion. Installation must follow these guidelines
and of the local authorities that have installation jurisdiction.
Gas Train Components - CFV boilers are equipped with a gas train that meets the
requirements of UL/cUL and ASME CSD-1, and also the requirements of FM and GE-
GAP (formerly IRI). The gas train and its components have been designed and tested
to operate for the highest combustion efficiency for the CFV units. Major components
are as noted in the current product specifications and O & M manual.
Gas Pressure Requirements - For proper and safe operation, each Model CFV boiler
requires a stable gas pressure input. The pressure requirements are listed in the O&M
Figure B7-17. Direct Vent Combustion kit
Fan/Blower
Venturi
Direct Vent Connection
Casing Support
Attachment
Flexible Connection
Adapter Flange
Gasket
B7-28
01/09
manual and current specifications and are added here for reference purposes.
The minimum inlet supply pressure must be as noted in Table B7-16 when firing the
boiler at low fire and high fire. Actual gas pressure should be measured when the
burner is firing using a manometer at the upstream test port connection on the main
gas valve. For a multiple unit installation, gas pressure should be set for a single unit
first, then the remaining units should be staged on to ensure that gas pressure droop
is not more than 1" w.c. and never below the required pressure. Fluctuating gas
pressure readings could be indicative of a faulty supply regulator or improper gas train
size to the boiler.
Table B7-16. Model CFV Minimum Gas Pressure Requirements
Gas Piping - CFV units are standardly equipped with a gas pressure regulator. If
upstream pressure exceeds 1 psig, an additional upstream regulator must be installed
along with a pressure relief valve. Note: Gas connection is at the left side of the boiler,
left hand side as you face the front of the boiler.
For buildings or boiler rooms with gas supply pressure exceeding 28" w.c. a "full lock-
up" type regulator is recommended along with proper overpressure protection (e.g.
relief valve). In addition to the regulator, a plug type or "butterball type" gas shutoff
cock should be installed upstream of the regulator for use as a service valve. This is
also required to provide positive shutoff and isolate the unit during gas piping tests.
any dirt, weld slag, or debris can deposit in the drip leg rather than into the boiler gas
train. The bottom of the drip leg should be removable without disassembling any gas
piping. The connected piping to the boiler should be supported from pipe supports
and not supported by the boiler gas train or the bottom of the drip leg.
Before starting the unit(s) all piping must be cleaned of all debris to prevent its'
entrance into the boiler gas train. Piping should be tested as noted in NFPA 54 and
the boiler must be isolated during any tests.
After initial startup, the inlet screen to the gas valve should be checked and cleaned
for any debris buildup
Boiler
Size
Pressure required at gas
train connection
Low Fire High Fire
10 7.0" w.c. 5.2" w.c.
15 7.0" w.c. 5.3" w.c.
20 7.0" w.c. 5.5" w.c.
25 7.0" w.c. 5.7" w.c.
30 8.5" w.c. 6.8" w.c.
40 10.5" w.c. 8.0" w.c.
50 9.5" w.c. 7.0" w.c.
60 10.0" w.c. 8.0" w.c.
B7-29
01/09
Gas Supply Pipe Sizing - For proper operation of a single unit or a multiple unit
installation, we recommend that the gas pipe sizing be sized to allow no more than
0.3" w.c. pressure drop from the source (gas header or utility meter) to the final unit
location. The gas supplier (utility) should be consulted to confirm that sufficient
volume and normal pressure are provided to the building at the discharge side of the
gas meter or supply pipe.
For installations of new boilers into an existing building, gas pressure should be
measured with a manometer to ensure sufficient pressure is available. A survey of all
connected "gas using devices" should be made. If appliances other than the boiler or
boilers are connected to the gas supply line, then a determination must be made of
how much flow volume (CFV = cubic feet per hour) will be demanded at one time
and the pressure drop requirement when all appliances are firing.
piping. Total equivalent length should be calculated from the utility meter or source to
the final unit connection. As a minimum guideline, gas piping Tables B7-17 through
B7-21 should be used. The data in these tables is from the NFPA 54 source book,
2006 edition.
To verify the input of each device that is connected to the gas piping, obtain the btu/
hr input and divide this input by the calorific value of the gas that will be utilized. For
instance, a 40 HP unit with 1,613,253 btu/hr input divided by a gas calorific value
of 1060 will result in a CFV flow of 1,522. The single boiler is approximately 20 feet
from the gas supply header source. And with a measured gas supply pressure of 10"
w.c. we find from Table 17 that a supply pipe size of 2" should be used as a
minimum.
B7-30
01/09
MODEL CFV MODEL CFV
MODEL CFV
MODEL CFV
Figure B7-23. Example gas piping <1 psig supply
B7-31
01/09
Pipe Size
Nominal 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
Actual I.D. 1.049 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"
Length in feet **Maximum Capacity in Cubic Feet of Gas per Hour (CFV)
10 514 1,060 1,580 3,050 4,860 8,580 17,500
20 363 726 1,090 2,090 3,340 5,900 12,000
30 284 583 873 1,680 2,680 4,740 9,660
40 243 499 747 1,440 2,290 4,050 8,290
50 215 442 662 1,280 2,030 3,590 7,330
60 195 400 600 1,160 1,840 3,260 6,640
70 179 368 552 1,060 1,690 3,000 6,110
80 167 343 514 989 1,580 2,790 5,680
90 157 322 482 928 1,480 2,610 5,330
100 148 304 455 877 1,400 2,470 5,040
125 131 269 403 777 1,240 2,190 4,460
150 119 244 366 704 1,120 1,980 4,050
175 109 209 336 648 1,030 1,820 3,720
200 102 185 313 602 960 1,700 3,460
**Fuel: Natural Gas
Pipe Size
Nominal 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
Actual I.D. 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"
Length in feet **Maximum Capacity in Cubic Feet of Gas per Hour (CFV)
10 678 1,390 2,090 4,020 6,400 11,300 23,100
20 466 957 1,430 2,760 4,400 7,780 15,900
30 374 768 1,150 2,220 3,530 6,250 12,700
40 320 657 985 1,900 3,020 5,350 10,900
50 284 583 873 1,680 2,680 4,740 9,600
60 257 528 791 1,520 2,430 4,290 8,760
70 237 486 728 1,400 2,230 3,950 8,050
80 220 452 677 1,300 2,080 3,670 7,490
90 207 424 635 1,220 1,950 3,450 7,030
100 195 400 600 1,160 1,840 3,260 6,640
125 173 355 532 1,020 1,630 2,890 5,890
150 157 322 482 928 1,480 2,610 5,330
175 144 296 443 854 1,360 2,410 4,910
200 134 275 412 794 1,270 2,240 4,560
**Fuel: Natural Gas
B7-32
01/09
Pipe Size
Nominal 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
Actual I.D. 0.622 0.824 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"
Length in
feet
**Maximum Capacity in Cubic Feet of Gas per Hour (CFV)
10
1,510 3,040 5,560 11,400 17,100 32,900 52,500 92,800 189,000
20
1,070 2,150 3,930 8,070 12,100 23,300 57,100 65,600 134,000
30
869 1,760 3,210 6,590 9,880 19,000 30,300 53,600 109,000
40
753 1,520 2,780 5,710 8,550 16,500 26,300 46,400 94,700
50
673 1,360 2,490 5,110 7,650 14,700 23,500 41,500 84,700
60
615 1,240 2,270 4,660 6,980 13,500 21,400 37,900 77,300
70
569 1,150 2,100 4,320 6,470 12,500 19,900 35,100 71,600
80
532 1,080 1,970 4,040 6,050 11,700 18,600 32,800 67,000
90
502 1,010 1,850 3,810 5,700 11,000 17,500 30,900 63,100
100
462 954 1,710 3,510 5,260 10,100 16,100 28,500 58,200
125
414 836 1,530 3,140 4,700 9,060 14,400 25,500 52,100
150
372 751 1,370 2,820 4,220 8,130 13,000 22,900 46,700
175
344 695 1,270 2,601 3,910 7,530 12,000 21,200 43,300
200
318 642 1,170 2,410 3,610 6,960 11,100 19,600 40,000
500
192 401 717 1,470 2,210 4,250 6,770 12,000 24,400
1000
132 275 493 1,010 1,520 2,920 4,650 8,220 16,800
1500
106 221 396 812 1,220 2,340 3,740 6,600 13,500
**Fuel: Natural Gas
B7-33
01/09
Pipe Size
Nominal 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
Actual I.D. 0.622 0.824 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"
Length in
feet
10
2,350 4,920 9,270 19,000 28,500 54,900 87,500 155,000 316,000
20
1,620 3,380 6,370 13,100 19,600 37,700 60,100 106,000 217,000
30
1,300 2,720 5,110 10,500 15,700 30,300 48,300 85,400 174,000
40
1,110 2,320 4,380 8,990 13,500 25,900 41,300 75,100 149,000
50
985 2,060 3,880 7,970 11,900 23,000 36,600 64,800 132,000
60
892 1,870 3,520 7,220 10,300 20,300 33,200 58,700 120,000
70
821 1,720 3,230 6,640 9,950 19,200 30,500 54,000 110,000
80
764 1,600 3,010 6,180 9,260 17,800 28,400 50,200 102,000
90
717 1,500 2,820 5,800 8,680 16,700 26,700 47,100 96,100
100
677 1,420 2,670 5,470 8,200 15,800 25,200 44,500 90,300
125
600 1,250 2,360 4,850 7,270 14,000 22,300 39,500 80,500
150
544 1,140 2,140 4,400 6,590 12,700 20,200 35,700 72,900
175
500 1,050 1,970 4,040 6,060 11,700 18,600 32,900 67,100
200
465 973 1,830 3,760 5,640 10,900 17,300 30,600 62,400
500
283 593 1,120 2,290 3,430 6,610 10,300 18,600 38,000
1000
195 407 897 1,380 2,360 4,550 7,240 12,000 26,100
1500
156 327 616 1,270 1,900 3,650 5,820 10,300 21,000
**Fuel: Natural Gas
B7-34
01/09
Pipe Size
Nominal 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
Actual
I.D.
0.622 0.824 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"
Length
in feet
10
3,190 6,430 11,800 24,200 36,200 69,700 111,000 196,000 401,000
20
2,250 4,550 8,320 17,100 25,600 49,300 78,600 139,000 283,000
30
1,840 3,720 6,790 14,000 20,900 40,300 64,200 113,000 231,000
40
1,590 3,220 5,880 12,100 18,100 34,900 55,600 98,200 200,000
50
1,430 2,880 5,260 10,800 16,200 31,200 49,700 87,900 179,000
60
1,300 2,630 4,800 9,860 14,800 28,500 45,400 80,200 164,000
70
1,200 2,430 4,450 9,130 13,700 26,400 42,000 74,300 151,000
80
1,150 2,330 4,260 8,540 12,800 24,700 39,300 69,500 142,000
90
1,060 2,150 3,920 8,050 12,100 23,200 37,000 65,500 134,000
100
979 1,980 3,620 7,430 11,100 21,400 34,200 60,400 123,000
125
876 1,770 3,240 6,640 9,950 19,200 30,600 54,000 110,000
150
786 1,590 2,910 5,960 8,940 17,200 27,400 48,500 98,900
175
728 1,470 2,690 5,520 8,270 15,900 25,400 44,900 91,600
200
673 1,360 2,490 5,100 7,650 14,700 23,500 41,500 84,700
500
384 802 1,510 3,100 4,650 8,950 14,300 25,200 51,500
1000
264 551 1,040 2,130 3,200 6,150 9,810 17,300 35,400
1500
212 443 834 1,710 2,570 4,940 7,880 13,900 28,400
**Fuel: Natural Gas
B7-35
01/09
Gas Header - For multiple unit installations, a single common gas header is
recommended with individual takeoffs for each boiler (See Figure B7-22). Boiler gas
manifold piping should be sized based on volume requirements and lengths between
each boiler and the fuel main header. Tables B7-22 through B7-29 indicate the
proper sizing for multiple units of equal size, placed on the factory standard center
with the indicated take off size. For installations with a mixed sized use, determine
the flow of each unit and total the input. With the total input, determine length of run
from the source and determine what size header will be needed for the flow of all
units firing. Pipe sizes are based on Table B7-17 with boiler gas line take-off at 20
feet from the header. If pipe runs are greater or if gas pressure is different, refer to the
Tables for pipe sizing.
Table B7-22. CFV 10 HP Boilers
# of
Units
1 2 3 4
Pipe Size
To Boiler
1-1/4" 1-1/4" 1-1/4" 1-1/4"
Header
Pipe Size
1-1/4" 1-1/4" 2" 2"
# of
Units
1 2 3 4
Pipe Size
To Boiler
1-1/2" 1-1/2" 1-1/2" 1-1/2"
Header
Pipe Size
1-1/2" 2" 2-1/2" 2-1/2"
# of
Units
1 2 3 4
Pipe Size
To Boiler
2" 2" 2" 2"
Header
Pipe Size
2" 2-1/2" 3" 3"
# of
Units
1 2 3 4
Pipe Size
To Boiler
2" 2" 2" 2"
Header
Pipe Size
2" 3" 3" 4"
# of
Units
1 2 3 4
Pipe Size
To Boiler
1-1/4" 1-1/4" 1-1/4" 1-1/4"
Header
Pipe Size
1-1/4" 2" 2" 2-1/2"
# of
Units
1 2 3 4
Pipe Size
To Boiler
1-1/2" 1-1/2" 1-1/2" 1-1/2"
Header
Pipe Size
1-1/2" 2" 2-1/2" 3"
# of
Units
1 2 3 4
Pipe Size
To Boiler
2" 2" 2" 2"
Header
Pipe Size
2" 2-1/2" 3" 4"
# of
Units
1 2 3 4
Pipe Size
To Boiler
2-1/2" 2-1/2" 2-1/2" 2-1/2"
Header
Pipe Size
2-1/2" 3" 4" 4"
Pipe sizing for multiple unit manifolds
B7-36
01/09
SPECIFICATIONS
MODEL CFV PRODUCT SPECIFICATIONS
A. The boiler shall be a Cleaver-Brooks Model CFV 700, single pass vertical
commercial Firetube design or approved equal. It shall be mounted on a heavy-
duty steel frame with premix forced draft burner and burner controls as a complete
package from one manufacturer.
B. Approvals - The complete package including the burner shall be Underwriters
Laboratories, Inc. listed and the official UL/cUL label shall be affixed to the
package attesting to its certification.
C. As a preassembled package, the standard boiler shall be factory fire tested.
D. The complete package as shipped, shall be ready for connections to water, fuel,
blowdown, and exhaust venting. Certain items may be shipped loose to prevent
their damage such as the safety valves and gauges.
E. The specified boiler shall have an output rating of _____ horsepower when fired
with Natural Gas [LP Gas] with a gas supply pressure of ____" w.c. Power supply
to the boiler shall be 115/1/60. Design pressure shall be 150# steam. Operating
characteristics shall be [___] psig steam. Steam boilers shall be supplied with
____ degrees F make-up water @ ____%.
F. Performance: shall be as specified in Paragraph 5 below.
1.1 BOILER SHELL
A. The boiler shell must be constructed in accordance with the ASME Code, either
Section I for high-pressure steam or Section IV for low-pressure steam. The vessel
must be subjected to the required inspections of the Code conducted by an
independent third party inspector. A signed inspection sheet shall be provided to
the purchaser and the appropriate ASME symbol shall be affixed or stamped onto
the boiler.
1.Boiler shall be mounted on base rails suitable for transporting by fork lift.
2.Burner housing shall be removable or hinge-mounted (50-60 HP) to allow tube
inspection.
3.Each carbon steel boiler tube shall utilize the AluFer heat transfer design
technology for high efficiency and reduction in overall size of the vessel and shall
be a minimum of 0.105 tube wall thickness.
4.To facilitate waterside inspection, 3 hand holes shall be provided.
5.An observation port for flame inspection shall be provided.
6.Boiler insulation shall consist of 2-inch fiberglass blanket, which shall be
covered with a powder coated sheet metal jacket. This jacket and insulation
design shall permit field removal and reattachment if necessary for inspection,
etc.
7.The entire boiler and base frame shall be factory painted.
B7-37
01/09
8.Exhaust vent shall be located at the rear of the boiler and shall be a slip
connection. Stack support shall be by means other than the boiler connection.
1.2 BOILER SHELL TAPPINGS/OPENINGS
A. The following boiler vessel tappings/openings shall be furnished:
1.Steam supply by NPT connection for high-pressure steam.
2.Bottom blowdown.
3.Feedwater Make-up.
4.Surface blowoff.
5.Chemical Feed.
6.High Water Level Overflow Drain to discharge water in the boiler if water level
reaches an unacceptable level.
2.0 STEAM BOILER TRIM (All piping and devices per ASME CSD-1)
A. Water Column
1.A water column shall be furnished complete with gauge glass and water column
blowdown valve.
a. Feedwater Pump control - shall be integral with the water column via probe control
device and electronics for on/off pump operation.
b. Low Water cutoff - shall be integral with the water column via probe control device
and solid state electronics mounted and wired in the control panel.
B. An Auxiliary Low Water Cutoff shall be provided. It shall be located on the top
centerline of the boiler using an internal probe and of the manual reset design.
C. For safety steam pressure lockout a high limit pressure control, manual reset shall
be provided. The device shall be mercury free.
D. To provide steam demand tracking a steam pressure transmitter shall be provided
that provides an input signal for burner positioning in accordance to steam
demand.
E. A 3" Steam Pressure Gauge shall be piped onto the trim piping, including an
inspectors test cock.
F. In accordance with the A.S.M.E. Code an approved A.S.M.E. rated and stamped
safety valve shall be provided and set at 150#.
3.0 BURNER AND BURNER CONTROLS
A. Mode of Operation - To minimize short cycling and provide highest efficiency the
burner for the specified boiler shall be of the electronic modulation with a
turndown ratio of 5:1 for Natural Gas for sizes of 30 horsepower and greater, and
4:1 for sizes below 30 horsepower. On/off or low/high burner operation shall not
be accepted.
B. The burner shall be enclosed in a NEMA 1 type enclosure. A lift off top cover shall
be provided to gain access to the burner and controls.
B7-38
01/09
C. Design - The burner design shall be of the linkage-less premix technology wherein
the fuel and air are mixed in the fan housing assembly prior to entering the burner
canister. Separately driven linkage or servo motor driven fuel and air valves shall
not be permitted.
1.Fan housing shall utilize non-sparking material and shall be approved for premix
operation.
2.The fan shall be driven by a variable speed motor which shall react to output
demand requirements via the demand control Motor shall be a high efficiency
DC Brushless type. Continuous speed synchronous motors will not be
acceptable.
D. Ignition of the fuel shall be of the direct spark design; separate pilot gas train is
not required. Dual ignition electrodes shall used for the spark generated from the
panel mounted ignition transformer.
E. Combustion shall take place on the surface of the burner canister. The canister
shall be constructed of Fecralloy material and stainless steel and shall be
warranted for five years against failure from defects or poor workmanship.
F. Air Filter - shall be fitted to the intake air venturi to filter the incoming air supply
when using boiler room air. The air filter shall be designed to be easily cleaned
and re-used.
G. Fuel - The burner shall be designed for operation with natural gas or LP gas. Gas
Train, shall be located at the front of the burner and along the left side of the boiler.
In accordance with UL/cUL and ASME CSD-1, the following components shall be
furnished:
1.Single body dual solenoid safety shutoff valve incorporating the following:
a. The valve shall be a 1:1 ratio valve with an integral trim regulator and shall operate
in relation to the fan speed. An air sensing line shall be connected from the air inlet
venturi (mounted to the fan motor) and to the gas valve for control of gas input.
b. As fan speed increases a negative pressure will be applied to the valve, allowing the
valve to open further, permitting more fuel to flow into the venturi for mixing. As fan
speed is reduced, fuel input shall be reduced accordingly. Air shall always lead fuel from
low to high or high to low.
2.Manual fuel shutoff valve - shall be located downstream of the gas valve and
used for CSD-1 leak testing.
3.Gas Pressure Interlocks - one shall be provided for sensing high gas pressure and
one provided to sense low gas pressure. Each control shall be of the manual
reset type.
4.Gas Pressure Regulator - shall be provided upstream of the gas valve to provide
regulated pressure to the gas train from the gas supply. This regulator shall be
suitable for a maximum of 1 psig gas pressure. If gas pressure exceeds 1 psig,
a gas pressure relief valve shall be furnished and upstream pressure regulator
that is of the full lockup type.
5.Manual Shutoff Valves - shall be provided upstream of the gas regulator to
manually close off the gas supply when servicing the gas train or isolating the
B7-39
01/09
boiler. A shutoff valve shall be provided at the burner for tightness checking of
the gas valve.
6.Combustion Air Proving Switch shall be provided to prove, prior to modulation
that the fan is operating properly.
H. Flame Safety
1.Flame sensing shall be accomplished with a flame rod and mounted in the
burner mounting plate, designed for easy removal for inspection or replacement.
4.0 CONTROL PANEL
A NEMA 1A type enclosure is furnished and located at the front of the boiler to house
the following components:
A. CB Falcon controller combining flame supervision, burner sequencing, modulating
control, and operating limit control
B. CB Falcon touchscreen display/operator interface.
C. Control Circuit Power On/Off Switch.
D. Demand switch.
E. Provide terminals for control interface wiring, customer connections, and
connections for incoming power.
F. Install solid state circuit boards for water level controls.
G. Selectable Options:
_____Alarm Light Package to provide indication of Low Water, Flame Failure,
Load Demand, Fuel Valve On, including a horn with silence switch for alarm
conditions.
5.0 PERFORMANCE
The proposed Boiler shall provide the following operating performance targets for
Natural Gas:
A. Efficiency - For 150# steam operating at 125#, the guaranteed Fuel to Steam
Efficiency shall be 81%. Efficiency rating shall account for radiation and
convection losses.
B. Emissions - NOx emissions shall be less than 20 PPM corrected to 3% O2 and
less than 10 PPM CO over the operating range of the burner turndown. If
emissions exceed this level, the boiler manufacturer shall correct at their expense
until this level is achieved on a repeatable basis.
C. Radiation losses shall be less than 0.5% of the rated input at maximum firing.
D. Steam quality shall be 99.5% at maximum firing regardless of operating pressure.
6.0 WARRANTY
The package boiler shall be warranted for a period of one year from date of start-up or
18 months from shipment whichever shall occur first.
B7-40
01/09
C-1
03-08
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Flue Gas Recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7
Optional Equipment (Partial Listing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9
EMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-34
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-36
Steam Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-36
Lower Drum (Mud Drum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-37
Drum Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-39
Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-39
Drum Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-40
Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-40
Convection Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-40
Casing and Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-42
Structural Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-43
Burner/Controls Information (Models A, BR, CN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-43
Flame Safeguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-44
Burner/Controls Information (Model CT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-44
Section C
Industrial Watertube Boilers
Section C
C-2
03-08
Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-50
Breeching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-50
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-59
Steam Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-59
Hot Water Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-73
ILLUSTRATIONS
Figure C-1. Model D Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-18
Figure C-2. Models DL and DLD Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-20
Figure C-3. Model DLDH Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-22
Figure C-4. Model DFE Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-24
Figure C-5. Model DW Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-26
Figure C-6. Model DLW Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-28
Figure C-7. General A Burner Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-30
Figure C-8. General BR Burner Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-31
Figure C-9. General CN Burner Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-32
Figure C-10. General CT Burner Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-33
Figure C-11. Drum Internals and Steam Purifiers for 1, 3, and 7 ppm Solids . . . . . . . . . . . . . . . . C-38
Figure C-12. Drum Internals and Separator for 99.5% Dry Steam . . . . . . . . . . . . . . . . . . . . . . . . C-38
Figure C-13. D Series Boiler Tube Cut-Away . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-39
Figure C-14. Tubes with Membrane design for Inner furnace. . . . . . . . . . . . . . . . . . . . . . . . . . . . C-41
Figure C-15. .D Series Boiler Enclosure Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-41
Figure C-16. Series Skid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-43
Figure C-17. Support Drum in Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-43
Figure C-18. Forced FGR System, Industrial Watertube Boiler (A, BR, CB Burners) . . . . . . . . . . . . C-47
Figure C-19. Induced FGR System, Industrial Watertube Boiler (CT Burner) . . . . . . . . . . . . . . . . . C-51
Figure C-20. Pier Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-52
Figure C-21. Right Hand Boiler Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-52
Figure C-22. Left Hand Boiler Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-52
Figure C-23. RH and LH Boiler Arrangement With Separate Stacks . . . . . . . . . . . . . . . . . . . . . . . C-53
Figure C-24. LH and RH Boiler Arrangement With Common Stack . . . . . . . . . . . . . . . . . . . . . . . C-53
Figure C-25. Two-Boiler Arrangement With Separate Stacks . . . . . . . . . . . . . . . . . . . . . . . . . . . C-54
Figure C-26. Breeching,; Top Outlet Transition Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-55
Figure C-27. Breeching; Gas Outlet Transition (Direct-to-Stack) . . . . . . . . . . . . . . . . . . . . . . . . . C-56
Figure C-28. Breeching; Gas Outlet Transition (Connection to horizontal breeching) . . . . . . . . . . . C-57
TABLES
Table C-1. Industrial Watertube Steam Boiler Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7
Table C-2. Standard Trim (Model D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10
Table C-3. Standard Trim (Models DL and DLD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-11
Table C-4. Standard Trim (Model DLDH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12
Table C-5. Standard Trim (Model DFE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13
Table C-6. 300 psig Steel Trim (Model D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-14
Table C-7. 300 psig Steel Trim (Models DL and DLD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-15
Table C-8. 300 psig Steel Trim (Model DLDH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-16
Table C-9. 300 psig Steel Trim (Model DFE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-17
Section C
C-3
03-08
Table C-10. Industrial Watertube Emission Data - Natural Gas (A, BR, CN Burners) . . . . . . . . . . . C-34
Table C-11. Industrial Watertube Emission Data -No. 2 Oil (A, BR, CN Burners) . . . . . . . . . . . . . . C-34
Table C-12. Industrial Watertube Emission Data - Heavy Oils (A, BR, CN Burners) . . . . . . . . . . . . C-34
Table C-13. Industrial Watertube Emission Data - Natural Gas (CT Burner) . . . . . . . . . . . . . . . . . C-35
Table C-14. Industrial Watertube Emission Data - No. 2 Oil (CT Burner) . . . . . . . . . . . . . . . . . . . C-35
Table C-15. Industrial Watertube Emission Data - Heavy Oils (CT Burner) . . . . . . . . . . . . . . . . . . C-35
Table C-16. Heating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-36
Table C-17. Maximum Heat Output (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-37
Table C-18. Maximum Heat Output (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-37
Table C-19. Burner Data (Model A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-45
Table C-20. Burner Data (Model BR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-45
Table C-21. Burner Data (Model CN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-45
Table C-22. Standard Offering (A, BR, and CN Burners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-46
Table C-23. Burner Data (Model CT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-48
Table C-24. Standard Offering (Model CT Burner). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-49
Table C-25. Industrial Watertube Boiler Stack Size Selection Chart . . . . . . . . . . . . . . . . . . . . . . . C-58
This section contains information on the Cleaver-Brooks D Series Industrial Watertube Boiler product line. The
D Series is named after its design. Tubes are assembled between the steam drum and mud drum forming the
furnace in the shape of a D, which provides maximum circulation and high steam quality. The D Series
consists of five Models: D, DL, DLD, DLDH and DFE. The models differ according to the size of their steam and
mud drums, the height and width of the boiler, and capacities.
Cleaver-Brooks Industrial Watertube Boilers range from 10,000 to 150,000 lbs/hr steam. Design pressure to
1000 psig. Super heat temperature to 750 F. High temperature hot water boilers range from 13.4 MMBtu/hr to
62.5 MMBtu/hr output. Model designations for the high temperature hot water boilers are DW and DLW.
Section C
C-4
03-08
The following features and benefits apply to Cleaver-Brooks Industrial Watertube
Boiler Products.
Boilers Six Furnace Wall Cooling:
Ensures minimal refractory maintenance and extends boiler life.
Ensures proper circulation with tiles to protect furnace floor tubes to.
Tangent Tube Design, 2" Tubes on 2" Centers
Provides greater uniform heat transfer.
Minimizes thermal stress with non-welded water-cooled, heating surfaces.
Provides cooler furnace temperature minimizing the formation of thermally-
produced NOx emissions.
Membrane Inner Furnace Wall, 2" Tubes on 4" Centers:
Eliminates by-pass of furnace gases into the convection section.
Minimizes both CO and NOx emissions.
Rear Furnace Wall:
Maximizes heat transfer area and minimizes refractory maintenance with
80% wall coverage with tubes m.
Allows stressless pressure vessel/tube expansion because of floating rear
wall with positive end wall seals.
Convection Section Design:
Enables easy tube removal with wide and narrow spacing between rows of
tubes.
Eliminates abrasion of tubes from sootblower action by locating sootblower
nozzle within the wide space area of tubes.
Maximizes heat transfer with even distribution of flue gases through the
utilization of vertical baffles.
Patented Drum Internals:
Eliminates, in many applications, the need for expensive two-or-three-
element feedwater control systems through use of Cleaver-Brooks patented
system of baffles to ensure stable water levels under dynamic load
conditions.
10 Gauge Double Casing:
Provides static zone to prevent flue gas entrapment and acid-corroding of
the casing.
Allows higher furnace pressures required to minimize NOx formations when
utilizing flue gas recirculation technologies.
Rugged and suitable for outdoor installation.
Section C
C-5
03-08
Heavy Base Frame:
Permits easy lifting, jacking, or skidding during initial installation.
Allows placement of piers, facilitating visual underside inspections and
simplifying general housekeeping.
Provides maximum support for boiler vessel.
Burners High Turndown Capability:
Reduces burner cycling.
Reduces fuel costs.
Is available for gas, oil or combination.
Integral Forced Draft Fan:
Eliminates need for special ducting or breeching.
Creates smaller overall package and an integral part of the burner windbox.
Reduces motor horsepower requirements.
Assures proper sizing for combustion air requirements.
Steam or Air Atomazation:
Provides clean, efficient firing of oil fuels.
Provides low steam consumption.
Provides packaged air compressor with air atomized burners.
Patented Fuel Oil Controller:
Consolidates function of four valves.
Eliminates need for up to 35 separate pipe fittings.
Provides ease of maintenance and operation.
Furnished completely piped and assembled.
Low NOx Capability:
Guaranteed NOx levels to 10 ppm available.
Provides ease of operation and installation.
Meets or exceeds EPA air quality regulations.
Controls Microprocessor-Based Flame Safeguard System:
Provides diagnostic capability with alpha-numeric display.
Is UL, FM, IRI, and CSA approved.
Retains last fault/lockout condition with non-volatile memory (refer to Boiler
Controls, Section 8 for more information on optional flame safeguard
systems).
Full Modulation Combustion Controls System:
Features single-point positioning for safety, simplicity, reliability, and ease of
start-up.
Section C
C-6
03-08
Maintains pressure or temperature setpoint automatically.
Features built-in low-fire hold.
Enables single switch quick changeover from gas firing to oil firing.
Cleaver-Brooks Water Column:
Comes with five probes for high and low water alarm conditions (audio-
visual alarm provided in boiler control panel) and dual redundant low water
cutoffs.
Complete Controls Package Includes:
All controls piped and wired.
Custom control systems (optional).
All wiring conforms to NEC and industry standards.
Atomizing Air Compressor (Optional):
Pre-piped (A and BR Burner) or mounted in a convenient console (CN
Burner).
Automatically-controlled and interlocked through flame safeguard system.
Flue Gas
Recirculation
Integrated Boiler/Burner/FGR Control Package
Satisfies FM/IRI requirements.
Assures high fuel-to-steam efficiency (no loss in efficiency over standard
package).
Offers synchronized FGR operation with boiler modulation.
Ensurer simplified control and safe and reliable operation with single-point-
positioning of fuel, air and FGR.
Is engineered specifically for CB Boilers.
Assures reliable, trouble-free operation with integrated safety controls.
Patented Dual Canister Burner Housing Design (Model A Burner) - Extended
Burner Drawer (Model BR & Model CN Burners):
Guarantees NOx emission control on natural gas and #2 oil-utilizing forced
FGR system configuration.
Improves CO performance.
Maintains flame stability and combustion control.
Assure complete mixing of flame and recirculating flue gases for excellent
NOx and CO control.
Proven Venturi-Type Burner Design
CT Burner venturi design allows for low NOx emissions through utilization of
induced FGR.
Mechanical Linkage Assembly
Minimizes complex controls.
Allows for single-point-positioning to synchronize fuel, air and FGR flow
rates.
Section C
C-7
03-08
Manual Shutoff Valve:
Allows for isolation of FGR system during maintenance periods while
allowing boiler to operate and maintain load.
PRODUCT OFFERING
Cleaver-Brooks Industrial Watertube Boilers range from 10,000 to 150,000 lbs/hr
steam. Design pressure to 1000 psig. Super heat temperature to 750 F.
High temperature hot water boilers range from 13.4 to 62.5 MMBtu/hr output.
Table C-1 shows Models D, DL, DLD, DLDH and DFE steam boilers and the
associated outputs.
An FGR system can be purchased with a new boiler or retrofit.
Standard Equipment 1. Included with each standard packaged unit are the following materials and
equipment:
Inner and outer 10-gauge casing.
Packaged burner assembly.
Electric single-point positioning full modulating combustion controls.
Forced draft fan and motor drive.
Sootblowers for heavy oil firing.
240 psig trim package.
Membrane inner furnace wall.
IRI requirements.
2. Each burner is furnished with a standard Cleaver-Brooks electric positioning
combustion control system designed to operate in conjunction with the burner
and fuel control valves provided.
The system includes the following major components:
Master pressure control.
Limiting pressure control.
Electric drive motor.
Control shaft and linkages.
Gas control valve (for gas or combination burners).
Fuel oil controller (for oil or combination burners).
Forced draft fan control.
The combustion control system is mounted on the unit at the plant and is shipped
as a completely integrated system.
3. The boiler is built in accordance with the following requirements:
American Society of Mechanical Engineers (ASME) Boiler and Pressure
Vessel Code, Section I, Power Boilers.
American Boiler Manufacturers Association (ABMA) Manual of Industry
Standards.
National Fire Protection Association (NFPA), 8501 Prevention of Furnace
Explosions in Fuel Oil and Natural Gas-Fired Single Burner Boiler Furnaces.
MODEL NO.
MAX OUT
A
LBS/HR
(STEAM)
D
26 16
34 21.4
42 26.8
52 37.41
60 43.92
68 50.22
76 57.17
86 65.12
94 72.62
DL
52 45.47
60 53.31
68 61.47
76 70.3
86 79.91
94 87.41
DLD
68 60.15
76 68.87
86 78.14
94 85.54
DLDH
60 63.4
68 76.3
76 85.6
86 97
94 106.2
102 115.6
110 124.9
118 134.1
DFE
85 81.3
98 101.5
110 111.5
121 121.6
132 151.7
A. DLDH with Economizer.
Table C-1. Industrial
Watertube Steam Boiler
Models
Section C
C-8
03-08
Steel Structures Painting Council (SSPC), Surface Preparation SP-l.
National Electric Code (NEC)
National Electrical Manufacturers Association (NEMA).
Insurance Requirements: Safety equipment and combustion controls described
above, which are Cleaver-Brooks standard, can be modified to meet Factory Mutual,
Military, or other requirements.
Industrial Risk Insurers: Equipment is furnished in compliance with published
requirements of the Industrial Risk Insurers as given in the latest IRI information
Single Burner Boiler Furnaces.
Table C-2 , through Table C-5 show boiler trim packages included with standard
design pressure of 260 psig.
Table C-6 through Table C-9 show boiler trim installed at 300 psig design pressure.
Optional Equipment
(Partial Listing)
The following options are available:
Boiler Options
Design pressure up to 1000 psig.
Superheaters.
Hinged manway covers in steam drum.
Clean out ports in front and rear convection wall.
Multiple 12" x 24" convection side access doors.
Warm up coil in lower drum.
Platforms and ladders.
Various steam quality drum internals.
Special blowdown valves.
Weatherproofing.
Wash drains.
Rear furnace access door.
Burner/Control Options
Special motors (TEFC, high efficiency, etc.).
NEMA enclosures.
Special combustion control systems: Single-point, parallel positioning, full
metering, cross-limited systems.
Cleaver-Brooks oxygen trim system.
Plant master, lead-lag, day-night controls, etc.
Feed water control systems (one, two, or three element).
Special burner packages.
Special insurance or code requirements.
Fuel Options
Low fire fuel change-over.
Special gas train sizes.
Section C
C-9
03-08
Gas strainer.
Special fuel shut-off values.
Special oil pump sets.
Alternate fuel firing.
For information on the following options please refer to the referenced
section:
Economizers (selected for specific job site conditions), Section G.
Optional Controls, Section D.
The following illustrations Figure C-1 thru Figure C-8) show dimensions for the
Industrial Watertube Product offering.
Figure C-1. Model D Dimensions
Figure C-2. Model DL and DLD Dimensions
Figure C-3. Model DLDH Dimensions
Figure C-4. Model DFE Dimensions
Figure C-5. Model DW Dimensions
Figure C-6. Model DLW Dimensions
Figure C-7. General A Burner Dimensions
Figure C-8. General BR Burner Dimensions
Figure C-9. General CN Burner Dimensions
Figure C-11. General CT Burner Dimensions
FGR sytems for Industrial Watertube boiler applications are custom engineered to
meet specific application requirements. Specific information regarding dimensions,
ratings, and performance data will be provided on a job-by-job basis. Contact your
local Cleaver-Brooks authorized representative for assistance.
Section C
C-10
03-08
VALVES MODEL D
SERVICE QUANTITY MFG. TYPE 26 34-42 52-76 86 94
VALVE SIZES
Safety Code Kunkle 252 Code Code Code Code Code
Feed Stop 1 Velan S-2054B 1-1/2 1-1/2 2 - -
Feed Stop 1 Velan F-2054B - - - 2-1/2 2-1/2
Feed Check 1 Lunk. 624 1-1/2 1-1/2 2 2-1/2 2-1/2
Drum Blow-off Tandem 1 Set Edw. 848-849 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4
Air Vent 1 Velan S-2074B 1/2 1/2 1/2 1/2 1/2
Continuous Blowdown 1 Velan S-2074B 1 1 1 1 1
Soot Blower Control 1 Velan S-2054B 2 2 2 2 2
Soot Blower Drain 1 Velan S-2074B 3/4 3/4 3/4 3/4 3/4
Soot Blower Drain 1 Velan S-2074B - - - 3/4 3/4
FEEDWATER REGULATOR ASSEMBLY
Feedwater Regulator 1 Fisher 667 EZ 1 1 1-1/2 2 2
Regulator By-pass (Throttle) 1 Velan S-2074B 1-1/4 1-1/4 1-1/2 2 2
Regulator By-pass (Shut-off) 2 Velan S-2074B 1-1/2 1-1/2 2 - -
Regulator By-pass (Shut-off) 2 Velan S-2074B - - - 2-1/2 2-1/2
Liquid Level Control (Shut-off) 2 Velan S-2054B 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2
Control Drain 1 Velan S-2054B 3/8 3/8 3/8 3/8 3/8
WATER COLUMN ASSEMBLY
Water Column 1 C-B Steel - - - - -
Water Gauge 1 Rel. 404-RS 3/4 3/4 3/4 3/4 3/4
Gauge Cocks 3 Rel. GC-451 3/4 3/4 3/4 3/4 3/4
Column Drain 1 Velan S-2054B 3/4 3/4 3/4 3/4 3/4
Gauge Drain 1 Velan S-2054B 3/8 3/8 3/8 3/8 3/8
Hi-Low Alarm 1 Warr. Probe - - - - -
Low Water Cut-off 2 Warr. Probe - - - - -
Note: Valve manufacturers listed are for reference only. Actual manufacturer may vary.
Table C-2. Standard Trim (Model D)
Section C
C-11
03-08
VALVES MODELS DL & DLD
SERVICE QUANTITY MFG TYPE 52 60 68 76 86 94
VALVE SIZES
Safety Code Kunkle 252 Code Code Code Code Code Code
Feed Stop 1 Velan S-2054B 2 2 - - - -
Feed Stop 1 Velan F-2054B - - 2-1/2 2-1/2 2-1/2 2-1/2
Feed Check 1 Lunk. 624 2 2 2-1/2 2-1/2 2-1/2 2-1/2
Drum Blow-off Tandem 1 Set Edw. 848-849 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4
Air Vent 1 Velan S-2074B 1/2 1/2 1/2 1/2 1/2 1/2
Continuous Blowdown 1 Velan S-2074B 1 1 1 1 1 1
Soot Blower Control 1 Velan S-2054B 2 2 2 2 2 2
Soot Blower Drain 1 Velan S-2074B 3/4 3/4 3/4 3/4 3/4 3/4
Soot Blower Drain 1 Velan S-2074B - - - 3/4 3/4 3/4
Feedwater Regulator 1 Fisher 667 EZ 1-1/2 1-1/2 2 2 2 2
Regulator By-pass (Throttle) 1 Velan S-2074B 1-1/2 1-1/2 2 2 2 2
Regulator By-pass (Shut-off) 2 Velan S-2074B 2 2 - - - -
Regulator By-pass (Shut-off) 2 Velan S-2074B - - 2-1/2 2-1/2 2-1/2 2-1/2
Liquid Level Control (Shut-off) 2 Velan S-2054B 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2
Control Drain 1 Velan S-2054B 3/8 3/8 3/8 3/8 3/8 3/8
Water Column 1 C-B Steel - - - - - -
Water Gauge 1 Rel. 404-RS 3/4 3/4 3/4 3/4 3/4 3/4
Gauge Cocks 3 Rel. GC-451 3/4 3/4 3/4 3/4 3/4 3/4
Column Drain 1 Velan S-2054B 3/4 3/4 3/4 3/4 3/4 3/4
Gauge Drain 1 Velan S-2054B 3/8 3/8 3/8 3/8 3/8 3/8
Hi-Low Alarm 1 Warr. Probe - - - - - -
Low Water Cut-off 2 Warr. Probe - - - - - -
Table C-3. Standard Trim (Models DL and DLD)
Section C
C-12
03-08
VALVES MODEL DLDH
SERVICE QTY MFG TYPE 60 68 76 86 94 102 110 118
VALVE SIZES
Safety Code Kunkle 252 Code Code Code Code Code Code Code Code
Feed Stop 1 Velan S-2054B - - - - - - - -
Feed Stop 1 Velan F-2054B 2-1/2 2-1/2 3 3 3 3 3 3
Feed Check 1 Lunk. 624 2-1/2 2-1/2 3 3 3 3 3 3
Drum Blow-off Tandem 1 Set Edw. 848-849 1-1/4 1-1/4 1-1/4 1-1/4 1-1/2 1-1/2 1-1/2 1-1/2
Air Vent 1 Velan S-2074B 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2
Continuous Blowdown 1 Velan S-2074B 1 1 1 1 1-1/2 1-1/2 1-1/2 1-1/2
Soot Blower Control 1 Velan S-2054B 2 2 2 2 2 2 2 2
Soot Blower Drain 1 Velan S-2074B 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4
Feedwater Regulator 1 Fisher 667 EZ 2 2 2 2 2 3 3 3
Regulator By-pass (Throttle) 1 Velan S-2074B 2 2 2-1/2 2-1/2 2-1/2 2-1/2 3 3
Regulator By-pass (Shut-off) 2 Velan S-2074B - - - - - - - -
Regulator By-pass (Shut-off) 2 Velan S-2074B 2-1/2 2-1/2 3 3 3 3 3 3
Liquid Level Control (Shut-off) 2 Velan S-2054B 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2
Control Drain 1 Velan S-2054B 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8
Water Column 1 C-B Steel - - - - - - - -
Water Gauge 1 Rel. 404-RS 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4
Gauge Cocks 3 Rel. GC-451 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4
Column Drain 1 Velan S-2054B 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4
Gauge Drain 1 Velan S-2054B 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8
Hi-Low Alarm 1 Warr. Probe - - - - - - - -
Low Water Cut-off 2 Warr. Probe - - - - - - - -
Table C-4. Standard Trim (Model DLDH)
Section C
C-13
03-08
VALVES MODEL DFE
SERVICE QTY MFG TYPE 85 98 110 121 132
VALVE SIZES
Feed Stop 1 Velan S-2054B - - - - -
Feed Stop 1 Velan F-2054B 3 3 3 4 4
Feed Check 1 Lunk. 624 3 3 3 4 4
Air Vent 1 Velan S-2074B 1/2 1/2 1/2 1/2 1/2
Continuous Blowdown 1 Velan S-2074B 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2
Feedwater Regulator 1 Fisher 667 EZ 2 2 3 3 3
Regulator By-pass (Shut-off) 2 Velan S-2074B - - - - -
Regulator By-pass (Shut-off) 2 Velan S-2074B 3 3 3 4 4
Table C-5. Standard Trim (Model DFE)
Section C
C-14
03-08
VALVES BOILER MODEL - D
SERVICE QTY MFG TYPE 26 34-42 52-76 86 94
VALVE SIZES
Feed Stop 1 Velan S-2054B 1-1/2 1-1/2 2 - -
Feed Stop 1 Velan F-1064C - - - 2-1/2 2-1/2
Feed Check 1 Edw. 838 1-1/2 1-1/2 2 - -
Feed Check 1 Lunk. 3072-C - - - 2-1/2 2-1/2
Air Vent 1 Velan S-2074B 1/2 1/2 1/2 1/2 1/2
Soot Blower Drain 1 Velan S-2074B - - - 3/4 3/4
Feedwater Regulator 1 Fisher 667 EZ 1 1 1-1/2 2 2
Regulator By-pass (Shut-off) 2 Velan S-2054B 1-1/2 1-1/2 2 - -
Regulator By-pass (Shut-off) 2 Velan F-1064C - - - 2-1/2 2-1/2
Table C-6. 300 psig Steel Trim (Model D)
Section C
C-15
03-08
VALVES BOILER MODELS - DL AND DLD
SERVICE QTY MFG TYPE 52 60 68 76 86 94
VALVE SIZES
Safety Code Kunkle 300 Code Code Code Code Code Code
Feed Stop 1 Velan S-2054B 2 2 - - - -
Feed Stop 1 Velan F-1064C - - 2-1/2 2-1/2 2-1/2 2-1/2
Feed Check 1 Edw. 838 2 2 - - - -
Feed Check 1 Lunk. 3072-C - - 2-1/2 2-1/2 2-1/2 2-1/2
Drum Blow-off Tandem 1 Set Edw. 848-849 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4
Air Vent 1 Velan S-2074B 1/2 1/2 1/2 1/2 1/2 1/2
Continuous Blowdown 1 Velan S-2074B 1 1 1 1 1 1
Soot Blower Control 1 Velan S-2054B 2 2 2 2 2 2
Soot Blower Drain 1 Velan S-2074B 3/4 3/4 3/4 3/4 3/4 3/4
Soot Blower Drain 1 Velan S-2074B - - - 3/4 3/4 3/4
Feedwater Regulator 1 Fisher 667 EZ 1-1/2 1-1/2 2 2 2 2
Regulator By-pass (Throttle) 1 Velan S-2074B 1-1/2 1-1/2 2 2 2 2
Regulator By-pass (Shut-off) 2 Velan S-2054B 2 2 - - - -
Regulator By-pass (Shut-off) 2 Velan F-1064C - - 2-1/2 2-1/2 2-1/2 2-1/2
Liquid Level Control (Shut-off) 2 Velan S-2054B 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2
Control Drain 1 Velan S-2054B 3/8 3/8 3/8 3/8 3/8 3/8
Water Column 1 C-B Steel - - - - - -
Water Gauge 1 Rel. 404-RS 3/4 3/4 3/4 3/4 3/4 3/4
Gauge Cocks 3 Rel. GC-451 3/4 3/4 3/4 3/4 3/4 3/4
Column Drain 1 Velan S-2054B 3/4 3/4 3/4 3/4 3/4 3/4
Gauge Drain 1 Velan S-2054B 3/8 3/8 3/8 3/8 3/8 3/8
Hi-Low Alarm 1 Warr. Probe - - - - - -
Low Water Cut-off 2 Warr. Probe - - - - - -
Table C-7. 300 psig Steel Trim (Models DL and DLD)
Section C
C-16
03-08
VALVES BOILER MODEL - DLDH
SERVICE QTY MFG TYPE 60 68 76 86 94 102 110 118
VALVE SIZES
Safety Code Kunkle 300 Code Code Code Code Code Code Code Code
Feed Stop 1 Velan S-2054B - - - - - - - -
Feed Stop 1 Velan F-1064C 2-1/2 2-1/2 3 3 3 3 3 3
Feed Check 1 Edw. 838 - - - - - - - -
Feed Check 1 Lunk. 3072-C 2-1/2 2-1/2 3 3 3 3 3 3
Drum Blow-off Tandem 1 Set Edw. 848-849 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4
Air Vent 1 Velan S-2074B 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2
Continuous Blowdown 1 Velan S-2074B 1 1 1 1 1 1 1 1
Soot Blower Control 1 Velan S-2054B 2 2 2 2 2 2 2 2
Feedwater Regulator 1 Fisher 667 EZ 2 2 2 2 2 3 3 3
Regulator By-pass (Throttle) 1 Velan S-2074B 2 2 2-1/2 2-1/2 2-1/2 2-1/2 3 3
Regulator By-pass (Shut-off) 2 Velan S-2054B - - - - - - - -
Regulator By-pass (Shut-off) 2 Velan F-1064C 2-1/2 2-1/2 3 3 3 3 3 3
Liquid Level Control (Shut-off) 2 Velan S-2054B 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2
Control Drain 1 Velan S-2054B 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8
Water Column 1 C-B Steel - - - - - - - -
Water Gauge 1 Rel. 404-RS 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4
Gauge Cocks 3 Rel. GC-451 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4
Column Drain 1 Velan S-2054B 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4
Gauge Drain 1 Velan S-2054B 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8
Hi-Low Alarm 1 Warr. Probe - - - - - - - -
Low Water Cut-off 2 Warr. Probe - - - - - - - -
Table C-8. 300 psig Steel Trim (Model DLDH)
Section C
C-17
03-08
VALVES MODEL DFE
SERVICE QTY MFG TYPE 85 98 110 121 132
VALVE SIZES
Feed Stop 1 Velan S-2054B - - - - -
Feed Stop 1 Velan F-2064C 3 3 3 4 4
Feed Check 1 Edw. 838 - - - - -
Feed Check 1 Lunk. 307-C 3 3 3 4 4
Air Vent 1 Velan S-2074B 1/2 1/2 1/2 1/2 1/2
Feedwater Regulator 1 Fisher 667 EZ 2 2 3 3 3
Regulator By-pass (Shut-off) 2 Velan S-2074B - - - - -
Regulator By-pass (Shut-off) 2 Velan F-1064C 3 3 3 4 4
Table C-9. 300 psig Steel Trim (Model DFE)
Section C
C-18
03-08
Figure C-1. Model D Dimensions - Sheet 1 of 2
Section C
C-19
03-08
MODEL D
26 34 42 52 60 68 76 86 94
DIMENSIONS (IN.)
A. Length, Over Casing 113.75 142.75 171.75 208 237 266 295 331.25 360.25
B. Length, Over Skid 144 173 202 238 267 296 325 361.5 390.25
C. Width, Gas Outlet 15 18 27 30 30 33 36 36 42
D. Height, Gas Outlet 54 54 54 54 66 66 66 66 75
E. Front to CL Gas Outlet 12.5 14 18.5 19.875 20 22 23 23 25.875
F. Skid to CL Gas Outlet 91 91 91 91 85 85 85 85 80.5
G. Skid to CL of Sootblower Flange
A
74 74 74 74 74 74 74 74 74
H. Distance Between Sootblowers - - - - - - - - -
I. Shipping Height (.375) 153.25 153.25 153.25 153.25 153.25 153.25 153.25 153.25 153.25
J . Overall Width 127 127 127 127 127 127 127 127 127
K. Upper Drum Diameter 36 36 36 36 36 36 36 36 36
L. Lower Drum Diameter 24 24 24 24 24 24 24 24 24
M. No. of Piers/CL to CL spacing (2) 48 (2) 60 (2) 76 (2) 94 (2) 108 (3) 82 (3) 92 (3) 104 (3) 114
N. Burner Refer to Figures C-7 thru C-10 for dimensions
WEIGHTS (LBS)
Weight, Dry
B
35200 40700 45870 52580 57970 66330 72490 79640 85250
Weight, Filled to Oper Level
B
41900 49350 56470 65610 72970 83280 91310 100990 108550
Weight, Flooded
B
44400 52540 60340 70340 78380 89380 98200 108630 116865
DRUM CONNECTION SIZES (IN.)
(1) Main Steam Outlet
C

4 4 6 6 6 8 8 8 8
(1) Feedwater Inlet 2 2 2 2 2 2 2.5 2.5 2.5
(2) Safety Valves
C

Code Code Code Code Code Code Code Code Code
(1) Blowdown (Surface) 1 1 1 1 1 1 1 1 1
Sootblower (if applicable)
A
2 2 2 2 2 2 2 2 2
(2) Water Column 1 1 1 1 1 1 1 1 1
(2) Level Control 1 1 1 1 1 1 1 1 1
(1) Chemical Feed 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
(1) Vent 1 1 1 1 1 1 1 1 1
(1) Blowdown (Mud drum) 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25
NOTES:
1. 12x16 manhole in each end of upper and lower drum. All tubes are 2 OD.
2. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified
dimension prints.
A. Boiler Model D, 76 thru 94, may use sootblowers on front and rear. All others may use one sootblower.
B. Weights do not include burner or accessories.
C. Steam outlet number and size of safety valves are based on a 150 psig operating pressure. Steam outlet and safety valve sizes
may vary with pressure increase and the actual steam outlet. For sizes with different operating pressure, and/or non-return valves,
Figure C-1. Model D Dimensions - Sheet 2 of 2
Section C
C-20
03-08
Figure C-2. Models DL and DLD Dimensions - Sheet 1 of 2
Section C
C-21
03-08

DL MODELS DLD MODELS
52 60 68 76 86 94 68 76 86 94
DIMENSIONS (IN.)
A. Length, Over Casing 208 237 266 295 331.25 360.25 266 295 331.25 360.25
B. Length, Over Skid 238 267 296 325 361.5 390.25 296 325 361.5 390.25
C. Width, Gas Outlet 30 33 36 42 42 42 36 42 42 42
D. Height, Gas Outlet 66 66 66 75 75 84 66 75 75 84
E. Front to CL Gas Outlet 19.875 21.5 23 26 26 25.875 23 26 26 25.875
F. Skid to CL Gas Outlet 105 105 105 100.5 100.5 96 105 100.5 100.5 96
G. Skid to CL of Sootblower
Flange
A
84 84 84 84 84 84 84 84 84 84
H. Distance Between Soot-
blowers
- - - - - - - - - -
I. Shipping Height (.375) 173.25 173.25 173.25 173.25 173.25 173.25 177 177 177 177
J . Overall Width 136.5 136.5 136.5 136.5 136.5 136.5 136.5 136.5 136.5 136.5
K. Upper Drum Diameter 36 36 36 36 36 36 42 42 42 42
L. Lower Drum Diameter 24 24 24 24 24 24 24 24 24 24
M. No. of Piers/CL to CL
spacing
(2) 94 (2) 108 (3) 82 (3) 92 (3) 104 (3) 114 (3)82 (3) 92 (3) 104 (3) 114
N. Burner Refer to Figures C-7 thru C-10 for Dimensions
WEIGHTS (LBS)
Weight, Dry
B
62700 68200 77550 83600 91300 96800 78900 85000 93000 98600
B
78700 86200 96990 105220 115600 131300 98700 107000 117700 133700
Weight, Flooded
B
83430 91610 103090 111830 122900 137200 107500 117800 129700 144200
C

8 8 8 8 10 10 8 8 8 10
(1) Feedwater Inlet 2 2 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5
(2) Safety Valves
C
Code Code Code Code Code Code Code (3) Code (3) Code (3) Code
(1) Blowdown (Surface) 1 1 1 1 1 1 1 1 1 1
A
2 2 2 2 2 2 2 2 2 2
(2) Water Column 1 1 1 1 1 1 1 1 1 1
(2) Level Control 1 1 1 1 1 1 1 1 1 1
(1) Chemical Feed 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
(1) Vent 1 1 1 1 1 1 1 1 1 1
(1) Blowdown (Mud drum) 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25
NOTES:
1. 12 x 16 manhole in each end of upper and lower drum. All tubes are 2 OD.
2. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension
prints.
A. Boiler Models DL and DLD, 76 thru 94, may use sootblowers on front and rear. All others may use one sootblower.
C. Steam outlet number and size of safety valves are based on 150 psig operating pressure. Steam outlet and safety valve sizes may vary
with pressure increase and actual steam outlet. For sizes with different operating pressure, and/or non-return valves, contact your local
Figure C-2. Models DL and DLD Dimensions - Sheet 2 of 2
Section C
C-22
03-08
Figure C-3. Model DLDH Dimensions - Sheet 1 of 2
Section C
C-23
03-08

MODEL DLDH
60 68 76 86 94 102 110 118
DIMENSIONS (IN.)
A. Length, Over Casing 237 266 295 331.25 360.25 389.25 418.25 447.25
B. Length, Over Skid 267 296 325 361.5 390.25 419.25 448.25 477.25
C. Width, Gas Outlet 36 36 40 42 45 50 55 55
D. Height, Gas Outlet 66 82 82 89 90 90 90 90
E. Front to CL Gas Outlet 23 23 25 26 24.375 30 32.5 32.5
F. Skid to CL Gas Outlet 107 99 99 95.5 95 95 95 95
A
67.5 67.5 67.5 67.5 67.5 67.5 67.5 67.5
H. Distance Between Sootblowers 40 40 40 40 40 40 40 40
I. Shipping Height (.375) 187 187 187 187 187 187 187 187
J . Overall Width 144 144 144 144 144 144 144 144
K. Upper Drum Diameter 42 42 42 42 42 42 42 42
L. Lower Drum Diameter 30 30 30 30 30 30 30 30
M. No. of Piers/CL to CL spacing (3) 54 (3) 82 (4) 62 (4) 70 (4) 76 (4) 87 (4) 96 (4) 105
WEIGHTS (LBS)
Weight, Dry
B
83500 93503 101247 108106 111666 119611 127596 135581
B
105400 118027 127801 138079 144330 154966 178337 176318
Weight, Flooded
B
112100 125997 135925 147813 155051 166674 165642 190000
C

8 8 10 10 10 10 12 12
(1) Feedwater Inlet 3 3 3 3 3 3 3 3
(2) Safety Valves
C

(3) Code (3) Code (3) Code (3) Code (3) Code (3) Code (3) Code (3) Code
(1) Blowdown (Surface) 1 1 1 1 1.5 1.5 1.5 1.5
A
2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5
(2) Water Column 1 1 1 1 1 1 1 1
(2) Level Control 2.5 2.5 3 3 3 3 3 3
(1) Chemical Feed 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
(1) Vent 1 1 1 1 1 1 1 1
(1) Blowdown (Mud drum) 1.25 1.25 1.25 1.25 1.5 1.5 1.5 1.5
NOTES:
1. 12x 16 manhole in each end of upper and lower drum. All tubes are 2 OD.
prints.
A. Boiler Model DLHD, 60 & 68, may use two sootblowers on rear, and Models DLDH, 76 thru 118, may use two sootblowers on front
and rear.
C. Steam outlet number and size of safety valves are based on 150 psig operating pressure. Steam outlet and safety valve sizes may
vary with pressure increase and actual steam outlet. For sizes with different operating pressure, and/or non-return valves, contact your
Figure C-3. Model DLDH Dimensions - Sheet 2 of 2
Section C
C-24
03-08
Figure C-4. Model DFE Dimensions - Sheet 1 of 2
Section C
C-25
03-08

MODEL DFE
85 98 110 121 132
DIMENSIONS (IN.)
A. Length, Over Casing 327 374.75 418.25 457.75 498
B. Length, Over Skid 357 404.75 448.25 487.75 528
C. Width, Gas Outlet 40 45 50 55 60
D. Height, Gas Outlet 90 90 90 90 90
E. Front to CL Gas Outlet 25 27.5 30 32.5 35
F. Skid to CL Gas Outlet 95 95 95 95 95
A
67.5 67.5 67.5 67.5 67.5
H. Distance Between Sootblowers 113.5 113.5 113.5 113.5 113.5
I. Shipping Height (.375) 200.25 200.25 200.25 200.25 200.25
J . Overall Width 151.375 151.375 151.375 151.375 151.375
K. Upper Drum Diameter 48 I.D. 48 I.D. 48 I.D. 48 I.D. 48 I.D.
L. Lower Drum Diameter 30 O.D. 30 O.D 30 O.D 30 O.D 30 O.D
M. No. of Piers/CL to CL spacing (4) 72 (4) 88 (4) 104 (4) 104 (4) 120
WEIGHTS (LBS)
Weight, Dry
B
117,250 130,750 143,350 154,750 166,350
B
154,300 170,400 188,050 204,100 220,450
Weight, Flooded
B
163,450 184,400 203,800 221,400 239,350
C

10 10 10 12 12
(1) Feedwater Inlet 3 3 3 4 4
(2) Safety Valves
C

Code Code Code Code Code
(1) Blowdown (Surface) 1.5 1.5 1.5 1.5 1.5
A
2.5 2.5 2.5 2.5 2.5
(2) Water Column 1 1 1 1 1
(2) Level Control 1 1 1 1 1
(1) Chemical Feed 0.5 0.5 0.5 0.5 0.5
(1) Vent 1 1 1 1 1
(1) Blowdown (Mud drum) 1.5 1.5 1.5 1.5 1.5
NOTES:
2. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed
for construction by certified dimension prints.
A. Boiler Model DFE 85 thru 132, may use two sootblowers on front and rear.
C. Steam outlet number and size of safety valves are based on a 150 psig operating pressure.
Steam outlet and safety valve sizes may vary with pressure increase and actual steam outlet. For
sizes with different operating pressure, and/or non-return valves, contact your local Cleaver-Brooks
Figure C-4. Model DFE Dimensions - Sheet 2 of 2
Section C
C-26
03-08
Figure C-5. Model DW Dimensions - Sheet 1 of 2
Section C
C-27
03-08
MODEL DW
26 34 42 52 60 68 76 86 94
DIMENSIONS (IN.)
A. Length, Over Casing 113 142 171 207 236 265 294 330.5 359.5
B. Length, Over Skid 144 173 202 238 267 296 325 361.5 390.25
C. Width, Gas Outlet 15 18 27 30 30 33 36 36 42
D. Height, Gas Outlet 54 54 54 54 66 66 66 66 75
E. Front to CL Gas Outlet 125 14 18.5 19.875 20 22 23 23 25.875
F. Skid to CL Gas Outlet 91 91 91 91 85 85 85 85 80.5
A
74 74 74 74 74 74 74 74 74
H. Shipping Height (.375) 153.25 153.25 153.25 153.25 153.25 153.25 153.25 153.25 153.25
I. Overall Width 127 127 127 127 127 127 127 127 127
J . Upper Drum Diameter 36 36 36 36 36 36 36 36 36
K. Lower Drum Diameter 24 24 24 24 24 24 24 24 24
L. No. of Piers/CL to CL spacing (2) 48 (2) 60 (2) 76 (2) 94 (2) 108 (3) 82 (3) 92 (3) 104 (3) 114
M. Burner Refer to Figures C-7 thru C-10 for dimensions
WEIGHTS (LBS)
Weight, Dry
B
35200 40700 45870 52580 57970 66330 72490 79640 85250
Weight, Flooded
B
44400 52540 60340 70340 78380 89380 98200 108630 116865
(1) Water Inlet/Outlet
C

- - - - - - - - -
(2) Safety/ Relief Valves
C
Code Code Code Code Code Code Code Code Code
A
2 2 2 2 2 2 2 2 2
(2) Water Column 1 1 1 1 1 1 1 1 1
(1) Vent 1 1 1 1 1 1 1 1 1
(1) Blowdown (lower drum) 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25
NOTES:
2. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimen-
sion prints.
A. Boiler Model DW, 76 thru 94, may use sootblowers on front and rear. All others may have one sootblower.
C.Water inlet/outlet size and number and size of safety/relief valve are variable, due to operating temperatures and pressures. Con-
tact your local Cleaver-Brooks authorized representative for job-specific information.
Figure C-5 Model DW Dimensions - Sheet 2 of 2
Section C
C-28
03-08
Figure C-6. Model DLW Dimensions - Sheet 1 of 2
Section C
C-29
03-08
MODEL DLW
52 60 68 76 86 94
DIMENSIONS (IN.)
A. Length, Over Casing 207 236 265 294 330.5 359.5
B. Length, Over Skid 238 267 296 325 361.5 390.25
C. Width, Gas Outlet 30 33 36 42 42 42
D. Height, Gas Outlet 66 66 66 75 75 84
E. Front to CL Gas Outlet 19.875 21.5 23 26 26 25.875
F. Skid to CL Gas Outlet 105 105 105 100.5 100.5 96
A
84 84 84 84 84 84
H. Shipping Height (.375) 173.25 173.25 173.25 173.25 173.25 173.25
I. Overall Width 136.5 136.5 136.5 136.5 136.5 136.5
J . Upper Drum Diameter 36 36 36 36 36 36
K. Lower Drum Diameter 24 24 24 24 24 24
L. No. of Piers/CL to CL spacing (2) 94 (2) 108 (3) 82 (3) 92 (3) 104 (3) 114
M. Burner Refer to Figure C-7 thru C-10 for dimensions
WEIGHTS (LBS)
Weight, Dry
B
62700 68200 77550 83600 91300 96800
Weight, Flooded
B
83430 91610 103090 111830 122900 13720
(1) Water Inlet/Outlet
C

- - - - - -
(2) Safety/ Relief Valves
C
Code Code Code Code Code Code
A
2 2 2 2 2 2
(2) Water Column 1 1 1 1 1 1
(1) Vent 1 1 1 1 1 1
(1) Blowdown (lower drum) 1.25 1.25 1.25 1.25 1.25 1.25
NOTES:
2. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for
construction by certified dimension prints.
A. Boiler Model DLW, 76 thru 94, may use sootblowers on front and rear. All others may have one
sootblower.(
C. Water inlet/outlet size and number and size of safety/relief valve are variable, due to operating tem-
peratures and pressures. Contact your local Cleaver-Brooks authorized representative for job-specif-
ic information.
Figure C-6. Model DLW Dimensions - Sheet 2 of 2
Section C
C-30
03-08
Figure C-7. General A Burner Dimensions
BURNER
MODEL
STANDARD
A B C D E F G H I J
A 66 60 67 24-1/4 54 70 115-1/8 52-1/8 21-3/4 33
Section C
C-31
03-08
BURNER
MODEL
STANDARD
A B C D E F G H I J
BR1 51-1/2 32 73 21-1/2 54-1/2 64 126-1/2 34-1/2 22 23
BR2 53-1/4 32 73 21-1/2 54-1/2 64 126-1/2 34-1/2 22 23
BR3 53-3/4 32 73 21-1/2 54-1/2 64 126-1/2 34-1/2 22 23
Figure C-8. General BR Burner Dimensions
NOTES:
1. Fuel train shipped loose and not included in above weights.
2. Weight includes forced draft fan and drive.
3. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimen-
sion prints.
Section C
C-32
03-08
BURNER
MODEL
STANDARD
A B C D E F G H I J
CN1 56-3/4 60-1/2 80-1/4 30-1/4 52 65 140-1/2 37-1/4 21-1/2 37-1/2
CN2 58-3/4 60-1/2 80-1/4 30-1/4 52 65 140-1/2 37-1/4 21-1/2 37-1/2
CN3 58-3/4 60-1/2 80-1/4 30-1/4 52 65 140-1/2 37-1/4 21-1/2 37-1/2
CN4 58-3/4 60-1/2 80-1/4 30-1/4 52 65 140-1/2 37-1/4 21-1/2 37-1/2
CN5 61-1/4 60-1/2 80-1/4 30-1/4 52 65 140-1/2 37-1/4 21-1/2 37-1/2
CN7 65-1/4 60-1/2 82 30-1/4 52 65 142 40-3/4 21-7/8 37-1/2
CN8 71-3/4 60-1/2 82 30-1/4 52 65 142 40-3/4 21-7/8 37-1/2
Figure C-9. General CN Burner Dimensions
Section C
C-33
03-08
BURNER
MODEL
A B C D E F G H
CT-1 54 60 60 49 59 83 138 66
CT-2 54 60 60 49 59 86 138 66
CT-3 60-3/4 60 60 53-1/2 59 89 142-1/2 66
CT-4 66-3/4 60 60 58-1/4 59 95 147-1/4 66
CT-5 66-3/4 60 60 58-1/4 59 95 147-1/4 66
CT-6 66-3/4 60 60 58-1/4 59 95 147-1/4 66
CT-7 66-3/4 72 72 58-1/4 59 95 153-1/4 78
CT-8 66-3/4 72 72 58-1/4 59 95 153-1/4 78
CT-9 74 72 72 63-1/4 59 95 158-1/4 78
CT-10 74 72 72 63-1/4 59 96 158-1/4 78
CT-11 74 72 72 63-1/4 59 96 158-1/4 78
CT-12 74 72 72 63-1/4 59 100 158-1/4 78
CT-13 74 72 72 63-1/4 59 100 158-1/4 78
CT-14 74 72 72 63-1/4 59 100 158-1/4 78
CT-15 74 72 72 63-1/4 65 100 164-1/4 78
CT-16 74 72 72 63-1/4 65 100 164-1/4 78
CT-17 81-1/4 72 72 70 65 102 171 78
CT-18 81-1/4 72 72 70 65 102 171 78
CT-19 81-1/4 72 72 70 65 102 171 78
CT-20 91-1/4 72 72 76 65 102 177 78
NOTES:
1. The accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension prints.
3. Burner Models CT-21 through CT-27 have the forced draft fan located remote from the burner/windbox assembly. Please contact your local Cleaver-Brooks
authorized representative for burner applications involving these models.
Figure C-10. General CT Burner Dimensions
Section C
C-34
03-08
Table C-10. Industrial Watertube Emission Data - Natural Gas (A, BR, CN Burners)
POLLUTANT
TYPICAL UNCONTROLLED EMISSIONS TYPICAL EMISSIONS CONTROLLED W/FGR
< 65,000 pph < 65,000 pph
CO ppm 200 200
lb/MMBtu .155 .155
NOx ppm 185 130
lb/MMBtu .25 .17
NOTES:
1. NOx Emissions for No. 2 oil are dependent upon fue-bound nitrogen content of oil. Emission levels indicated assume a fuel bound nitrogen content
of.01% by weight.
2. The emission information provided is for reference only and should not be utilized for permitting purposes without the expressed written
consent of Cleaver-Brooks Division of Aqua-Chem, Inc. All information is based on 3% O
2
.
Table C-11. Industrial Watertube Emission Data -No. 2 Oil (A, BR, CN Burners)
POLLUTANT
TYPICAL UNCONTROLLED EMISSIONS
< 65,000 pph
CO ppm 200
lb/MMBtu .158
NOx ppm 435
lb/MMBtu .58
NOTES:
1. NOx Emissions from heavy oils are dependent upon fuel-bound nitrogen content of oil. Emission levels indicated assume a fuel
bound nitrogen content of.4% by weight.
2. The emission information is for reference only and should not be utilized for permitting purposes without the ex-
pressed written consent of Cleaver-Brooks Division of Aqua-Chem, Inc. All information is based on 3% O
2
.
Table C-12. Industrial Watertube Emission Data - Heavy Oils (A, BR, CN Burners)
POLLUTANT
< 65,000 pph < 65,000 pph
CO ppm 200 200
lb/MMBtu .146 .146
NOx ppm 110 40
lb/MMBtu .13 .05
NOTE: The emission information provided is for reference only and should not be utilized for permitting purposes without the expressed
written consent of Cleaver-Brooks Division of Aqua-Chem, Inc. All information is based on 3% O
2
.
EMISSIONS
The emission data included in this section consists of uncontrolled and controlled levels of
nitrogen oxides (NO
X
) and carbon monoxide (CO) for Cleaver-Brooks D, DL, DLD, DLDH and
DFE Industrial Watertube Boilers equipped with Cleaver-Brooks Model A, BR, CN or CT burners.
The following tables include typical emission levels. Because individual boiler performance can
vary, contact your local Cleaver-Brooks authorized representative for specific levels of
performance for your application. Emission data for natural gas, No. 2 oil, and No. 6 oil are
presented in Table C-10 through Table C-15.
Cleaver-Brooks Industrial Watertube Boilers are available with a standard burner package or
optional flue gas recirculation (FGR) package.
The Cleaver-Brooks FGR packages are integrated boiler/burner/control packages designed
specifically for Cleaver- Brooks boilers.
Section C
C-35
03-08
POLLUTANT
<85,000 pph 86,000-105,000 pph 106,000-150,000 pph 15,000-150,000 pph
CO ppm 200 200 200 200
lb/MMBtu .155 .155 .155 .155
NOx ppm 150 157 165 75
lb/MMBtu .20 .21 .22 .10
NOTES:
1. NOx Emissions for No. 2 oil are dependent upon fue-bound nitrogen content of oil. Emission levels indicated assume a fuel bound nitrogen content
of.01% by weight.
2
.
POLLUTANT
<85,000 pph 86,000-105,000 pph 106,000-150,000 pph 15,000-150,000 pph
CO ppm 200 200 200 200
lb/MMBtu .15 .15 .15 .15
NOx ppm 85 93 101 30
lb/MMBtu .10 .11 .12 .035
NOTE: The emission information provided is for reference only and should not be utilized for permitting purposes without the expressed
written consent of Cleaver-Brooks Division of Aqua-Chem, Inc. All information is based on 3% O
2
.
POLLUTANT
15,000-150,000 pph 15,000-150,000 pph
CO ppm 200 200
lb/MMBtu .158 .158
NOx ppm 380 260
lb/MMBtu .51 .35
NOTES:
1. NOx Emissions from heavy oil are dependent upon fuel bound nitrogen content of oil. Emission levels indicated assume a fuel bound nitrogen con-
tent of.4% by weight.
2
.
Table C-14. Industrial Watertube Emission Data - No. 2 Oil (CT Burner)
Table C-13. Industrial Watertube Emission Data - Natural Gas (CT Burner)
Table C-15. Industrial Watertube Emission Data - Heavy Oils (CT Burner)
Section C
C-36
03-08
ENGINEERING DATA
The following engineering data will
assist in selecting and specifying
Cleaver-Brooks Industrial Water-
tube Boilers.
Table C-16 shows heating surfaces
for the IWT Boilers.Table C-17 and
Table C-18show temperature and
pressure information for selection of
high temperature hot water boilers.
Steam Drum Model D and DL boilers have 36"
ID steam drums, constructed of SA-
515 Grade-70 steel plate. Models
DLD and DLDH boilers have 42"ID
steam drums; the DFE has a 48
Drum constructed of SA- 515
Grade-70 steel plate. All drums are
of welded construction in strict con-
formance with the ASME Power
Boiler Code. All drums are stress-
relieved, and welded seams are
radiographed and hydrostatically
tested at
1-1/2 times design pressure. The
drum incorporates elliptical heads
with 12"x 16"manholes on each
end, and is wholly supported by the
tubes, so no extra supporting steel
is required. All tubes are expanded
into the drums.
The steam drum has the following
external connections:
One main steam outlet, flanged.
Two 12"x 16"manways.
One feedwater inlet.
Two or three safety valve flanged
connections (as required).
One blowdown connection,
screwed.
One soot blower connection,
screwed.
Two water column connections,
screwed.
Two feedwater regulator
connections, screwed.
One chemical feed connection,
screwed.
Two lifting Lugs.
MODEL NO.
CONV
HEATING
SURFACE
(SQ-FT)
FURNACE
HEATING
SURFACE
(PROJ)
(SQ-FT)
TOTAL
HEATING
SURFACE
(SQ-FT)
FURNACE
VOLUME
(CU-FT)
D
26 1120 241 1361 317
34 1517 302 1819 425
42 1911 369 2280 527
52 2407 449 2856 654
60 2806 511 3317 754
68 3206 580 3786 855
76 3595 634 4229 951
86 4087 726 4313 1081
94 4470 793 5263 1184
DL
52 2912 518 3430 903
60 3393 593 3986 1048
68 3870 676 4546 1194
76 4346 751 5097 1328
86 4947 848 5795 1510
94 5418 923 6341 1654
DLD
68 3774 673 4447 1188
76 4248 747 4995 1321
86 4825 842 5667 1502
94 5284 919 6203 1645
DLDH
60 4000 650 4650 1111
68 4564 737 5301 1261
76 5126 818 5944 1411
86 5806 923 6729 1599
94 6368 1004 7372 1750
102 6930 1089 8019 1900
110 7495 1172 8667 2050
118 8056 1253 9309 2200
DFE
85 5707 923 6663 1750
98 6622 1063 7685 2024
110 7461 1187 8648 2274
121 8223 1305 9528 2501
132 9000 1416 10416 2733
Table C-16. Heating Surface
Section C
C-37
03-08
STEAM BOILER
MODEL NO.
MAX OUT
A
MMBTU/HR
(STEAM)
D
26 16
34 21.4
42 26.8
52 37.41
60 43.92
68 50.22
76 57.17
86 65.12
94 72.62
DL
52 45.47
60 53.31
68 61.47
76 70.3
86 79.91
94 87.41
DLD
68 60.15
76 68.87
86 78.14
94 85.54
DLDH
60 63.4
68 76.3
76 85.6
86 97
94 106.2
102 115.6
110 124.9
118 134.1
DFE
85 81.3
98 101.5
110 111.5
121 121.6
132 151.7
A. DLDH with economizer.
The steam drum is fitted with an internal feed
pipe, chemical feed pipe, and blowdown piping.
Water level control baffling is installed to ensure
that all steam released from the generating tubes
is released behind the baffles and not through the
water level. Standard patented drum internals
consist of steam separators or dryers that are
installed to ensure the steam leaving the drum
will contain not more than 1/2 of 1 percent
moisture when boiler water concentrations are
maintained in accordance with ABMA
recommendations. Special drum internals for
more stringent moisture content are available.
See Table C-11 and Table C-12 for illustration of
drum internals.
Lower Drum (Mud
Drum)
The lower drum is 24" OD of SA-53 Grade-B
seamless pipe, and is of fusion-welded
construction, or 30" OD of SA-515, Grade-70,
welded plate (DLDH and DFE boiler). The lower
drum is stress relieved, seams are radiographed,
and hydrostatically tested at 1-1/2 times design
pressure. The drum incorporates two 12" x 16"
manways - one at each end - and required blow-
drum connections.
Internally, the drum has a blowdown guide baffle
to ensure effective blowdown of the lower drum
without disturbing water circulation in the unit.
HOT WATER GENERATORS
MODEL NO.
MAX OUT
MM
BTU/HR
DW
26 13.4
34 17.9
42 22.5
52 28.2
60 32.7
68 37.5
76 41.7
86 47.5
94 51.9
DLW
52 33.8
60 39.3
68 44.8
76 50.3
86 57.1
94 62.5
Table C-17. Maximum Heat Output
(Hot Water)
Table C-18. Maximum Heat Output (Steam)
Section C
C-38
03-08
Figure C-11. Drum Internals and Steam Purifiers for 1, 3, and 7 ppm Solids
Figure C-12. Drum Internals and Separator for 99.5% Dry Steam
Section C
C-39
03-08
Figure C-13. D Series Boiler Tube Cut-Away
MEMBRANE
The drum is supported by the structural steel frame (skid) and has welded guide
lugs that fit into the base frame, permitting expansion of the drum within the skid,
thereby eliminating potential expansion stresses.
Drum Enclosure The steam drum is shop-insulated with mineral wool block and enclosed in a
welded 10-gauge steel casing. All drum heads are shop-insulated and enclosed in a
10-gauge steel casing. No further insulation is required in the field.
Furnace The furnace (combustion chamber) employs 2" OD, SA-178A electric resistance
welded tubes, arranged for maximum coverage of all six furnace walls. In a D type
watertube boiler, the furnace tubes generate more than half of the steam produced
by the boiler, although the furnace represents only about 15% of the reported
surface. Due to the high heat absorption rates present in the furnace, D tubes are
placed in a tangent spacing arrangement to provide as much water-cooled surface
as possible. With the exception of the inner furnace wall, which is membrane
construction, extended metallic surfaces are not used. See Table C-13.
All tubes in the furnace are accessible for mechanical tube cleaners. No headers are
employed in the boiler, and all tubes terminate in the upper and lower drums. Both
floor and roof tubes are designed with adequate pitch to ensure drainage and proper
circulation without swedging ends of tubes.
The six-wall furnace cooling is arranged as follows:
Front wall - Tubes closely spaced around burner.
Tangent outer side wall - 2" tubes spaced on 2" centers.
Membrane sealed inner wall - 2" tubes spaced on 4" centers.
Tangent floor - 2" tubes spaced on 2" centers.
Tangent roof - 2" tubes spaced on 2" centers.
Rear wall - Triple row of tubes.
Furnace exit - Double row of screen tubes.
Section C
C-40
03-08
Access: Access to furnace is through burner opening in front wall or optional rear
access door.
Observation: Two air-cooled observation ports, with Pyrex eye shields, provided in
rear wall.
Air Pressure Test: Inner seal-welded 10-gauge casing, subjected to an air pressure
test of 8" WC. It is considered tight if air pressure drop does not exceed 2" WC in 5
minutes.
Flue Gas Outlet: One flanged rectangular flue gas outlet, sized for desired flue gas
velocity and arranged for field welding, will be provided. Top gas outlet is also
available on the D, DL and DLD models
Convection Tubes Definition
The convection section, or boiler section, of a D type boiler are those tubes to
which heat is transmitted mainly by convection from the products of combustion.
Tubes
The convection section consists of 2" OD, wall tubes. The tubes are SA-178 electric
resistance-welded construction in accordance with ASME standards.
Tube Arrangement
The tubes are arranged with longitudinal rows of tubes in alternate wide and narrow
spacing to ensure proper and effective arrangement of soot-blowing equipment. This
arrangement also allows removal of any tube without the necessity of removing
adjacent tubes. All tubes in the boiler section are expanded into the upper and lower
drums. No swaged or finned tubes are used in the convection section, thereby
allowing heating surface to be reported based on actual tube surface, not extended
metal surfaces or fins.
Baffling
The convection bank is designed to eliminate the need for longitudinal baffles. A
vertical steel deflector baffle is placed immediately in front of the flue gas outlet
connection in order to prevent any short-circuiting of flue gas at the outlet. The
boiler incorporates vertical baffles located to maintain gas velocities and transfer
rates.(Figure C-14).
Soot Blowers
On heavy oil fired units, soot blowers are installed to provide the operator with a
means of cleaning the boiler while it is in operation. The soot blower element is
installed on the outside row of tubes, and blows an approximate 180 arc using
steam piped from the steam drum. Where the length of the convection bank
requires a blower in excess of 20 feet, two soot blowers are provided - one entering
from the rear of the unit and one from the front.
Soot blower bearings are of the welded-type, which eliminates problems of
misalignment associated with bolted bearings. The soot blower is a valve-in-head
type and arranged for manual operation by means of a chain. Purging air is piped to
the soot blower from the burner windbox to provide continuous cleaning of the
inside of the element, and to prevent combustion gases from leaking back to the
valve mechanism in the soot blower head. On boilers without sootblowers, wall
boxes and bearing are provided.
Section C
C-41
03-08
Figure C-14. Tubes with Membrane design for Inner furnace.
design.
Membrane Design
The inner furnace wall separating the furnace from the
convection section incorporates welded extended
surfaces on each side of the tube. After the tubes are
installed the adjacent surface fins are seal-welded
forming a gas tight membrane inner wall.
Membrane construction for the outer furnace wall and
the outer convection wall is available as an option.
Inner furnace wall
Outer furnace and
with membrane
convection wall
Figure C-15. .D Series Boiler Enclosure Construction
2-1/2 BLOCK (LOW DENSITY)
Section C
C-42
03-08
Internal Cleaning
The internal surfaces of all tubes, both convection and furnace types, can be
mechanically cleaned using either electric or pneumatic driven tube cleaners. Acid
cleaning procedures are also available.
Tube Removal
The use of the alternate wide-and-narrow spacing of boiler tube rows makes it
possible to remove and replace individual tubes in the convection section without
the necessity of cutting and removing adjacent tubes. In other staggered convection
bank designs, it is often necessary to remove many good tubes in order to provide
physical clearance to remove a damaged tube.
Casing and
Insulation
Design
The unit is enclosed by a double panel casing, with that portion of the casing
exposed to the products of combustion completely seal-welded to form an air and
gas tight enclosure. The outer casing panels are skip-welded and are suitable for
indoor installation (seal-welded for outdoor optional).
The casing is supported off the structural steel frame and is not welded or attached
to tubing, thereby ensuring free expansion of pressure parts within the casing
enclosure.
Casing and Wall Design
Construction of the boiler enclosure is as follows (Figure C-15):
1. Front Wall - Furnace Area:
3", 4-way interlocking tile.
4" Hi-temperature block insulation.
10-gauge inner seal welded casing.
2-1/2 low density block insulation.
1/4 burner front plate.
2. Rear Wall:
3", 4-way interlocking tile.
4" Hi-temperature block insulation.
2-1/2 low density block insulation,
1/4 outer casing.
3. Convection Section and Furnace Side Wall and Roof:
4-3/8 low-density mineral wool block.
10-gauge outer steel casing.
4. Casing Finish:
Painted with high-temperature enamel paint prior to shipment.
Furnace Floor
Furnace floor tubes are covered with 1-1/2 square edge tile.
Section C
C-43
03-08
Figure C-16. Series Skid Assembly
Figure C-17. Support Drum in Skid
Structural Frame Models D, DL, DLD, DLDH and DFE boilers (see Figure C-16 and Figure C-17) are
supported by a heavy structural steel frame skid assembly. The skid assembly
consists of two 14" wide flange beams running parallel to the drum. The beams are
attached by means of heavy steel plates that form the saddle and support for the
lower drum. The skid assembly also incorporates 10 ga. floor plate of the boiler
beneath the furnace area and convection section. The skid assembly is fabricated
as a complete structure prior to assembly of the unit. This method of support, using
saddle plates and guide lugs, permits the lower drum to ride in the saddle plates,
thus permitting expansion of the pressure parts in the structural frame and casing
enclosure of the boiler. Stops are provided during assembly to limit movement of
the drum within the expected expansion limits.
To facilitate lifting and handling of the boiler, lifting lugs are welded to the upper
drum. In addition, the main beams of the skid are coped and reinforced to provide
space beneath the end of the beam for jacking of the unit as required during
installation. Holes are provided in the main beams for use by riggers to drag or lift
the unit by its base frame.
Burner/Controls
Information (Models
A, BR, CN)
Each application requires burner selection based on boiler and overall project
requirements. Table C-19, Table C-20, and Table C-21 show the standard Cleaver-
Brooks burners and associated inputs and fuel requirements. Once the boiler has
been selected, the burner is matched based on the input requirements for the boiler.
Table C-22 shows the standard offering for each burner package.
The burner assembly is attached to the front wall of the boiler with all components
readily accessible for inspection and maintenance.
Section C
C-44
03-08
The oil burner is either low pressure air or steam atomized ignited by gas pilot. The
main gas burner is also ignited by a gas pilot.
The gas burner is designed for a 8:1 turndown when supplied with 10 psig gas
pressure, turndown on oil is 6:1 when supplied with 125 psig oil pressure.
The burner operates with full modulation through single point positioning controls. A
switch is provided to permit changeover from automatic, fully-modulated firing, to
continuous firing at any desired rate between minimum and maximum. Control
safeguards assure that the burner always returns to the minimum firing position for
ignition.
For air-atomized oil-fired boilers (air atomazation is optional), filtered primary air for
atomizing the fuel oil is provided independent of the combustion air by a motor-
driven air compressor. The fuel oil pump may be mounted near the boiler, or at a
remote location.
For burning heavy oil, the burner is equipped with a combination steam-electric
heater, each controlled by a thermostat. Both heaters are installed in a single
compact shell, and are mounted, piped, and wired on the burner.
The thermostatic controls are set to cut out the electric heater when steam is
available. A metering valve permits circulation of hot oil to the burner at all times.
An automatic purge pump system back-purges the burner drawer oil piping and
nozzle upon shut-down and returns any unburned oil to the storage tank.
The FGR system used with the A, BR and CN burner and controls, is shown in
Figure C-18.
Flame Safeguard The burner is equipped with a fully automatic flame safeguard system to ensure pre-
purge, proper light-off, shutdown on flame failure, and post-purge on shutdown. The
system is designed to meet FM, IRI, and CSA requirements.
The control system includes safety interlocks to shut down the system in the event
of any of the following, as required for the fuel or fuels being fired:
Flame failure.
High steam pressure.
Low drum water level.
Low atomizing steam pressure (oil or combination gas/oil burners).
Low fuel oil pressure (oil or combination gas/oil burners).
Low fuel oil temperature (oil or combination gas/oil burners).
High fuel oil temperature (oil or combination gas/oil burners, IRI only).
Low or high fuel gas pressure.
Forced draft fan failure.
Burner/Controls
Information (Model
CT)
Each application requires burner selection based on boiler and overall project
requirements. Table C-23 shows the Model CT burner selections and the associated
inputs and fuel requirements. Burner selection is based upon input requirements for
the boiler. Table C-24 shows standard non FGR offerings for the Model CT burner
equipment package.
The burner assembly is seal-welded to the front wall of the boiler, with all comp-
onents readily accessible for inspection and maintenance. The windbox is not
insulated for ambient combustion air, and is fabricated of ASTM A-36 plate,
complete with structural framing, support legs, access door, and splitter vanes and
baffles for equalizing air flow distribution to the burner.
Section C
C-45
03-08
GAS PRESSURE (INCHES H
2
O)
OIL
PRESSURE
(PSIG)
4 GAS LINE
W/4 GC VALVES
4 GAS LINE
W/4 MAXON VALVES
BURNER
MODEL
MAX
INPUT
(MBTU)
HP
(OIL)
A
HP
(GAS)
FM IRI FM IRI
A-1 13.8 10 10 10.5 12.3 8.9 9.1 100
A-2 16.9 15 10 15.7 18.4 13.3 13.6 100
A-3 16.6 15 10 15.0 17.6 12.6 13.0 100
A-4 18.6 15 10 18.8 22.0 15.9 16.3 100
A-5 19.7 20 15 21.0 24.7 17.7 18.2 100
A-6 22.2 25 20 26.1 30.7 22.0 22.5 100
A-7 22.9 25 20 27.8 32.7 23.4 24.0 100
A-8 26.5 30 25 36.8 43.3 31.0 31.8 100
A. Air compressor for atomizing air belt driven from FD fan motor. 25 CFM required.
Table C-19. Burner Data (Model A)
GAS PRESSURE (INCHES H
2
O)
OIL
PRESSURE
(PSIG)
BURNER
MODEL
MAX
INPUT
(MBTU)
HP
(OIL)
A
HP
(GAS)
4 GAS LINE W/4
GC VALVES
4 GAS LINE W/4
MAXON VALVES
6 GAS LINE W/4
MAXON VALVES
FM IRI FM IRI FM IRI
BR-1 31.0 15 15 45.8 56.6 36.4 38.3 26.3 28.0 100
BR-2 36.0 20 20 60.7 74.9 48.4 50.8 34.9 37.1 100
BR-3 40.2 25 25 75.1 92.5 60.0 63.0 43.3 46.1 100
BR-4 42.4 30 30 83.0 102.1 66.4 69.7 47.9 51.0 100
A. BR Burner (if air-atomized) has separate 7.5 hp motor to drive atomizing air compressor. 35 cfm required.
Table C-20. Burner Data (Model BR)
GAS PRESSURE IN INCHES H
2
O
OIL
PRESSURE
(PSIG)
4 GAS LINE W/4
MAXON VALVES
6 GAS LINE W/4
MAXON VALVES
BURNER
MODEL
MAXIMUM
INPUT
(MBTU)
HP
(OIL)
A
HP
(GAS)
FM IRI FM IRI
CN-1 46.5 20 20 61.5 65.4 39.6 43.3 100
CN-2 49.8 30 30 70.3 74.8 45.5 49.7 100
CN-3 63.5 40 40 108.8 115.5 70.4 76.9 100
CN-4 66.0 50 50 117.0 124.2 75.9 82.9 100
CN-5 77.1 60 60 134.6 142.8 87.8 95.8 125
CN-7 75.0 60 60 148.9 157.8 97.6 106.4 125
CN-8 81.3 75 75 - - 113.8 123.9 125
NOTES:
1. All horsepower requirements shown are for altitudes up to 1500 feet above sea level.
A. CN Burner (if air-atomized) has separate 15 hp motor to drive atomizing air compressor. 70 cfm required.
Table C-21. Burner Data (Model CN)
Section C
C-46
03-08
BURNER MODEL
AND SIZE
STANDARD EQUIPMENT
A
1-8
BR
1-4
CN
1-8
FORCED DRAFT FAN
1 x x x Fan driven by open drip-proof motor.
2 X X X Damper at FD fan outlet.
3
X
Type of damper:
a. Rotary (as used on Firetube Boiler Product Line).
- X X b. Characterized Quadrant (Rotary), NOT a Butterfly Type Damper.
4 X X X Combustion air-proving switch (CAPS) mounted and wired.
ATOMIZING MEDIUM
5 X X X C-B low pressure air or steam-atomized.
6
X
Type of air compressor drive (if air-atomized):
a. Belt driven from FD fan motor.
- X - b. Motor driven module mounted on burner.
- - X c. Motor driven module mounted in CN console, remote from burner (field piping and wiring required).
7 X X X Atomizing air proving switch (AAPS) mounted and wired on compressor.
CONTROLS & ELECTRICAL
8 X X X Cleaver-Brooks standard electric positioning controls.
9 X X X C-B 100 flame safeguard control with lead sulfide scanner.
10 X X X Controls remote from control enclosure have NEMA 1 housing.
11 X - - Control enclosure: controls are mounted in NEMA 1A panel, mounted on burner.
12 - X - NEMA 12 panel, mounted on burner.
13 - - X NEMA 1A compartment of CN console for Model CN-100 thru CN-600 (oil fired).
14 - - X NEMA 1A panel mounted on burner for Model CN-700 (gas-fired only).
15 X X X Steam pressure controls (HLPC, OLPC, LFPC and MPC) and 8-1/2 steam gauge all on a common manifold
assembly, shipped separate from burner (field piping and wiring required).
16 X X - Fuses and starters for FD fan motor, air compressor motor and fuel oil heater all mounted and wired on burner.
17 - - X Fuses and starters for air compressor motor and fuel oil heater all mounted and wired in CN console (field wiring
required between console and burner). Starter only for F.D. fan motor, shipped loose (field mounting and wiring
required).
18 X X X Electric current characteristics 230-460V/3-phase/60Hz.
19 X X X Control circuit transformer mounted and wired on burner.
MISCELLANEOUS:
22 X X X Turndown ratio of burner - 6:1 for oil firing, 8:1 for gas firing.
FUEL
24 X X X Gas pilot for all fuel series.
NOTE: Standard equipment listed here is included only with burner model indicated by an X
HLPC - High-Limit Pressure Control
OCPC - Operating Limit Pressure Control
LFPC - Low-Fire Pressure Switch
MPC - Modulating Pressure Control
Table C-22. Standard Offering (A, BR, and CN Burners)
Section C
C-47
03-08
A forced draft fan of centrifugal-type construction, arrangement four, with downblast
discharge provides combustion air for the burner system. The fan is mounted
directly on top of the windbox for applications up to 80,000 pph of steam (may be
less than 80,000 lbs/hr with certain FGR conditions). In applications exceeding
80,000 pph of steam, the forced draft fan is mounted remote from the windbox.
The combustion air fan is supplied with a variable inlet vane-type damper, inlet
screen, and silencer to reduce fan noise to 85 dBA at a distance of three (3) feet
from the fan. The combustion air fan utilizes a 240V or 480V, 3-phase, 60 Hz,
electric motor drive. Special voltages and frequencies are available.
The gas burner is of multi-spud injector-type design, utilizing fuel staging within the
flame envelope for reduction in thermal NOx formation. The burner is designed to
provide 10:1 turndown on natural gas when supplied with constant 15 psig gas
pressure at the inlet to the gas pressure regulator.
The oil burner is of the low-pressure, steam-atomizing type, and is designed to
provide 8:1 turndown when supplied with constant 175 psig oil pressure at the
inlet to the fuel oil train.
Both the gas and oil burners utilize a spark-ignited, gas-pilot ignition system.
The burner operates with full modulation through single-point-positioning controls.
A switch is provided to permit changeover from automatic, fully modulated firing, to
continuous firing at any desired rate between minimum and maximum. Control
safeguards assure that the burner always returns to the minimum firing position for
ignition.
In forced FGR applications, the FGR fan can be mounted on the boiler as shown in
Figure C-18, mounted on a separate pedestal, or mounted on the floor.
Figure C-18. Forced FGR System, Industrial Watertube Boiler (A, BR, CN Burners)
Section C
C-48
03-08
Figure C-19. Induced FGR System, Industrial Watertube Boiler (CT Burner)
Section C
C-49
03-08
Table 1:
BURNER MODEL
NOMINAL LOAD
REFERENCE
LB/HR
FD FAN MOTOR
HP
NATURAL GAS FIRING
HEAT INPUT
NO. 2 FUEL OIL FIRING
HEAT INPUT
MMBTU/HR MMBTU/HR
CT-1 15,000 15 20 19
CT-2 20,000 20 26 25
CT-3 25,000 20 32 31
CT-4 29,000 25 38 37
CT-5 32,000 30 42 41
CT-6 35,000 30 46 45
CT-7 38,000 40 50 49
CT-8 42,000 40 54 52
CT-9 45,000 50 58 56
CT-10 48,000 50 62 60
CT-11 51,000 50 66 64
CT-12 54,000 60 70 68
CT-13 57,000 60 74 72
CT-14 60,000 60 78 76
CT-15 63,000 75 82 79
CT-16 66,000 75 86 83
CT-17 69,000 75 90 87
CT-18 72,000 75 94 91
CT-19 75,000 75 98 95
CT-20 79,000 100 102 99
CT-21 82,000 100 106 103
CT-22 85,000 100 110 107
CT-23 96,000 125 123 119
CT-24 105,000 125 133 129
CT-25 115,000 150 146 141
CT-26 124,000 150 157 152
CT-27 134,000 200 168 163
NOTES
-Minimum required gas supply pressure to main gas pressure regulator is 15 psig.
-Minimum required oil pump supply pressure to oil fuel train is 175 psig.
-With fuel supply pressures listed, the turndown is 10:1 on gas 8:1 on oil.
-Nominal load reference and FD fan motor hp are for non-FGR applications.
Table C-23. Burner Data (Model CT)
Section C
C-50
03-08
Table C-24. Standard Offering (Model CT Burner).
Table 1:
BURNER MODEL AND SIZE
STANDARD EQUIPMENT ON CT BURNER
CT
1-20
CT
21-27
FORCED DRAFT FAN
1 X X Fan driven by open drip proof motor.
2 X X Damper at FD fan inlet.
3
X
X
FD Fan Location:
a. On windbox.
b. Remote from burner.
4 X X Combustion air proving switch (CAPS) mounted and wired.
ATOMIZING MEDIA (OIL-FIRED UNITS)
5 X X Steam atomization standard.
CONTROLS & ELECTRICAL
6 X Cleaver-Brooks standard electric positioning controls.
7 X Cleaver-Brooks parallel positioning controls.
8 X X C-B 100 flame safeguard control with lead sulfide scanner.
9 X X Controls remote from control enclosure have NEMA 1 housing.
10 X X NEMA 12 panel, mounted on boiler.
11 X X Steam pressure controls (High Limit Pressure Control, Operating Limit Pressure Control, Low-Fire Pres-
sure Control and Modulating Pressure Control) and 8-1/2 steam gauge all on a common manifold assem-
bly, shipped separate from burner (field piping and wiring required).
12 Starter for FD fan motor.
13 X X Electric current characteristics 230-460V, 3-phase, 60-Hz.
14 X X Control circuit transformer mounted and wired on burner.
FUEL
15 X X Gas pilot for all fuel series.
NOTE: Standard equipment listed here is included only with burner model indicated by an X.
Section C
C-51
03-08
Boiler Room
Information
Figure C-19 shows the recommended pier arrangement for industrial watertube
boilers. Figure C-20, through Figure C-24 show different boiler and stack
arrangements for industrial watertube boilers.
Breeching If more than one boiler is connected to a common stack or breeching, an outlet
damper and damper regulator is required unless otherwise noted.
Refer to Figure C-25 through Figure C-27 for breeching transition dimensions, and
to Table C-25 for stack size selection.
Section C
C-52
03-08
Figure C-19. Pier Arrangement
Figure C-20. Right Hand Boiler Arrangement Figure C-21. Left Hand Boiler Arrangement
Section C
C-53
03-08
Figure C-22. RH and LH Boiler Arrangement With Separate Stacks
Figure C-23. LH and RH Boiler Arrangement With Common Stack
Section C
C-54
03-08
Figure C-24. Two-Boiler Arrangement With Separate Stacks
Section C
C-55
03-08
BOILER MODEL
DIMENSIONS IN INCHES
A B C
D
26
34
42
52
60
68
76
86
94
15
18
27
30
30
33
36
36
42
36
36
36
36
39
39
39
39
42
86-3/4
86-3/4
86-3/4
86-3/4
98-3/4
98-3/4
98-3/4
98-3/4
107-3/4
DL
52
60
68
76
86
94
30
33
36
42
42
42
39
39
39
39
42
42
86-3/4
98-3/4
98-3/4
107-3/4
107-3/4
116-3/4
NOTES:
1. Dimensions vary per stack size and velocity.
2. Must be shipped loose for field installation.
3. For DLD-DLDH, contact your local Cleaver-Brooks authorized representative.
Figure C-25. Breeching,; Top Outlet Transition Piece
Section C
C-56
03-08
BOILER MODEL
A B C
D
26
34
42
52
60
68
76
86
94
54
54
54
54
66
66
66
66
75
15
18
27
30
30
33
36
36
42
36
36
36
36
36
36
36
36
36
DL
68
76
86
94
66
75
75
84
36
42
42
42
36
36
36
36
NOTES
1. Dimensions vary per stack size and velocities.
Figure C-26. Breeching; Gas Outlet Transition (Direct-to-Stack)
Section C
C-57
03-08
BOILER MODEL
A B C D E
D
26
34
42
52
60
68
76
86
94
54
54
54
54
66
66
66
66
75
15
18
27
30
30
33
36
36
42
36
36
36
36
39
39
39
39
42
35
35-1/2
35-1/2
35-1/2
41-1/2
41-1/2
41-1/2
41-1/2
46
24
24
24
24
25-1/2
25-1/2
25-1/2
25-1/2
27
DL
52
60
68
76
86
94
66
66
66
75
75
84
30
33
36
42
42
42
39
39
39
39
42
42
41-1/2
41-1/2
41-1/2
46
46
50-1/2
25-1/2
25-1/2
25-1/2
25-1/2
27
27
NOTES:
1. Dimensions vary per stack size and velocity.
Figure C-27. Breeching; Gas Outlet Transition (Connection to horizontal breeching)
Section C
C-58
03-08
STACK DIAMETER
IN.
WEIGHT (LBS)
STACK DIAMETER
IN.
WEIGHT (LBS)
3/16
PLATE
1/4
PLATE
3/16
PLATE
1/4
PLATE
24
27
30
33
36
39
42
1305
1460
1632
1787
1959
2113
2268
1749
1956
2187
2394
2623
2830
3037
45
48
51
54
57
60
63
2439
2593
2765
2940
3080
3220
3400
3267
3474
3705
3910
4140
4350
4570
The stack weights shown include the base ring, clean-out door, and connection for breeching.
Table 1:
FLUE GAS FLOW TO
STACK
LBS/HR
STACK
DIAMETER
IN.*
FREE AREA
SQ-FT
FLUE GAS VELOCITY
FPM AT 560 F
GAS TEMP
ELEVATION
FT
MULTIPLICATI
ON
FACTOR
MINIMUM MAXIMUM MINIMUM MAXIMUM
12,910
15,510
21,210
24,410
32,010
36,010
43,010
50,010
57,010
66,010
75,010
84,010
94,010
104,010
115,010
126,010
137,510
150,010
162,510
178,010
192,010
206,010
221,010
237,010
255,010
271,010
15,500
21,200
24,400
32,000
36,000
43,000
50,000
57,000
66,000
75,000
84,000
94,000
104,000
115,000
126,000
137,500
150,000
162,500
178,000
192,000
206,000
221,000
237,000
255,000
271,000
287,000
24
28
30
34
36
39
42
45
48
51
54
57
60
63
66
69
72
75
78
81
84
87
90
93
96
99
3.012
4.125
4.747
6.121
6.874
8.296
9.621
11.045
12.566
14.186
15.904
17.720
19.635
21.647
23.758
25.967
28.274
30.680
33.183
35.785
38.484
41.282
44.179
47.173
50.265
53.456
1840
1620
1920
1710
1995
1860
1920
1940
1945
1990
2020
2030
2050
2060
2080
2085
2090
2100
2100
2130
2140
2145
2150
2155
2170
2180
2200
2200
2200
2240
2245
2220
2225
2220
2250
2260
2260
2270
2270
2270
2270
2270
2270
2270
2300
2300
2300
2300
2310
2310
2310
2310
0- 500
501-1000
1001-1500
1501-2000
2001-2500
2501-3000
3001-3500
3501-4000
4501-4500
4501-5000
5001-5500
5501-6000
6001-6500
6501-7000
1.0
1.025
1.05
1.07
1.085
1.105
1.12
1.15
1.17
1.19
1.22
1.24
1.26
1.28
* Dimensions vary per stack size and flue gas velocities.
If boiler is more than 500 feet above sea level, multiply the actual gas flow to stack by factor given and select the stack diameter that corre-
sponds to the corrected gas flow.
Based on a 25 ft high steel stack, the following weight will apply for estimating purposes.
the above stack diameters apply, dependent upon the flue gas flow to the stack as determined from the performance sheet.
Table C-25. Industrial Watertube Boiler Stack Size Selection Chart
C-59
Section C
(Steam Boiler Specification)
Shop-Assembled Steam Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-60
General Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-60
Packaged Watertube Boiler(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-61
Design Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-61
Drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-61
Boiler and Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-62
Boiler Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-63
Sootblower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-65
Boiler and Trim Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-65
Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-66
Economizer (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-67
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-67
Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-69
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-70
Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-70
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-71
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-71
Field Quality Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-71
Demonstrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-71
needs and application. A separate specification is provided for steam boiler packages and high temperature hot water pack-
ages.
Industrial Watertube Steam Boiler Specifications Section C
C-60
PART 1 GENERAL 1.1 SHOP-ASSEMBLED STEAM BOILER
This specification shall govern the construction features, materials, fabrication, inspection, and
preparation for shipment of packaged-type, shop-assembled, watertube steam generating
equipment with burner assembly, all necessary appurtenances, controls and auxiliary equipment
mounted to the maximum practical extent, as an integral unit on a steel base so as to make a
complete self-contained assembly.
1.2 GENERAL REQUIREMENTS
A. Proposal
1. Complete description, drawings, and material specifications
and performance shall accompany each proposal.
B. Standards and Codes
1. The following regulatory codes and standards, publication issue
in effect at date of invitation for bids, form a part of this
specification. All applicable components shall be designed and
constructed in accordance with these codes with additions or
modifications as required by this specification.
a. American Society of Mechanical Engineers (ASME) Boiler
and Pressure Vessel Code, Section I, Power Boilers.
b. American Boiler Manufacturers Association (ABMA)
Manual of Industry Standards.
c. Underwriters Laboratories (UL), UL 795 Commercial-
Industrial Gas-Fired Heating Equipment.
d. National Fire Protection Association (NFPA), 8501
Prevention of Furnace Explosions in Fuel Oil and Natural
Gas-Fired Single Burner Boiler Furnaces.
e. Steel Structures Painting Council (SSPC), Surface
Preparation SP-l.
f. National Electric Code (NEC)
g. National Electrical Manufacturers Association (NEMA).
2. All equipment shall comply with the state, provincial or
municipal laws and regulations governing the location where
the equipment is to be installed.
C. Documentation Requirements
1. Dimension drawing with dry and flooded weights, major
component identification, and service connection location and
size.
2. Electrical drawings including elementary ladder logic and field
component interconnection diagram. Fuel train schematics.
3. Two (2) copies of certified ASME Manufacturers Data Reports
on the pressure vessel.
4. Operating and maintenance manuals.
5. Recommended spare parts list.
D. Design Requirements
1. Design continuous capacity: _____lb/hr.
2. Design pressure: _____psig.
3. Operating pressure: _____psig.
Section C Industrial Watertube Steam Boiler Specifications
C-61
4. Final steam temperature: _____F.
5. Steam quality (solids): _____ppm.
6. Feedwater temperature: _____F.
7. Elevation above sea level: _____ft.
8. Electrical characteristics: _____Volts, _____phase, ____Hz.
9. Primary fuel: _____, Supply pressure ______.
10. Standby fuel _____, Supply pressure ______.
11. Insurance requirements _____.
E. Manufacturer
1. Subject to compliance with requirements, provide watertube
boiler manufactured by Cleaver-Brooks, Division of Aqua-
Chem, Inc.
F. Efficiency Guarantee
1. Fuel-to-steam efficiency at above capacity is ____% when firing
oil and ____% when firing gas.
G. Heating Surface
1. The unit will have the following heating surface:
a. Boiler heating surface: _____sq-ft.
b. Water wall projected surface: _____sq-ft.
c. Total heating surface: _____sq-ft.
d. Furnace volume: _____cu-ft.
PART 2 PRODUCTS 2.1 PACKAGED WATERTUBE BOILER(S)
Boilers shall be factory-assembled, packaged, and mounted on heavy steel base frame, complete
with integral forced draft burner, burner controls, boiler trim, and refractory. Boilers shall be
assembled and wired so that only water, steam, fuel, blowdown, electrical, and vent connections
are required.
2.2 DESIGN PRESSURE
The pressure vessel shall have a design pressure of 260 psig in accordance with ASME Power
Boiler Construction Code, Section 1, and the laws of the state or province in which the equipment
is to be installed. The boiler shall be registered with the National Board of Boiler and Pressure
Vessel Inspectors (Provincial Boiler Inspection Agency in Canada), and with the specific state or
provincial boiler inspection department.
2.3 DRUMS
A. The boiler shall have one upper steam drum and one lower mud
drum extending the full length of the boiler setting. Each drum head
shall have a 12" x 16" manhole opening with cover, yoke, and
gasket. Furnish one operating set of gaskets and two complete spare
sets. Drums shall be X-rayed and stress relieved as required, and
under the inspection of the Hartford Steam Boiler Inspection and
Insurance Company.
1. Steam Drum - The unit shall incorporate a steam drum of SA-
515 grade 70 steel plate (70,000 psig tensile strength) welded
construction in strict conformance with the ASME Power Boiler
Code. The drum will be stress-relieved, seams radiographed,
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and hydrostatically tested at 1-1/2 times the design pressure.
a. The steam drum shall be fitted with an internal feed pipe,
chemical feed pipe, and the blowdown pipe. Water level
control baffling is to be installed to ensure that all steam
released from the generating tubes is released behind the
baffles and not through the water level. Drum internals
shall consist of steam separators or dryers, which are
installed to ensure that the steam leaving the drum
contains not more than 1/2 of 1% moisture when boiler
water concentrations are maintained in accordance with
ABMA recommendations.
2. Lower Drum - The lower drum shall be of fusion-welded
construction and will be stress-relieved, seams radiographed,
and hydrostatically tested at 1-1/2 times the design pressure.
The lower drum shall be fitted with an internal blowdown guide
baffle to ensure effective blowdown of the lower drum
disturbance to the water circulation in the unit.
B. Drum Connections
1. Provide the following openings in the drums for piping
connections, all flanges shall be raised face and drilled 300
psig ANSI.
a. Steam outlet: _____One (1) flanged.
b. Safety valves: _____as required by ASME.
c. Sootblower: _____One (1) 2" screwed.
d. Water Column: _____Two (2) 1" screwed.
e. Feedwater Regulator: _____Two (2) 1" screwed.
f. Top Vent: _____One (1) 1" screwed.
g. Continuous Blowdown: _____One (1) 1" screwed.
h. Chemical Feed: _____One (1) 1/2 screwed.
i. Feedwater: _____One (1) 2" screwed.
j. Blowdown: _____One (1) 1-1/4 screwed.
2. All openings shall be properly protected from damage and
weather during shipment.
2.4 BOILER AND FURNACE
A. Furnace
1. The furnace shall employ six-wall cooling with the following:
a. Front wall tubes closely spaced around the burner.
b. Membrane inner furnace wall.
c. Tangent floor, roof, and outer furnace wall.
d. Triple row of rear wall tubes.
e. Double row of screen tubes at furnace exit.
2. All tubes shall terminate in the upper and lower drums. No
headers are to be used, and all heating surface in the furnace is
based on actual projected tube surface and membrane surface.
All tubes shall be cleanable by mechanical tube cleaners. All
tubes to be expanded into upper and lower drums.
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B. Boiler Section
1. The boiler convection section shall consist of 2" OD tubes SA
178A Grade A arranged in line with longitudinal rows of tubes
arranged on wide and narrow spacing to ensure proper and
effective arrangement of sootblowing equipment. This
arrangement shall also permit removal of any tube without the
necessity of removing adjacent tubes.
C. Tube Material
1. All tubes in the unit for boiler and furnace shall be 2" OD, of
SA-178, Grade A, electric resistance welded construction in
accordance with ASME Code.
D. Superheater (Optional)
1. A bare tube, completely drainable superheater shall be
furnished as an integral part of the boiler. All superheater
elements and headers shall be of suitable carbon and alloy
steel material of a thickness required for temperature and
pressure prevailing under maximum load conditions. The
superheater shall be equipped with a weld end superheater
outlet connection and safety valve nozzle, drain, vent,
thermometer, and thermocouple connections as required by the
design. Safety valve, drain valve, vent valve, and thermometer
shall be included. (A steam sampling connection shall be
provided by the owner in the connecting steam line).
Superheater outlet header is equipped with a connection for the
customers automatic start-up and shut-down vent valve size.
Piping contractor or others shall furnish and install an
automatic controlled vent valve when superheater is subjected
to low load conditions.
2. All super heater tube material subject to radiant furnace heat
shall be constructed of alloy steel suitable for the temperatures
involved.
2.5 BOILER ENCLOSURE
A. Casing
1. The boiler shall be enclosed with Cleaver-Brooks standard
double panel casing with the portion of the casing exposed to
the products of combustion completely seal welded to form an
air and gas tight enclosure. The outer casing panels shall also
be welded.
2. The casing is to be supported off the structural steel frame and
shall not be welded or attached to tubing, thereby ensuring free
expansion of pressure parts within the casing enclosure.
B. Arrangement of Casing
1. Construction of the boiler casing enclosure shall be as follows
a. Front Wall - Furnace Area
1) 3", 4-way interlocking tile.
2) 4" high-temperature block insulation.
3) 10-gauge inner seal welded casing.
4) 2-1/2 low density block insulation.
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5) 1/4 burner front plate.
6) 2.5.2.2 Rear Wall - Furnace Area
7) 3", 4-way interlocking tile.
8) 4" high-temperature block insulation.
10) 2-1/2 low-density block insulation.
b. Convection Section - Furnace
2) 4-3/8 low-density mineral wool block.
C. Furnace Floor
1. Furnace floor tubes shall be covered with 1-1/2 square edge
tile.
D. Drum Enclosure
1. The steam drum shall be shop-insulated with mineral wool
block and enclosed in a welded 10-gauge casing. All drum
heads will be shop-insulated and enclosed in a 10-gauge
casing. No further insulation in the field shall be required.
E. Access
1. Access to the furnace shall be through the burner opening in
the front wall, and through a separate refractory lined door on
the rear wall.
F. Observation
1. Two (2) air-cooled observation ports, with Pyrex eye shields,
shall be provided in the rear wall.
G. Air Pressure Test
1. The inner seal welded 10-gauge casing shall be subject to an
air pressure test of 8" WC, and shall be considered
satisfactorily tight if the air pressure drop does not exceed 2"
WC in five (5) minutes.
H. affling
1. The convection section shall contain vertical baffles of 10-
gauge steel to direct the flow of flue gases. The baffles shall not
require removal for tube replacement.
I. Insulation
1. The setting and insulation shall be so designed to ensure that a
maximum average casing surface temperature of 130F is not
exceeded under full load firing with an ambient air temperature
of 80F and with a surface air velocity of two feet per second
when burner is at maximum output. The manufacturer shall
guarantee the design against overheating, warping, or burning
of the casing.
2. Pressure Connection
a. Provide a sensing location in furnace, free of turbulence
from flame, for draft control sample connection.
J. Painting
1. The surfaces shall be prepared per SSPC SP-l specifications
C-65
and finished with rust resistant primer and a high-quality, high-
temperature finish coat of enamel paint.
2.6 SOOTBLOWER
A. Provide, at a minimum, wall box(es) and bearings for boiler being
fired on natural gas and No. 2 oil. When heavy oil is specified,
provide the following:
1. Sootblowers shall be steam operated, valve-in-head type, and
shall be furnished complete with wall sleeves, clamps,
hangers, supports, operating chains, and other appurtenances
required for a complete installation.
2. Blower elements shall be so arranged that all parts of the
heating surfaces shall be cleaned of any soot deposits when
rotated by manual or automatic means.
3. Elements shall be of such length, diameter, and total nozzle
area that, for the operating pressure involved, there will be no
significant difference in the cleaning effect between the nozzle
nearest the inlet and those farthest from the inlet of the
element.
4. Sootblower piping shall include a valve, chain-operated from
the floor, in addition to an auxiliary steam-stop valve, and drain
connection.
5. Sootblowers shall be fitted with scavenging air ports, and shall
be connected by tubing to the draft fan in a manner to provide
sufficient air, for continuous scavenging of the blowers.
2.7 BOILER AND TRIM ACCESSORIES
A. Each unit shall be provided with the following trim (and quantity),
which shall be designed for a minimum of 240 psig.
1. Steam Pressure Gauge (1).
2. Safety Valves, Consolidated/Kunkle (ASME Code).
3. Feedwater Regulator, Fisher 2500 (1).
4. Feedwater Regulator By-Pass, Velan S254B (1).
5. Feedwater Regulator Shutoff, Velan S274B (2).
6. Water Column, Cleaver-Brooks (1).
7. Water Gauge, Reliance 404-RS (1).
8. Feedwater Regulator Drain, Velan S274B (1).
9. Gauge Cocks, Reliance No. GC-451 (3).
10. Column Drain, Velan S274B (1).
11. Gauge Drain, Velan S274B (1).
12. Hi-Low Alarm, Warrick Probe (1).
13. Low Water Cutoff, Warrick Probe (2).
14. Feed Stop, Velan S254B (1).
15. Feed Check, Lunkenheimer 624 (1).
16. Drum Blowdown Valve, Edwards No. 848-849 (1 Set).
17. Air Vent, Velan S274B (1).
18. Continuous Blowdown, Velan/Vogt S2054B (1).
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19. Chemical Feed Stop, Edwards No. 848 (1).
20. Chemical Feed Check, Edwards No. 838 (1).
21. Auxiliary Low-Water Cutoff, Float Magnetrol #249 (1).
22. Sootblower Shutoff, Velan S254B (1 when required).
23. Sootblower Drain, Velan S274B (1 when required).
B. All above items, including required piping and supports, shall be
assembled in the shop to assure proper fit. Drain piping shall be
extended for installation of valves at hand height.
2.8 BURNER
A. Provide the unit with a forced-draft, register-type burner, arranged to
burn natural gas complete with gas electric ignition and observation
port. The burner shall be of a type that can be readily converted to
oil in the future. The windbox shall be ruggedly constructed and of a
proven design which will assure an even supply of air to all
quadrants of the burner register. The burner shall be a standard
product of the boiler manufacturer specifically designed for the
boiler.
B. Forced Draft Fan
1. The assembly shall be attached to the windbox in such a way
that will allow easy access for maintenance. An inlet screen
shall be provided, and the air volume shall be regulated by inlet
vanes. The fan shall develop sufficient static pressure to ensure
proper distribution of air over the entire turndown range of the
burner.
C. Operating and Safety Controls
1. The unit shall be provided with a full complement of operating
and safety controls, consisting of not less than the following
items and features, which shall be shop assembled:
a. Automatic gas-electric ignition system for gas operation.
2. Underwriters Laboratories listed and Factory Mutual approved
microprocessor burner programming and safety controller to
automatically provide proper cycling for pre-combustion purge,
ignition, start, stop, post-combustion purge and safety
shutdown, for use on gas firing and oil firing. This controller
shall be a standard product of the boiler manufacturer.
3. Electronic type flame failure protection as part of the program
controller to provide safety shutdown on failure of either the
main flame or the pilot flame, with manual reset, flame failure
and high temperature alarm, all on either oil or gas-firing.
4. Separate high-pressure safety cutoff for steam and low-fire hold
pressure control.
5. Separate auxiliary low-water safety cutoff for water level with
momentary bypass pushbutton for blowdown function.
6. Blower damper to automatically proportion combustion air to
firing rate.
7. Air flow safety switch.
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8. The following gas valve trains shall be mounted on the burner
windbox. All electrical devices shall be prewired to terminals
within a burner mounted box. The gas train will be made from
Schedule 40 pipe. Sizes 4" and above shall be with butt-weld
fittings.
9. The pilot gas train shall conform to NFPA-8501 and be of the
interruptible type consisting of two (2) pilot gas solenoid
valves, one (1) pilot vent valve, one (1) manual shutoff valve,
and a gas pressure regulator.
10. The main gas train shall conform to NFPA-8501 and consist of
two (2) main gas valves with one valve having an overtravel
protection interlock, a flow control valve, a gas pressure
regulator, one (1) vent valve, one (1) manual gas shutoff valve,
high and low gas pressure limit protection, and main gas valve
leak-test provisions.
D. The oil burner shall be of the steam-atomizing type for fully-
automatic operation. Low pressure air-atomazation is available as an
option. Air-atomizing burners shall be supplied with a self-
lubricating air compressor. The entire module, a motor driven air
compressor and lubricating system, is to be mounted either on the
front of the boiler or in a console that can be set adjacent to the
boiler. The burner design shall assure proper fuel-air mixture for
smoke-free operation at all loads. When firing heavy oil, a positive
automatic burner oil gun purge system shall be provided to purge the
oil gun on each shutdown of the burner.
E. The fuel train shall be constructed with Schedule 40 piping, and
shall conform to NFPA-8501 requirements consisting of the
appropriate pressure and temperature limits (if heavy oil is used),
and one (1) fuel valve with valve seal overtravel interlock. If No. 2 oil
is used, a second valve is required. All electrical devices shall be
prewired to terminate within a burner mounted box.
F. All controls for the boiler shall be enclosed in a suitable cabinet,
with hinged door and lock, containing all necessary relays, magnetic
starters, contactors, terminal blocks, fuse blocks, fuses,
transformers, switches, rheostats, and colored indicating lights. All
instruments on the panel front shall be identified by nameplate. An
alarm horn shall be provided on the panel to indicate flame failure
and low water level. All wire terminations shall be numbered in
accordance with the applicable wiring diagram. All wiring shall
conform with the National Electric Code.
1. Electronic continuity tests shall be provided on all circuits to
ensure minimal start-up time.
2.9 ECONOMIZER (OPTIONAL)
Refer to Economizer, Section G, for specification.
2.10 CONTROLS
A. Feedwater Control Valve
1. Provide a single element pneumatic system consisting of a
steam drum water level sensing device that controls a
diaphragm-operated control valve. The control valve shall be a
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tight shut-off with air-to-open type. Provide means to control
set point and proportional band.
B. Feedwater - Two-Element Control (Optional)
1. The feedwater system shall be of the two-element control type.
Drum level shall be maintained by integrating both steam flow
and water level signals to control final drum level. A master
controller, steam flow element (orifice plate), pressure
transducers and drum level transducers shall be included.
C. Feedwater - Three-Element Control (Optional)
1. The feedwater system shall be of the three-element control
type. Drum level shall be maintained by integrating steam flow,
water level and feedwater flow signals to control final drum
level. A master controller, steam flow and water flow elements
(orifice plates), pressure transducers and drum level transducer
shall be included.
D. Combustion Control - Single-Point
1. Provide a full modulating single-point electronic combustion
control package consisting of the following:
a. Master controller shall maintain steam pressure at boiler
outlet within 3% of set point.
b. The control shall be capable of handling load swings from
a steady state condition to an increase or decrease in load
equal to 20% of the maximum rated capacity of the boiler.
c. Provide a single jackshaft to regulate the flow of air and
fuel(s) to the burner. The jackshaft shall be driven from an
electric drive in response to the master steam pressure
controller. Provide characterizable fuel and air cams for
the optimizing of combustion fuel-to-air ratio throughout
the firing range.
E. Combustion Control - Parallel Positioning (Optional)
1. Provide a combustion control system that uses the concept of
controlling the fuel and air flows through separate actuators.
Provide a controller for boiler master, air flow controller, and
fuel flow controller. If a multiple-boiler application, include a
plant master controller.
2. The combustion control system shall be configured to interface
to a stand-alone burner management system. This interface
shall include interlocks for purge and low fire release.
F. Combustion control - Full Metering (Optional)
1. Provide a single-fuel-fired combustion control system that uses
the concept of parallel metering of fuel(s) and air with cross-
limiting. For multiple boiler applications, include a plant master
single-loop controller in addition to a boiler-master, fuel flow
controller(s), and an air flow controller.
2. The combustion control system shall be configured to interface
to a stand-alone burner management system. This interface
shall include interlocks for purge and low-fire release.
3. Steam header pressure shall be controlled to within one
percent of set point without excessive hunting or overshooting.
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G. Monitoring and Recording (Optional)
1. The following items shall be recorded. Measuring devices such
as orifice plate and transmitters shall also be included:
a. Steam flow.
b. Water flow.
c. Steam pressure.
d. Stack temperature.
e. Economizer outlet stack temperature.
f. Feedwater temperature at economizer inlet.
g. Fuel water temperature at economizer outlet.
h. Fuel Flow.
i. Drum Level.
j. Percent Oxygen.
H. Multi-point indicator shall be provided for:
a. Furnace pressure.
b. Windbox pressure.
c. Boiler outlet.
I. A multi-point annunciator shall be provided for the following as
applicable:
a. Flame failure.
b. High-low gas pressure.
c. High-low oil pressure.
d. High-low oil temperature.
e. Low atomizing media.
f. Combustion air.
g. Main and pilot failure.
h. Drum level, High-low.
i. High steam pressure.
J. The annunciator shall include alarm horn, silence and test switch.
K. Forced Flue Gas Recirculation - (Optional)
L. Induced Flue Gas Recirculation (Optional)
Refer to FGR specifications.
PART 3 EXECUTION 3.1 GUARANTEE
1. Steam will contain not more than 1/2 of 1% moisture when
boiler water concentrations are maintained in accordance with
ABMA recommendations.
2. The boiler manufacturer shall guarantee the steam generating
capacity and thermal efficiency as stated herein, while the unit
is being fired with the primary fuel at the specified operating
conditions.
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3. Performance and efficiency tests shall be conducted
immediately after completion of start-up. The manufacturer
must have a representative in attendance at the time the test is
conducted.
4. All equipment is to be guaranteed against defective design,
workmanship, or material for one year from the date of initial
operation, not to exceed eighteen (18) months from shipment.
3.2 TESTING
A. A shop hydrostatic test shall be performed at 1-1/2 times the design
pressure under the inspection of the Hartford Steam Boiler
Inspection and Insurance Company.
B. The boiler casing shall be subjected to a shop internal air test at a
minimum pressure of 8" WC, and held for five minutes without
dropping 2" WC to ensure that no leaks are present. Any detected
leaks shall be corrected.
C. Provide electronic continuity tests on all circuits to ensure minimal
start-up time.
3.3 EXAMINATION
C-71
Examine and verify size, location, and condition of concrete pads upon which boilers
are to be installed. Do not proceed with installation until unsatisfactory conditions
have been corrected.
3.4 INSTALLATION
A. General
1. Install boilers in accordance with manufacturers installation
instructions, requirements of state, provincial and local code,
and requirements of the local utility company. Maintain
manufacturers recommended clearances around and over
boilers.
B. Support
1. Install boilers on 15" high concrete pads. Pads to be located
under each boiler drum saddle.
C. Erection
1. Assemble boiler trim shipped loose or unassembled for
shipment purposes. Follow manufacturers installation
instructions.
D. Gas Piping
1. Connect gas piping to boiler, full size of boiler gas train inlet,
and provide union with sufficient clearance for burner removal
and service.
E. Oil Piping
1. Connect oil piping to boiler, full size of inlet to burner, and
provide shutoff valve and union with sufficient clearance for
burner removal and service.
F. Steam and Condensate Piping
1. Connect supply, return, and blowdown boiler tappings as
indicated, with shutoff valve and union, or flange, at each
connection.
G. Breeching
1. Connect breeching to boiler outlet, full size of outlet.
3.5 CLEANING
Flush and clean boilers, upon completion of installation, in accordance with manufacturers
instructions.
3.6 FIELD QUALITY CONTROL
A. Hydrostatically test assembled boiler and piping in accordance with
applicable sections of ASME Boiler and Pressure Vessel Code.
B. A representative of the National Board of Boiler and Pressure Vessel
Inspectors (or Provincial Boiler Inspection Agency in Canada) shall
inspect boiler installation, piping connections, and observe
hydrostatic testing and for certification of completed boiler units.
3.7 DEMONSTRATIONS
A. Services
1. After testing and inspection is complete, provide the services of
an authorized factory service representative to perform start-up
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and operation demonstration services.
B. Start-Up
1. Perform services in accordance with manufacturers written
start-up instructions. Test controls and demonstrate compliance
with requirements. Replace or repair damaged or
malfunctioning controls and equipment.
C. Maintenance and Operation Training
1. As part of the maintenance and operating instructions, review
data in operating and maintenance manual, including
preventative maintenance schedule and procedures, and
procedures for obtaining repair parts and technical assistance.
Demonstrate all phases of operation including start-up and
shut-down. Schedule training with Owner, and provide at least
7-day notice to Architect/Engineer.
D. Factory-trained authorized service and parts representative shall be
located within 4 hours of boiler plant.
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03-08
Section C
(Hot Water Generator Specifications)
Shop-Assembled Watertube Hot Water Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-74
General Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-74
Packaged Watertube Generator(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-75
Design Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-75
Drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-75
Boiler and Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-76
Boiler Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-76
Sootblower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-78
Generator and Trim Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-78
Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-78
Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-80
Instrumentation and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-80
Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-81
Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-81
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-81
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-82
Field Quality Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-82
Demonstrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-82
needs and application. A separate specification is provided for steam boiler packages and high temperature hot water pack-
ages.
Section C Industrial Watertube Hot Water Generator Specifications
C-74
03-08
PART 1 GENERAL 1.1 SHOP-ASSEMBLED WATERTUBE HOT WATER GENERATOR
This specification shall govern the construction features, materials, fabrication, inspection,
and preparation for shipment of packaged-type, shop-assembled, watertube hot water gen-
erating equipment with burner assembly, all necessary appurtenances, controls, and auxil-
iary equipment mounted to the maximum practical extent, as an integral unit on a steel
base so as to make a complete self-contained assembly.
1.2 GENERAL REQUIREMENTS
A. Proposal
1. Complete description, drawings, and material specifications
and performance shall accompany each proposal.
B. Standards and Codes
1. The following regulatory codes and standards, publication
issue in effect at date of invitation for bids form a part of this
specification. All applicable components shall be designed and
constructed in accordance with these codes with additions or
modifications as required by this specification.
a. American Society of Mechanical Engineers (ASME) Boiler
and Pressure Vessel Code, Section I, Power Boilers.
2. American Boiler Manufacturers Association (ABMA) Manual of
Industry Standards.
3. Underwriters Laboratories, Inc. (UL), UL 795, Commercial-
Industrial Gas-Fired Heating Equipment.
4. National Fire Protection Association (NFPA), 85A, Prevention
of Furnace Explosions in Fuel Oil and Natural Gas-Fired Single
Burner Boiler Furnaces.
5. Steel Structures Painting Council (SSPC), Surface Preparation
SP-1.
6. National Electric Code (NEC).
7. National Electrical Manufacturers Association (NEMA).
8. All equipment shall comply with the state, provincial or
municipal laws and regulations governing the location where
the equipment is to be installed.
C. Documentation Requirements
1. Dimension drawing with dry and flooded weights, major
component identification, and service connection location and
size.
2. Electrical drawings including elementary ladder logic and field
component interconnection diagram.
3. Fuel train schematics.
4. Two (2) copies of certified ASME Manufacturers Data Reports
on the pressure vessel.
5. Operating and maintenance manuals.
6. Recommended spare parts list.
D. Design Requirements
1. Design continuous capacity: _____Btu/hr.
2. Design supply temperature: _____F.
3. Design return temperature: _____F.
Industrial Watertube Hot Water Generator Specifications Section C
C-75
03-08
4. Operating pressure: _____psig.
5. Flow rate:_____gph.
6. Elevation above sea level: _____ft.
7. Electrical characteristics: _____Volts, _____phase, _____Hz.
8. Primary fuel: _____, Supply pressure _____.
9. Standby fuel: _____, Supply pressure _____.
10. Insurance Requirements _____.
E. Manufacturer
1. Subject to compliance with requirements, provide watertube
generator manufactured by Cleaver-Brooks; Division of Aqua-
Chem, Inc.
F. Efficiency Guarantee
1. Fuel-to-water efficiency at above capacity is ____% when firing
oil and ____% when firing gas.
G. Heating Surface
1. The unit will have the following heating surface:
a. Boiler heating surface: _____sq-ft.
b. Water wall projected surface: _____sq-ft.
c. Total heating surface: _____sq-ft.
d. Furnace volume: _____cu-ft.
PART 2 PRODUCTS 2.1 PACKAGED WATERTUBE GENERATOR(S)
Generator shall be factory-assembled, packaged, mounted on heavy steel base frame, complete
with integral forced draft burner, burner controls, generator trim, and refractory. Factory-assemble
and wire generators so that only water, steam, fuel, blowdown, electrical, and vent connections
are required.
2.2 DESIGN PRESSURE
A. The pressure vessel shall have a design pressure of 260 psig in
accordance with ASME Power Boiler Construction Code Section 1,
and the laws of the state or province in which the equipment is to be
installed. The generator shall be registered with the National Board
of Boiler and Pressure Vessel Inspectors (or Provincial Boiler
Inspection Agency in Canada), and with the specific state or
provincial boiler inspection department.
2.3 DRUMS
The generator shall have one upper drum and one lower mud drum extending the full length of the
generator setting. The upper drum shall be of all welded construction, and shall be complete with
all necessary openings. The lower drum shall be of all welded construction, and shall be complete
with all necessary openings and internal water distribution pipe. The lower drum shall have a
flanged thermal sleeve type water inlet connection. The lower drum internals shall be of the jet
inducing circulation and mixing type. The upper drum head shall have a 12" x 16" manhole open-
ing with plate, yoke, and gasket. Furnish one operating set of gaskets and two complete spare sets.
Drums shall be X-rayed and stress-relieved, as required, and under the inspection of the Hartford
Steam Boiler Inspection and Insurance Company.
B. Drum Connections
1. Provide the following openings in the drums for all accessories
and piping connections. All flanges shall be raised faced and
C-76
03-08
drilled 300 psig ANSI.
a. Supply: one (1) flanged.
b. Return: one (1) flanged.
c. Safety relief valves: (as required by ASME) flanged.
d. Water column: two (2) 1" screwed.
e. Top vent: one (1) 1" screwed.
f. Chemical feed: one (1) 1/2 screwed.
g. Blowdown: one (1) 1-1/4 screwed.
2. All openings shall be properly protected from damage and
weather during shipment.
2.4 BOILER AND FURNACE
A. Furnace
1. The furnace shall employ six-wall cooling with the following:
a. Front wall tubes closely spaced around the burner.
b. Membrane inner furnace wall.
c. Tangent floor, roof, and outer furnace wall.
d. Triple row of rear wall tubes.
e. Double row of screen tubes at furnace exit.
2. All tubes shall terminate in the upper and lower drums. No
headers are to be used, and all heating surfaces in the furnace
are based on actual projected tube surface and membrane
surface. All tubes shall be cleanable by mechanical tube
cleaners. All tubes to be expanded into upper and lower
drums.
B. Boiler Section
1. The boiler convection section shall consist of 2" OD tubes
arranged in line with longitudinal rows of tubes arranged on
wide and narrow spacing to ensure proper and effective
arrangement of sootblowing equipment. This arrangement
shall also permit removal of any tube without the necessity of
removing adjacent tubes.
2. Tube Material
a. All tubes in the unit for boiler and furnace shall be 2" OD,
SA-178, Grade A, electric resistance-welded construction
in accordance with ASME Code.
2.5 BOILER ENCLOSURE
A. Casing
1. The boiler shall be enclosed with Cleaver-Brooks standard
double-panel casing with the portion of the casing exposed to
the products of combustion completely seal-welded to form an
air and gas-tight enclosure. The outer casing panels shall also
be welded.
2. The casing is to be supported off the structural steel frame and
shall not be welded or attached to tubing, thereby ensuring
free expansion of pressure parts within the casing enclosure.
C-77
03-08
B. Arrangement of Casing
1. Construction of the boiler enclosure shall be as follows:
a. 2.5.2.1 Front Wall - Furnace Area
b. 3", 4-way interlocking tile.
c. 4" high-temperature block insulation.
d. 10-gauge inner seal welded casing.
e. 2-1/2 low density block insulation.
f. 1/4 burner front plate.
g. 2.5.2.2 Rear Wall - Furnace Area
h. 3", 4-way interlocking tile.
i. 4" high-temperature block insulation.
j. 10-gauge inner seal welded casing.
k. 2-1/2 low-density block insulation.
2. 2.5.2.3 Convection Section - Furnace
a. 10-gauge inner seal welded casing.
b. 4-3/8 low-density mineral wool block.
C. Furnace Floor
1. Furnace floor tubes shall be covered with 1-1/2 square edge
tile.
D. Drum Enclosure
1. The steam drum shall be shop-insulated with mineral wool
block and enclosed in a welded 10-gauge casing. All drum
heads will be shop-insulated and enclosed in a 10-gauge
casing. No further insulation in the field shall be required.
E. Access
1. Access to the furnace shall be through the burner opening in
the front wall, and through a separate (optional) refractory
lined door on the rear wall.
F. Observation
1. Two (2) air-cooled observation ports, with Pyrex eye shields,
shall be provided in the rear wall.
G. Air Pressure Test
1. The inner seal welded 10-gauge casing shall be subject to an
air pressure test of 8" WC, and shall be considered
satisfactorily tight if the air pressure drop does not exceed 2"
WC in five (5) minutes.
H. Baffling
1. The convection section shall contain vertical baffles of 10-
gauge steel to direct the flow of flue gases. The baffles shall not
require removal for tube replacement.
I. Insulation
1. The setting and insulation shall be so designed to ensure that a
maximum casing surface temperature of 130F is not exceeded
under full load firing with an ambient air temperature of 80F
and with a surface air velocity of two feet per second when
C-78
03-08
burner is at maximum output. The manufacturer shall
guarantee the design against overheating, warping, or burning
of the casing.
J. Pressure Connection
1. Provide a sensing location in furnace, free of turbulence from
flame, for draft control sample connection.
K. Painting
1. The surfaces shall be prepared per SSPC SP-l specifications
and finished with rust resistant primer and a high-quality, high-
temperature finish coat of enamel paint.
2.6 SOOTBLOWER
Provide, at a minimum, wallbox and bearings for natural gas and No. 2 oil fired units. If a heavy
oil is specified, then provide a pneumatic sootblowing system including lances and controller for
automatic operation upon operator initiation. If owner does not have plant air available, the con-
tractor is to supply an appropriately sized air compressor/receiver.
2.7 GENERATOR AND TRIM ACCESSORIES
A. Each unit shall be provided with the following trim, designed for a
minimum of 240 psig:
1. Drum pressure gauge (1).
2. Safety valves, Consolidated/Kunkle (ASME Code).
3. Water column, Cleaver-Brooks (1).
4. Water gauge, Reliance 404-RS (1).
5. Gauge cocks, Reliance no. GC-451 (3).
6. Column drain, Velan S274B (1).
7. Gauge drain, Velan S274B (1).
8. Low water cutoff, Warrick probe (2).
9. Drum blow-off valve, Edwards No. 848-849 (1 Set).
10. Air vent, Velan S274B (1).
11. Continuous blow-off, Velan/Vogt (1).
B. All above items, including required piping and supports, shall be
assembled in the shop to assure proper fit. Drain piping shall be
extended for installation of valves at hand height.
2.8 BURNER
A. Provide a forced-draft, register-type burner arranged to burn the
specified fuels complete with gas electric ignition, observation port.
The windbox shall be ruggedly constructed, and of a proven design
that will assure an even supply of air to all quadrants of the burner
register. The burner shall be a standard product of the generator
manufacturer, specifically designed for the generator.
B. Forced Draft Fan
1. Assembly shall be attached to the windbox in such a way that
will allow easy access for maintenance. An inlet screen shall
be provided, and air volume regulated by inlet vanes. The fan
shall develop sufficient static pressure to insure proper
distribution of air over the entire turndown range of the burner.
C-79
03-08
C. Operating and Safety Controls
1. The unit shall be provided with a full complement of operating
and safety controls consisting of not less than the following
items and features which shall be shop assembled:
a. Automatic gas-electric ignition system for gas operation.
b. Underwriters Laboratories listed, and Factory Mutual
approved microprocessor burner programming and safety
controller to automatically provide proper cycling for pre-
combustion purge, ignition, start, stop, post-combustion
purge, and safety shutdown for the fuels as specified. This
controller shall be a standard product of the generator
manufacturer.
c. Electronic-type flame failure protection as part of the
program controller to provide safety shutdown on failure of
either the main flame or the pilot flame, with manual
reset, flame failure and high temperature alarm, all on
either oil or gas-firing.
d. Separate high-pressure safety cutoff and low fire hold
pressure control.
e. A mounted 8-1/2 diameter pressure gauge for drum
pressure.
f. Blower damper to automatically proportion combustion air
to firing rate.
g. Air flow safety switch.
D. If natural gas is specified, then the following is to be provided:
1. Main manual gas shutoff valve with square head and wrench
handle.
2. Gas pressure regulators for both pilot and main gas.
3. Gas control valve to regulate gas flow.
4. Gas safety shutoff valves to conform to Underwriters
Laboratories and the specified site insurance carrier
requirements, consisting of main shutoff valve(s). As a
minimum, one valve shall be with a proof-of-closure switch.
5. Two (2) pilot gas solenoid valves, pilot vent valve, and manual
stop cock.
E. If oil is specified, provide the following:
1. Main shutoff valve (two required for light oil).
2. Integral fuel oil metering controller with pressure gauges and
temperature gauges if heavy oil.
3. Components to be Factory Mutual and Underwriters
Laboratories approved. The configuration, along with safety
interlocks, shall be in accordance with the specified site
insurance requirements.
4. If heavy oil, a reverse oil-purge pump shall be supplied to
evacuate the oil gun on burner shutdown.
C-80
03-08
F. All controls for the generator shall be enclosed in a suitable cabinet,
with hinged door and lock, and containing all necessary relays,
magnetic starters (if provided), conductors, terminal blocks, fuse
blocks, fuses, transformers, switches, rheostats and colored
indicating lights. All instruments on the panel front shall be
identified by nameplate. Provide, on the panel, an alarm horn to
indicate flame failure and low-water level. All wire terminations
shall be numbered in accordance with the applicable wiring
diagram. All wiring shall be done in conformity with the National
Electric Code.
G. Two (2) 6" diameter pressure gauges and two (2) 5" diameter
thermometers to be field-installed into the supply and return lines.
H. Provide an interlock to the burner operation for low water
circulation. This shall include an orifice plate and differential
pressure transmitter to be field-installed. The contractor shall supply
appropriate flanges. The generator manufacturer to supply a three-
valve manifold assembly for the transmitter.
2.9 TESTS
A. A shop hydrostatic test shall be performed at 1-1/2 times the design
pressure under the inspection of the Hartford Steam Boiler
Inspection and Insurance Company.
B. The generator casing shall be subjected to a shop internal air test at
a minimum pressure of 8" WC and held for five minutes without
dropping 2" WC to insure that no leaks are present. Any detected
leaks shall be corrected.
C. Provide electronic continuity tests on all circuits to ensure minimal
start-up time.
2.10 INSTRUMENTATION AND CONTROL
A. System Instrumentation (Optional)
1. Provide a freestanding panel piped, pre-wired with a finish
coat of paint complete with the following:
2. Four (4) pen recorder for water flow, water supply temperature,
water return temperature, and stack temperature.
3. Draft gauges, illuminated vertical scales for windbox pressure,
furnace pressure and boiler outlet pressure.
4. Temperature indicators, digital readouts for return water
temperature, supply water temperature and stack temperature.
5. Annunciator, first-out indication, silence and reset buttons, per
Instrument Society of America (ISA) standard F3M-3-14.
6. Canopy light.
B. Combustion Control - Single Point
1. Provide a full modulating single point electronic positioning
combustion control consisting of the following:
a. Master regulator to maintain temperature at generator
outlet within 3% of control setpoint.
C-81
03-08
b. Control shall be capable of swings from a steady state
condition to an increase or decrease in load equal to thirty
(30)% of the maximum rated capacity of the generator.
c. Single jackshaft to regulate the flow of air and fuel to the
burner. The jackshaft shall be driven from an electric drive
in response to the master regulator. Provide
characterizable fuel and air cams for the optimizing of
combustion fuel-to-air ratio throughout the firing range.
PART 3 EXECUTION 3.1 GUARANTEE
A. The generator manufacturer shall guarantee the Btu/hr generating
capacity at the specified temperatures and pressures, and (fuel-to-
water) efficiency as stated herein, while the unit is being fired with
the primary fuel at the specified operating conditions.
B. Performance and efficiency tests shall be conducted immediately
after completion of start-up. The manufacturer must have a
representative in attendance at the time the test is conducted.
C. All equipment is to be guaranteed against defective design,
workmanship, or material for one year from the date of initial
operation, not to exceed eighteen (18) months from shipment.
3.2 EXAMINATION
Examine and verify size, location, and condition of concrete pads upon which the generators are
to be installed. Do not proceed with installation until unsatisfactory conditions have been cor-
rected.
3.3 INSTALLATION
A. General
1. Install generators in accordance with manufacturers
installation instructions, requirements of state, provincial and
local code, and requirements of local utility company. Maintain
manufacturers recommended clearances around and over
generators.
B. Support
1. Install generators on 15" high concrete pads.
C. Erection
1. Assemble generators trim shipped loose or unassembled for
shipment purposes. Follow the manufacturers installation
instructions.
D. Gas Piping
1. Connect gas piping to the generators, full size of generator gas
train inlet, provide union with sufficient clearance for burner
removal and service.
E. Oil Piping
1. Connect oil piping to the generators, full size of inlet to burner,
provide shutoff valve and union with sufficient clearance for
burner removal and service.
F. Connect supply and return piping.
G. Breeching
1. Connect breeching to generator outlet, full size of outlet.
C-82
03-08
3.4 CLEANING
Flush and clean generators upon completion of installation, in accordance with manufacturers
instructions.
3.5 FIELD QUALITY CONTROL
A. Hydrostatically test-assembled generator and piping in accordance
with applicable sections of ASME Boiler and Pressure Vessel Code.
B. Arrange with National Board of Boiler and Pressure Vessel
Inspectors (or Provincial Boiler Inspection Agency in Canada) for
inspection of generator installation, piping connections, observation
of hydrostatic testing, and for certification of completed generator
units.
3.6 DEMONSTRATIONS
A. Services
1. After testing and inspection is complete, provide the services of
an authorized factory service representative to perform start-up
and operation demonstration services.
B. Start-Up
1. Perform services in accordance with manufacturers written
start-up instructions. Test controls and demonstrate
compliance with requirements. Replace or repair damaged or
malfunctioning controls and equipment.
C. Maintenance and Operation Training
1. As a part of the maintenance and operating instructions,
review data in operating and maintenance manual, including
preventative maintenance schedule and procedures, and
procedures for obtaining repair parts and technical assistance.
Demonstrate all phases of operation including start-up and
shut-down.
2. Schedule training with the owner, and provide at least 7-day
notice to the Architect/Engineer.
D-1
06-08
Section D
CONTROLS
TABLE OF CONTENTS
HAWK ICS LEVEL COMPARISON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
CB-HAWK ICS BOILER MANAGEMENT CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-7
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-7
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-8
SPECIFICATIONS - PARALLEL POSITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-12
CB-HAWK ICS COMBUSTION AIR FAN VARIABLE SPEED DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-15
CB-HAWK ICS OXYGEN MONITORING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-18
CB-HAWK ICS ETHERNET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-21
CB-HAWK ICS PAGING and REMOTE DIAL-UP ACCESS with MODEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-23
CB-HAWK ICS LEAD/LAG FOR TWO BOILER SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-24
APPLICATION AND SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-25
CB-HAWK ICS LEAD/LAG for up to EIGHT BOILERS SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-26
APPLICATION AND SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-28
Section D
D-2
06-08
CB780E CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-29
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-29
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-30
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-30
SAMPLE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-31
CB120-120E CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-32
CB100E CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-34
CB110 CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-36
LEAD/LAG SYSTEMS (TWO BOILER LEAD/LAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-38
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-39
LEAD/LAG SYSTEMS (TWO THROUGH FOUR BOILER LEAD/LAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-41
LOW FIRE HOLD CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-44
MINIMUM TEMPERATURE LOW FIRE HOLD CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-45
ASSURED LOW FIRE CUTOFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-47
REMOTE MODULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-48
Section D
D-3
06-08
AUTOMATIC FUEL CHANGEOVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-49
SAMPLE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-49
OXYGEN TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-50
CB-HAWK ICS ADAC ADVANCED DEAERATOR CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-55
LCS-150E LEVEL CONTROL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-63
Section D
D-4
06-08
HAWK ICS LEVEL COMPARISON
Table D-1. Hawk ICS Level Comparison
Feature Base L32B Intermediate L32I Advanced L35E
Processor L32E L32E L35E
5.5"Monochrome Screen Standard N/A N/A
6"Color Screen N/A Standard N/A
10"Color Screen N/A Optional Standard
Honeywell CB780E Standard Standard Standard
Fireye CB120E Optional Optional Optional
O2 Monitoring External Optional Optional
O2 Trim & Programming External External Integrated
O2 Hardware N/A Optional Optional
Variable Speed Drive Programming N/A Included Included
Variable Speed Drive Hardware N/A Optional Optional
Parallel Positioning Programming N/A External Integrated
Parallel Positioning Hardware N/A Optional Optional
Additional 4 User Analog Inputs (Base 2 IN's Only) Optional Optional Included
Expanded Annunciation/3 User DI Optional Optional Included
Combustion Air/Ambient Temperature Monitoring N/A Optional Optional
2 Boiler Lead/Lag Programming Included Included Included
2 Boiler Lead/Lag Hardware Optional Optional Optional
Dual Set Points Included Included Included
Stack Temp with High Cutoff Set Point Included Included Included
Thermal Shock Protection Included Included Included
Assumed Boiler Efficiency Reading Included Included Included
Corrected Boiler Efficiency Reading N/A With O2 Option With O2 Option
Hot Stand By Included Included Included
Ethernet Communications Included Included Included
E-Mail and Paging (text messaging only) via Internet Optional Optional Optional
Paging Via Phone Line (Requires modem) Optional Optional Optional
Lan/Wan Interfacing Optional Optional Optional
Building Automation Interface Optional Optional Optional
Remote Monitoring Software (Rs-View) Optional Optional Optional
Level Master Interface (Level and Alarm Only) N/A Included Included
Master Panel Lead/Lag 3-8 Boilers Optional Optional Optional
Remote Modulation or Set Point Input (See Note 1) Included Included Included
Remote Stop/Start (See Note 1) Included Included Included
PLC Based Combustion Control Included Included Included
Alternate Fuel Capabilities Included Included Included
Flash Card Reader - Touch Screen Included Included Included
Flash Card Reader - Processor Included Included Included
Draft Control - Integrated in PLC External External Included
Alarm Bell Included Included Included
Alarm Silencer Button Via Touch Screen Included Included Included
N/A = Not Available
Note 1: Not avaialble when either 2 boiler Lead/Lag or
Master Panel options are selected
Section D
D-5
03-08
CB-HAWK ICS Integrated Boiler Control System
The CB-HAWK ICS is a state-of-the-art boiler control system that integrates the
functions of a Programmable Controller and Burner Management Controller, as well
as other boiler operating and ancillary controls. The CB-HAWK ICS system
incorporates a graphical Human Machine Interface (HMI), which displays boiler
parameters, fault annunciation and alarm history, as well as providing access to
boiler configuration and control functions. The CB-HAWK ICS system includes
complete boiler firing rate controls for steam or hot water boilers. The CB-HAWK
ICSs advanced technology features utilize the latest communication methods, such
as Modbus, Ethernet, and the Internet. The CB-HAWK ICS also has the capability of
interfacing with various building/plant automation systems. Additional features
include lead/lag capability; e-mailing and paging of alarms, remote monitoring, and
HMI alarm history printing.
The CB-HAWK ICS Integrated Control System may be used on most types of steam
or hot water boilers, including firetube, industrial watertube, and commercial
watertube. It is designed to operate with a gas, oil, or combination burner using a
single-point modulating control or a parallel-positioning fuel-air ratio control system.
In addition to installation on new boilers, the CB-HAWK ICS can be added as a
retrofit to existing boilers. Contact your local authorized Cleaver-Brooks
representative for details.
The CB-HAWK ICS system is offered in Advanced, Intermediate, and Base
packages. Table D-1 shows a feature comparison.
Advanced Technology Standard Features:
Integrates control function of burner sequencing and safety with firing rate, fuel-
air ratio, and operating limit controls
Incorporates a programmable controller
Touch screen graphical human machine interface (HMI)
Monitors and displays connected boiler parameters
Optimizes boiler firing rate control
Alarm/fault indication and history
On-screen fault diagnostics
Built-in two boiler lead/lag control
Night/day setback control
Remote modulation
Remote setpoint
Assured low fire cut-off
Assured start permissive safety interlocking
High stack temperature alarm and shutdown
Boiler efficiency calculations
Section D
D-6
03-08
Optional Features:
E-Mail and pager alarm/fault forwarding
Fuel-air ratio control
Display of boiler water level with optional CB Level Master (Advanced and
Intermediate systems only)
Building/plant automation system interface
Remote monitoring and diagnostics
O
2
monitoring and trim
Internet parts and service lookup
Lead/lag capability for multiple boiler systems
Variable speed drive on combustion air fan
Expanded annunciation
Safety Provisions and Diagnostics:
A. Integrated Burner Management
Utilizes the CB780E or CB120E flame safety control
Communicates with the programmable controller via Modbus
Burner Control status, faults, and diagnostics displayed on HMI
B. Integrated Boiler Controls
Operating and modulating controls
Variable speed drive fault shutdown communicates via Modbus (optional)
Password protection of programmable controller logic
Password protection of parallel positioning control (optional)
Powerful Display/Diagnostic Capabilities:
Touch screen graphical human machine interface (HMI).
Advanced system: 10 color touch screen
Intermediate system: 6 color touch screen standard - 10 color screen optional
Base system: 5.5 monochrome touch screen
HMI allows easy screen navigation to monitor various boiler parameters &
diagnostics and to configure boiler controls.
Displays alarms/faults, burner status, and flame signal from the flame safety
control.
Diagnostics in plain English and prioritized fault annunciation simplify
troubleshooting. Last 100 faults are stored.
Displays boiler steam pressure, water temperature, firing rate, Stack
temperature, boiler efficiency, combustion air temperature (optional), Flue
gas O
2
concentration (optional), combustion air fan motor speed and kw
(vsd option), combustion air pressure (with VSD option), water level (CB-
Level Master option), shell water temperature (steam boilers), and other
control points.
Displays boiler operating status (e.g. Warm Up , Auto/Manual , Boiler
On , fuel selection, etc.).
Displays boiler firing rate control parameters
Section D
D-7
03-08
and settings.
Provides remote monitoring and diagnostic capabilities (optional).
Touch screen controls simplify screen navigation and boiler configuration
Reliable and accurate controls using microprocessor-based programming
Simplified Servicing:
Diagnostics and fault history, up to 100 faults, through touch screen display
simplifies troubleshooting procedures
E-Mail forwarding and paging of system fault codes (optional)
Connection to user building automation system (optional)
PRODUCT OFFERING
Included in each CB-HAWK ICS system is the following:
Programmable controller
Touch screen HMI
Modbus communication interface to burner management or optional
Variable Speed Drive
Built-in Ethernet/IP capability via L35E (Advanced system) or L32E
(Intermediate and Base) processors
Various controller input/output modules
Flame safety controller (CB780E or CB120E)
Various temperature and pressure sensors
E-mailing via Ethernet
Optional Features and Equipment: (see individual specifications for these options)
OPC server software for interface with building/plant automation system
Lead/Lag control of multiple boilers
Fuel-Air Ratio Control system and actuators
Variable speed drive for combustion air fan motor
O
2
analyzer and/or external O
2
trim system
Combustion air temperature sensor
Economizer stack flue gas temperature, feed water temperature, oil
temperature, and gas & oil pressure sensors
Steam, water, and fuel flow monitoring
CB Level Master primary safety water level control
Paging via phone line with modem
ENGINEERING DATA
Supply voltage: 120 VAC (+10%/-15%) 50 or 60 Hz.
Maximum total connected load: 1200 VA
Operating temperature limits: 32 to 130F
Section D
D-8
03-08
85% RH continuous, non-condensing, humidity
0.5G continuous vibration
CB-HAWK ICS Integrated Boiler Control System
PART 1 GENERAL 1.1 GENERAL
A. Each unit shall be factory equipped with a boiler control system
providing technology and functions equal to the CB-Hawk ICS boiler
control system.
B. Each Boiler Control System shall be factory equipped with a pre-
configured Programmable Controller and Human Machine Interface
(HMI).
PART 2 PRODUCTS 2.1 MAJOR SYSTEM COMPONENTS
A. Major system components shall include:
1. Programmable controller
2. Touch screen HMI
3. Modbus communication interface to burner management or
optional Variable Speed Drive
4. Various controller input/output modules
5. One burner management controller and wiring sub-base
6. One flame scanner: Infrared, Ultra-Violet, or UV Self-Check
7. One flame amplifier, to correspond with the selected flame
scanner
8. Various temperature and pressure sensors
B. Major functions that the Boiler Control System shall provide:
1. Automatic sequencing of the boiler through standby,
pre-purge, pilot flame establishing period, main flame
establishing period, run and post purge
2. Flame proving and lockout on flame failure during pilot flame
proving, main flame proving, or run
3. Low fire damper/valve position for flame ignition trials
4. Full modulating control of fuel and combustion air
5. Utilize solid state controls and sensors to provide various
control functions, such as:
a. On/Off, and Modulating control
b. Modulating control algorithm shall be Proportional-
Integral-Derivative (PID) type
c. Thermal shock protection based on water temperature
and setpoint
d. Various high and low limit alarms and shutdowns
6. Touch screen graphical operator interface and monitoring
a. Manual control of the boiler-firing rate utilizing control
screens on the HMI to increment and decrement the firing
rate
Section D
D-9
03-08
b. On screen indication of burner management controller
status and diagnostics
c. On screen real-time display of all connected process
parameters
d. On screen display of system alarms and faults
e. On screen history of alarms and faults
f. On screen water level indication (optional) and alarm(s)
g. Printing Alarm/Fault history
7. E-mail or paging of boiler alarms (with either Ethernet/IP or
modem option)
8. Building/plant automation system interface (with Ethernet/IP
option)
9. Ethernet communications (with Ethernet/IP option)
10. Tamper resistant control logic and password protection.
11. Night/day setback control
12. Stack flue gas, combustion air (optional), and shell (water)
temperatures
13. Boiler efficiency calculation (corrected efficiency with O2
option - Advanced and Intermediate systems)
14. Outdoor reset for hot water boilers
15. Remote modulation or firing rate setpoint control
16. Assured low fire cut-off (ALFCO)
17. Assured start permissive safety interlocking
C. The Boiler Control System shall provide the following safety
provisions for:
1. Integrated burner management
a. Examine all load terminals to assure it is capable of
recognizing the true status of the external controls, limits
and interlocks. If any input fails this test, the burner
management system should lockout on safety shutdown.
b. Closed-loop logic test verifies integrity of safety critical
loads (ignition, pilot, and main fuel valves) and must be
c. Pre-ignition interlocks (fuel valve proof of closure, etc.)
and flame signal checked during Standby and Pre-Purge.
d. Dynamic checking of the flame signal amplifier. The
control flame signal amplifier must be able to recognize a
no flame signal during this dynamic amplifier check.
e. Safe start check and expand check to include monitoring
flame signal during standby.
f. High and Low fire switches checked for proper
sequencing.
g. Tamper-proof purge timing and safety logic.
2. Integrated boiler controls
a. Operating and Modulating control
b. Variable Speed Drive (if used) fault shutdown
Section D
D-10
03-08
c. Password protection of programmable controller Logic
d. Password protection of parallel positioning control (if
used)
D. The Boiler Control System shall provide annunciation and
diagnostics:
1. Active alarm annunciation
2. Provide historical alarm information for on screen display
3. Detects and isolates an alarm, and reports internal circuit
faults
4. Printer output capable for logging alarms
5. Capability of printing alarm history of date, time, cycle of
occurrence and date and time of acknowledgement up to the
most recent 100 faults
6. English text description of the system fault and troubleshooting
procedures
7. Water level indication and low water shutdown alarm
8. Dynamic self-checking
E. The Boiler Control System shall be able to operate in these
environmental conditions.
1. Supply Voltage: 120 VAC (+10%/-15%) 50 or 60 Hz
2. Maximum total connected load: 1200 VA
3. Operating temperature limits: 32 to 130F
4. 85% RH continuous, non-condensing, humidity
5. 0.5G continuous vibration
F. All Boiler Control System wiring shall be in accordance with the
National Electrical Codes and local electrical codes.
G. Boiler Control System component functions shall be as follows:
1. Burner Management Controller: Provides burner sequencing
logic to meet FM/IRI/UL/cUL approval body requirements.
2. Touch Screen Graphical Interface: Provides user interface to
the control system, boiler overview screen with connected
boiler parameter readouts, burner management control status
screen, alarm banners, diagnostic screens for fault
troubleshooting, alarm history screen, system firing rate screen
and system configuration screens.
3. Modbus communication network: provides communication
between the programmable controller and burner management
system (and optional Variable Speed Drive).
4. Various programmable controller input/output modules:
Provides interface for discrete powered and/or isolated relay
signals, as well as for analog signals, from and/or to other
input/output devices.
Section D
D-11
03-08
5. Stack temperature sensor: measures and transmits a signal to
the programmable controller in relation to boiler exit flue gas
temperature. It is used for indication and in the calculation of
boiler efficiency; it can also be used for high stack temperature
alarm and shutdown.
6. Steam pressure transmitter (steam boiler): provides an analog
signal to the programmable controller for indication of boiler
steam pressure; utilized for on/off and modulating control of the
burner.
7. Water temperature transmitter (hot water boilers): provides an
analog signal to the programmable controller for indication of
boiler water temperature; utilized for thermal shock protection,
on/off, and modulating control of the burner.
8. Water (shell) temperature sensor (steam boilers): measures and
transmits a signal to the programmable controller in relation to
boiler water temperature; used for indication and thermal
shock protection.
H. Optional equipment/features (see also individual Boiler Book
sections below)
1. Lead/Lag Control for multiple boiler systems
2. Parallel Positioning hardware (Advanced and Intermediate
systems)
3. Variable Speed Drive for combustion air fan motor (Advanced
and Intermediate systems)
4. O2 analyzer and/or external O2 trim system
5. Combustion air temperature sensor (Advanced and
Intermediate systems): measures and transmits a signal to the
programmable controller in relation to the combustion inlet
temperature for indication and for use in the calculation of
boiler efficiency; also can be used for high combustion air
temperature alarm and shutdown, based on setpoint
6. Economizer flue gas inlet and outlet temperatures, feed water
temperature, economizer water in and out temperature (no
thermocouple inputs with Base system)
7. Steam, water & fuel flow monitoring
8. CB Level Master primary safety water level control
9. Email and paging (text messaging) via Ethernet
10. Paging via phone line (requires modem)
11. Building automation interface
12. Remote monitoring with RSView software
Section D
D-12
03-08
HAWK ICS Parallel Positioning System
PART 1 GENERAL The purpose of the parallel positioning system is to control fuel, combustion air and
flue gas recirculation (FGR) if applicable. Individual actuators will be used to control
each of above functions.
PART 2 PRODUCTS
2.1 CONTROLLER - A/B COMPACT LOGIX PLC COMPRISING THE
FOLLOWING COMPONENTS
Row 1
Processor L35E
SM2 Modbus Module
Power Supply 1769-PA4
Discrete Input Module 1769-IA16
Discrete Output Module 1769-OW8I
Analog Input Module 1769-IF4
Analog Output Module 1769-OF2
Themocouple input module 1769-IT6
Discrete Input Module 1769-IA16
Analog Output Module1769-OF2
Row 2
Power Supply 1769-PA2
Analog Output Module 1769-OA16
Expansion cable
Right hand terminator
2.2 HMI (HUMAN MACHINE INTERFACE)
10 color PanelView touch screen with serial communication.
2.3 ACTUATORS
Quantity up to 4.
Typical actuators arrangement:
Combustion air
Gas
Oil
FGR
Section D
D-13
03-08
ACTUATOR SPECIFICATIONS
General: Reversing Motor with Position Feedback
Application: Control of Dampers and Fuel Valves
Note- Position will be controlled by a PLC; no Servo-Positioning Module is required.
Rotary: 90 Degree Rotation
30 Second Timing (for 90 Degrees)
36 in-lb Torque
0.1% Resolution (over 90 Degrees)
Electrical:
120 VAC Preferred
Control Signal: Pulse position with 0-10 VDC feedback
Duty: Continuous
Enclosure: NEMA 1 Minimum; NEMA 3 or 4 Optional
Approvals:
UL Listed or Recognized and/or FM Approved
Environmental: Temperature 0-130F.
Whenever possible design without linkages shall be used.
Control Description
Control shall be parallel positioning with cross limiting.
Note: System will not be capable for simultaneous fuel firing.
Air control
Firing rate control signal is compared with corrected fuel actuator position signal.
Highest of the two values is a control signal for the combustion air actuator. Velocity
limitter with adjustments in both directions (up and down) shall be provided.
Control signal to the actuator is compared with feedback signal. If unacceptable
error is detected for the preset amount of time, system will be shut down and fault
will be annunciated.
Fuel control
Firing rate control signal is compared with air actuator position signal. Lowest of the
two values is an input to the function generator. Output of the function generator is a
control signal for the fuel actuator. Function generator has to have a minimum of 10
break points. The X-axis and Y-axis parameters must follow the relationship:
X[1] < X[2] < X[3] <... < X[n]
Y[1] < Y[2] < Y[3] < < Y[n]
Where n is the number of break points (20 maximum).
Velocity limiter with adjustments in both directions (up and down) shall be
provided.
Section D
D-14
03-08
FGR control
Firing rate control signal is compared with air actuator position signal. Lowest of the
two values is an input to the function generator. Output of the function generator is
a control signal for the FGR actuator. Function generator has to have a minimum of
10 break points. The X-axis parameters must follow the relationship:
X[1] < X[2] < X[3] <... < X[n]
Where n is the number of break points (20 maximum).
Velocity limitter with adjustments in both directions (up and down) shall be
provided.
Section D
D-15
03-08
CB-HAWK ICS COMBUSTION AIR FAN
VARIABLE SPEED DRIVE
Provides variable speed output to the burners Combustion Air Fan blower motor for
the purpose of improving boiler efficiency and reducing electrical energy
consumption.
Improved Efficiency:
Energy Savings:
Reduces electrical energy consumption
Soft starting reduces electrical and mechanical stress on the motor,
extending the life of the motor
Provides Substantial Savings from Mid to Low Fire modulation points
Average Payback in approximately 6 8 Months
Communication:
Communicates with the Boiler Controller via Modbus
Provides Drive process information on the Boiler Control Panel Display
Provides Drive faults and troubleshooting suggestions, in Plain English , on
Boiler Control Panel Display
PRODUCT OFFERING
Cleaver-Brooks shall supply the following equipment:
Adjustable Frequency Variable Speed Drive.
VSD Compatible Combustion Air Fan Motor.
Section D
D-16
03-08
ENGINEERING DATA
Drive:
Ambient Operating Temperatures: 32 122F
Altitude: 3300 Ft (1000 m) Max without derating
Shock: 15G peak for 11ms duration (1.0 ms)
Vibration: 0.152 mm (0.0006 in.) displacement, 1G peak
Voltage Tolerance: -10% of minimum, +10% of Maximum
Frequency Tolerance: 47 63 Hz
Input Phases: Three-phase input provides full rating of all drives, Single-
phase operation provides 50% of rated current
Frequency Accuracy: Digital Input Within 0.01% of set output
frequency, Analog Input Within 0.4% of maximum output frequency
Intermittent Overload: 110% Overload capability for up to
1 minute, 150% Overload capability for up to 3 seconds
Current Limit Capability: Proactive Current Limit programmable from 20 to
160% of rated output current; Independently programmable proportional
and integral gain
Line Transients: Up to 6000 volts peak per IEEE
C62.41-1991
Ground Fault Trip: Phase-to-ground on drive output
Short Circuit Trip: Phase-to-phase on drive output
Drive Overcurrent Trip: Software 20 to 160% of rated current, Hardware
200% of rated current (typical), Instantaneous 220 to 300% of rated
current (dependent on drive rating)
Electronic Motor Overload Protection: Class 10 protection with speed
sensitive response. Investigated by U.L. to comply with N.E.C. Article 430,
UL File E59272 Volume 12
See Drive Manual for other, Model and Voltage Specific, specifications.
Motor:
Motor suitable for variable speed drive service
Variable Torque, 3 phase
Other specifications based on Specific Horsepower, Voltage, and Frequency
requirements. Contact your local Authorized Cleaver-Brooks Representative
for further details.
Section D
D-17
03-08
CB-HAWK ICS Combustion Air Fan Variable
Speed Drive
PART 1 GENERAL A. The Boiler Manufacturer shall provide a Variable Speed Drive
controller for use on the burners Combustion Air Fan blower motor
for the purpose of providing Improved Boiler Efficiency and Reduced
Electrical Energy consumption.
B. The Drives voltage, frequency, and current ratings shall be rated in
accordance with the electrical requirements as dictated by job site
specifics, and for the properly rated motor horsepower.
C. The Variable Speed Drive must be capable of communicating over
the Modbus protocol.
D. A Motor suitable for variable speed drive service must be supplied
for use in conjunction with the Variable Speed Drive, and sized to
match the motor requirements of the Combustion Air Fan Blower.
E. Variable Speed Drive shall be interlocked with boiler control to
ensure safe operation.
Section D
D-18
03-08
CB-HAWK ICS OXYGEN MONITORING SYSTEM
The CB-HAWK ICS Oxygen Monitoring System provides indication and monitoring
of the boilers exit flue gas O
2
concentration. In conjunction with Stack Flue Gas
and Combustion Air Temperature measurements, the system also provides means
for a more accurate boiler efficiency calculation.
If O
2
Trim is desired see page D-50, Oxygen Trim, of the CB Boiler Book.
Integrated Type In-Situ Zirconia Oxygen Analyzer:
Reduces wiring, piping and installation costs
Allows replacement of the zirconia cell on site
Built-in heater assembly of the probe can be replaced on site
Can be configured on site without opening the cover using an infrared
sensor
O
2
measurement circuitry built into probe head electronics
O
2
Level percentages displayed on the Boiler Control Panel Human Machine
Interface (HMI)
Provides accurate Boiler Efficiency Calculations with the CB-HAWK ICS
Programmable Controller
Separate analyzer/converter display panel not required
User Configurable Alarm Points
Low O
2
Alarm
Analyzer Probe is Direct Insertion, In-situ Zirconia Type Which Provides:
High accuracy
Fast Response
Proven Reliability
Section D
D-19
03-08
PRODUCT OFFERING
In-Situ Zirconia Probe and Analyzer
Process Variable% O
2
Readout on Control Panel HMI
Accurate Efficiency Calculations
Options:
Separate O
2

Converter/Display Panel
Replacement Zirconia Cell
Auto Calibration Pneumatics
Replacement Heater Assembly
Remote Indicator/Alarm
Probe Stack Mounting Adapter
Calibration Gas Kit
ENGINEERING DATA
Ambient Temperature: -4 to 131F (-20 to +55C)
Sample Gas Temperature: 32 to 1292F (0 700C)
Sample Gas Pressure: -1.5 to 73.8 in Hg (-5 to +250 kPa)
Output Signal: 4 20mA DC, One Point, Maximum Load Resistance 550 Ohms
Digital Output (HART): 250 500 Ohms
Contact Output Signal: Two Points, 30 VDC 3A, 250 VAC 3A (one is fail safe
normally open)
Contact Input Signal: Two Points
Reference Air: Natural Convection, Instrument Air, pressure compensated
Instrument Air: 200 kPa plus the pressure in the furnace
Power Supply: 100 240 VAC, 50/60Hz
Power Consumption: Max 300 W, approx. 100 W for ordinary use
CB-Hawk ICS Oxygen Monitoring System
PART 1 GENERAL A. This specification covers the hardware and monitoring functions of
the CB-HAWK ICS Oxygen monitoring system. The system monitors
and displays Oxygen concentration and is used, in conjunction with
combustion air and stack flue gas temperature sensors, to calculate
the overall efficiency of the boiler.
B. The system shall be completely configured from the factory requiring
only job specific data to be entered (or modified) in the field.
Note: O
2
Sensor Requires calibration in the field!
Section D
D-20
03-08
PART 2 PRODUCTS 2.1 HARDWARE
A. Hardware shall consist of the following:
1. Oxygen Sensor
2. Integrated type Zirconia Oxygen Analyzer
3. Direct Insertion Type
4. Built-in Heater Assembly
5. 4-20mA DC Process Variable Output
6. Heater to be of field replaceable construction
7. Cell to be of field replaceable construction
B. Analyzer
1. Shall be of the Integrated Type (in probe head)
2. Provide 4 20mA DC Signal output in relation to process
variable for remote display
C. Monitoring System
1. Indicate O
2

Percentages
2. Provide Low O
2

Alarm Indication
3. Perform Efficiency Calculations and display results using
O
2

percentages
PART 3 EXECUTION This system is applicable to modulating burners using the CB-HAWK ICS Integrated
Control System. This system shall monitor and display O
2

concentration in the
boilers exit flue gas and provide overall boiler efficiency calculations.
Section D
D-21
03-08
CB-HAWK ICS ETHERNET COMMUNICATION
The CB-HAWK ICS Ethernet communication package provides Ethernet
communications between the CB-HAWK ICS programmable controller and other
Ethernet compatible devices such as the Boiler Room Master Lead/Lag Control
Panel, Building/Plant automation system, and the Internet.
Provides communication between the CB-HAWK ICS programmable controller
unit and other Ethernet Compatible Devices
Provides interface capability with many Building/Plant automation systems
when utilizing OPC server or protocol bridge
Provides interface with plants LAN/WAN
Provides interface to the Internet (requires static IP address)
E-mailing of boiler alarms/faults
Provides means of connection between various boiler room control systems,
such as the CB-HAWK ICS Master Panel for lead/lag control
Provides means of connection to a remote Personal Computer
Ethernet Industrial Protocol
IEEE 802.3 Physical and Data Link Standard
Ethernet TCP/IP protocol suite industry standard
Control and Information Protocol (CIP) Compliant
PRODUCT OFFERING
Optional Ethernet Communication Hub (necessary for stand-alone boiler (no
Master Panel) connection to LAN/WAN and/or Paging Modem option)
E-mail functionality requires customer provided e-mail service and address
ENGINEERING DATA
Modular connection to CB-HAWK ICS Programmable Controller unit
Ethernet Industrial Protocol (Allen-Bradley EPIC)
Follows Ethernet Rules and Practices
High Noise Rejection
Cabling: Category 5E rated twisted pair cable (solid core, PVC jacket with RJ45
connections).
Meets Open Industrial Network Standards
IEEE 802.3 Physical and Data Link Standard
Ethernet TCP/IP protocol suite industry standard
Control and Information Protocol (CIP) Compliant
OPC (OLE Process Control) communication compatibility with RSLinx OPC
Server software
Section D
D-22
03-08
CB-HAWK ICS Ethernet Communication
PART 1 GENERAL The Boiler Manufacturer shall furnish and install a control module capable of
Ethernet communications between the boilers programmable logic control system
and other Ethernet compatible devices, as needed, and provide the following
minimum requirements:
A. Interface with the Compact Logix Programmable Controller Protocol
B. Ethernet Industrial Protocol (Allen-Bradley EPIC)
C. Follows Ethernet Rules and Practices
D. High Noise Rejection
E. Open Industrial Network Standards
F. IEEE 802.3 Physical and Data Link Standard
G. Ethernet TCP/IP protocol suite industry standard
H. Control and Information Protocol (CIP) Compliant
Section D
D-23
03-08
CB-HAWK ICS PAGING and REMOTE
DIAL-UP ACCESS with MODEM
Provides Paging of Alarms Faults, via Modem, from the CB-HAWK ICS Control System to the
customer provided pager or a compatible cell phone.
Paging of boiler system alarms. (Paging Service and Pagers furnished by
customer)
Allows Remote Dial-Up Access for monitoring and troubleshooting.
PRODUCT OFFERING
Remote Access Paging Modem
Easy to use configuration software
Requires customer provided, dedicated phone line
Requires customer provided Paging Service and pagers (or paging
compatible cell phones)
Requires Pager Numbers and PINs supplied by customer
Configure up to 10 unique pagers
ENGINEERING DATA
Voltage: 24 VDC
Baud Rate: 56K
Type: External, Serial
Paging functionality utilizes TAP Protocol
CB-HAWK ICS Paging and Remote Dial-up Access With Modem
PART 1 GENERAL The boiler manufacturer shall provide a Paging and Remote Dial-Up Access Modem,
using customer provided paging systems for the purpose of paging boiler system
alarms and providing remote access to the control system.
Pager number(s) and PINs to be supplied by customer.
Dedicated telephone connection to be supplied by customer.
Section D
D-24
03-08
CB-HAWK ICS LEAD/LAG FOR TWO
BOILER SYSTEMS
Provides Lead/Lag control for a two-boiler system when used in conjunction with the CB-
HAWK ICS integrated boiler control system.
Controls Header Pressure and Temperature:
Maintains steam pressure or hot water supply temperature based on system
load demand.
Compensates for varying losses between boiler and header.
Sequences of Operation for Two Boilers:
Provides maximum system efficiency.
Reduces cycling and boiler wear; thereby reducing maintenance and downtime
costs.
Optimizes fuel savings.
Lead/Lag Start with Lead/Lag Modulation:
Lead boiler operates at full capacity prior to starting lag boiler.
Lag boiler starts modulation when lead boiler reaches maximum firing rate
position.
Ideal for steam boilers.
Lead/Lag Start with Unison Modulation:
Lag boiler operates at the same firing rate as a lead boiler.
Ideal for hot water boilers.
PRODUCT OFFERING
Boiler control for each boiler shall be CB-HAWK ICS.
Pressure (steam) or temperature (hot water) transmitter shipped loose for
mounting in the common header.
Section D
D-25
03-08
CB-HAWK ICS Lead/lag For Two-Boiler Systems
A. Lead/Lag Start with either Lead/Lag or Unison Modulation.
B. Boilers Start and Stop
1. Steam pressure, or hot water temperature, is compared with
the setpoint and controllers processor executes PID algorithm.
Lead boiler is commanded to come on line first. Lag boiler is
commanded to come on line when a firing rate signal for the
lead boiler reaches lag boiler start point. Lag boiler is
commanded to stop when a firing rate signal for the lag boiler
reaches lag boiler stop point.
C. Lead/Lag Modulation - Lag boiler starts modulation after lead boiler
reaches maximum firing rate.
D. Unison Modulation - Firing rates for both boilers are equal.
E. Hot Standby - System shall have a provision for keeping lag boiler in
hot standby. Standby routine shall be based on a water temperature
signal.
1.2 APPLICATION AND SYSTEM REQUIREMENTS
A. This option is applicable to full modulation burners utilizing the CB-
HAWK ICS advanced boiler control system and modulating controls.
B. All logic for Lead/Lag Control shall reside in the boiler controller. No
additional control panels shall be required.
Section D
D-26
03-08
CB-HAWK ICS LEAD/LAG for up to EIGHT
BOILERS SYSTEM
Provides Lead/Lag control for up to eight boilers when used in conjunction with the
CB-HAWK ICS integrated boiler control system.
Controls Header Pressure and Temperature:
Maintains steam pressure or hot water supply temperature based on system
load demand.
Benefits:
Maximizes system efficiency.
Reduces cycling and boiler wear, thereby reducing maintenance and downtime
costs.
System shall be provided with a sequence to automatically rotate sequence in
which the boilers are fired. Rotation shall be based on the elapsed time.
Lead/Lag Start with Lead/Lag Modulation:
Lead boiler operates at full capacity prior to starting lag boiler #1.
Lag boiler #1 starts when the lead boilers firing rate is close to the maximum.
Operator can select this parameter via HMI.
Lag boiler #1 starts modulation when the lead boiler reaches the maximum
firing rate position.
Subsequent lag boilers operate in the same fashion.
Ideal for steam boilers.
Lead/Lag Start with Unison Modulation:
Lead boiler operates at full capacity prior to starting the lag boiler.
All boilers operate at the same firing rate as the lead boiler.
Ideal for Hot Water boiler systems.
Section D
D-27
03-08
PRODUCT OFFERING
Boiler control for each boiler shall be the CB-HAWK ICS.
Pressure (Steam) or temperature (Hot Water) transmitter shipped loose for
mounting in the common header.
Master Control Panel shipped loose for field mounting.
Requires Ethernet/IP Communication Option
CB-HAWK ICS Lead/lag for up to Eight Boilers System
A. Lead/Lag Start with either Lead/Lag or Unison Modulation.
B. Boilers Start and Stop
1. Steam pressure, or hot water temperature on hot water
systems, is compared with the setpoint and controllers
processor executes PID algorithm. Lead boiler is commanded
to come on-line first. Lag boiler #1 is commanded to come on-
line when a firing rate signal for the lead boiler reaches lag
boiler start point. Lag boiler #1 is commanded to stop when a
firing rate signal for the lead boiler reaches lag boiler stop
point.
2. Lag boiler #2 is commanded to come on-line when a firing rate
signal for the lag boiler #1 reaches lag boiler #2 start point.
Lag boiler #2 is commanded to stop when a firing rate signal
for the lag boiler #1 reaches lag boiler #2 stop point.
3. Subsequent boilers operate in a similar fashion.
C. Lead/Lag Modulation
1. Lag boiler #1 starts modulation after lead boiler reaches
maximum firing rate (or firing rate selected by the operator).
2. Lag boiler #2 starts modulation after lag boiler #1 reaches
maximum firing rate (or firing rate selected by the operator).
3. Subsequent boilers operate in a similar fashion.
D. Unison Modulation - Firing rates for all boilers are equal.
E. Hot Standby - System shall have a provision for keeping lag boilers
in hot standby. Standby routine shall be based on a water
temperature signal.
F. Firing Sequence Selection - Sequence in which boilers come on-line
shall be selected via HMI. Adequate check shall be provided that
does not allow improper sequence selection.
G. Automatic Rotation of the Boilers - System shall be provided with a
sequence to automatically rotate sequence in which the boilers are
fired. Rotation shall be based on the elapsed time.
Section D
D-28
03-08
1.2 HMI (HUMAN MACHINE INTERFACE)
A. Master panel shall include HMI for display and selection of the
following parameters:
B. Display
1. Available boilers
2. Number of boilers required
3. Selected sequence of firing
4. Control output to each boiler
5. Header steam pressure or water temperature on hot water
systems
6. Setpoint
7. Elapsed time from last rotation
C. Selection
1. Number of boilers
2. Sequence of firing
3. Automatic or manual rotation
4. Individual boiler start and stop points with timers
5. Setpoint
6. Proportional, integral and derivative gains for control algorithm
1.3 APPLICATION AND SYSTEM REQUIREMENTS
A. This option is applicable to full modulation burners utilizing the CB-
HAWK ICS advanced boiler control system and modulating controls.
B. Logic for Lead/Lag control shall reside in the Master Control Panel.
Communication between the Master Panel and the individual Boiler
Control Panels shall be via Ethernet communication or hard wiring.
Section D
D-29
06-08
CB780E CONTROL
The CB 780E is a microprocessor-based flame safeguard control used to monitor the
presence of a flame inside a boiler, and to sequence the burner through several stages of
operation to provide proper air purge, ignition, normal operation and shut down for safe
operation.
Dynamic self-check logic and diagnostics:
Dynamic self-check safety circuit checks microprocessor and safety relay to
ensure safe and proper operation.
Dynamic input check verifies controls ability to recognize the true status of
external controls, limits and interlocks.
Closed-loop logic test verifies integrity of safety critical loads (ignition, pilot, and
main fuel valves) for proper operation.
Pre-ignition interlocks and flame signal checked during Standby and Pre-Purge.
Tamper-proof Purge Timer Card.
Valve Proving System
Programmable valve proving system provides fuel valve proof-of-closure.
Powerful Display/Diagnostic Capabilities:
2 line x 20 character Vacuum Fluorescent Display is easy to read under all
lighting conditions.
Status and diagnostic messages displayed in English Language with no scrolling
necessary (Spanish also available).
Displays flame signal in Volts dc, eliminating need for separate meter.
Displays burner hours and numbers of cycles.
Diagnostic displays include on/off status of inputs and outputs, RUN/TEST
switch status, selected purge time, amplifier type and configuration data.
Fault history (retained in non-volatile memory) displays the cycle, hours, code,
description, and condition for the last six fault occurrences.
Capability to mount display on front of Control Panel for improved access, or
remotely, in separate control room. (Optional)
5 LEDs on base provide at-a-glance status of Power On, Pilot, Flame, Main
Section D
D-30
06-08
Valves, and Alarm conditions (Power LED blinks periodically to indicate proper
control operation).
Diagnostic display capabilities are further enhanced by the optional CB783
Expanded Annunciator which provides 36 additional specific HOLD and Fault
messages, as well as 26 LEDs to indicate current status or first-out alarm
indication (user-selectable).
Communication capabilities to a local or remote Personal Computer, with
optional CB-LINKcommunications module and Combustion System Manager
software (runs under Microsoft Windows).
Application Flexibility:
Purge Timing Cards available in 30, 60, 90 seconds or 2-1/2 minutes cover a
wide range of applications, while eliminating need for a separate purge timer.
Separate output for ignition transformer simplifies applications requiring early
spark termination.
Selectable configuration jumpers allow application-specific configuration.
Communication interface capability.
Simplified Servicing:
Diagnostic and fault history information available through display simplifies
troubleshooting procedures.
Removable access covers for checking voltage at terminals.
5-function RUN/TEST switch eases start-up procedure.
Flame signal display facilitates pilot/light-off test procedures.
PRODUCT OFFERING
Included in each CB 780E system is the following:
One CB780E chassis, including display module.
One Purge Timer Card.
One wiring sub-base.
One flame scanner, either Infrared, Ultra-Violet, or UV Self-Check.
One flame amplifier, to correspond with the selected flame scanner.
Included with the optional CB783 Expanded Annunciator:
One CB783 Annunciator.
All limits and interlocks are wired into wiring sub-base to provide individual
hold/fault indication on LEDs of Expanded Annunciator, as well as on display
module of CB 780E control.
ENGINEERING DATA
Supply voltage: 120 Vac (+10%/-15%) 50 or 60 Hz.
Maximum total load: 2000 VA.
Section D
D-31
06-08
Load rating-fuel valve output: 65 VA pilot duty plus 1150 VA inrush, 460 VA
opening, 250 VA holding.
Operating temperature limits: -40 to 140 F.
Maximum ambient humidity: 85% non-condensing.
CB780E Control
PART 1 GENERAL Flame safeguard shall be a Cleaver-Brooks Model CB 780E 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 flame failure. The system shall provide status, fault history, and
diagnostic information by means of a two-line alpha-numeric display and alarm/
status LEDs. The system shall be approved by UL, FM, and CSA, and shall be
acceptable by IRI.
Section D
D-32
06-08
CB120/120E CONTROLS
The CB120 is a microprocessor-based burner management control system designed
to provide the proper burner sequencing, ignition, and flame monitoring protection
on automatically ignited oil, gas , and combination fuel burners. In conjunction with
limit and operating controls, it programs the burner/blower motor, ignition, and fuel
valves to provide for proper and safe burner operation
The CB120E includes all of the features of the CB120 with the addition of an
alphanumeric display.
Display and Diagnostic Capabilities:
(CB120E) 2 x 16 character display with keypad. Available display types are
vacuum fluorescent (VFD) and liquid crystal (LCD). VFD has increased
brightness and extended operating temperature range to -40F. Messages are
spelled out in English (optional Spanish version is also available). Provides
indication of flame signal during operation.
Lockout history stores last 10 lockouts with burner cycle and burner hour when
occurred.
Display module can be mounted remotely from the CB120 for external
indication (optional).
Optional expanded annunciator provides increased messaging and diagnostic
capabilities.
Optional communication via Modbus with local or remote PC.
Modular Design:
Interchangeable program modules in English or Spanish.
Adjustable purge time programmable via display.
Chassis available for infrared, ultra-violet, or UV self-check flame scanners.
Reduces part replacement costs.
Section D
D-33
06-08
PRODUCT OFFERING
Included in each CB120 System is the following:
Chassis with corresponding flame ampliifier
Plug-In Programmer Module.
Wiring base.
Flame scanner - either infrared, ultra-violet, or UV self-check.
Included in each CB120E System is the following:
All of the above
Alphanumeric display
Display is required for Modbus communication or to access special functions.
ENGINEERING DATA
Supply voltage: 120 Vac (+10%/-15%) 50/60 Hz.
Fuel valve output load rating: 65 VA pilot duty plus 3850 VA inrush, 700 VA
open, 250 VA hold.
Operating temperature limits: -40C (-40F) to 60C (140 F). LCD display min.
temp. limit -20C (-4F).
CB120/120E Control
PART 1 GENERAL Flame safeguard shall be a Cleaver-Brooks Model CB120/120E 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 flame failure. CB120E system shall provide status, fault history,
and diagnostic information by means of a 2 x 16 VFD or LCD display. The system
shall be approved by UL, FM, and CSA, and shall be acceptable by IRI.
Section D
D-34
06-08
CB100E CONTROL
The CB100E is a microprocessor-based, flame safeguard control used to monitor
the presence of a flame inside a boiler, and include various interlocks to ensure safe
operation. The flame safeguard also sequences the burner through several stages of
operation to provide proper air purge, ignition, normal operation and shut down for
safe operation.
Display and Diagnostic Capabilities:
2 x 16 Backlit LCD display with a 3-key tactile dome keypad indicates 38
different messages regarding status and fault indication. Messages are spelled
out in English. (Optional Spanish version is also available.) Provides indication
of flame signal during operation.
Provides indication of burner cycles and run time.
Non-volatile memory retains last 6 fault/lockout conditions on power failure.
Display module can be mounted in cabinet door for external indication.
(Optional)
Optional E300 expansion module provides additional 31 messages pertaining
to fault or hold status indication.
Communication with local or remote PC by means of an optional E500
communication module.
Modular Design:
Interchangeable program modules in English or Spanish.
Purge time is selected via dip switches.
Interchangeable amplifiers for infrared, ultra-violet, or UV self-check flame
scanners.
Section D
D-35
06-08
PRODUCT OFFERING
Included in each CB100E System is the following:
One chassis, including a dust cover.
One 2-line display module.
One Programmer Module.
One flame scanner, either infrared, ultra-violet, or UV self-check.
One flame amplifier to correspond with the selected flame scanner.
Included with optional E300 Expansion Module is:
One E300 expansion module.
One wiring subbase.
One interconnection cable to E100E.
All interlocks are wired into wiring sub base to provide individual hold/fault
indication on display of CB100E control.
ENGINEERING DATA
Supply voltage: 120 Vac (+10%/-15%) 50/60 Hz.
Fuel valve output load rating: 1250 VA opening, 500 VA holding.
Operating temperature limits:32 F to 125 F.
CB100E Control
PART 1 GENERAL Flame safeguard shall be a Cleaver-Brooks Model CB100E microprocessor-based
control to monitor all critical boiler and burner interlocks, control and supervise
burner light-off sequence, and initiate an orderly safety procedure in the event of
interlock or flame failure. The system shall provide status, fault history, and
diagnostic information by means of a 2 x 16 backlit LCD display. The system shall
be approved by UL, FM, and CSA, and shall be acceptable by IRI.
Section D
D-36
06-08
CB110 CONTROL
The CB 110 is a micro-processor-based, flame safeguard control used to monitor
the presence of a flame inside a boiler, and include various interlocks to ensure safe
operation. The flame safeguard also sequences the burner through several stages of
operation to provide proper air purge, ignition, normal operation and shut down for
safe operation.
Self Diagnostics:
Seven LED display provided to indicate: Fan, High Fire, Low Fire, Ignition,
Flame detected, Auto and Alarm.
23 Fault indications.
Modular Design:
Interchangeable amplifiers for infrared, ultra violet, or UV self-check flame
scanners.
Easily upgradeable to a CB 100E by replacing programmer and display
modules.
PRODUCT OFFERING
Included in each CB 110 System is the following:
One CB 110 chassis, including dust cover.
One Programmer/Display Module.
One wiring subbase.
One flame scanner, either infrared, ultra-violet, or UV self-check.
Section D
D-37
06-08
One flame amplifier to correspond with the selected flame scanner.
ENGINEERING DATA
Supply voltage: 120Vac (+10%/-15%) 50/60 Hz.
Fuel valve output load rating: 1250 VA opening, 500 VA holding.
Operating temperature limits: -40 F to 125 F
CB110 CONTROL
PART 1 GENERAL Flame safeguard shall be a Cleaver-Brooks Model CB 110 microprocessor-based control to
monitor all critical boiler and burner interlocks, control and supervise burner light-off
sequence, and initiate an orderly safety procedure in the event of interlock or flame failure.
The system shall provide status, fault history, and diagnostic information by means of an
LED display. The system shall be approved by UL, FM, and CSA, and shall be acceptable by
IRI.
Section D
D-38
06-08
LEAD/LAG SYSTEMS (TWO BOILER LEAD/
LAG)
This section contains information on Multiple Boiler Lead/Lag systems. For Lead/
Lag systems used with boilers equipped with the CB-HAWK ICS system, refer to the
CB-HAWK ICS Two Boiler Lead/Lag and Eight Boiler Lead/Lag sections.
Controls Actual Header Pressure and Temperature:
Maintains steam or hot water supply to system load.
Sequences Operation of Two Boilers:
Maximum system efficiency.
Reduces cycling and boiler wear reducing maintenance and downtime costs.
Lead/Lag Start with either Lead/Lag Modulation or Lead/Lag High-Low Fire:
Ideal where load swings are infrequent and small such as heating applications.
Lead/Lag Start with either Unison Modulation or Unison High-Low Fire:
Boilers operate in unison when both are on line.
Ideal where load swings are frequent and large, such as process applications.
PRODUCT OFFERING
Lead/Lag selector switch mounted on one boiler.
On-off and firing rate controls shipped loose for mounting in common
header piping.
Minimum temperature low-fire-hold control steam boilers.
Low-fire-hold control hot water boilers.
Components shall be Underwriters Laboratories approved for intended
service.
Section D
D-39
06-08
Lead/Lag Systems (Two-boiler Lead/lag)
A. Lead/Lag Start with either Lead/Lag Modulation or Lead/Lag High-
Low Fire.
B. The boiler manufacturer shall supply a control system to lead and
lag two boilers. The system shall start, stop, and control the firing
rate of both boilers.
C. Upon system demand, the lead boiler shall start and operate to full
capacity prior to starting the lag boiler. When both boilers are on
line, the lead shall always operate to full capacity and the lag shall
operate between minimum and maximum output to satisfy demand
requirements.
D. When system demand decreases, the lag boiler shall return to the
minimum firing rate position and shut off. A further decrease shall
cause the lead boiler to reduce its firing rate to minimum and shut
off.
E. A switch shall be provided to rotate the lead position between both
boilers.
F. For steam boilers, a means shall be provided to maintain minimum
boiler water temperature at low-fire when the boilers are off line.
G. For hot water boilers, a means shall be provided to keep the boilers
at low-fire rate until a predetermined minimum temperature is
reached. This releases the boiler to automatic operation from the
firing rate control.
H. All components shall be Underwriters Laboratories approved for
intended service.
I. Lead/Lag Start with either Unison Modulation or Unison High-Low-
Fire.
J. The boiler manufacturer shall supply a control system to lead and
lag start of two boilers. The system shall start, stop, and control the
firing rate of both boilers.
K. Upon system demand, the lead boiler shall start and operate to full
capacity prior to starting the lag boiler. When both boilers are on
line, they shall operate in unison between minimum and maximum
output to satisfy demand requirements.
L. When system demand decreases, both boilers shall reduce their
firing rate, in unison, to minimum. The lag boiler shall shut off and
the lead boiler shall operate between minimum and maximum until
demand is satisfied, and then shut off. A switch shall be provided to
rotate the lead position between both boilers.
M. For steam boilers, means shall be provided to maintain minimum
boiler water temperature at low-fire when boilers are off line.
N. For hot water boilers, means shall be provided to keep boilers in a
low-fire-hold mode until a predetermined minimum temperature is
reached. This shall then release the boiler to automatic operation
from firing rate control.
Section D
D-40
06-08
O. All components shall be Underwriters Laboratories approved for
intended service.
P. The lead/lag system is a specialized digital control that sequences
the starting, stopping, and controls modulation firing rate for two
boilers. It can be used for either steam or hot water applications.
1.2 APPLICATION
This option is applicable to full modulation burners utilizing standard Cleaver-Brooks modu-
lating controls.
Section D
D-41
06-08
LEAD/LAG SYSTEMS (TWO THROUGH
FOUR BOILER LEAD/LAG)
The lead-lag system is a specialized digital control that sequences the starting,
stopping, and controls modulation firing rate for two through four boilers. It can be
used for either steam or hot water applications.
PID Control Logic:
Precise control.
Monitors rate of change to anticipate needs of system, turning boilers on or off
as needed.
Lead/Lag Start and Modulation:
Provides optimal control action for different applications.
Lead boiler rotates automatically every 24 hours or manually selected for fixed
lead position.
Boilers Controlled From Header Pressure or Temperature:
Maintain constant steam or hot water supply to system load.
Compensate for varying losses between boiler and header.
Sequences Optimal Number of Boilers on Line:
Maximum system efficiency.
Reduces cycling and boiler wear reducing maintenance and downtime costs.
PRODUCT OFFERING
Lead/lag sequencing control system for full modulating boilers (four boilers
maximum).
Relays on control system panel for start-stop control of boilers.
Pressure or temperature sensor and immersion well.
Assured low-fire cutoff upon boiler shut off (steam and hot water boilers).
Minimum temperature low-fire-hold control (steam boilers).
Low-fire-hold control (hot water boilers).
Section D
D-42
06-08
ENGINEERING DATA
Voltage input: 115 V, 60 Hz
Power consumption: 30 VA maximum
Output rating:
Relays: 1 amp inductive, 10 amp resistive at 115 V, 60 Hz. (up to 4 relays used,
plug in type).
Firing rate signal: 0 to 135 ohm resistive.
Sensor ranges:
Temperature: -30 F to 250 F accuracy plus or minimum 1F.
Pressure: 0-30 psig, 0-100 psig, 0-200 psig accuracy 1% full scale.
Standby battery: Operates for 100 days minimum with overall average life of 5
years.
Maximum ambient temperature: 120 F.
Lead/lag Systems (Two Through Four Boiler Lead/lag)
A. The boiler manufacturer shall furnish a microprocessor based control
system. The control shall be engineered and programmed exclusively
for the operation of multiple steam or hot water full modulation
boilers. It shall incorporate the following integrated functions:
1. Manual or automatic lead stage rotation; boiler sequencing and
burner firing rate (modulation control). The control shall be of
modular construction to facilitate field modification, upgrading
or repair. It shall include the following features.
B. The control shall have the capability of operating in a temperature or
pressure mode. Temperature sensors shall be of the thermistor type,
suitable for insertion into a 3/8 ID well. Standard operating range
shall be -30 F to +250 F. Pressure sensors shall be of the 4-20
ma type. Standard operating range shall be 0-30, 0-100, 0-150 or
0-200 psig.
C. The control shall provide an integral sensor set point adjustment.
The set point shall be adjustable in 1 F or 1 psig increments (1/10
psig increments for 0-30 psig units) via a multi-turn knob. The
setting value shall be stored in EEPROM indefinitely.
D. The control shall provide a LED bar graph display of each boilers
approximate percent modulation. The control shall also provide a
digital LED display of actual temperature or pressure, set point
temperature or pressure, gain adjustment and each boilers exact
percent modulation. In addition, the digital display shall be used to
indicate the following four control settings as they are being
adjusted:
1. Modulation start point shall be adjustable from 50 to 100%.
This setting determines the percent modulation a stage must
achieve before the next stage is activated. There shall be
independent adjustment of this setting for each burner.
Section D
D-43
06-08
2. Purge timer shall be adjustable from 0-9.9 minutes. This
setting determines the delay time between a burner being
started and the beginning of modulation.
3. Set back (additional set point) shall be adjustable from 0-75
F/psig (0-7.5 psig on 0-30 psig units). This setting
determines the F/psig drop from the primary set point
whenever the setback mode is activated. An off setting shall
also be included for complete burner shutdown. The set back
mode shall be activated by an external switch closure.
4. Standby timer shall be adjustable from 1-60 minutes. This
setting determines the delay period which must elapse before
any designated standby boilers are activated. The timing
sequence shall begin when all active boilers reach 100% firing
rate.
E. LEDs shall be provided to indicate the lead stage and all activated
stages.
F. A lithium coin type battery shall be included to maintain the
correct lead stage and lead stage rotation timer in the event of
power failure. Storage capacity shall be 100 days.
G. A four position selector switch shall be provided to set the operating
mode of each stage. Positions include on, auto, off and standby.
H. The control shall have the capability of operating up to four full
modulation boilers. Each stage shall have the following outputs:
1. A normally open contact to start/stop the burner.
2. A 0-135 ohm output to independently control each burners
firing rate.
I. The control shall be UL listed, tested per Standard 873.
Temperature Indicating and Regulating Equipment. It shall be CSA
listed, tested per Standard C22.2 Number 24-1987 Temperature
Indicating and Regulating Equipment. It shall also be approved for
use in NYC by the City of New York; Department of Buildings,
Bureau of Electrical Control and Department of Environmental
Protection, Bureau of Air Resources.
J. A surface mounted, locking steel, NEMA 1 type, minimum 18
gauge enclosure shall be provided.
1.2 APPLICATION
This option is applicable to full modulation burners utilizing standard Cleaver-
Brooks modulating controls.
Section D
D-44
06-08
LOW FIRE HOLD CONTROL
Prevents Automatic Control of Burner Firing Rate Until Pre- Determined Boiler
Water Temperature is Reached:
Equalizes water temperature in boiler.
Reduces possibility of thermal shock to pressure vessel and refractory.
PRODUCT OFFERING
Cleaver-Brooks shall provide a boiler water temperature control with sensor and
immersion well. The control is Underwriters Laboratories approved for intended
service and shall be mounted and wired on the boiler.
RECOMMENDED USE
The use of this control is recommended where a minimum temperature control has
not been installed and where operating personnel may not be diligent in manually
placing the boiler at low fire until the boiler shell is of equal temperature throughout.
Note: In an emergency one can override this control by placing the Manual-Auto switch in the
Manual position.
Low Fire Hold Control
The boiler manufacturer shall furnish and install a control to sense boiler water
temperature. The control shall maintain burner in a low-fire hold mode until a pre-
set temperature is satisfied. This shall then release boiler to automatic control of
system demand. Control shall be Underwriters Laboratories approved for intended
service.
1.2 APPLICATION
This option is applicable to full modulation and high-low fire burners.
BB_D-03-06
Section D
D-45
06-08
MINIMUM TEMPERATURE LOW FIRE
HOLD CONTROL
Maintains Minimum Boiler Water Temperature in Steam Boilers at Low-Fire Mode
of Operation During Off Periods:
Reduces lag-time to steaming rate.
Operational mode-manual or automatic.
PRODUCT OFFERING
Cleaver-Brooks shall supply:
Boiler water temperature control and immersion well.
Interface relay.
Operation mode.
Manual selector switch.
Automatic activated by remote on-off boiler control device.
Components Underwriters Laboratories approved for intended service.
RECOMMENDED USE
A common procedure at many steam boiler installations is to shut the boiler off
overnight, during weekends, or during holidays. During this off period boiler water
temperature decreases. This can effectively decrease boiler metal and refractory
temperatures to near room temperature. After this off period the boiler is placed
back into operation. Due to low boiler water temperature and a steam pressure
demand the boiler will immediately position itself at high fire. The important factors
to remember are that metals expand when heated; contract when cooled. This is
also true of boiler refractory. With repeated heating and cooling of any boiler,
premature deterioration of boiler refractory, metals, and resultant tube leakage can
occur. To minimize these effects, the installation of a combination minimum
temperature-low fire hold control is recommended.
Occasionally there are objections to the use of a combination minimum
temperature-low fire hold control. If the off period will be of prolonged duration
maintaining minimum temperature could represent a considerable waste of fuel.
Under this condition it is recommended that a low fire hold control be installed.
06-08
Section D
D-46
06-08
Minimum Temperature Low Fire Hold Control
The boiler manufacturer shall furnish and install a control to sense boiler water
temperature. The control shall have an adjustable set point to maintain a minimum
temperature at a pre-set level when the boiler is off line. This shall be accomplished
at the burners minimum firing rate. The function can be activated either manually or
automatically. Components shall be Underwriters Laboratories approved for
intended service.
1.2 APPLICATION
Section D
D-47
06-08
ASSURED LOW FIRE CUTOFF
Assures that the burner shuts off at minimum firing rate when signaled from remote
disable source:
Prevents shutoff at firing rates above low fire.
PRODUCT OFFERING
Cleaver-Brooks shall provide terminal connection points for remote disable/enable
signals, and internally wire additional electrical components necessary to perform
this function.
Assured Low Fire Cutoff
The boiler manufacturer shall make provisions to accept remote enable/disable
signal contact. Any disable signal shall cause the burner to return to minimum low
fire position prior to shutting off the main fuel.
1.2 APPLICATION
Section D
D-48
06-08
REMOTE MODULATION
Provides burner modulation from a customer supplied 4-20 ma control signal.
Ties boiler firing rate control with customer control system (for example, building
management, boiler room master, lead-lag control).
PRODUCT OFFERING
Standard Equipment
Resistor kit to allow standard firing rate motor to operate from a 4-20 ma
control signal.
Relay with gold flashed contacts to switch between automatic and manual
operation.
Manual firing rate potentiometer to allow local manual operation.
Optional Equipment
Local remote firing rate control selector switch.
Allows control of firing rate from standard local firing rate controller or
remote 4-20 ma signal.
Remote Modulation
1.1 GENERAL
Furnish and install components to allow burner to modulate from a remote 4-20 ma
control signal. Provisions shall be made for local manual firing rate control.
1.2 APPLICATION
This option is applicable to full modulation burners utilizing standard Cleaver-Brooks
modulating controls.
Section D
D-49
06-08
AUTOMATIC FUEL CHANGEOVER
Provides sequence to allow burner to automatically change fuel.
Interfaces boiler-burner control with customer control system and avoids
premium charges for fuel.
PRODUCT OFFERING
A selector switch. With selector switch in the AUTO position, burner shall fire
primary fuel when auxiliary contact governing fuel selection (for an example,
gas pressure switch or outdoor thermostat) is closed. Upon opening of the
above contact: a burner shall modulate to the minimum firing rate position,
shutdown and restart firing stand by fuel.
Fuel auto changeover switch (a low gas pressure switch or outdoor thermostat).
This switch may be furnished by the boiler supplier, customer, or utility.
Automatic Fuel Changeover
The boiler manufacturer shall furnish sequence to allow an automatic changeover
from primary to stand by fuel and back. An automatic fuel changeover shall be
initiated by gas pressure, outdoor temperature or other dry contact.
1.2 APPLICATION
This option is applicable to dual-fuel (i.e., gas-oil fired) boilers with exception of
Model LE Boilers.
Section D
D-50
06-08
OXYGEN TRIM
The C-B Model O
2
Trim System is a complete package used to maintain optimum
fuel-to-air ratios and maximum fuel efficiency.
Microprocessor-Based Control System Ensures Dependable Operation and Precise
Oxygen Control:
Selectable single point, automatic calibration (based on an internal, real-time
clock) or dual point manual calibration mode.
Dual calibration ensures accurate oxygen readings.
Ten segment set point curves ensure accurate tracking of oxygen set points on
both gas or oil fuels.
The oxygen sensing cell in the analyzer probe is easily removed for service and
replacement.
Recorder output of oxygen values is operator selectable for either 4-20 ma or 1-
5 Vdc. Firing rate output is 1-5 Vdc.
The Model C-B O2 Trim System Incorporates Dual Analyzer Displays:
A large LED display for oxygen levels.
40 character, back-lit, LCD for display of configuration and other data.
Display is used for friendly prompts during programming calibration, service,
and monitoring.
The Controller Display is a Back-lit LCD Which Will Display the Following in Both
Digital and Bar Graph Format:
Process variable (% O
2
).
Set point.
Control Output.
Graphic trending of O
2
or firing rate on controller display for up to 24 hours.
Graph timing is selectable.
Section D
D-51
06-08
Two Alarm Contacts Which Are User-Configurable for Any of the Following
Functions:
Low O
2
alarm.
Low O
2
shutdown.
High stack temperature alarm and/or boiler cutoff (when used with optional
stack temperature transmitter).
Analyzer malfunction.
Time delay may be incorporated into these contacts.
Analyzer Probe is Direct Insertion, In-Situ Type Which Provides:
High accuracy.
Fast response.
Reliability.
PRODUCT OFFERING
Oxygen trim system can be supplied for either fuel trim or air trim.
NEMA 12 Control Panel with the following:
Oxygen analyzer.
Oxygen probe (15.75").
Oxygen controller.
Fuel selection indicator lights.
Pneumatic control components and actuator.
In-situ probe with zirconia cell.
Firing rate transducer.
50 ft. cable for probe and firing rate transducer.
Optional Equipment
Pneumatic actuator for switch over.
Stack temperature transmitter for display on analyzer.
Control panel stand.
Probe filter (stainless steel).
Probe stack mounting adaptor.
27" probe.
ENGINEERING DATA
Probe:
Sample Gas Temperature: 0 to 1100 F.
Insertion length: 15.75", 27".
Ambient Temperature: 14 to 176 F.
Material in contact with gas: Stainless Steel, Zirconia.
Section D
D-52
06-08
Installation: Flange mounting (equivalent to 2" 150 lbs FF. ANSI flange).
Enclosure: NEMA 4.
Weight: Insertion length 15.75" approximately 9 lbs. Insertion length 27"
approximately 12 lbs.
Control Panel:
Power Supply: 110/120 Vac, 3 amps, 50/60 Hz.
Dimensions: 20" H x 20" W x 13" D.
Weight: Approximately 70 lbs.
Ambient Temperature: 32 to 122 F.
Air Supply: 25-126 psig instrument air dry, oil free.
Outputs:
Control: 3-15 psig.
Recorder: O
2
value 1-5 Vdc or 4-20 ma.
Firing Rate 1-5 Vdc.
Contact: 250 Vac, 2 amps.
Low O
2
alarm.
Low O
2
shutdown.
Oxygen Trim
A. This specification covers the hardware and control of the C-B O
2

Trim System. The system adjusts the fuel-to-air ratio in order to
maintain maximum efficiency and features reliable monitoring and
control of oxygen concentrations.
B. The system shall be completely configured from factory, requiring
only job-specific data to be entered (or modified) in the field.
Controller/analyzer shall be shipped with default values and have a
limit on the range of adjustments where applicable.
Hardware shall consist of the following:
A. Oxygen Sensor - The oxygen sensor shall be:
1. Zirconia cell with temperature held constant by a heater.
2. Probe is in-situ type to provide fast response to changes in O
2

levels.
B. Analyzer - The analyzer shall be:
1. 4-20 ma O
2
output signal with linearly proportional to a 0-
Section D
D-53
06-08
20%
2. Capable of single-point automatic calibration or dual point
manual calibration. Single point calibration is programmable
based on an internal time clock.
3. Able to provide a contact closure during calibration, which will
be wired into controller to override trim function during
calibration.
4. Response 90% within five (5) seconds after gas is
introduced.
C. Capable of providing the following control and monitoring ability in
the analyzer:
1. Display interactive operation.
2. Analog bar display format on screen.
3. Indicate average O
2
computation.
4. Maximum and minimum O
2
levels.
5. Large LED display of O
2
level.
6. 40 character dot matrix back-lit LCD display of configuration
and other data.
7. Self testing for cell life.
8. Analog output range of 0-20% O
2
computation.
9. Efficiency calculations (with temperature transmitter option).
D. Controller: - Controller shall:
1. Be microprocessor based.
2. Have means for indicating the process variable (% oxygen)
setpoint, and output: each of these in both digital and bar
graph format with range 0-20%.
3. Allow for switching between automatic and manual control,
and for changing the setpoint and output.
4. Accept 4-20 ma signal from the O
2
analyzer, a calibration
contact from the analyzer, and a firing rate signal from a boiler-
mounted potentiometer.
5. Accept dry contact indication of fuel being fired. The front
panel display of the control shall be a bit mapped LCD type
with a switch that allows operation and system adjustments to
be performed from a menu. The display panel shall also
include trend and alarm features for real-time, history, and
allow viewing of related data while making adjustments.
E. The control panel of the controller shall also have the following
features:
1. Dedicated page key to be used for screen selection.
2. Programmed function key to define fuel type.
3. Mode key to determine auto or manual mode.
4. Failure light.
5. Alarm light.
6. 8 character display description.
Section D
D-54
06-08
7. Oxygen level recorder output 4-20 ma or 1-5 Vdc.
8. Firing rate output 1-5 Vdc.
F. The system shall continuously monitor oxygen concentration in
boiler flue gas and adjust fuel or air flow to maintain oxygen level at
set point. Set point shall be dependent on boiler firing rate and fuel
selection inputs to controller. Controller shall determine set point
internally based on these inputs, through separate curves ( function
generators ) for each fuel. The rate-of-change of the firing rate input
shall be limited to allow for the response time of the gases traveling
through the boiler. Control to be direct acting. Proportional- plus-
Integral (PI) with integral-only response to set point changes. Gain
shall be varied based on firing rate, with faster response at high
firing rates and slower response at low firing rates. Control to
incorporate anti-reset windup capabilities when output reaches its
limit. Since trim output must be able to add or subtract from fuel or
air flow, the normal or no trim output shall be 50%.
2.2 APPLICATION
This system is applicable to modulating burners that utilize a Cleaver-Brooks fuel oil
controller (on oil firing) and/or specific gas pressure regulators (on gas firing).
Contact your local Cleaver-Brooks authorized representative for specific details.
Section D
D-55
06-08
CB-HAWK ICS ADAC ADVANCED DEAERA-
TOR CONTROL
The CB ADAC Advanced Deaerator Control provides a PLC based control system for
a deaerator, surge tank, two tank deaerator-and-surge, or Duo-tank installations.
The system is capable of controlling operation of boiler feed and/or transfer pumps,
maintaining tank levels, monitoring and responding to system demands, and
recording/annunciating alarm conditions.
The ADAC can run as a stand-alone system or tie into a CB-HAWK ICS Master Panel
or customer building automation system.
Standard Features:
Integration of various deaerator and surge tank devices in a common control
system
Touch screen graphical Human Machine Interface (HMI)
Deaerator and surge tank water level modulating controls
Chemical feed pump control
Boiler feed pump control - up to 6 pumps via variable speed drive, soft starters,
combination starters, or contactors
Surge tank feed pump control (transfer pumps) - up to 3 pumps
Pump alternating, lead/lag, and automatic rotation
Serial, Ethernet, BAS, web server communications capability
Control of remote devices (valves, etc.)
Alarm/fault annunciation and history with audible alarm
Red/Yellow/Green stack light for visual status indication
Cumulative pump run time totals for maintenance purposes
Optional Features:
10 PanelView in lieu of 6 (10 is standard on two tank systems)
Dial-up paging modem (selecting this option and Ethernet communication
requires Ethernet PanelView and 5 port Ethernet hub)
Alarm bell, horn, or electric sounder
GEMS Mini Sure Site level indicator with 4-20 mA transmitter or discrete level
switches
Steam or water flow transmitters
Manual hard wired controls for any 4-20 mA controlled valve
Siemens motorized make-up valve
RSLinx OPC compliant remote monitoring software
Recirculation bypass (tank one only)
NEMA 4/12 entrance panel
NEMA 4x electrical panel
Section D
D-56
06-08
PRODUCT OFFERING
Standard Features, Single Tank System:
Compact Logix L32E processor
6 color touch screen HMI
Stack light
Programming and I/O cards for the following:
I/O for 1-6 pumps using contactors, soft starters, or combination starters
Hard wired fixed location level inputs for Hi and Low water alarms
Low water pump cutoff audible alarm output
Stack light outputs
Recirculation bypass output
Chemical feed relay
Boiler 1-6 Feed Water Required inputs
Analog inputs for tank pressure, temperature, level, and discharge header
pressure
Optional Features, Single Tank System:
NOTE: Options must be selected in order; each option requires all of the preceding
ones.
Standard Features, Duo Tank or DA-and-Surge System:
Compact Logix L32E processor
10 color touch screen HMI
Stack light
Programming and I/O cards for the following:
I/O for 1-6 boiler feed pumps and 1-3 transfer pumps using contactors, soft
starters, or combination starters
Hard wired fixed location level inputs for HI and LO water alarms, and low
water pump cutoff for 2 tanks
Audible alarm output
Stack light outputs
Option 1 Feedwater make up valve analog output
Option 2 1-6 pump proving flow switch inputs
Option 3 Single tank system emergency make up valve
Option 4 1-3 VSD driven pumps I/O
Option 5 4-6 VSD driven pumps I/O
Option 6 1-6 feed pump (1 pump per boiler) VSD driven pump analog inputs
Section D
D-57
06-08
Recirc bypass output
Chemical feed relay
Boiler 1-6 Feed Water Required inputs
Pump proving switch inputs for up to 6 feed pumps and 3 transfer pumps
DA tank pressure analog input
Tank temperature, level, discharge header pressure inputs for 2 tanks
1 customer configured analog input (future)
Optional Features, Duo Tank or DA-and-Surge System:
NOTE: Options must be selected in order; each option requires all of the preceding
ones.
ENGINEERING DATA
Supply voltage: 120 VAC (102 VAC - 132 VAC), 50 or 60 H z
Maximum total connected load: 500 VA
Operating temperature limits: 32 to 130F
Humidity: 85% relative humidity continuous, non-condensing
0.5G continuous vibration
CB ADAC Advanced Deaerator Control
A. Each ADAC system shall be factory equipped with a pre-configured
Programmable Controller and Human Machine Interface.
B. System shall provide control logic for the following:
1. 1-6 feed pumps and 1-3 transfer pumps
2. Make up water level control for DA tank or DA and Surge
3. Low Water, Hi Water, and Aux Low Water alarms
4. Chemical feed control
Option 1 Feedwater make up valve analog output Tank 2
Option 2 Tank 1 Emergency make up valve analog output for 2 Tank systems
Option 3 Tank 2 Emergency make up valve analog output for 2 Tank systems
Option 4 I/O for 1-3 feed pumps and 1 transfer pump VSD driven
Option 5 I/O for 4-6 feed pumps and 2-3 transfer pump VSD driven
Section D
D-58
06-08
PART 2 PRODUCTS 2.1 STANDARD SYSTEM AND OPTIONS
A. Hardware Platform - Standard System
1. Compact Logix L32E Processor
2. Power Supply
3. Discrete Input Module
4. Discrete Output Module
5. Analog Input Module 4 Channel
6. Analog Input Module 8 Channel
7. Analog Output Module 2 Channel
8. Analog Output Module 8 Channel
9. Right Termination End Cap
10. HMI Display, 6 Serial Color - Standard on single tank systems
11. HMI Display, 10 Serial Color Standard on two tank systems,
optional on single tank systems
B. Optional Components
1. Remote Access Paging Modem
2. Veris Current Switch - sized for pump
3. Electric actuators for pump water recirculation bypass - sized
for system
4. PowerFlex 70, 400, or 700 Variable Speed Drive
2.2 SENSORS AND TRANSMITTERS
A. Tank level indication
1. Standard
a. DA tank - GEMS Mini Sure Site with transmitter
b. Surge tank - GEMS Mini Sure Site with transmitter
2. Optional
a. DA tank - Differential pressure level transmitter
Rosemount 3051CD
b. Surge tank - Differential pressure level transmitter
Rosemount 3051CD
B. Tank Pressure and Temperature (see table)
Tank Pressure/Temperature Transmitters
C. Pump flow proving sensors
1. Pressure switch mounted after each pump or differential
pressure switch across pump. Monitor pump running status
with Veris current switch.
D. Sierra flow transmitters - sized per application
Standard Optional
DA tank pressure transmitter Setra-256 Rosemount-3051
DA pump discharge pressure transmitter Setra-256 Rosemount-3051
Surge tank transfer pump pressure transmitter Setra-256 Rosemount-3051
DA tank temperature transmitter ARI Rosemount-3144
Surge tank temperature transmitter ARI Rosemount-3144
Section D
D-59
06-08
2.3 VALVES
A. Make-up water valves - all sized per application
1. DA tank make-up valve - Siemens SK electronic actuator with
optional 3 valve bypass and strainer
2. DA tank emergency or raw water make-up valve - Siemens SK
electronic actuator with optional 3 valve bypass and strainer
3. Surge tank make-up valve - Siemens SK electronic actuator
with optional 3 valve bypass and strainer
2.4 PUMPS
A. Feed water pumps - Grundfos
B. Transfer pumps - Grundfos
2.5 SOFTWARE DEVELOPMENT PLATFORM
(software not required - for informational purposes only)
A. RSLogix 5000 (controller logic programming)
B. Allen-Bradley Panel Builder (HMI programming)
C. RSView32 (control room display and data acquisition)
D. RSLinx OEM version (OPC server - Building Automation System)
2.6 MAJOR FUNCTIONS THAT THE ADAC SYSTEM SHALL PROVIDE:
(controller functions based on customer configuration and purchase of options)
A. Feed water pump control
1. System will be able to support up to 6 pumps, selected using
the HMI (no PC or additional software required). Upon
selection, graphics and control logic will be activated
automatically.
2. Pumps may be part of a common header or may feed individual
boilers. If part of a common header pumps may be configured
to operate in a lead/lag sequence based on system demand.
3. Order of pump alternation can be automatically rotated to share
running time and wear equally between pumps.
4. For a common boiler feedwater pump discharge system, PLC
monitors 4-20 mA pressure/flow signal from boiler feedwater
header to determine when to command pumps to start/stop. In
a VSD system the 4-20 mA pressure/flow signal will determine
VSD output.
5. If the pumps are feeding individual boilers, pumps will be
turned on/off based on individual boiler feed water pressure
(when using VSDs) or discrete 110 VAC signals from each
boiler.
6. PLC/VSDs can only control pumps that are in AUTO mode.
Pumps in manual will run continuously. The hard wired Aux
Low Water pump cutoff will prevent pumps from running in any
mode if water level drops below set point.
B. Transfer pump control
1. System will be able to support up to 3 pumps for transferring
water from the Surge tank to the DA. Pumps are selected using
the HMI; no PC or additional software required. Upon
selection, graphics and control logic will be activated
automatically.
Section D
D-60
06-08
2. Pumps may be configured to operate in a lead/lag sequence
based on system demand. In addition, order of pump
alternation can be automatically rotated to share running time
and wear equally between pumps.
C. DA make-up water level control
1. The lead pump runs continuously. If DA tank level falls below
set point, make up valve is already fully open, and condensate
tank discharge pressure falls below set point, the PLC will
command the lag pump to start.
2. When surge tank discharge pressure falls below set point, the
PLC will sound an alarm. Operator must respond to the alarm
condition and reset the alarm.
3. When level control is in manual mode, the make up valve can
be opened or closed from the HMI screen, or optionally by a
manual potentiometer. Either method will allow the operator to
manually adjust the valve between fully open and fully closed
to control the incoming flow of make up water.
D. Surge tank make up water level control
1. The PLC receives a 4-20 mA signal indicating surge tank water
level. Signal is compared to the operator input set point and
valve modulates accordingly to control the incoming flow of
make-up water.
2. When the valve is in manual mode the HMI or optional manual
potentiometers will allow the operator to manually adjust the
valve between fully open and fully closed.
E. Pump Lead/Lag and Alternating Control
1. Selection of pumps and rotation schedule are configurable
from the HMI. PLC will monitor all pumps and determine
availability; pumps may be taken out of rotation for
maintenance.
2. When system is in auto rotation, if a pump is not available the
PLC will alternate to the next available one. If no pumps are
available an alarm will sound, requiring manual reset. PLC will
maintain equal run time between all pumps.
3. If Lead/Lag option is selected, pump start/stop set points are
set from the HMI. Start point is based on percentage of set
point achieved by previous pump in sequence. PLC internal
timers will maintain minimum load fluctuations.
4. If Lead/Lag and VSD options are selected, VSD% to start/stop
lag pump is set from the HMI. When lag function is activated,
VSDs function in unison modulation until the speed reaches
VSD stop point; then lag pump shuts off.
5. When pump alternation is selected, alternation schedule is
configured from the HMI. When current pump run time is met,
next pump will start and come up to speed; previous pump will
then stop.
F. Chemical Feed Control
1. One set of dry contacts wired to terminal blocks will be
provided to change state when any boiler feed pump is
Section D
D-61
06-08
running, enabling customer chemical feed pump.
2.7 ADDITIONAL ADAC SYSTEM FUNCTIONS:
A. A pressure sensor mounted in steam space monitors Deaerator
pressure.
B. A set of contacts on each pumps overload relay provides indication
of pump failure. If VSDs or soft starters are used, a fault contact is
monitored by the PLC to indicate pump failure.
C. A set of contacts on each pump starter indicates pump running. If
VSDs or soft starters are used, a contact is monitored by the PLC to
indicate run status.
D. A selector switch is mounted at each pump starter to allow Hand-
Off-Auto switching. Hand ignores all external signals except Aux
Low Water Cutoff, Off ignores all signals and prevents pump from
running, Auto allows pump to run based on commands from the
PLC.
2.8 ALARM FEATURES
A. DA Tank water level alarms
1. Low Water If water level as indicated by the tank level
device falls to a pre-set point, the PLC will sound an alarm,
display a message on the HMI, log a message to the alarm
history file, and turn on the appropriate stack light.
2. Low Low Water If water level falls further to the pre-set Low
Low Water point, the PLC will sound an alarm, display a
message on the HMI, log a message to the alarm history file,
and turn on the appropriate stack light.
3. Hi Water If water level as indicated by the tank level device
rises to a pre-set point, the PLC will sound an alarm, display a
message on the HMI, log a message to the alarm history file,
and turn on the appropriate stack light.
4. Aux Low Water If water level falls to the pre-set Aux Low
Water point, the hard wired Aux Low Water device will open,
signalling the PLC and shutting down all pumps for that tank.
The PLC will sound an alarm, display a message on the HMI,
log a message to the alarm history file, and turn on the
appropriate stack light.
B. Surge Tank water level alarms (same as above)
2.9 ADAC COMMUNICATION OPTIONS
A. Ethernet connectivity
1. PLC features an OPC compliant Ethernet/IP port for connection
to a Building/Plant Automation System or Local Area Network.
2. Remote monitoring/data logging available using RSView
software.
3. Connection to CB HAWK ICS Master Panel (Note: Existing
Master Panels would require a program upgrade and possibly
a processor upgrade to use this option).
4. Compliance with IEEE 802.3 Physical and Data Link, TCP/IP
protocol, and Control and Information Protocol (CIP) standards.
Section D
D-62
06-08
B. Other communication options
1. Communication to most major building management system
interfaces such as Johnson Controls Metasys, ASHRAE
Bacnet, LON, and Siemens will be available via a Cleaver-
Brooks protocol translator bridge. Check with Cleaver-Brooks
for specific information.
2. Data can be transferred by Ethernet through a CB Master Panel
to a customer BAS. If a Master Panel is unavailable, the
protocol translator can be configured to communicate directly
between the ADAC and the customer BAS.
Section D
D-63
03-08
CB LCS-150E LEVEL CONTROL SYSTEM
The Cleaver-Brooks LCS-150E Level Control System utilizes a level transmitter and
a programmable controller to control water level and water level alarms. System
includes modulating make-up valve with user-selectable manual or automatic
control.
Standard Features
Programmable controller with display
Set points, alarm points, transmitter span, and PI controls configurable using
controller keypad
Manual or automatic control of make-up valve
Easy-to-read level indication
No sight glass - water is contained in a pressure-tight housing
PRODUCT OFFERING
The following are included as standard in each LCS-150E control system:
Programmable controller
Controller display with keypad
I/O module
Level sensor and transmitter
Modulating feed water valve and actuator
Alarm horn and silence button
High, Low, and Low Water Cut-Off alarm lights
ENGINEERING DATA
Supply voltage 120 VAC
Max load 3 amps
Ambient temperature range 32 - 130 deg F
Humidity, non condensing 5-95%
Degree of protection
- Display/keypad: IP65, Type 3R, Type 12R
- Panel Nema 4/12
- Lights and switches IP66
- Level indicator /transmitter Nema 4
- Siemens valve Nema 1; optional weather shield will change it to Nema 3R
Section D
D-64
03-08
CB LCS-150E Level Control System
A. Each LCS-150E system shall be factory equipped with controller
including display and I/O, NEMA 12 cabinet, and GEMS magnetic
level sensor with transmitter.
B. System shall provide the following functions:
1. Adjustable transmitter span
2. Adjustable water level set point
3. Adjustable high water alarm point (with differential)
4. Adjustable low water alarm point (with differential)
5. Adjustable low water cutoff point (with differential)
6. Adjustable P and I (proportional and integral gain) parameters
7. Manual or automatic make-up valve operation
8. On-screen alarm indication and relay outputs for high water,
low water, low water cutoff, and general alarms
9. Alarm Silence input
PART 2 PRODUCTS 2.1 STANDARD SYSTEM
A. Hardware Platform
1. Pico GFX Controller with backlit graphic display
2. Power Supply 115VA/24VDC 30 Watts
3. I/O module:
(12) 24VDC inputs
(4) relay outputs
(1) 0-10 VDC analog output for make-up valve
(1) 0-10 VDC input for level transmitter
B. Level sensor and transmitter
1. GEMS Mini Sure Site magnetic level indicator
2. Level transmitter 4-20 mA
C. Make-up valve
1. Siemens modulating feed water valve - sized per application
2. Electronic actuator 0-10 VDC
D. Alarms
1. Panel mounted alarm horn
2. Alarm silence switch
3. LED alarm lights for High and Low Water and Low Water Cut-
Off
E-1
03-08
CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
POLLUTANTS AND CONTROL TECHNIQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
NITROGEN COMPOUNDS (NOx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
NOx CONTROL TECHNOLOGIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4
POST COMBUSTION CONTROL METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
Selective Non-catalytic Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
Selective Catalytic Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
COMBUSTION CONTROL TECHNIQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
Low Excess Air (LEA) Firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
Low Nitrogen Fuel Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
Burner Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
Water/Steam Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
Flue Gas Recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7
CHOOSING THE BEST NOx TECHNOLOGY FOR THE JOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7
Turndown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8
Excess Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8
Carbon Monoxide (CO) Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9
Total Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9
SULFUR COMPOUNDS (SOx). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9
CARBON MONOXIDE (CO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-10
PARTICULATE MATTER (PM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-10
CARBON MONOXIDE (CO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-11
PARTICULATE MATTER (PM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-12
VOLATILE ORGANIC COMPOUNDS (VOCs)/HYDROCARBONS (HC) . . . . . . . . . . . . . . . . . . . . . . E-12
CALCULATING BOILER EMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-13
Emission Level Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-13
Correcting Emissions to 3% Oxygen (15% Excess Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-13
Converting Emissions between PPM And Lb/MMBTU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-14
Calculation of Annual Emissions for Industrial Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-16
NEW SOURCE PERFORMANCE STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-18
Section E
EMISSIONS
Section E
E-2
03-08
ILLUSTRATIONS
Figure E-1. Effects of Fuel-Bound Nitrogen on NOx Emissions for Fuel Oils . . . . . . . . . . . . . . . . . .E-4
Figure E-2. Selective Non-Catalytic Reduction (SNCR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5
Figure E-3. Selective Catalytic Reduction (SCR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5
Figure E-4. Effects of Fuel Sulfur Content on SOx Emissions for Fuel Oils . . . . . . . . . . . . . . . . . . .E-9
Figure E-5. CO Emissions Conversion Curves, 3% Oxygen, (15% Excess Air) . . . . . . . . . . . . . . . . .E-14
Figure E-6. NOx Emissions Conversion Curves, 3% Oxygen, (15% Excess Air) . . . . . . . . . . . . . . . .E-15
Figure E-7. SOx Emissions Conversion Curves, 3% Oxygen, (15% Excess Air) . . . . . . . . . . . . . . . .E-15
Figure E-8. Volatile Organic Compound Conversion Curves, 3% Oxygen, (15% Excess Air) . . . . . . .E-16
Figure E-9. Annual NOx Emissions for 250-800 Horsepower Boilers, NOx = 110 ppm
(Corrected to 3% O
2
) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-17
(Corrected to 3% O
2
) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-17
(Corrected to 3% O
2
) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-17
(Corrected to 3% O
2
) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-18
(Corrected to 3% O
2
) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-18
Figure E-14. Summary of Federal EPA Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-20
Section E
E-3
03-08
INTRODUCTION
This section of the Boiler Book contains background information regarding boiler
emissions.
This section does not include emission performance for individual Cleaver-Brooks
boiler models. Emission information for each product is included in the specific
section of the Boiler Book for the product or you can contact your local Cleaver-
Brooks authorized representative for the necessary information.
POLLUTANTS AND CONTROL TECHNIQUES
Combustion of standard fossil fuels (natural gas and ASTM Grade Oil) in commercial
and industrial boilers results in the following nine emissions; carbon dioxide,
nitrogen, oxygen, water, carbon monoxide, nitrogen oxide, sulfur oxides, volatile
organic compounds, and particulate matter. The latter five products of combustion
are considered pollutants and are known to, either directly or indirectly, cause
harmful affects on humans and the environment.
The following section describes the formation and control of each of the pollutants in
commercial and industrial boilers:
Carbon Monoxide
Nitrogen Oxides
Sulfur Oxides
Volatile Organic Compounds/Hydrocarbons
Particulate Matter
NITROGEN COMPOUNDS (NOX)
Although there is evidence proving NOx, in itself, is harmful to humans, the main
reason NOx is considered an environmental problem is because it initiates reactions
that result in the production of ozone and acid rain. Ozone and acid rain can
damage fabric, cause rubber to crack, reduce visibility, damage buildings, harm
forests and lakes, and cause health problems. By controlling NOx levels, along with
the other pollutants, the levels of acid rain and ozone can be reduced.
The principal nitrogen pollutants generated by boilers are nitric oxide (NO) and
nitrogen dioxide (NO
2
), collectively referred to as NOx.
The contribution from different NOx sources to the total NOx levels varies among
metropolitan areas. In general, the contribution of mobile sources to the total NOx
level ranges from 60 to 80 percent: For stationary sources, it ranges between 20
and 40 percent. A significant portion of the NOx from stationary sources can be
attributed to residential, commercial, and industrial sources, including industrial
boilers. In industrial boilers, NOx is primarily formed in two ways; thermal NOx

and
fuel NOx:
Thermal NOx is formed when nitrogen and oxygen in the combustion air
combine with one another at the high temperatures in a flame. Thermal NOx
makes up the majority of NOx formed during the combustion of gases and light
oils.
Fuel NOxis formed by the reaction of nitrogen in the fuel with oxygen in the
combustion air. It is rarely a problem with gaseous fuels. But in oils containing
significant amounts of fuel-bound nitrogen, fuel NOx

can account for up to 50%
of the total NOx emissions.
NOx emissions from boilers are influenced by many factors. The most significant
Section E
E-4
03-08
factors are flame temperature and the amount of nitrogen in the fuel. Other factors
affecting NOx

formation are excess air level and combustion air temperature.
While flame temperature primarily affects thermal NOx formation, the amount of
nitrogen in the fuel determines the level of fuel NOx emissions. Fuel containing
more nitrogen results in higher levels of NOx emissions (see Figure E-1). Most NOx
control technologies for industrial boilers, with inputs less than 100 MMBtu/hr,
reduce thermal NOx and have little affect on fuel NOx. Fuel NOx is most
economically reduced in commercial and industrial boilers by switching to cleaner
fuels (fuels containing less fuel-bound nitrogen), if available.
NOX

CONTROL TECHNOLOGIES
NOx controls can be classified into two types: post combustion methods and
combustion control techniques. Post combustion methods address NOx

emissions
after formation while combustion control techniques prevent the formation of NOx
during the combustion process. Post combustion methods tend to be more
expensive than combustion control techniques and generally are not used on boilers
with inputs of less than 100 MMBtu/hr. Following is a list of different NOx

control
methods.
Post combustion control methods include:
Selective Non-Catalytic Reduction
Selective Catalytic Reduction
Combustion control techniques include:
Low Excess Air Firing
Low Nitrogen Fuel Oil
0
0
Increasing
Fuel-Bound Nitrogen (% weight)
N
O
x

E
m
i
s
s
i
o
n
s
(
p
p
m

a
t

3
%

O
2
)
I
n
c
r
e
a
s
i
n
g
Figure E-1. Effects of Fuel-Bound Nitrogen on NOx
Emissions for Fuel Oils
Section E
E-5
03-08
Burner Modifications
Water/Steam Injection
Flue Gas Recirculation
Each method results in a different degree of NOx control. For example, when firing
natural gas, low excess air firing typically reduces NOx by 10%, flue gas
recirculation by 75%, and selective catalytic reduction by 90%.
POST COMBUSTION CONTROL METHODS
Selective Non-
catalytic Reduction
Selective non-catalytic reduction involves the injection of a NOx reducing agent,
such as ammonia or urea, into the boiler exhaust gases at a temperature of
approximately 1400-1600 F (see Figure E-2). The ammonia or urea breaks down
the NOx in the exhaust gases into water and atmospheric nitrogen. Selective non-
catalytic reduction reduces NOx up to 70%. However, the technology is extremely
difficult to apply to industrial boilers that modulate or cycle frequently. This is
because the ammonia (or urea) must be injected in the flue gases at a specific flue
gas temperature. And, in industrial boilers that modulate or cycle frequently, the
location of the exhaust gases at the specified temperature is constantly changing.
Thus, it is not feasible to apply selective non-catalytic reduction to industrial boilers
that have high turndown capabilities and modulate or cycle frequently.
Selective Catalytic
Reduction
Selective catalytic reduction involves the injection of ammonia in the boiler exhaust
gases in the presence of a catalyst (see Figure E-3). The catalyst allows the
ammonia to reduce NOx levels at lower exhaust temperatures than selective non-
catalytic reduction. Unlike selective non-catalytic reduction, where the exhaust
*
*
*
*
*
AMMONIA (NH
3
)
FLUE GAS
NO
x
NO
x
NO
x
NH
3
NH
3
NH
3
H
2
O
H
2
O
H
2
O
N
2
N
2
NO
x
CLEAN GAS
CATALYST
Figure E-3. Selective Catalytic Reduction (SCR)
*
*
*
*
*
AMMONIA (NH
3
) FLUE GAS TEMPERATURE
1400 - 1600 F
CLEAN GAS
FLUE GAS
NO
x
NO
x
NO
x
NH
3
NH
3
NH
3
H
2
O
H
2
O
H
2
O
N
2
N
2
NO
x
Figure E-2. Selective Non-Catalytic Reduction (SNCR)
Section E
E-6
03-08
gases must be approximately 1400-1600 F, selective catalytic reduction can be
utilized where exhaust gasses are between 500 F and 1200 F, depending on the
catalyst used. Selective catalytic reduction can result in NOx reductions up to 90%.
However, it is costly to use and can rarely be cost justified on boilers with inputs
less than 100 MMBtu/hr.
COMBUSTION CONTROL TECHNIQUES
Combustion control techniques reduce the amount of NOx emission by limiting the
amount of NOx

formation during the combustion process. This is typically
accomplished by lowering flame temperatures. Combustion control techniques are
more economical than post combustion methods and are frequently utilized on
industrial boilers requiring NOx controls.
Low Excess Air
(LEA) Firing
As a safety factor to assure complete combustion, boilers are fired with excess air.
One of the factors influencing NOx formation in a boiler is the excess air levels. High
excess air levels (>45%) may result in increased NOx formation because the excess
nitrogen and oxygen in the combustion air entering the flame will combine to form
thermal NOx. Low excess air firing involves limiting the amount of excess air that is
entering the combustion process in order to limit the amount of extra nitrogen and
oxygen that enters the flame. Limiting the amount of excess air entering a flame is
accomplished through burner design and can be optimized through the use of
oxygen trim controls. Low excess air firing can be used on most boilers and
generally results in overall NOx reductions of 5-10% when firing natural gas.
Low Nitrogen Fuel
Oil
When firing fuel oils, NOx

formed by fuel-bound nitrogen can account for 20-50%
of the total NOx level. One method to reduce NOx levels from boilers firing distillate
oils is through the use of low nitrogen fuel oil. Low nitrogen oils can contain up to
15-20 times less fuel-bound nitrogen than standard No. 2 oil (less than 0.001%
fuel-bound nitrogen). When low NOx

oil is fired in firetube boilers utilizing flue gas
recirculation, NOx reductions of 60%-70% over NOx emissions from standard No.
2 oils have been achieved. Low nitrogen oil is used most frequently in southern
California.
Burner
Modifications
Burner modifications for NOx control involve changing the design of a standard
burner in order to create a larger flame. Enlarging the flame results in lower flame
temperatures and lower thermal NOx formation which, in turn, results in lower
overall NOx

emissions. The technology can be applied to most boiler types and
sizes. It is most effective when firing natural gas and distillate fuel oil and has little
affect on boilers firing heavy oil. To comply with the more stringent regulations,
burner modifications must be used in conjunction with other NOx reduction
methods, such as flue gas recirculation. If burner modifications are utilized
exclusively to achieve low NOx

levels (30 ppm), adverse affects on boiler operating
parameters such as turndown, capacity, CO levels, and efficiency may result. It is
important to address all aspects of boiler performance when selecting NOx

control
technologies.
Water/Steam
Injection
Water or steam injection can be utilized to reduce NOx levels. By injecting water or
steam into the flame, flame temperatures are reduced, thereby lowering thermal
NOx formation and overall NOx levels. Water or steam injection can reduce NOx up
to 80% (when firing natural gas) and can result in lower reductions when firing oils.
There is a practical limit to the amount of water or steam that can be injected into
Section E
E-7
03-08
the flame before condensation problems are experienced. Additionally, under normal
operating conditions, water/steam injection can result in a 3-10% boiler efficiency
loss. Many times water or steam injection is used in conjunction with other NOx
control methods such as burner modifications or flue gas recirculation.
Flue Gas
Recirculation
Flue gas recirculation, or FGR, is the most effective method of reducing NOx
emission from industrial boilers with inputs below 100 MMBtu/hr. FGR entails
recirculating a portion of relatively cool exhaust gases back into the combustion
process in order to lower the flame temperature and reduce NOx formation. It is
currently the most effective and popular low NOx technology for firetube and
watertube boilers. And, in many applications, it does not require any additional
reduction equipment to comply with regulations.
Flue gas recirculation technology can be classified into two types; external or
induced.
External flue gas recirculation utilizes an external fan to recirculate the flue
gases back into the flame. External piping routes the exhaust gases from the
stack to the burner. A valve controls the recirculation rate, based on boiler input.
Induced flue gas recirculation utilizes the combustion air fan to recirculate the
flue gases back into the flame. A portion of the flue gases are routed by duct
work or internally to the combustion air fan, where they are premixed with the
combustion air and introduced into the flame through the burner. New designs
of induced FGR that utilize an integral FGR design are becoming popular among
boiler owners and operators because of their uncomplicated design and
reliability.
Theoretically, there is no limit to the amount of NOx

reduction with FGR; practically,
there is a physical, feasible limit. The limit of NOx reduction varies for different fuels
80% for natural gas and 20-25% for standard fuel oils.
The current trends with low NOx technologies are to design the boiler and low NOx
equipment as a package. Designing as a true package allows the NOx control
technology to be specifically tailored to match the boiler's furnace design features,
such as shape, volume, and heat release. By designing the low NOx technology as a
package with the boiler, the adverse effects of the low NOx technology on boiler
operating parameters (turndown, capacity, efficiency, and CO levels) can be
addressed and minimized.
CHOOSING THE BEST NOX TECHNOLOGY FOR THE JOB
What effect does NOx control technology ultimately have on a boiler's performance?
Certain NOx controls can worsen boiler performance while other controls can
appreciably improve performance. Aspects of the boiler performance that could be
affected include turndown, capacity, efficiency, excess air, and CO emissions.
Failure to take into account all of the boiler operating parameters can lead to
increased operating and maintenance costs, loss of efficiency, elevated CO levels,
and shortening of the boiler's life.
The following section discusses each of the operating parameters of a boiler and
how they are related to NOx control technologies.
Section E
E-8
03-08
Turndown Choosing a low NOx technology that sacrifices turndown can have many adverse
effects on the boiler. When selecting NOx controls, the boiler should have a
turndown capability of at least 4:1 or more, in order to reduce operating costs and
the number of on/off cycles. A boiler utilizing a standard burner with a 4:1
turndown can cycle as frequently as 12 times per hour or 288 times a day because
the boiler must begin to cycle at inputs below 25% capacity.
With each cycle, pre- and post-purge air flow removes heat from the boiler and
sends it out the stack. The energy loss can be reduced by using a high turndown
burner (10:1), which keeps the boiler on even at low firing rates.
Every time the boiler cycles off, before it comes back on, it must go through a
specific start-up sequence for safety assurance. It takes between one to two
minutes to get the boiler back on line. If there is a sudden load demand, the
response cannot be accelerated. Keeping the boiler on line assures a quick response
to load changes.
Frequent cycling also deteriorates the boiler components. The need for maintenance
increases, the chance of component failure increases, and boiler downtime
increases. So, when selecting NOx control, always consider the burners turndown
capability.
Capacity When selecting the best NOx control, capacity and turndown should be considered
together because some NOx control technologies require boiler derating in order to
achieve guaranteed NOx reductions. For example, flame shaping (primarily
enlarging the flame to produce a lower flame temperature thus lower NOx levels)
can require boiler derating, because the shaped flame could impinge on the furnace
walls at higher firing rates.
However, the boiler's capacity requirement is typically determined by the maximum
load in the steam/hot water system. Therefore, the boiler may be oversized for the
typical load conditions that may occur. If the boiler is oversized, its ability to handle
minimum loads without cycling is limited. Therefore, when selecting the most
appropriate NOx

control, capacity and turndown should be considered together for
proper boiler selection and to meet overall system load requirements.
Efficiency Some low NOx controls reduce emissions by lowering flame temperature,
particularly in boilers with inputs less than 100 MMBtu/hr. Reducing the flame
temperature decreases the radiant heat transfer from the flame and could lower
boiler efficiency. The efficiency loss due to the lower flame temperatures can be
partially offset by utilizing external components, such as an economizer. Or, the
offset technique can be inherent in the NOx

design.
One technology that offsets the efficiency loss due to lower flame temperatures in a
firetube boiler is flue gas recirculation. Although the loss of radiant heat transfer
could result in an efficiency loss, the recirculated flue gases increase the mass flow
through the boiler thus the convective heat transfer in the tube passes increases.
The increase in convective heat transfer compensates for losses in radiant heat
transfer, with no net efficiency loss. When considering NOx control technology,
remember, it is not necessary to sacrifice efficiency for NOx reductions.
Excess Air A boiler's excess air supply provides for safe operation above stoichiometric
conditions. A typical burner is usually set up with 10-20% excess air (2-4% O
2
).
NOx controls that require higher excess air levels can result in fuel being used to
heat the air rather than transferring it to usable energy. Thus, increased stack losses
and reduced boiler efficiency occur. NOx controls that require reduced excess air
Section E
E-9
03-08
levels can result in an oxygen deficient flame and increased levels of carbon
monoxide or unburned hydrocarbons. It is best to select a NOx control technology
that has little effect on excess air.
Carbon Monoxide
(CO) Emissions
High flame temperatures and intimate air/fuel mixing are essential for low CO
emissions. Some NOx control technologies used on industrial and commercial
boilers reduce NOx levels by lowering flame temperatures by modifying air/fuel
mixing patterns. The lower flame temperature and decreased mixing intensity can
result in higher CO levels.
An induced flue gas recirculation package can lower NOx levels by reducing flame
temperature without increasing CO levels. CO levels remain constant or are lowered
because the flue gas is introduced into the flame in early stages of combustion and
the air fuel mixing is intensified. Intensified mixing offsets the decrease in flame
temperature and results in CO levels that are lower than achieved without FGR. But,
the level of CO depends on the burner design. Not all flue gas recirculation
applications result in lower CO levels.
Total Performance Selecting the best low NOx control package should be made with total boiler
performance in mind. Consider the application. Investigate all of the characteristics
of the control technology and the effects of the technology on the boiler's
performance. A NOx control technology that results in the greatest NOx reduction is
not necessarily the best for the application or the best for high turndown, adequate
capacity, high efficiency, sufficient excess air, or lower CO. The newer low NOx
technologies provide NOx reductions without affecting total boiler performance.
SULFUR COMPOUNDS (SOX)
The primary reason sulfur compounds, or SOx, are classified as a pollutant is
because they react with water vapor (in the flue gas and atmosphere) to form
sulfuric acid mist. Airborne sulfuric acid has been found in fog, smog, acid rain, and
snow. Sulfuric acid has also been found in lakes, rivers, and soil. The acid is
extremely corrosive and harmful to the environment.
The combustion of fuels containing sulfur (primarily oils and coals) results in
pollutants occurring in the forms of SO
2
(sulfur dioxide) and SO
3
(sulfur trioxide),
together referred to as SOx (sulfur oxides). The level of SOx emitted depends directly
on the sulfur content of the fuel (see Figure E-5). The level of SOx emissions is not
dependent on boiler size or burner design. Typically, about 95% of the sulfur in the
fuel will be emitted as SO
2
, 1-5% as SO
3
, and 1-3% as sulfate particulate. Sulfate
particulate is not considered part of the total SOx emissions.
1200
1000
800
600
400
200
0
0 .2 .4 .6 .8 1.0 1.2 1.4 1.6 1.8 2.0
Sulfur in Fuel (% weight)
*Based on EPA AP-42 Estimates
S
O
x

E
m
i
s
s
i
o
n

L
e
v
e
l
*
(
p
p
m

a
t

3
%

O
2
)
Figure E-4. Effects of Fuel Sulfur Content on SOx Emissions for Fuel Oils
Section E
E-10
03-08
Historically, SOx pollution has been controlled by either dispersion or reduction.
Dispersion involves the utilization of a tall stack, which enables the release of
pollutants high above the ground and over any surrounding buildings, mountains, or
hills, in order to limit ground level SOx emissions. Today, dispersion alone is not
enough to meet more stringent SOx emission requirements; reduction methods
must also be employed. Methods of SOx reduction include switching to low sulfur
fuel, desulfurizing the fuel, and utilizing a flue gas desulfurization (FGD) system.
Fuel desulfurization, which primarily applies to coal, involves removing sulfur from
the fuel prior to burning. Flue gas desulfurization involves the utilization of
scrubbers to remove SOx emissions from the flue gases.
Flue gas desulfurization systems are classified as either non-regenerable or
regenerable. Non-regenerable FGD systems, the most common type, result in a
waste product that requires proper disposal. Regenerable FGD converts the waste
by-product into a marketable product, such as sulfur or sulfuric acid. SOx emission
reductions of 90-95% can be achieved through FGD. Fuel desulfurization and FGD
are primarily used for reducing SOx

emissions for large utility boilers. Generally the
technology cannot be cost justified on industrial boilers.
For users of industrial boilers, utilizing low sulfur fuels is the most cost effective
method of SOx reduction. Because SOx emissions primarily depend on the sulfur
content of the fuel, burning fuels containing a minimal amount of sulfur (distillate
oil) can achieve SOx reductions, without the need to install and maintain expensive
equipment.
CARBON MONOXIDE (CO)
Carbon monoxide is a pollutant that is readily absorbed in the body and can impair
the oxygen-carrying capacity of the hemoglobin. Impairment of the body's
hemoglobin results in less oxygen to the brain, heart, and tissues. Even short-term
over exposure to carbon monoxide can be critical, or fatal, to people with heart and
lung diseases. It may also cause headaches and dizziness in healthy people.
During combustion, carbon in the fuel oxidizes through a series of reactions to form
carbon dioxide (CO
2
). However, 100 percent conversion of carbon to CO
2
is rarely
achieved in practice and some carbon only oxidizes to the intermediate step, carbon
monoxide.
Older boilers generally have higher levels of CO than new equipment because CO
has only recently become a concern and older burners were not designed to achieve
low CO levels. In today's equipment, high levels of carbon monoxide emissions
primarily result from incomplete combustion due to poor burner design or firing
conditions (for example, an improper air-to-fuel ratio) or possibly a leaky furnace.
Through proper burner maintenance, inspections, operation, or by upgrading
equipment or utilizing an oxygen control package, the formation of carbon monoxide
can be controlled at an acceptable level.
PARTICULATE MATTER (PM)
Emissions of particulate matter (PM) from combustion sources consist of many
different types of compounds, including nitrates, sulfates, carbons, oxides, and any
uncombusted elements in the fuel. Particulate pollutants can be corrosive, toxic to
plants and animals, and harmful to humans.
Section E
E-11
03-08
Particulate matter emissions generally are classified into two categories, PM and
PM
10
. PM
10
is a particulate matter with a diameter less than 10 microns. All
particulate matter can pose a health problem. However, the greatest concern is with
PM
10
, because of its ability to bypass the body's natural filtering system.
PM emissions are primarily dependent on the grade of fuel fired in the boiler.
Generally, PM levels from natural gas are significantly lower than those of oils.
Distillate oils result in much lower particulate emissions than residual oils.
When burning heavy oils, particulate levels mainly depend on four fuel constituents:
sulfur, ash, carbon residue, and asphalenes. These constituents exist in fuel oils,
particularly residual oils, and have a major effect on particulate emissions. By
knowing the fuel constituent levels, the particulate emissions for the oil can be
estimated.
Methods of particulate control vary for different types and sizes of boilers. For utility
boilers, electrostatic precipitators, scrubbers, and baghouses are commonly utilized.
For industrial and commercial boilers, the most effective method is to utilize clean
fuels. The emission levels of par-
Methods of SOx reduction include switching to low sulfur fuel, desulfurizing the fuel,
and utilizing a flue gas desulfurization (FGD) system. Fuel desulfurization, which
primarily applies to coal, involves removing sulfur from the fuel prior to burning.
Flue gas desulfurization involves the utilization of scrubbers to remove SOx
emissions from the flue gases.
Flue gas desulfurization systems are classified as either non-regenerable or
regenerable. Non-regenerable FGD systems, the most common type, result in a
waste product that requires proper disposal. Regenerable FGD converts the waste
by-product into a marketable product, such as sulfur or sulfuric acid. SOx emission
reductions of 90-95% can be achieved through FGD. Fuel desulfurization and FGD
are primarily used for reducing SOx

emissions for large utility boilers. Generally the
technology cannot be cost justified on industrial boilers.
For users of industrial boilers, utilizing low sulfur fuels is the most cost effective
method of SOx reduction. Because SOx emissions primarily depend on the sulfur
content of the fuel, burning fuels containing a minimal amount of sulfur (distillate
oil) can achieve SOx reductions, without the need to install and maintain expensive
equipment.
CARBON MONOXIDE (CO)
Carbon monoxide is a pollutant that is readily absorbed in the body and can impair
the oxygen-carrying capacity of the hemoglobin. Impairment of the body's
hemoglobin results in less oxygen to the brain, heart, and tissues. Even short-term
over exposure to carbon monoxide can be critical, or fatal, to people with heart and
lung diseases. It may also cause headaches and dizziness in healthy people.
During combustion, carbon in the fuel oxidizes through a series of reactions to form
carbon dioxide (CO
2
). However, 100 percent conversion of carbon to CO
2
is rarely
achieved in practice and some carbon only oxidizes to the intermediate step, carbon
monoxide.
Older boilers generally have higher levels of CO than new equipment because CO
has only recently become a concern and older burners were not designed to achieve
low CO levels. In today's equipment, high levels of carbon monoxide emissions
primarily result from incomplete combustion due to poor burner design or firing
Section E
E-12
03-08
conditions (for example, an improper air-to-fuel ratio) or possibly a leaky furnace.
Through proper burner maintenance, inspections, operation, or by upgrading
equipment or utilizing an oxygen control package, the formation of carbon monoxide
can be controlled at an acceptable level.
PARTICULATE MATTER (PM)
Emissions of particulate matter (PM) from combustion sources consist of many
different types of compounds, including nitrates, sulfates, carbons, oxides, and any
uncombusted elements in the fuel. Particulate pollutants can be corrosive, toxic to
plants and animals, and harmful to humans.
Particulate matter emissions generally are classified into two categories, PM and
PM
10
. PM
10
is a particulate matter with a diameter less than 10 microns. All
particulate matter can pose a health problem. However, the greatest concern is with
PM
10
, because of its ability to bypass the body's natural filtering system.
PM emissions are primarily dependent on the grade of fuel fired in the boiler.
Generally, PM levels from natural gas are significantly lower than those of oils.
Distillate oils result in much lower particulate emissions than residual oils.
When burning heavy oils, particulate levels mainly depend on four fuel constituents:
sulfur, ash, carbon residue, and asphalenes. These constituents exist in fuel oils,
particularly residual oils, and have a major effect on particulate emissions. By
knowing the fuel constituent levels, the particulate emissions for the oil can be
estimated.
Methods of particulate control vary for different types and sizes of boilers. For utility
boilers, electrostatic precipitators, scrubbers, and baghouses are commonly
utilized. For industrial and commercial boilers, the most effective method is to
utilize clean fuels. The emission levels of particulate matter can be lowered by
switching from a residual to a distillate oil or by switching from a distillate oil to a
natural gas. Additionally, through proper burner set-up, adjustment and
maintenance, particulate emissions can be minimized, but not to the extent
accomplished by switching fuels.
VOLATILE ORGANIC COMPOUNDS (VOCS) / HYDROCARBONS (HC)
Volatile organic compounds, or VOCs, are compounds containing combinations of
carbon, hydrogen, and sometimes oxygen. VOCs vaporize easily once emitted into
the air and are of concern because of their role in ground level ozone formation. In
reference to boiler performance, they are often referred to as hydrocarbons and
generally are divided into two categories methane and non-methane.
Formation of VOCs in commercial and industrial boilers primarily result from poor or
incomplete combustion due to improper burner set-up and adjustment. To control
VOC emissions from commercial and industrial boilers, no auxiliary equipment is
needed; properly maintaining the burner/boiler package will keep VOC emissions at
a minimum. Proper maintenance includes keeping the air/fuel ratio at the
manufacturer's specified setting, having the proper air and fuel pressures at the
burner, and maintaining the atomizing air pressure on oil burners at the correct
levels. An improperly maintained boiler/burner package can result in VOC levels
over 100 times the normal levels.
Section E
E-13
03-08
CALCULATING BOILER EMISSIONS
Emission Level
Units
This section describes the different units for emission levels. Emission levels can be
provided in many different units depending on whether the measurement is volume
or mass based.
Correcting
Emissions to 3%
Oxygen (15%
Excess Air)
The following equation shows how to correct emission readings to 3% oxygen (15%
excess air). Because boilers don't always operate at 3% oxygen, it is necessary to
convert ppm values measured at various excess air levels to 3% oxygen for
comparison and regulation compliance purposes. To correct emission levels to 3%
oxygen that are referenced to excess air levels other than 3%, use the following
equation.
ppm Parts per Million Indicates emission levels on
a volume basis. Sometimes may be shown as
ppm
v
. Part per million must be referenced to
some oxygen level (excess air level) which, for
industrial boilers, is typically 3% oxygen (15%
excess air). Actual measurements recorded dur-
ing boiler testing are usually in ppm.
lb/MMBtu Pounds per Million Btu Indicates emission
levels on a mass basis. Emission levels are
shown in pounds of pollutant per million Btu input
to the boiler. This level is useful when hourly or
annual emission levels must be determined.
lb/hr Pounds per Hour Indicates emission levels
on a mass basis. This unit represents the amount
of pollutant emitted on an hourly basis.
tpy Tons per Year Indicates emission levels on a
mass basis. This unit corresponds to the annual
pollutant levels.
lb/10
6
cu-ft Pounds per Million Cubic Feet Indicates
emission levels on a mass basis. This unit is
used for gaseous fuels and indicates the emis-
sion level in pounds per million cubic feet of fuel
(gaseous fuel) input to the boiler. This is useful
when the actual gas usage of the boiler is known.
lb/10
3
gal Pounds per Thousand Gallons Indicates
emission levels on a mass basis. This unit is
used for liquid (oil) fuels and indicates the emis-
sion level in pounds per thousand gallons of oil
fired. This is useful when the actual oil usage of
the boiler is known
ppm (@3%) =
21 3
21 O
2
(actual)
x ppm (actual)
Example: What is the NOx level corrected to 3% oxygen
a measured level of 27 ppm at 7.1% oxygen? for
ppm (@3%) =
21 3
21 7.1
x 27 =35 ppm NOx
Section E
E-14
03-08
CO Emissions (ppm)
0.00
0.02
0.04
0.08
0.10
0.12
0.14
0.16
C
O

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t
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)
0.18
No. 6 Oil
No. 2 Oil
Propane
Natural
Dry Analysis
0 20 40 60 80 100 120 140 160 180 200
Conversion Equations
No. 2 Oil:
ppm = (lb/MMBtu)*1290
lb/MMBtu = (ppm)/1290
No. 6 Oil:
Natural Gas:
Propane:
Gas
Figure E-5. CO Emissions Conversion Curves, 3% Oxygen, (15% Excess Air)
Converting
Emissions Between
PPM And Lb/MMBTU
Although emission levels can be given in many different units, the most common are ppm (corrected to
3% oxygen) and lb/MMBtu. Conversion between these two types of units is very simple; however, it
does depend on the fuel type and excess air level.
The following graphs and equations show the relationships and conversions between ppm (corrected
to 3% oxygen) and lb/MMBtu. If the conversion involves a ppm level referenced to an oxygen level
other than 3%, the ppm level must be corrected to 3% oxygen (see previous section) before using the
following graphs (Figure E-5 through Figure E-8) and equations .
Section E
E-15
03-08
No. 2 and No. 6 Oil
Propane
Natural Gas
0.28
0.26
0.24
0.22
0.20
0.18
0.16
0.14
0.12
0.10
0.08
0.06
0.04
0.02
0.00
0 20 40 60 80 100 120 140 160 180 200
NO
x
Emissions (ppm)
N
O
x

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s

(
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/
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t
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)
Dry Analysis
No. 2 and No. 6 Oil:
Natural Gas:
Propane:
2.4
2.2
2.0
1.8
1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0.0
0 100 200 300 400 500 600 700 800 9001000 1100 1200
SO
x
Emissions (ppm)
S
O
x

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(
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/
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t
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)
Figure E-6. NOx Emissions Conversion Curves, 3% Oxygen, (15% Excess Air)
Dry Analysis
No. 2 and No. 6 Oil
Figure E-7. SOx Emissions Conversion Curves, 3% Oxygen, (15% Excess Air)
Section E
E-16
03-08
0.060
0.055
0.050
0.045
0.040
0.035
0.030
0.025
0.020
0.015
0.010
0.005
0.000
0 10 20 30 40 50 60 70 80 90 100
VOC Emissions (ppm)
Dry Analysis
V
O
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/
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)
No. 2 and No. 6 Oil
Natural Gas and Propane
Natural Gas and Propane
ppm = (Ib/MMBtu)*2500
Figure E-8. Volatile Organic Compound Conversion Curves, 3% Oxygen, (15% Excess Air)
Calculation Of
Annual Emissions
for Industrial Boilers
Many provisions of the 1990 Clean Air Act Amendments assess the impact of pollution sources based
on the potential annual emissions (usually expressed as tons per year, or tpy). When addressing indus-
trial boilers, the potential annual emissions of NOx are of concern and frequently must be calculated.
Following is an example of how to calculate the potential annual NOx emissions for industrial boilers.
To determine the annual NOx emissions for an industrial boiler, three items must be known:
1. The NOx emission factor for the boiler.
2. The maximum rated input for the boiler.
3. The maximum allowable hours of operation for the boiler.
Once the information above is obtained, the following equation can be used to determine annual emis-
sions.
Emission Factor x Boiler Input x Annual Hours of Operation = Total Annual Emissions
For example, the calculation of the total annual NOx emissions for an 800 hp boiler operating 24
hours/day, 365 days/year and having a NOx level of 110 ppm would be as follows.
Emission Factor = 0.13 lb/MMBtu (110 ppm = 0.13 lb/MMBtu)
Boiler Input = 33.5 MMBtu/hr (Based on 80% Efficiency)
Annual Hours of Operation = 8760 hours/year (24 hours/day x 365 days/year)
Substituting this data into the previous equation yields the annual NOx

emissions for this specific
boiler, which is 19.1 tpy.
0.13 lb NOx
x x x
33.5 MMBtu 8760 hrs 1 ton
19.1 tpy NOx
MMBtu hr year 2000 lb
=
Section E
E-17
03-08
The following graphs (Figure E-9 through Figure E-13) indicate the annual NOx emissions for boiler
sizes 250-800 horsepower firing natural gas at maximum input operating 24 hours/day, 365 days/
year. They are for NOx emission levels of 110, 60, 30, 25, and 20 ppm.
800 HP
700 HP
600 HP
500 HP
400 HP
350 HP
300 HP
250 HP
20
15
10
5
0
1000 2000 3000 4000 5000 6000 7000 8000 9000
Annual Hours of Operation
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(
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)
Efficiency = 80%
800 HP
700 HP
600 HP
500 HP
400 HP
350 HP
300 HP
250 HP
4
3
2
1
0
1000 2000 3000 4000 5000 6000 7000 8000 9000
Efficiency = 80%
A
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(
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)
Figure E-9. Annual NOx Emissions for 250-800 Horsepower Boilers, NOx = 110
ppm (Corrected to 3% O
2
)
(Corrected to 3% O
2
)
800 HP
700 HP
600 HP
500 HP
400 HP
350 HP
300 HP
250 HP
5
4
3
2
1
0
1000 2000 3000 4000 5000 6000 7000 8000 9000
Efficiency = 80%
A
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(
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y
)
Figure E-11. Annual NOx Emissions for 250-800 Horsepower Boilers, NOx = 25 ppm (Corrected to 3% O
2
)
The following graphs (Figure E-9 through Figure E-13) indicate the annual NOx emissions for boiler
sizes 250-800 horsepower firing natural gas at maximum input operating 24 hours/day, 365 days/
year. They are for NOx emission levels of 110, 60, 30, 25, and 20 ppm.
Section E
E-18
03-08
NEW SOURCE PERFORMANCE STANDARDS
The Federal EPA has established nationally uniform source-specific regulations
through the New Source Performance Standards, or NSPS, for which all applicable
sources must comply. The standards, which set minimal requirements for individual
sources, address approximately 65 categories of new or modified stationary sources,
including industrial boilers.
The NSPS for industrial boilers regulate levels for NOx, SOx, and particulate matter.
The regulated pollutants and requirements vary for different fuels and boiler sizes.
There are currently three categories for the NSPS:
Boilers with inputs greater than 250 MMBtu/hr
Boilers with inputs between 100-250 MMBtu/hr
Boilers with inputs between 10-100 MMBtu/hr
The Small Boiler NSPS apply to all new, modified, or reconstructed boilers with
inputs between 10-100 MMBtu/hr where construction, modification, or
800 HP
700 HP
600 HP
500 HP
400 HP
350 HP
300 HP
250 HP
5
4
3
2
1
0
1000 2000 3000 4000 5000 6000 7000 8000 9000
Efficiency = 80%
A
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N
O
x

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(
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)
800 HP
700 HP
600 HP
500 HP
400 HP
350 HP
300 HP
250 HP
12
10
8
6
4
2
0
1000 2000 3000 4000 5000 6000 7000 8000 9000
Efficiency = 80%
A
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(
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)
(Corrected to 3% O
2
)
(Corrected to 3% O
2
)
Section E
E-19
03-08
reconstruction commenced after June 9, 1989. The Small Boiler NSPS set emission
standards for SOx and particulate matter for boilers firing coal, distillate and residual
oil, and wood. The Small Boiler NSPS also dictate record keeping requirements
regarding fuel usage for all fuels, including natural gas. Record keeping
requirements and compliance standards for the different emissions depends on the
type of fuel fired and on the boiler size. For a summary of the Small Boiler NSPS,
see Figure E-14.
Be sure your boiler complies with the New Source Performance Standards as non-
compliance may result in fines and/or forced boiler shutdown.
Contact your local Cleaver-Brooks authorized representative if you have questions
regarding the New Source Performance Standards.
Section E
E-20
03-08
New Source Performance Standards for Boilers 10100 MMBtu/hr
Built or Modified After 6/9/1989
RULES FOR SULFUR DIOXIDE (SO
2
) EMISSIONS
1. Coal Firing
1.2 lb SO
2
/MMBtu Limit all 10-100 MMBtu.
90% SO
2
reduction required if >75 MMBtu and >55% annual coal capacity.
Initial performance testing required within 180 days of start-up.
30 day rolling average used in calculations.
Continuous Emission Monitoring System (CEMS) required except:
Fuel analysis may be used (before cleanup equipment).
Units <30 MMBtu may use supplier certificate for compliance.
2. Residual Oil Firing
Limit of 0.5 lb SO
2
/MMBtu or 0.5% sulfur in fuel.
CEMS required to meet SO
2
limit except fuel analysis can be used as fired condition before cleanup equipment.
Fuel sulfur limit compliance can be:
Daily as fired fuel analysis.
As delivered (before used) fuel analysis.
Fuel supplier certificate for units <30 MMBtu.
Initial performance testing and 30 day rolling average required except for supplier certificate.
3. Distillate Oil Firing (ASTM grades 1 and 2)
Limit 0.5% sulfur in fuel (required in ASTM standard).
Compliance by fuel supplier certificate.
No monitoring or initial testing required.
RULES FOR PARTICULATE MATTER (PM) EMISSIONS
1. General
Limits established only for units between 30-100 MMBtu.
All coal, wood and residual oil fired units >30 MMBtu must meet opacity limit of 20%, except one 6 minute/hour opacity of 27%. CEMS
required to monitor opacity.
2. Coal Firing
0.05 lb/MMBtu limit if >30 MMBtu and >90% annual coal capacity.
0.10 lb/MMBtu limit if >30 MMBtu and <90% annual coal capacity.
20% opacity (CEMS) and initial performance tests on both PM limit and opacity.
3. Wood Firing
0.10 lb/MMBtu limit if >30 MMBtu and >30% annual wood capacity.
0.30 lb/MMBtu limit if >30 MMBtu and <30% annual wood capacity.
Opacity limits and initial testing per above.
4. Oil Firing
All units >30 MMBtu subject to opacity limit, only residual oil firing must use CEMS.
Initial performance testing required.
REPORTING REQUIREMENTS
Owners or operators of all affected units must submit information to the administrator, even if they are not subject to any emis-
sion limits or testing. Required reports include:
Information on unit size, fuels, start-up dates and other equipment information.
Initial performance test results, CEMS performance evaluation.
Quarterly reports on SO
2
and/or PM emission results, including variations from limits and corrective action taken.
For fuel supplies certificate, information on supplies and details of sampling and testing for coal and residual oil.
Records must be maintained for two years.
Figure E-14. Summary of Federal EPA Rules
A-1
03-08
CRITERION BOILERS MODEL 4WG (Wet-Back) 100-800 HP
Low NOx (LE)
PROMETHEAN BOILERS MODEL 4WI (Wet-Back) 100-800 HP
Low NOx (LE) and Ultra Low NOx (NT)
MODEL CBL (Wet-Back) 900-1800 HP
Low NOx (LE)
CRITERION BOILERS MODEL ICB (Intercooled Back) 100-800 HP
Low NOx (LE) Available
MODEL CEW OHIO SPECIAL (Wet-Back) 100-225 HP
MODEL CB OHIO SPECIAL (Dry-Back) 100-225 HP
MODEL CBE (Dry-Back) 60-80 HP
MODEL CB (Dry-Back) 15-100 HP
PROMETHEAN BOILERS MODEL CB-LE (Dry-Back) 125-800 HP
Low NOx (LE) and Ultra Low NOx (NT)
A1
A2
A3
A4
A5
A6
A7
A8
A9
Section A - Firetube boilers
MODEL CBR (Dry-Back) 125-800 HP
A10
BBA0_03-06
GENERAL INFORMATION pages A2-A10
A11
OPTIMIZED BOILER PACKAGE
Firetube Boilers
A-2
03-08
The Cleaver-Brooks line of firetube boilers include the following features and bene-
fits:
Packaged Design with
Integral Front Head:
Integral front head provides proper burner/boiler compatibility for maximum
efficiency 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 operational requirements.
Built and tested to ASME standards.
Fully UL cUL approved package.
Single Point
Positioning
Combustion Control
Package:
Accurate, repeatable combustion control for responsiveness to load swings.
Single point linkage assembly for air and fuel simplifies adjustments and reduces
start-up and maintenance costs.
Unique variable contour.cam assembly allows accurate adjustment and enhances
safe operation of the boiler.
Micro-Processor based burner control provides accurate sequencing and
continuous monitoring for optimum safety, efficiency, and reliability.
Low Stack
Temperatures:
Guaranteed efficiency (Promethean) at 25, 50, 75 and 100% firing rate.
Reduced fuel and operating costs.
Low Excess Air: Operates at 3% O
2
with less than 200 ppm CO for maximum combustion
efficiency.
High efficiency and low maintenance requirements.
High Steam Quality: Large steam space and liberal surface area ensure high steam quality, free from
entrained particles of moisture (98.5% dry).
Quiet Operation: Integral front head with vibration free combustion air fan provides quiet operation.
Ideal for sound critical applications, like hospitals and schools.
Heavy duty motor with direct drive, maintenance free, case-less fan.
Integral forced draft fan diminishes 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 efficiency
and durable construction.
All units finished with hard enamel paint coating.
Firetube Boilers
A-3
03-08
Customer Service and
Support:
Boiler start-up, final adjustment, and operator training provided with all firetube
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.
Total after-sale support.
PRODUCT OFFERING
The firetube product offering is available in the following models.
The Promethean Boiler Model CB-LE 125-800 HP is also a firetube
product offering with the integral burner and low NOx emission.
125-800 hp.
150-300 psig high pressure steam.
30 or 125 psig hot water.
Gas - NOx reductions options 60, 30 ppm (LE), 15-<9 ppm (NT) and
70 ppm NOx with No. 2 oil and 0.015% fuel bound nitrogen.
The Promethean Boiler Model 4WI 100-800 HP (standard offering)
is a firetube product with integral burner providing maximum boiler effi-
ciency, a wide range of size, pressures and premium control packages.
Four-pass Wet-Back design.
Gas - NOx reductions options 60-30 ppm (LE), 15-<9 ppm (NT) and
Firetube Boilers
A-4
03-08
The Criterion Boiler Model 4WG 100-800 (standard offering) pro-
vides the advantages of the Cleaver-Brooks four-pass wetback design with a
gun burner.
four-pass wetback design.
Natural gas, light oil.
Gas - NOx reductions options 60, 30 ppm (LE), 15-<9 ppm (NT) and
The Criterion Model ICB Boiler 100-800 is a firetube product,
designed to provide high quality steam or hot water. Its revolutionary design
incorporates the key features and benefits of both the Wet-Back and Dry-
Back firetube boilers.
Three or four-pass Intercooled design.
100 800 hp.
150 300 psig high pressure steam.
Gas - NOx reductions options 60, 30 ppm (LE) and 70 ppm NOx with
No. 2 oil and 0.015% fuel bound nitrogen.
The CB Model CBL 800-1500 HP Boiler (standard offering) line pro-
vides high quality steam utilizing a boiler/burner package (consult factory for
applications over 1500 HP).
Three or four-pass wetback design.
900-1800 hp.
Gas - Low NOx 30 ppm (LE).
Firetube Boilers
A-5
03-08
The Model CB Boiler is the original firetube product offering providing
excellent boiler efficiency, covering the smaller size range.
The Model CBE Boiler (standard offering) provides high quality steam or
hot water, utilizing a baseline boiler/burner design.
Three-pass dryback design.
60-80 hp.
Natural gas or light oil.
The Model CB Ohio Special Boiler (standard offering) design is based
on operator requirements for the state of Ohio, under the rules and regula-
tions for unattended units.
Four-pass dryback design (100 hp).
Two-pass dryback design (125-225 hp).
150, 200 and 250 psig high pressure steam.
The Model CEW Ohio Special Boiler (standard offering) baseline design
is based on operator requirements for the state of Ohio, under the rules and
regulations of unattended units.
Three-pass wetback design.
100-225 hp.
Firetube Boilers
A-6
03-08
Natural gas or light oil.
The Model CBR Ohio Special Boiler
125-800hp.
Steam and hot water.
Same available pressures as equivalent Model CB/CBLE/CBW/4WI.
Capable of firing natural gas, #2-#6 oil, bio-gas, digester gas or town
gas.
Low NOx capabilitiesnatural gas only.
Containerization from 125-800hp will reduce delivered to jobsite
price for large boilers that would otherwise be shipped on flatracks.
Enhanced heat transfer through the use of rifled tubes enables
Cleaver-Brooks to reduce the number of tubes, thus reducing the
overall weight and shell diameters while maintaining high fuel-to steam
efficiency.
MODEL NUMBER, FUEL SERIES NUMBER, HORSEPOWER, AND DESIGN PRESSURE
The model designation for Cleaver-Brooks firetube 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 CB700-100-150ST would represent a model CB boiler, natu-
ral gas fired, 100 hp, 150 psig steam design pressure.
All Cleaver-Brooks firetube boilers are built in accordance with ASME Codes and,
with the exception of the Ohio Special Boilers and CBL Boilers, UL/cUL standards.
Insurance requirements (e.g., Industrial Risk Insurance IRI, Factory Mutual FM,
etc.) or special local code requirements may dictate additional controls or equip-
ment to be included. Please contact your local Cleaver-Brooks authorized represen-
tative for assistance in completing your specification or for additional information
and optional equipment.
Firetube Boilers
A-7
03-08
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03-08
F-1
03-08
Section F
STACKS
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4
Selection Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4
Special Stack Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7
Safety Specifications and Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7
Use of Noncombustible Enclosure or Chase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7
Clearance to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8
Connecting to the Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8
Expansion and Installation Concerns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8
Clearances For Noncombustible Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-15
Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-15
Stack Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-17
Typical Stack Arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-17
SAMPLE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-21
Section F
F-2
03-08
ILLUSTRATIONS
Figure F-1. System Extension Above Boiler Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8
Figure F-2. Thermal Expansion Between Two Fixed Points in Stack System . . . . . . . . . . . . . . . . . F-9
Figure F-3. Graphs for Calculating Thermal Expansion Movement . . . . . . . . . . . . . . . . . . . . . . . . F-10
Figure F-4. Maximum Unsupported Distance Between Elbows, Tees, orWyes . . . . . . . . . . . . . . . . F-10
Figure F-5. Maximum Support and Guide Assembly Spacing for Vertical, Horizontal, and
Sloping Stack Runs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-11
Figure F-6. Cable Guying Specifications for Roof Level Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . F-11
Figure F-7. Roof Framing and Curb Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-14
Figure F-8. Cable Guying Installation Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-14
Figure F-9. Model CBS-II Double Wall Stack Construction and Joint Details . . . . . . . . . . . . . . . . . F-16
Figure F-10. Model ICBS Fiber-Insulated Stack Construction and Joint Details . . . . . . . . . . . . . . . F-16
TABLES
Table F-1. Stack Product Offering and Application Information . . . . . . . . . . . . . . . . . . . . . . . . . . F-5
Table F-2. System Component Names and Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6
Table F-3. Maximum Stack Height Supported Per Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . F-12
Table F-4. Roof Opening Size for Penetration of Roof Support Assemblies . . . . . . . . . . . . . . . . . . F-15
Table F-5. Stack System Clearances to Combustible Materials . . . . . . . . . . . . . . . . . . . . . . . . . . F-18
Table F-6. Weight of Straight Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-19
This section contains information on the complete line of stacks. This line includes stack components in single,
double, and triple wall construction for discharging combustion gases and fumes from boilers, heaters, ovens
and other sources generating exhaust vapors at temperatures up to 1400 F.
Section F
F-3
03-08
Custom Built to Customer Specifications Using CAD Technology:
Assures proper system sizing and design.
Provides complete system drawing.
Provides bill of material based on prefabricated CB-Stack components.
System Designed to Use Standard Components:
Reduces on-site construction costs.
Additions and modifications can be made easily and economically.
All components are completely compatible.
10 Year Factory Warranty:
Guaranteed to last.
Longest warranty in the business.
Backed by Cleaver-Brooks.
Quick-Ship 10 Day Factory Delivery:
Provides the customer "What they want - when they want it".
Reduces downtime.
Efficient job construction scheduling.
Lowest Clearance to Combustibles:
Reduces needed clearances to combustibles and non- combustibles.
Increases usable floor space.
Saves on construction costs.
Shipped on Pallets and Shrink-Wrapped:
Simplified on-site handling.
Protects materials until installation.
Reduces freight damage.
No Welding or On-Site Fabrication Required:
Saves time and labor costs.
Components are light and easily assembled by one or two people.
No special equipment or supervision required.
Stack Sections and Fittings are Continuous Welded:
Prevents leakage from vented gases.
Meets stringent UL and ULC requirements.
Patented Spacer Design:
Section F
F-4
03-08
Assures consistent product alignment and support.
Built to perform under the most demanding conditions.
Built With Captive Nuts and Bolts:
Allows easy installation without the risk of losing hardware.
Saves on installation time and cost.
PRODUCT OFFERING
Cleaver-Brooks manufactures a complete line of fully compatible stack components
as follows:
Ameri-Vent type "B": gas vent.
Model CBS-I: single wall stainless steel.
Model CBS-II: double wall air insulated.
Model ICBS: double wall - 1", 2", and 4" material insulated.
See Table F-1 for the product that best fits your specific application.
Selection
Considerations
The information in this section applies to product selection which is governed by
four major considerations:
Type of heating equipment.
Fuels to be burned and vapor or gases to be removed.
Exhaust operating temperatures of the equipment.
Building use and type of construction materials used.
All CBS/ICBS chimney components will be custom fabricated for your
installation.
Cleaver-Brooks application engineers design and size stack systems based on data
provided by the engineer or contractor. These data include information such as job-
site elevation, equipment and fuel type, equipment input (Btu/hr), flue gas
temperature, as well as site dimensions and the need for offset, drains, fittings, roof
penetration, etc.
These data are used to generate a detailed installation drawing and component
parts list. Prior to fabricating the parts at our plant, the installation drawing and
parts list are returned to the engineer or contractor for verification. It is the
engineers or contractors sole responsibility to field verify all dimensions,
components, and layouts on the installation drawing. This verification must include
an authorized signature and date before the order will be fabricated and shipped.
Special Stack
Applications
Cleaver-Brooks can help in the design, layout and manufacture of the following
special stack applications:
Grease duct venting systems.
Engine/turbine venting systems.
Solid fuel venting systems.
Special stack applications may require unique design and product modifications.
Contact your local Cleaver-Brooks authorized representative for assistance.
Standard Components, Table F-2, lists the names and part numbers for the various
components of all Cleaver-Brooks model lines. Each model line has its own letter
designation. N is used to identify CBS-I single wall components. Double wall CBS-II
Section F
F-5
03-08
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Section F
F-6
03-08
PART NAME
DESCRIPTION
PART NUMBERS
MODEL NO. CBS-I CBS-II ICBS-1" ICBS-2" ICBS-4"
Straight pipe section
A
N18 S18 A18 B18 D18
N30 S30 A30 B30 D30
N42 S42 A42 B42 D42
90 tee NT90 ST90 AT90 BT90 DT90
45 tee NT45 ST45 AT45 BT45 DT45
Wye NY SY AY BY DY
Drain wye NDY SDY ADY BDY DDY
15 elbow NEB15 SEB15 AEB15 BEB15 DEB15
Expansion joint NEJ SEJ AEJ BEJ DEJ
Bellows joint NBJ SBJ ABJ BBJ DBJ
Fixed adjustable length NFAL SFAL AFAL BFAL DFAL
Nozzle section NNS SNS ANS BNS DNS
Drain section NDS SDS ADS BDS DDS
Horizontal drain NHD SHD AHD BHD DHD
Stack base drain NSBD SSBD ASBD BSBD DSBD
Drain plug NDP SDP ADP BDP DDP
Inspection plug NIP SIP AIP BIP DIP
Slip joint NSJ SSJ ASJ BSJ DSJ
Stepped increaser NSIR SSIR ASIR BSIR DSIR
Wall penetration assembly NWPA SWPA AWPA BWPA DWPA
Roof support assembly - SRSA ARSA BRSA DRSA
Penetration assembly - SPA APA BPA DPA
Storm collar NSC SSC ASC BSC DSC
Tall cone flashing NTCF STCF ATCF BTCF DTCF
Stack closure ring NSCR SSCR ASCR BSCR DSCR
Stack termination cap NSTC SSTC ASTC BSTC DSTC
Open termination NOT SOT AOT BOT DOT
Stack exit cone NSEC SSEC ASEC BSEC DSEC
Containment band CB1 CB1 CB1 CB1 CB1
Closure bands - CB2 ACB2 BCB2 DCB2
Half closure bands - HCB2 AHCB2 BHCB2 DHCB2
Boiler adapters NBA SBA ABA BBA DBA
Generator adapters NGA SGA AGA BGA DGA
Stack support assembly NSSA SSSA ASSA BSSA DSSA
Split clamp flange NSCF SSCF ASCF BSCF DSCF
Half split angle ring NHSAF SHSAR AHSAR BHSAR DHSAR
Split angle ring NSAR SSAR ASAR BSAR DSAR
Hanger bracket NHB SHB AHB BHB DHB
Floor alignment guide NFAG SFAG AFAG BFAG DFAG
Wall guide assembly NWGA SWGA AWGA BWGA DWGA
Transition band - STB ATB BTB DTB
Wall support assembly NWSA SWSA AWSA BWSA DWSA
Fiber insulation strips - - INS-3 INS-3 INS-3
A. Straight pipe sections are custom fabricated to required lengths but are priced at 18, 30, and 42 in. lengths. For example, a 24 in. straight
pipe section will be billed at the 30 in. section price.
Table F-2. System Component Names and Part Numbers
Section F
F-7
03-08
uses the letter S.. Fiber-Insulated components use the letter A for 1" insulated, B for
2" insulated, and D for 4" insulated.
Every part shipped for your order has a label listing the component part number.
The first two digits identify the stack inner diameter. For example, a part labeled
16SEJ11 is a 16" ID, double wall, expansion joint. The last two digits of the part
number are for manufacturing control.
A part labeled 24BT9011 is a 24" ID, 90 tee that is fiber insulated with 2" of
insulation between its inner and outer walls.
ENGINEERING DATA
Information in this section outlines typical installation requirements when installing
a stack or breeching to a Cleaver- Brooks boiler. Actual installation and
arrangements will be dictated by design, state, provincial or local codes, job-site
conditions and number of boilers installed.
This information, in addition to information listed in Table F-1, will assist you in
determining equipment required.
For special applications or additional information contact your local Cleaver-Brooks
Application Cleaver-Brooks CBS/ICBS stack systems comply with the requirements of the
approval bodies listed in Table F-1. These stack systems are not for installation in
one and two family dwellings.
These stack systems must be installed as complete systems that originate at the
boiler and terminate outdoors.
Installing or using CBS or ICBS stack systems, or parts of systems, in ways other
than those specified can be hazardous.
Always contact local building and/or fire officials concerning application restrictions
and installation inspection procedures. Obtain all required building permits.
Safety
Specifications and
Clearances
All CBS/ICBS stack systems should be sized in accordance with the instructions
provided by the manufacturer and pertinent job-site data.
The stack system must never be jacketed, wrapped, or enclosed in combustible
materials. Never place insulation in required clearance spaces or ventilation
openings.
Use of
Noncombustible
Enclosure or Chase
The following information on noncombustible chase and clearance to combustibles
pertains to all applications, except grease duct systems:
When the stack extends through any story above the one in which the boiler is
located, including drop ceilings and crawl spaces, it must be enclosed in a
continuous enclosure made of noncombustible materials. This enclosure or
chase should extend from the first ceiling above the boiler to, or through, the
roof of the building. Refer to Figure F-1. It must maintain the integrity of the fire
separations required for the construction and occupancy classification of the
building.
When the stack is installed in a noncombustible enclosure, this enclosure
becomes an extension of the boiler room to the outside of the building. It must
be designed and sized to allow boiler room air to mix with outside air. This
means there must be sufficient clearance between the walls of the enclosure
and the stack, its supports, and its guides.
Section F
F-8
03-08
Clearance to
Combustibles
Care must be taken when using combustible material around the stack. Refer to
"Clearances for Non-Combustible Enclosures" in this section for recommended
clearances.
Connecting to the
Boiler
CBS/ICBS stack systems, in most applications, can be connected directly to, and
supported by the boiler. Refer to Table F-6 for typical stack weights. For special
applications contact your local Cleaver-Brooks authorized representative.
Expansion and
Installation
Concerns
When stack systems are exposed to the heating and cooling of normal operation,
the components will expand and contract. The systems are designed to adjust to
this movement, provided the amount and direction of expansion is accurately
calculated, and the system is correctly installed.
The amount of thermal expansion that will occur depends on the length of
breeching, height of the stack, temperature of the flue gas, and arrangement of the
system. Therefore, the following must be considered.
Thermal Expansion
The CBS/ICBS systems use two different parts to compensate for thermal expansion
between two fixed points in the system. They are: expansion joints and bellows
joints.
Each type of joint is:
Designed to compensate for linear expansion only.
Never used to correct for misalignment between components.
Not load bearing. Therefore, these systems are usually between support or
guide assemblies.
Expansion Direction
To determine expansion direction, it is necessary to understand how the expansion
or bellows joint works. The expansion or bellows joint itself does not expand. In
fact, the opposite happens. It compresses to absorb the movement of the parts
expanding around it. This expansion movement occurs from fixed points in the
system toward the expansion or bellows joint. Refer to Figure F-3
Figure F-1. System Extension Above Boiler Room
Section F
F-9
03-08
Calculating Expansion
The amount of thermal expansion that will occur is calculated by the following
equation:
Expansion = 1" per 100 of stack per 100 F above ambient temperature.
Expansion is calculated between fixed points in the system. If more than 1/4" of
expansion will occur between fixed points, an expansion or bellows joint must be
installed within that run of stack.
Thermal expansion can also be determined using the graphs shown in Figure F-3.
Support Assemblies
CBS/ICBS support assemblies are load bearing items. They are designed to carry the
weight of the system and withstand expansion forces.
Support assemblies are connected to the inner wall flange of the stack. They must
always be bolted or otherwise tied into rigid structural building supports. They must
never be suspended from lightweight rods or tubing.
Three different types of support assemblies are used:
Stack support assembly (SSA).
Wall support assembly (WSA).
Roof support assembly (RSA).
Figure F-2. Thermal Expansion Between Two Fixed Points in Stack System
Section F
F-10
03-08
Figure F-3. Graphs for Calculating Thermal Expansion Movement
Figure F-4. Maximum Unsupported Distance
Between Elbows, Tees, orWyes
Section F
F-11
03-08
Figure F-5. Maximum Support and Guide Assembly
Spacing for Vertical, Horizontal, and Sloping Stack Runs
Refer to Figure F-3 for the maximum stack height supported per assembly.
Support assemblies must also be located within 6 of elbows, tees, or wyes. It may
be necessary to reduce this spacing if anticipated expansion is greater than 1/4"
between fixed points.
Refer to Figure F-4 for the maximum unsupported distance between elbows, tees, or
wyes.
Refer to Figure F-5 for the maximum support and guide assembly spacing for
vertical, horizontal and sloping stack runs.
Guide Assemblies
Guide assemblies are designed to provide lateral support and guidance for the stack
system. They must be rigidly mounted to the building and plumb with the stack.
Guide assemblies are not tied into, or attached to, the stack in any way, but they do
bear part of the overall load in horizontal and sloped runs.
Three types of guide assemblies are used:
Figure F-6. Cable Guying Specifications for Roof Level Guide
Section F
F-12
03-08
Table F-3. Maximum Stack Height Supported Per Assembly
MODEL ID (INCHES) SSA (FT)
WSA
RSA (FT)
CBS-I 6-48 210
78
A
CBS-II 6-16 210 78
18 203 77
20 192 75
22 189 73
24 178 70
26 175 68
28 169 65
30 162 63
32 155 61
34 148 58
36 142 56
42 121 49
48 100 42
ICBS-1
6-10 210 78
12 188 70
14 163 61
16 144 53
18 134 51
20 128 49
22 123 48
24 120 47
26 105 41
28 104 41
30 104 40
32-34 103 40
36 101 40
42 87 35
48 77 30
ICBS-2
6 210 78
8 198 73
10 165 61
12 141 52
14 123 45
16 109 40
18 103 39
20 98 38
22 95 37
24 93 36
26-28 83 33
30-32 82 32
34 81 32
36 81 31
42 70 28
48 61 24
ICBS-4
6 143 53
8 119 44
10 102 37
12 89 33
14 79 29
16 71 26
18 67 25
20 65 25
22 63 24
24 62 24
26-34 57 22
36 56 22
42 49 20
48 43 17
NOTE:
1. A. Single wall VSI-I piping prohibits the use of penetration as-
semblies. A transition to double wall VSI-II pipe will be required
where the piping passes through a penetration assembly.
2. Numbers in table are in inches.
3. SSA =Stack Support Assembly.
4. WSA =Wall Support Assembly.
5. RSA =Roof SUpport Assembly.
Section F
F-13
03-08
Split angle rings.
Wall guide assemblies.
Floor alignment guides.
The maximum spacing between any two guide assemblies, or between a support
assembly and a guide assembly, is 15 for vertical runs and 12 for horizontal or
sloping runs. Refer to Figure F-5.
The maximum height a vertical stack can extend above its uppermost guide or guy
cable location is 9. Refer to Figure F-6.
Load Bearing
When designing or installing a CBS/ICBS stack, remember the inner stack wall is
the load bearing member. All stack supports must be connected to the inner wall
flanges.
Outer or center walls (three wall stack) are not designed to bear loads. They act as
jackets only. Never connect system supports or pierce these walls.
Roof Penetrations
Proper selection and use of various components at the location the system
penetrates the roof, are based on a number of factors, including roof material
(combustible/noncombustible), the use of noncombustible enclosures or chases,
and the general layout of the system.
When a stack system passes through a roof made of combustible materials, a
penetration or roof assembly that consists of a ventilated storm collar must be used.
These assemblies are specifically designed to provide the proper clearances and
ventilation openings. These assemblies must be installed without modifications and
all ventilation openings must remain open and unobstructed.
When the stack system passes through floors or zones above the boiler room, it
must be installed in a noncombustible enclosure or chase. The enclosure must
extend to, or above, the roof deck and a penetration or roof assembly must be used
regardless of the roof material.
A third roof penetration uses tall cone flashing along with a storm collar. This
method may only be used if:
The roof deck and framing materials are noncombustible.
The stack does not pass through floors, drop ceiling or other occupance zones
on its way to the roof.
The area above the boiler, to the roof level, is basically open, providing adequate
air movement around the system.
Roof Opening Size, Framing and Curbing
Opening size varies according to stack OD. In most cases the opening will be square
and cut so it is basically flush with the framing members. If the roof is made of
noncombustible materials, the roof opening may be round.
The opening must be level and provide attachment points for external brackets. The
opening should be boxed in with structural steel or wood framing on all four sides.
The framing must be capable of supporting the load, or the penetration assembly,
when the stack is exposed to wind loading and thermal expansion forces.
Section F
F-14
03-08
Figure F-7. Roof Framing and Curb Details
Figure F-1. Cable Guying Installation Details
On sloping roofs, a level curb must be constructed and tied into the openings
framing so that the stack maintains its true vertical positions.
Both framing and curbing can be constructed of combustible materials if proper
clearances are maintained.
Table F-4 list roof openings for all models in width of square, or diameter of circle.
Figure F-7 shows roof framing and curbing details for flat or sloping roofs.
Cable Guying Above the Roof - Guy cables are an acceptable method of providing
lateral support to stack sections that extend above the roof level. A stack should not
use cable guying at locations higher than 15 above a roof, pier or superstructure
may be used for this type of application. The stack may also extend 9 above guy
cable connections. Refer to Figure F-7 andFigure F-8.
Above the Roof Guiding
Stacks extending more than 24 above a roof, pier or wall should use a guide
assembly rigidly mounted to a superstructure, tower, or wall. The structure must be
capable of supporting lateral wind load and maintain plumb alignment between the
guide assemblies and the stack.
Figure F-8. Cable Guying Installation Details
Section F
F-15
03-08
Clearances For
Noncombustible
Enclosures
Although consistent clearances are not critical, a minimum open area equivalent to
a 1-1/2" clearance between the enclosure, its supports and guides, must exist at
any plane within the enclosure. Refer to Figure F-1.
Clearances to
Combustibles
When installed within the same room or zone as the boiler, the stack must have a
minimum air space clearance to combustible construction, including building
insulation and electrical wiring as listed in Table F-5.
These minimum clearances must never be altered in any way. Lower than listed flue
gas temperatures do not alter the clearances listed. For example, if the maximum
flue gas temperature in a model CBS-II system will be 500 F, the full clearance for
that diameter listed for 1000 F stack system must be used.
When smaller clearances are desired, specify model ICBS fiber insulated stacks.
To assist with selection, the following figures will provide basic construction details
of the different types of stacks:
Figure F-9 shows model CBS-II double wall stacks.
Figure F-10 shows model ICBS fiber insulated stacks.
Each model includes:
Spacer bands that hold the sections together and maintain the proper air space
between the walls.
One air space is designed into model CBS-II.
Model ICBS are available with 1", 2", or 4" of fiber insulation between the walls.
For information on single wall or type "B" gas vent stacks, contact your local
Stack Weight Table F-6 lists weights of all models in pounds per linear foot. These weights
STACK ID
(INCHES)
WIDTH OF SQUARE OR DIAMETER OF CIRCLE
CBS-II ICBS-1" ICBS-2" ICBS-4"
6 17-1/2 17-1/2 19-1/2 23-1/2
8 19-1/2 19-1/2 21-1/2 25-1/2
10 21-1/2 21-1/2 23-1/2 27-1/2
12 23-1/2 23-1/2 25-1/2 29-1/2
14 25-1/2 25-1/2 27-1/2 31-1/2
16 27-1/2 27-1/2 29-1/2 33-1/2
18 29-1/2 29-1/2 31-1/2 35-1/2
20 31-1/2 31-1/2 33-1/2 37-1/2
22 33-1/2 33-1/2 35-1/2 39-1/2
24 35-1/2 35-1/2 37-1/2 41-1/2
26 37-1/2 37-1/2 39-1/2 43-1/2
28 39-1/2 39-1/2 41-1/2 45-1/2
30 41-1/2 41-1/2 43-1/2 47-1/2
32 43-1/2 43-1/2 45-1/2 49-1/2
34 45-1/2 45-1/2 47-1/2 51-1/2
36 47-1/2 47-1/2 49-1/2 53-1/2
42 53-1/2 53-1/2 55-1/2 59-1/2
48 59-1/2 59-1/2 61-1/2 65-1/2
Table F-4. Roof Opening Size for Penetration of Roof Support Assemblies
Section F
F-16
03-08
Figure F-9. Model CBS-II Double Wall Stack
Construction and J oint Details
Figure F-10. Model ICBS Fiber-Insulated Stack Construction
and J oint Details
Section F
F-17
03-08
include the stack sections and connecting hardware.
Typical Stack
Arrangements
The purpose of a stack and breeching on a boiler is to conduct the products of
combustion to a point of safe discharge (atmosphere).
The forced draft design of Cleaver-Brooks burner and boiler combinations,
eliminates the need for a stack designed to create a draft. A static pressure of 1/
2" WC at the boiler flue gas outlet will have no appreciable effect on burner
operation. Refer to the individual product sections for allowable pressure variations.
If the stack height is over 150 or if an extremely large breeching and stack
combination cause excessive draft, a simple barometric damper can be located in
the breeching - close to the stack.
Automatic or special draft controls are not required and are not recommended,
except where dictated by state, provincial or local codes.
A manual or automatic open-close outlet damper can be installed on a single boiler
installation, and is recommended for safety concerns on a multiple common
breeching or stack installation.
The amount of condensation in the stack will vary with the type of fuel utilized, the
type and operating pressure or temperature of the boiler, and the stack flue gas
temperature.
Stack condensation is most likely to occur on boiler installations where light loads or
intermittent firing causes a cool stack condition, which results in condensation of
the water vapor in the flue gas.
The following items should be considered when planning to keep stack
condensation to a minimum:
The boiler should be sized as close as possible to the true operating load.
Oversized boilers should be avoided.
An off-set stack is recommended, with bottom clean-out and drain connection,
to prevent any condensed water from draining back into the flue gas side of the
boiler.
State, provincial and local codes may govern the stack height above the roof. If
down drafts are unavoidable, the stack outlet can be provided with a ventilator.
A rain cap or hood should be used at the top of the stack to minimize the entrance
of snow or rain.
Section F
F-18
03-08
MODEL
NO.
ID
1000F
CHIMNEY
1400 F
CHIMNEY
500F
GREASE
DUCT
CBS-I 6-48 - - 18
CBS-II 6-8 6 6 7
10-12 6 6 8
14-16 6 6 9
18 7 8 10
20 7 9 10
22 8 10 11
24 8 12 11
26 8 13 12
28 9 14 12
30 9 16 13
32 10 17 13
34 10 19 14
36 10 20 14
42 18 20 16
48 18 20 17
ICBS-1
6-16 2 2 3
18 3 4 4
20 3 5 4
22 3 7 5
24 4 8 5
26 4 9 6
28 5 11 6
30 5 12 7
32 5 14 7
34 6 15 8
36 6 16 8
42 14 16 10
48 14 16 11
ICBS-2
&
ICBS-4
6-16 0.5 0.5 1.0

18 1.0 2.0 2.0
20 1.5 4.0 2.0
22 2.0 5.0 3.0
24 2.0 6.0 3.0
26 3.0 8.0 4.0
28 3.0 9.0 4.0
30 4.0 11.0 5.0
32 4.0 12.0 5.0
34 5.0 13.0 6.0
36 5.0 15.0 6.0
42 12.0 15.0 8.0
48 12.0 15.0 9.0
NOTE: Numbers in table above are in inches.
Table F-5. Stack System Clearances to Combustible
Materials
Section F
F-19
03-08
STACK ID
(INCHES)
WEIGHT IN POUNDS PER LINEAR FOOT
CBS-I CBS-II ICBS-1" ICBS-2" ICBS-4"
6 2.43 4.83 7.01 9.85 17.01
8 3.25 6.17 9.01 12.36 20.49
10 4.05 7.50 11.01 14.83 23.96
12 4.86 8.84 13.00 17.32 27.43
14 5.67 10.17 15.00 19.81 30.90
16 6.48 11.66 16.99 22.30 34.37
18 7.29 12.84 18.99 24.78 37.83
20 8.09 14.18 20.97 27.26 41.29
22 8.89 15.51 22.97 29.74 44.76
24 9.71 16.85 24.98 32.23 48.23
26 10.51 21.88 30.33 38.31 55.65
28 11.32 23.43 32.45 40.91 59.33
30 12.13 24.99 34.67 43.64 63.05
32 12.94 26.55 36.90 46.35 66.74
34 13.75 28.10 39.13 49.08 70.44
36 14.56 29.66 41.35 51.79 74.13
42 16.97 34.83 48.01 59.92 85.21
48 19.40 40.20 54.69 68.08 96.31
Table F-6. Weight of Straight Stack
Section F
F-20
03-08
NOTES
F-21
03-08
Section F
Stack Specifications
The following sample specification is provided by Cleaver-Brooks to assist you in specifying your customers
Section F
F-22
03-08
PART 1 GENERAL 1.1 COMPONENT SPECIFICATIONS
PART 2 PRODUCTS 2.1 STANDARD SPECIFICATIONS
A. Boiler stack and breeching components, supports and terminations
shall be factory prefabricated.
B. All stack and breeching components shall be tested and listed by
Underwriters Laboratories (UL and ULC), for use with building
heating equipment burning gas, liquid, or solid fuels, as described
in NFPA 211, Chapter 2.
C. All stacks and breechings will have inner walls of 20-gauge Type
304 stainless steel for gas and No. 2 oil, or 20-gauge Type 316
stainless steel for coal, solid fuels, and No. 4 thru No. 6 oil.
D. Outer walls shall be 24-gauge aluminum-coated steel for sizes up to
24" ID and 20-gauge for sizes of 26" to 48" ID.
E. The stack and breeching shall be engineered, approved, and
manufactured for the boiler equipment manufacturer.
F. The stack and breeching manufacturer must supply complete CAD
system design drawings which include a complete component bill of
materials.
G. Stack and breeching systems must be designed to adjust to thermal
expansion caused by the heating and cooling of normal boiler
operation.
H. All stack and breeching components must be warranted for a
minimum of 15 years when installed according to the
manufacturers installation instructions.
I. The stack and breeching shall comply with national safety
standards and all building codes where applicable.
J. The stack section joints shall be field sealed by use of containment
bands with captive fasteners and high temperature joint sealant.
K. All stack and breeching components shall be shipped on pallets and
shrink-wrapped to simplify on-site handling and protect materials
until installation.
L. The system is to maintain air-tight integrity at pressures up to 72"
WC at room temperature.
M. The system shall have a ______" minimum clearance to
combustibles with flue gas temperatures greater than 1000 F and
not exceeding 1400 F continuous, and a _____" minimum
clearance to combustibles with flue gases not exceeding 1000 F
continuous.
2.2 SPECIFICATIONS SPECIFIC TO DOUBLE WALL AIR INSULATED
COMPONENTS
There shall be a minimum of 1" air space between the inner and outer wall.
2.3 SPECIFICATION SPECIFIC TO DOUBLE WALL 1", 2", OR 4" MATERIAL
INSULATED COMPONENTS
There shall be a minimum of (1", 2", or 4") bonded fiber insulation between the
inner and outer wall.
Section F
F-23
03-08
Section F
F-24
03-08
Notes
G-1
03-08
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3
Standard Economizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4
Condensing Economizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4
DIMENSIONS AND WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-13
Section G
ECONOMIZERS
Section G
G-2
03-08
ILLUSTRATIONS
Dimension Diagram, C2X Condensing Economizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6
Economizer Mounting to Firetube Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-10
Installation options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-10
Typical Piping Diagram, CCE/CRE Economizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-11
Typical Piping Diagram, Condensing Economizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-12
TABLES
Firetube Boiler Economizers Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5
Dimensions, C2X Condensing Economizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7
Economizer Weights, C2X Condensing Economizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7
Firetube Boiler Economizer Performance Data (Model CB Boilers) . . . . . . . . . . . . . . . . . . . . . . . . G-8
Firetube Boiler Economizer Efficiencies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8
This section contains information on Economizers. An economizer recovers heat from flue gases and uses it to
increase boiler feedwater temperatures, prior to entering the boiler. Cleaver-Brooks offers a variety of types,
sizes, and custom designs. Each assures proper match for your specific firetube or watertube boiler.
Section G
G-3
03-08
Reduces Fuel Use and Cost:
Recovers heat from flue gases that would otherwise be wasted.
Heat is used to raise boiler feedwater temperature prior to entering the boiler.
Load Changes:
Rapid changes in load demands can be met faster due to higher feedwater
temperature.
Emissions:
Reduced fuel-firing rates for any given steam output means reduced NOx
emissions.
ASME Construction:
Ensures high quality design and manufacturing standards.
Provides safety and reliability.
High Efficiency Heat Exchanger:
Provides uniform fin-to-tube contact for maximum heat transfer.
Fin tubing offers up to 12 times the heat exchange surface of bare tubing of the
same diameter.
Self-Draining Design:
Suitable for outdoor installation.
Low Pressure Drop:
Provides low gas side pressure drops.
Permits use of smaller forced draft fans.
Permits use of existing fans in almost all installations.
Gas Tight Combustion Stack:
Stainless Steel casing.
Compact dimensions provide for easy installation.
Guaranteed Efficiency on Model CB Firetube Boilers:
$10,000 rebated for every full 1.0% efficiency point less than guaranteed.
Section G
G-4
03-08
PRODUCT OFFERING
Standard
Economizers
Cleaver-Brooks offers a line of custom-engineered economizers for boiler sizes up to
and including 150 MMBtu/hr. input. The model CRE Fuel Economizers are
available for firetube boilers up to 1800 HP.
Standard Equipment
Standards for all C-B Economizers include:
Designed and fabricated in accordance with the ASME Boiler and Pressure
Vessel Code, UM stamp standard, U stamp and Section I optional.
Thermometer and safety valve connections at the feedwater headers.
Incorporates self-draining design.
Safety valve.
Optional Equipment
Vertical or horizontal flue gas flow patterns on rectangular design.
Utilization of waste gas.
Soot blowers for oil firing.
Condensing
Economizers
In addition to incorporating many of the standard economizer features, the Model
C2X condensing economizer utilizes a 2-stage design allowing makeup water to be
heated before it enters the deaerator, or in a second stage between the deaerator
and the boiler.
DIMENSIONS AND WEIGHTS
Information in this section outlines typical dimensions and weights of an
economizer.
Table G-1 lists dimensions and weights for a CCE and CRE Economizers typically
installed with a firetube boiler.
Figure G-1 and Table G-2 give dimensions for the C2X condensing economizer.
Table G-3 lists C2X weights.
The selection of an economizer for a particular application will depend on type and
capacity of the boiler and job site conditions.

Section G
G-5
03-08
BOILER
HP
ECONOMIZER
MODEL
NUMBER
DIMENSIONS
(APPROX) DRY
UNIT
WEIGHT
(LBS) WIDTH
(IN.)
DEPTH
(IN.)
HEIGHT
(IN.)
100 hp CCE 16A6AL 30RD - 25 270
125 hp CCE 18D7AL 30RD - 37 380
150 hp CCE 18D7AL 30RD - 37 381
200 hp CCE 18E6AL 30RD - 41 410
250 hp CRE 30H7AL 52 43 58.3 1320
300 hp CRE 30H7AL 52 43 58.3 1320
350 hp CRE 30F7AL 52 43 50 1120
400 hp CRE 36F7AL 60 50 50 1470
500 hp CRE 36G 6AL 60 50 54.2 1596
600 hp CRE 36H5AL 60 50 58.3 1716
700 hp CRE 36J5AL 60 50 66.8 1961
800 hp CRE 36J5AL 60 50 66.8 1961
NOTES:
2. Boiler firing natural gas only.
3. Boiler operating pressure is 125 psig (acceptable tolerance is
5 psig).
4. Contact your local Cleaver-Brooks representative for sizing detail.
Model CCEs are cylindrical
Model CREs are rectangular
Table G-1. Firetube Boiler E+Plus Economizers Dimensions and Weights
(Model CB Boilers)
Section G
G-6
03-08
Figure G-1. Dimension Diagram, C2X Condensing Economizer
BB
Section G
G-7
03-08
Table G-2. Dimensions, C2X Condensing Economizer
Table G-3. Economizer Weights, C2X Condensing Economizer
PERFORMANCE DATA
Tables listed here contain performance data for:
Gas fired, 100 through 800 hp firetube boilers operating at 125 psig, and
utilizing a CCE or CRE fuel economizer.
For additional operating pressures, load capacity or fuel selections, contact your
Table G-4 lists typical water and gas side temperatures when utilizing a CCE or CRE
Economizer with a firetube boiler.
Table G-5 lists typical increases in efficiency for a firetube boiler.
Figure G-2 shows CB-LE and 4WI efficiencies using the C2X 2-stage economizer.
Notice
Do not use on boilers equipped with flue gas recirculation. Contact your local
4WI Boilers CBLE Boilers
Boiler HP
Economizer
Model
Economizer
Dry Weight
Economizer
Wet Weight Boiler HP
Economizer
Model
Economizer
Dry Weight
Economizer
Wet Weight
250-300 C2X-2M386AL 1980 2130 250-300 C2X-2M386AL 1980 2130
350-400 C2X-2M3A6AL 2220 2410 350 C2X-2M3A6AL 2220 2410
500 C2X-2R3A6AL 2520 2730 400 C2X-2M3A6AL 2220 2410
600 C2X-2R3B6AL 2820 3070 500 C2X-2R3A6AL 2520 2730
700 C2X-2S3B6AL 3240 3530 600 C2X-2R3B6AL 2820 3070
800 C2X-2S3C6AL 3720 4060 700 C2X-2S3B6AL 3240 3530
800 C2X-2S3C6AL 3720 4060
Section G
G-8
03-08
BOILER
HP
LOAD
%
ECONOMIZER
MODEL NO.
WATER SIDE GAS SIDE
ENERGY
SAVED
BTU/HR
HEATING
SURFACE
SQ-FT
FLOW
PPH
TEMPERATURE PRESS.
DROP
PSIG
FLOW
PPH
TEMPERATURE PRESS.
DROP
IN. WC IN F OUTF IN F OUT F
100 100 CCE-16A6AL 3356 227 258 1.5 3611 410 303 0.22 125500 151
125 100 CCE-18D6AL 4195 227 275 3.92 4586 465 301 0.13 247800 316
150 100 CCE-18D7AL 5034 227 265 5.44 5432 420 290 0.18 229900 316
200 100 CCE-18E6AL 6711 227 256 10.4 7191 395 295 0.2 229400 309
250 100 CCE-30H7AL 8389 227 271 0.01 9158 460 310 0.1 451800 733
300 100 CRE-30H7AL 10067 227 265 0.01 10910 435 304 0.14 466800 733
350 100 CRE-30F7AL 11745 227 259 0.01 12638 410 301 0.26 447500 611
400 100 CRE-36F7AL 13423 227 262 0.02 14470 425 304 0.24 571900 733
500 100 CRE-36G6AL 16779 227 251 0.03 17883 385 299 0.24 490900 699
600 100 CRE-36H5AL 20134 227 247 0.03 21399 370 305 0.24 476200 645
700 100 CRE-36J5AL 23490 227 245 0.03 24895 365 300 0.24 513600 753
800 100 CRE-36J5AL 26846 227 245 0.04 28491 370 304 0.31 597700 753
NOTES:
1. Feedwater temperature to economizer is at least 220 F (Deaerated).
2. Boiler operating pressure is 125 psig (acceptable tolerance 5 psig).
3. Gas side flow (pph) determined with 10% excess air (50 to 100% of capacity).
4. Continuous modulated feedwater flow must be provided.
5. Boiler firing natural gas
6. Contact your local Cleaver-Brooks representative for sizing detail.
Table G-4. Firetube Boiler CCE/CRE Economizer Performance Data (Model CB Boilers)
BOILER
HP
LOAD
%
ECONOMIZER
MODEL NO.
EFF
W/0
ECON
% FUEL
SAVED
EFF
WITH
ECON
100 hp 100 CCE-16A6AL 82.05 2.50 84.55
125 hp 100 CCE-18D6AL 80.76 3.84 84.6
150 hp 100 CCE-18D7AL 81.81 3.04 84.85
200 hp 100 CCE-18E6AL 82.40 2.34 84.74
250 hp 100 CRE-30H7AL 80.87 3.52 84.39
300 hp 100 CRE-30H7AL 81.46 3.07 84.53
350 hp 100 CRE-30F7AL 82.05 2.55 84.6
400 hp 100 CRE-36F7AL 81.89 2.84 84.73
500 hp 100 CRE-36G6AL 82.83 2.01 84.84
600 hp 100 CRE-36H5AL 83.07 1.63 84.7
700 hp 100 CRE-36J5AL 83.30 1.54 84.84
800 hp 100 CRE-36J5AL 83.18 1.55 84.73
NOTES:
1. Feedwater temperature to Economizer 227 F (Deaerated).
2. Selections are based on best Btu savings per dollar costs.
3. Boiler is firing natural gas.
4. Boiler operating pressure is 125 psig (acceptable tolerance
5 psig).
4. Contact your local Cleaver-Brooks representative for sizing de-
tail.
Table G-5. Firetube Boiler CCE/CRE Economizer
Efficiencies
Section G
G-9
03-08
Figure G-2 shows CB-LE and 4WI efficiencies using the C2X 2-stage economizer.
Efficiencies are based on the following conditions:
C-B published stack-loss method and condensate removal
Ambient air temperature of 80 deg F
15% excess air in exhaust
Feed water at 227 deg F circulated through lower economizer stage
Includes C-B published radiation and convection losses
Figure G-2. C2X Efficiencies
ENGINEERING DATA
Information in this section outlines typical installation. Actual installation and piping
arrangements will be dictated by design, state, provincial or local codes, and job-site
conditions.
CBLE & 4WI Boiler Efficiency with 2-stage economizer
Natural Gas, Operating 80-125 psig
84
85
86
87
88
89
90
91
25 50 75 100
Makeup water @50
0
F
% Makeup water
E
f
f
i
c
i
e
n
c
y

%
Section G
G-10
03-08
Firetube Boilers - Installation
Economizers weighing over 500 lb must be supported either by the four (4) support
channels on the economizer base or from the ceiling by threaded rods.
The economizer outlet transition can typically support up to 500 lb stack or breeching
(dead weight only). Economizer support still required as described above.
If an expansion joint is used, the economizer and stack must be supported to ensure all
loading is removed from the expansion joint.
Refer to Figure G-3 for suggested mounting to a firetube boiler.
Figure G-4 shows installation options using external supports (floor or ceiling mounted)
for horizontal and vertical flow units.
For information on other Cleaver-Brooks Firetube Boilers, contact your local Cleaver-
Note: Spool between economizer and boiler may be required to clear front head
davit arm (consult factory).
Feedwater Piping
Piping arrangements are dictated by ASME Code, location of the economizer in
relation to the boiler, and feedwater regulating system.
Figure G-5 shows a typical CCE/CRE economizer piping arrangement.
Figure G-6 shows a typical C2X condensing economizer piping arrangement.
BOLT SPECIFICATIONS
Boiler hp 100 125-200 250-350 400-800
No. of Bolts 8 12 12 16
Bolt Size 3/8 - 16 (threads per inch)
Bolt Circle 13-7/8 17-7/8 21-7/8 25-7/8
Vent Open-
ing (OD)
12 16 20 24
NOTES:
2. For allowable weights on vent stub refer to dimensions and
weights in this section.
3. For information on stacks refer to Section F.
Figure G-3. E+Plus Economizer Mounting to Firetube
Boiler (Model CB Boilers)
Support structure
by others
Support structure
by others
Vertical Flow Units
Horizontal Flow Units
Figure G-4. Installation options
Section G
G-11
03-08
Figure G-5. Typical Piping Diagram, CCE/CRE Economizers
Section G
G-12
03-08
Figure G-6. Typical Piping Diagram, Condensing Economizers
G-13
03-08
Section G
CCE Cylindrical Economizers
for Firetube Boilers
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-14
Construction Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-14
Quality Control And Code Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-15
The following sample specification is provided by Cleaver- Brooks to assist you in specifying your customers
Section G
G-14
03-08
Specifications for CCE cylindrical economizers shall include the furnishing of
(__CCE-XXXX) complete packaged, extended surface boiler economizer(s), as
furnished by Cleaver-Brooks.
PART 2 PRODUCTS 2.1 CONSTRUCTION SPECIFICATIONS
A. The economizer's heating surface shall be a multiple circular coil
design with manifold for minimum water pressure drop as required:
Headers: thickness: Sch80; material: [ ] SA 53 GrB carbon steel or
[ ] TP304 stainless steel.
Alternate finned tube heating surfaces:
[ ] 316L stainless steel tube x .065" minimum wall thickness with
aluminum fin x .020" thickness x .50 high brazed to the tube
[ ] Carbon steel tube SA 178 ERW GrA x .085" minimum wall
thickness with carbon steel fin x .030" thickness x .50 high brazed
to the tube
[ ] Duplex stainless steel tube x .049" minimum wall thickness with
stainless steel fin x .020" thickness x .50 high brazed to the tube
Fins per inch shall be per fuel type fouling requirements.
B. The gas tight housing shall consist of a structural reinforced design
shell and designed with a 10GA minimum thickness SA36 carbon
steel thickness cylindrical lid ([ ] alternate 304 stainless steel).
18GA stainless steel 'gull wing' type access doors shall be provided
which can provide for complete access to the heating surface for
inspection and/or cleaning. In addition the inspection panels shall
be hinged and secured by quick release tension latches requiring no
tools to open and close for access to the heating surface. Access
doors shall be insulated with 2" thickness of high temperature
insulation and shall contain a stainless steel door panel. Customer
stack mating flanges and gaskets shall also be provided and
designed to match the economizer gas connections. Exterior
surfaces other than stainless shall be painted with high temperature
paint suitable for exhaust temperatures entering and for outdoor
installation. Additional required equipment included shall include:
(2) 50-300(F 3" dial bimetallic water thermometers with well, (2)
150-750(F 3" dial adjustable bimetallic flue gas temperature
thermometers. (1) 250 PSI ASME safety relief valve.
C. Maximum heat transfer performance shall result from counter flow
water to the exhaust gas flow, maximizing entering temperature
differences. A condensate drain catch ring assembly with 1" NPT
drain shall be provided for draining condensation away from the
boiler as it could occur either within the economizer and/or
economizer outlet stack breaching. The economizer's design shall
also include an internal heat resistant design exhaust gas damper,
allowing for the reduction of combustion back pressure as required,
and/or for controlling exhaust gas temperature exiting, and/or for
controlling heat transfer for minimum performance as necessary.
Section G
G-15
03-08
PART 2 PRODUCTS 2.2 SELECTION PARAMETERS
Design Requirements
Performance design parameters for the economizer are as
follows:
Primary fuel type: [ ] natural gas [ ] No.2 fuel oil
Maximum Firing output rate to the economizer:
Exhaust Flow Rate, pph:
-Inlet exhaust temperature (f:
Cooled exhaust temperature (f:
-Pressure drop " W.C. Max.:
Water Flow Rate, lbs/hr:
-Entering Temp.(f:
-HeatedTemp.(f:
Press. Drop, psig
Heat transferred, MBtu/hr.:
PART 3 EXECUTION 3.1 QUALITY CONTROL AND CODE REQUIREMENTS
A. Economizer is to be designed and fabricated in accordance with the
ASME Boiler and Pressure Vessel Code, Section VIII Division I (UM
stamp).
Options available:
[ ] Optional U stamp.
[ ] Optional Section I stamp
[ ] Optional CRN stamp
B. Minimum design temperature is to be 700 F.
C. Unit shall be hydrostatically tested at 1.5 times the design pressure
in the presence of a Code Inspector.
D. Unit is to be ASME Code Stamped, and is to include nameplate and
applicable code papers.
Section G
G-16
03-08
NOTES
G-17
03-08
Section G
CRE Rectangular Economizers
for Firetube Boilers
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Construction Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Quality Control And Code Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
The following sample specification is provided by Cleaver- Brooks to assist you in specifying your customers
Section G
G-18
03-08
Specifications for CRE rectangular economizers shall include the furnishing of
(__CRE-XXXX) complete packaged, extended surface boiler economizer(s), as
furnished by Cleaver-Brooks.
PART 2 PRODUCTS 2.1 CONSTRUCTION SPECIFICATIONS
A. The economizer's heating surface shall consist of finned tubes
attached to water manifolds as mounted to the exterior of the shell
to minimize corrosion and to achieve low liquid pressure drop. The
finned tubes shall be attached with compression fittings to the
header manifolds for ease of tube replacement requiring no welding.
The finned tube shall have a maximum of 2 rows in the exhaust
stream in order to achieve visual access of the heating surface and
effective cleaning when needed. The finned tubes shall not have
any tube to tube welds in the exhaust flow for extended economizer
life:
Header manifold: thickness: Sch80; material: [ ] SA 53 GrB carbon
steel or [ ] TP304 stainless steel.
[ ] Carbon steel tube SA 178 ERW GrA x .085" minimum wall
thickness with carbon steel fin x .030" thickness x .50 high brazed
to the tube
[ ] Duplex stainless steel tube x .049" minimum wall thickness with
stainless steel fin x .020" thickness x .50 high brazed to the tube
Fins per inch shall be per fuel type fouling requirements.
B. The gas tight housing shall consist of a structural reinforced design
exterior and designed with a 10GA minimum thickness SA36
carbon steel thickness ([ ] alternate 304 stainless steel). A hinged
access door shall be provided which can provide for complete
access to the heating surface for inspection, cleaning, or tube
removal. The economizer shall be insulated with 2" thickness of
high temperature insulation and shall be lined with 304 stainless
steel. A pair of stack adapters and gaskets shall also be provided to
connect the economizer flanged exhaust connections with the boiler
exhaust diameter size for slip fit connection.
C. Exterior surfaces other than stainless shall be painted with high
temperature paint suitable for exhaust temperatures entering and for
outdoor installation. Additional required equipment included shall
include: (2) 50-300(F 3" dial bimetallic water thermometers with
well, (2) 150-750(F 3" dial adjustable bimetallic flue gas
temperature thermometers, (1) 250 PSI ASME safety relief valve.
Section G
G-19
03-08
D. Maximum heat transfer performance shall result from counter flow
water to the exhaust gas flow, maximizing entering temperature
differences. A condensate drain catch ring assembly with 1" NPT
drain shall be provided for draining condensation away from the
boiler as it could occur either within the economizer and/or
economizer outlet stack breaching. The economizer's design shall
also include an internal heat resistant design exhaust gas damper,
allowing for the reduction of combustion back pressure as required,
and/or for controlling exhaust gas temperature exiting, and/or for
controlling heat transfer for minimum performance as necessary.
PART 2 PRODUCTS 2.2 SELECTION PARAMETERS
Performance design parameters for the economizer are as follows:
Maximum Firing output rate to the economizer:
Exhaust Flow Rate, pph:
-Inlet exhaust temperature (F:
Cooled exhaust temperature (F:
-Pressure drop " W.C. Max.:
Water Flow Rate, lbs/hr:
-Entering Temp.(F:
-Heated Temp.(F:
Press. Drop, PSIG
Heat transferred, MBtu/hr.:
PART 3 EXECUTION 3.1 QUALITY CONTROL AND CODE REQUIREMENTS
A. Economizer is to be designed and fabricated in accordance with the
ASME Boiler and Pressure Vessel Code, Section VIII Division I (UM
stamp).
Options available:
[ ] Optional U stamp.
[ ] Optional Section I stamp
[ ] Optional CRN stamp
B. Minimum design temperature is to be 700 F.
C. Unit shall be hydrostatically tested at 1.5 times the design pressure
in the presence of a Code Inspector.
D. Unit is to be ASME Code Stamped, and is to include nameplate and
applicable code papers.
Section G
G-20
03-08
NOTES
G-21
03-08
Section G
C2X 2-Stage Condensing Economizers
Boiler exhaust to feedwater preheater economizer(s) model number C2X-XXXXXX shall be furnished and installed
in the exhaust duct of the boiler(s) in accordance with the following specifications, as supplied by Cleaver-
Brooks. The Economizer shall be a rectangular configuration designed for ease of installation, shall include two
separate water manifolds for make-up water and boiler feedwater, and shall be designed, manufactured and
tested in accordance with the requirements of Section VIII, Division I or Section I (as required) of the ASME
Boiler and Pressure Vessel Code. It shall be stamped to a minimum of 250 PSIG design pressure to the
appropriate Section and hydrostatically tested to 375 PSIG.
The economizers heating surface shall consist of finned tubes attached to water manifolds as mounted to the
exterior of the shell to minimize corrosion and to achieve low liquid pressure drop. The finned tubes shall be
attached with compression fittings to the header manifolds for ease of tube replacement requiring no welding.
The finned tube shall have a maximum of 2 rows in the exhaust stream in order to achieve visual access of the
heating surface and effective cleaning when needed. The finned tubes shall not have any tube to tube welds in
the exhaust flow for extended economizer life. Fins per inch shall be per fuel type fouling requirements.
Header manifold:
Thickness: Sch80
Material: [ ] SA 53 GrB carbon steel or [ ] TP304 stainless steel.
[ ] 316L stainless steel tube x .065 minimum wall thickness with aluminum fin x .020 thickness x .50 high
brazed to the tube
[ ] Carbon steel tube SA 178 ERW GrA x .085 minimum wall thickness with carbon steel fin x 030 thickness
x .50 high brazed to the tube
[ ] Duplex stainless steel tube x .049 minimum wall thickness with aluminum fin x .020 thickness x .50 high
brazed to the tube
[ ] 316L stainless steel tube x .065 minimum wall thickness with stainless steel fin x.020 thickness x .50 high
brazed to the tube
The gas tight housing shall consist of a structurally reinforced exterior with a 10GA minimum thickness SA36
carbon steel ([ ] alternate 304 stainless steel) body. A hinged access door shall be provided which can provide
for complete access to the heating surface for inspection, cleaning, or tube removal. The economizer shall be
insulated with 2 thickness of high temperature insulation and shall be lined with 304 stainless steel. A pair of
stack adapters and gaskets shall also be provided to connect the economizer flanged exhaust connections with
the boiler exhaust diameter size for slip fit connection.
Section G
G-22
03-08
Exterior surfaces other than stainless shall be painted with high temperature Cleaver Brooks Blue paint suitable
for exhaust temperatures entering and for outdoor installation. Additional required equipment included shall
include: (4) 50-300F 3" dial bimetallic water thermometers with well, (2) 150-750F 3" dial adjustable
bimetallic flue gas temperature thermometers, (1) 300 PSI ASME safety relief valve for the boiler feedwater
loop, and (1) 150 PSI ASME safety relief valve for the make-up water loop.
Maximum heat transfer performance shall result from counter flow water to the exhaust gas flow, maximizing
entering temperature differences. A condensate drain catch ring assembly with 1 NPT drain shall be provided
for draining condensation away from the boiler as it occurs either within the economizer and/or economizer
outlet stack breaching. The economizers design shall also include an internal heat resistant design exhaust
gas damper, allowing for the reduction of combustion back pressure as required, and/or for controlling exhaust
gas temperature exiting, and/or for controlling heat transfer for minimum performance as necessary.
Performance design parameters for the economizer are as follows:
Economizer Design Considerations:
Exhaust Gas:
Flow Rate, pph:
Inlet Temperature F:
Outlet Temperature F:
Pressure drop W.C. Max:
Make-Up Water:
Flow Rate, gpm:
Pressure Drop, PSIG:
Boiler Feedwater:
Flow Rate, gpm:
Pressure Drop, PSIG:
Heat transferred, MBtu/hr:
H-a
06-08
Section H
FEEDWATER SYSTEMS
Chemical Feed Systems and Metering Pumps
Spraymaster Deaerators (Duo Tank)
Boilermate Deaerators
Surge Tanks
Boiler Feed Systems
Filters
Flash Tank Heat Exchangers
Softeners
Dealkalizers
Blowdown Separators
Blowdown Heat Recovery Systems
Sample Coolers
H1a & b
H2
H4
H5
H6
H7
H8
H9
H10
H11
H12
H13
H14
Traymaster Deaerators
H3
Spraymaster Classic and Spraymaster Signature Deaerators
H-b
Feedwater Systems
Notes
H1a-1
03-08
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-4
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-6
RETURN ON INVESTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-10
Flash Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-10
Exhaust Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-10
Surface Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-10
Chemical Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-10
Makeup Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-10
Sewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-10
Intangibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-10
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-11
ILLUSTRATIONS
Figure H1a-1. Spraymaster Tank Supports and Saddles, Details and Dimensions . . . . . . . . . . . . . H1-7
Figure H1a-2. Spraymaster Deaerator Dimensions and Ratings (Single Tank) - Sheet 1 of 2 . . . . . . H1-8
TABLES
Table H1a-1. Spraymaster Deaerator Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-4
Section H1a
SPRAYMASTER CLASSIC
DEAERATORS (Single Tank)
Spraymaster Deaerators (Single Tank) Section H
H1a-2
03-08
The Cleaver-Brooks designed deaerator assures high purity effluent by removing
oxygen and other dissolved gases in boiler feed. Thus, it is the answer to long-
lasting boiler equipment for industrial and commercial boiler users. Built of
corrosion-resistant alloys for lifetime service, the deaerator employs those basic
principles of gas removal proven most effective and economical to every boiler
owner. Contact your local Cleaver-Brooks authorized representative for component
sizing information.
Section H Spraymaster Deaerators (Single Tank)
H1a-3
03-08
Low Profile Design:
Low head allows installation in space restricted areas.
Two-Stage Deaeration in a Common Vessel:
Recycle pumps are not required.
Packaged for easy maintenance.
ASME Code Design (Section VIII):
Assures deaerator vessel quality in materials and fabrication to meet safety
requirements.
Internal Stainless Steel Vent Condenser:
Protects deaerator vessel against corrosive gases while providing a means for
removal of corrosive gases from boiler feedwater.
Self-Cleaning Water Spray Valve:
Angles associated with the water spray valve assembly and actual water spray
pattern, maintains deposit-free surfaces.
Reduces maintenance requirements.
Internal Automatic Check Valves Prevent Back Flooding:
Both the water spray valve and steam atomizing valve are in the normally closed
position under no flow conditions.
Prevents steam back-flow through the water spray valve and water back flow
through the steam atomizing valve.
Removable Water Spray Inlet Assembly:
Flanged assembly allows easy access for maintenance and/or inspections.
Stainless Steel Deaeration Assembly:
Ensures a longer life of wetted materials in intimate contact with corrosive
liquids and released corrosive gases.
Pressurized Tank Reduces Flashing and Minimal Venting:
Recovery of exhaust and turbine steam.
Saves Btus that would normally be exhausted to atmosphere. Improves plant
efficiency.
Auto Vent Valve Eliminates Dissolved Gases at Start-Up:
Atmospheric contamination virtually eliminated for incoming water.
Exceeds ASME Recommendations for Oxygen Level:
Guaranteed to remove oxygen concentrations to 0.005 cc/liter while operating
between 5% and 100% capacity.
Carbon dioxide concentrations are practically reduced to zero.
H1a-4
03-08
Capacity Not Affected by Mixed Inlet Temperature:
Consistent performance under variable conditions.
Integral Level Control Automatically Introduces Cold Water Make-Up to
Supplement Condensate Only When Necessary to Meet Boiler Demand:
Saves Btus by accepting condensate before cold make-up water. Maintains a
minimal water level within the deaerator vessel to prevent damage to the boiler
feedpumps, and to maintain system operation.
Variety of Tank Sizes to Handle Volume-Swings in Condensate Return:
Provides flexibility for selecting a tank for specific applications, limiting the loss
of hot condensate to drain.
Packaged Units for Cost Effective Installation:
Complete packages are pre-fabricated in the manufacturing facility to ensure
piping alignment and control wiring function. The unit is partially disassembled,
and match marked for efficient field re-assembly.
Available in Horizontal and Vertical Configuration:
Provides adaptability for installation in space restricted areas.
Internal Pump Suction Vortex Breakers:
Eliminates the problems of loss in NPSHA and cavitation associated with the
creation of vortices within pump suction piping.
PRODUCT OFFERING
Information in this section applies directly to Cleaver- Brooks packaged
Spraymaster Deaerators ranging from 7,000 to 280,000 pounds/hour. For larger
capacities contact your local Cleaver-Brooks authorized representative. The product
offering for Spraymaster Deaerators is shown in Table H1a-1.
MODEL NO.
RATING
(LBS/H)
TANK
CAPACITY
STORAGE CAP.
(MIN)
SM- 7 7000 230 16
SM-15 15000 300 10
SM- 30 30000 600 10
SM- 45 45000 900 10
SM -70 70000 1400 10
SM-100 100000 2000 10
SM-140 140000 2800 10
SM-200 200000 4000 10
SM- 280 280000 5600 10
NOTE: Model number designation (example, SM-7) is: SM =Spraymaster
Deaerator. 7 =7,000 lbs/hr rating. Optional tank sizes available, contact
your local Cleaver-Brooks authorized
representative.
Table H1a-1. Spraymaster Deaerator Product Offering
H1a-5
03-08
The Spraymaster Deaerator is a pressurized low-headroom system designed to
remove dissolved oxygen in boiler feedwater to 0.005 cc per liter, or less, and
eliminate carbon dioxide. A typical deaerator package includes the deaerator tank
mounted on a stand of appropriate height along with all operating controls, feed
pumps assembled and piped (typically knocked down for shipment and field
assembly). The tank conforms to section VIII of the ASME code.
The main deaerating portion is located internally and consists of a water collector
and steam atomizing valve. Built into a flange on top of the tank is a spring loaded
water spray nozzle which includes an automatic and manual vent valve.
Packaged Spraymaster systems offer substantial advantages through, lower cost
installation and simplified operation and maintenance. Spraymaster Deaerators
arrive on site ready for hookup to your water, steam, and electric power connections.
The deaerator stand comes with feed pump/motor set mounted on a solid base. The
base is specially reinforced to prevent vibration wear on vital system components.
Rugged square structural tubing combines lasting strength with generous working
space for inspection or routine servicing.
Control Panel
The control panel, complete with starters, fuse protection, switches, lights and pre-
wired terminal blocks is mounted on the stand assembly. Wiring to feed pump motor
and all controls is standard.
Deaerator Tank
ASME construction - certified to 50 psig. All tanks provided with manhole,
individual pump suction tappings and other openings as required. Saddles or legs
standard on all sizes. Select from sizes for 5 to 30 minutes of storage to overflow.
Piping
Pump and motor sets are mounted on individual bases before mounting on stand
base.
Individual suction piping (including strainer, shutoff valve, flexible connector) are
provided for all feed pumps.
Standard Equipment
Spraymaster deaerator.
Deaerator storage tank.
Deaerator water inlet atomizing valve.
Deaerator steam inlet atomizing valve.
Deaerator manual and automatic vent.
Gauge glass.
Feedwater thermometer.
Required tappings.
Optional Equipment
Steam pressure reducing valve.
H1a-6
03-08
Three valve bypass and strainer (PRV).
Water level controller with make-up valve.
Three valve bypass and strainer (MUV).
Steam relief valves.
High water alarm.
Low water alarm.
Low water pump cut off.
High temperature condensate diffuser tube (over 227 F).
Boiler feed pump and motor sets.
Recirculation orifice or relief valve
Suction shutoff valve.
Suction strainer.
Suction flexible fitting.
Discharge check valve.
Discharge shutoff valve.
Discharge pressure gauge.
Discharge manifold.
Overflow drainer.
Control panel.
Chemical feed quill.
Vacuum breaker.
Insulation and lagging.
Sentinel relief valve.
Tank drain valve.
Back pressure relief valve.
Magnesium anode (not available with lined tanks).
Stand.
Packaging
Fully packaged, factory piped and wired.
Half packaged, suitable for field erection with interconnecting piping and wiring
by others.
Dimensions and ratings for Spraymaster Deaerators are shown in Figure H1a-1 and
Figure H1a-2.
H1a-7
03-08
Figure H1a-1. Spraymaster Tank Supports and Saddles, Details and Dimensions
TANK CAPACITY (GALLONS)
230 300 450 600 700 900 1000 1400 2000 2800 4000 5600
LEGS SADDLES
A 47 67.5 102 86 102 95 102.5 138 156 138 128 145
B 52.5 74 108.5 92.5 108.5 101 108.5 144 162 144 134 151
C 29.5 38 38 44.75 44.75 44.75 44.75 50 52 62 72 83
D 31.25 40 40 46.75 46.75 57 57 62 67 77.5 88 98.75
E 12 14.25 16 16 17 17 19.75 19 21.5 22.5 24.5 26
F 0.875 1 1 1 1 6.125 6.125 6 7.5 7.75 8 7.875
G 5.5 6.5 6.5 6.5 6.5 N/A N/A N/A N/A N/A N/A N/A
H 7 9.75 9.75 13.75 13.75 N/A N/A N/A N/A N/A N/A N/A
" C" " D"
" B"
" A"
" F" " G" /2
" G"
" H"

(4) .875" E HOLES
FOR .75" E BOLTS
TANK SUPPORT LEGS
STANDARD ON 36"
48" & 54" TANKS
" E"
SADDLES
" D" " C"
" B"
" A"
(4) 1.125" E HOLES
FOR .75" E BOLTS
6
" F"
" E"
FRONT HEAD FRONT HEAD
H1a-8
03-08
Figure H1a-2. Spraymaster Deaerator Dimensions and Ratings (Single Tank) - Sheet 1 of 2
230 300 450 600 700 900 1000 1400 2000 2800 4000 5600
1050 1700 2150 2200 2450 2600 2800 4100 4900 5700 7300 9450
3600 7850 10700 11750 13450 15500 17000 25450 33650 41550 52500 73600
36 x 71 48 x 96 48 x 134 54 x 118 54 x 136 60 x 129.5 60 x 142.5 66 x 177 72 x 200 84 x 184 96 x 179 108 x 199
A Overall Height 58 70 70 76 76 82 82 88 94 108 120 132
B Overall Width 51 63 63 69 69 75 75 81 87 99 111 123
C Front Head 8 10 10 11 11 12 12 14 15 17.5 20 21.5
D Water Inlet - SM 7 17.5 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
Water Inlet - SM 15 thru 100 N/A 20 22 22 22 22 22 22 22 22 22 22
Water Inlet - SM140 N/A N/A N/A N/A N/A N/A N/A 18 18 18 18 18
E Steam Inlet 6.5 40 42 42 42 42 42 42 42 42 42 42
F Level Alarm 32 50 54 54 54 54 54 56 56 56 56 56
G High Temperature Return 27 55 62 62 62 62 62 63 63 63 63 63
Tank Weight (Flooded) (lb)
SM TANK RATINGS
Capacity (Gal. to Overflow)
Tank Weight (Dry) (lb)
Tank Size (Dia x Length)
TANK DIMENSIONS
1. Mounted at dim. "H"(top of tank) on non-packaged units.
2. Tank mounted on non-packaged units.
3. Packaged units only. Mounted on front of stand.
4. Suction piping includes strainer, gate valve and flexible connector.
5. All couplings are 3000# F.S.
6. All flanges are 150# F.F. except as noted.
7. SM-200 is the same as SM-100 and SM-280 is the same as SM-140 except 2 water & steam inlets are used per vessel (dual inlet).
8. Customer to plug all fittings not being used.
9. Mount tank above pump at elevation necessary for static head including safe allowance for piping friction as approved by pump manufacturer.
10. Deaerator tank is built to ASME Code.
12. Add Suffix "P"to Model No. for packaged units (SMP-45).
13. Optional tanks available for 5 minutes storage (except SM7 & SM15), other combinations of capacities as required - contact your local Cleaver-Brooks
14. Dimension "B"will change depending on controls required - contact your local Cleaver-Brooks authorized representative.
15. No interconnecting piping or wiring furnished on non-packaged units unless specified, contact your local Cleaver-Brooks representative for specific piping
or wiring furnished on packaged assemblies.
16. Weights shown are without controls or packaging - contact your local Cleaver-Brooks representative for additions.
17. Capacities other than shown as standard available by proper selection of controls - contact your local Cleaver-Brooks authorized representative.
18. Optional tank sizes and ratings available - contact your local Cleaver-Brooks authorized representatives.
19. Lifting lugs are for lifting empty tank only.
FRONT VIEW RIGHT SIDE
(NOTE 14)
1/2"NPTAUTO. VENTVALVE
"R"NPT. MANUAL VENTVALVE
8 9 10
4 3 1 1 5
20 2
14
6
7 11
16 15 (NOTE 2) (NOTE 1)
(NOTE 3) 17
(NOTE 4) 19
18
12
13
1
22
21
21
0 "E" "D"
SM7 - 230 GALLON
WATER &STEAM INLETDETAIL
(4) "E5"DIA. HOLES
FOR "F6"DIA. BOLTS
(9"FOR SM15)
"C" 0"
"N"
"D" "E" "F" "G" "J" "H" "K"
"M"
2"DIA. HOLE
IN LIFTING LUGS
"L"
STAND HEIGHT
VARIES PER
PROJECT
REQUIREMENTS
"C3"
"D4"
"B"
12"
"A"
5"
TANK
DIA.
"B2"
"A1"
"P"
H1a-9
03-08
Figure H1-2. Spraymaster Deaerator Dimensions and Ratings (Single Tank) - Sheet 2 of 2
H Level Control 44.5 60 79 79 79 79 79 90 90 90 90 90
J Relief Valve 38.5 66 * 70 70 70 70 70 100 100 100 100 100
K Relief Valve 50 66 * 86 86 86 86 86 111 111 111 111 111
L Relief Valve N/A N/A N/A N/A N/A N/A N/A 122 122 122 122 122
M Drain 10 30 98 84 98 93 103 135 153 135 127 144
N Overflow 5 10 10 10 10 10 10 14 14 14 14 14
P Overflow 10 0 0 3.75 3.75 6.75 6.75 6.5 8 14.5 26.5 27.5
Sprayhead
R Manual Vent Valve Size
230 300 450 600 700 900 1000 1400 2000 2800 4000 5600
A1 Overall Length 52.5 74 108.5 92.5 108.5 101 108.5 144 162 149 134 151
B2 C/L to C/L Bolt Holes 47.5 69 102.5 87.5 102.5 95 102.5 138 155 146 127 144
C3 Overall Width 49 62 66 64 66 71 71 76 83 86.5 102 113
D4 C/L to C/L Bolt Holes 46 59 63 61 63 68 68 73 80 79.5 99 110
E5 Hole Size 0.75 1 1 0.75 1 1.125 1.125 1.25 1.125 1.125 1.125 1.25
F6 Anchor Bolt Size 0.625 0.875 0.875 0.625 0.875 1 1 1.125 1 1 1 1.125
1 Relief Valve Size
2 Overflow Size 1.5" NPT 3" NPT 3" NPT 3" NPT 3" NPT 3" NPT 3" NPT 4"-150#FF 4"-150#FF 4"-150#FF 6"-150#
FF
6"-150#FF
3 Steam Inlet Size
4 Water Inlet Size
5 High Temperature Return Size 1.5" NPT 1.5" NPT 2" NPT 2" NPT 2" NPT 2" NPT 2" NPT 3" NPT 3" NPT 3" NPT 3" NPT 3" NPT
6 Drain Size 1.5" NPT 2" NPT 2" NPT 2" NPT 2" NPT 2" NPT 2" NPT 2" NPT 2" NPT 2" NPT 2" NPT 2" NPT
7 Suction Size 2.5" NPT 2.5" NPT 2.5" NPT 2.5" NPT 2.5" NPT 2.5" NPT 2.5" NPT
4"-150#FF 4"-150#FF 4"-150#FF 4"-150#
FF
4"-150#FF
8 Thermometer (3/4" NPT)
9 Sample (1/2" NPT)
10 Chemical Feed (1" NPT)
11 Recirculation (1" NPT)
12 Gauge Glass Assembly
13 Level Controller (1.5" NPT)
14 Make-Up Valve
15 Pressure Gauge
16 Thermometer
17 Control Panel (Optional)
18 Feed Pump/Motor (Optional)
19 Suction Piping (Optional)
20 Manway Size - SM 7 20" N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
Manway Size - SM 15 thru 70 N/A 28" 28" 28" 28" 28" 28" 28" 28" 28" 28" 28"
Manway Size - SM100, 200 N/A 32" 32" 32" 32" 32" 32" 32" 32" 32" 32" 32"
Manway Size - SM140, 280 N/A N/A N/A N/A N/A N/A N/A 36" 36" 36" 36" 36"
21
22 Overflow Drainer (Optional)
RATINGS for
SPRAYMASTER MODEL
SM-7 7000 1" NPT
SM-15 15000
SM-30 30000
SM-45 45000
SM-70 70000
SM-100 100000
SM-140 140000
SM-200 (NOTE 7) 200000
SM-280 (NOTE 7) 280000
* 2 relief valve tappings for SM 300 located at 66" are offset 6" on either side of top centerline.
STAND DIMENSIONS
SM15 SM45 SM70 SM100/200
230
300 thru 700
300 thru 5600
Contact Your Local Cleaver-Brooks Authorized Representative
See Table Below
See Table Below
TANK SIZES RATING (lb/hr) Conn 3 Steam Inlet Conn 4 Water Inlet
2000 thru 5600
300 thru 5600
300 thru 5600
300 thru 5600
2000 thru 5600
2000 thru 5600
6"-150#FF Flg
8"-150#FF Flg
6"-150#FF Flg
3"-150#FF Flg
6"-150#FF Flg
6"-150#FF Flg
6"-150#FF Flg
8"-150#FF Flg
1.5"-150#RF Flg
2"-150#RF Flg
2"-150#RF Flg
2.5"-150#RF Flg
3"-150#RF Flg
4"-150#RF Flg (2)
3"-150#RF Flg
4"-150#RF Flg (2)
6"-150#FF Flg
Level Alarms (Optional) (1" NPT)
SM140/280
0.75 0.75 0.75 1 1.5 2
SM30
CONNECTIONS AND TRIM
H1a-10
03-08
2Na
2
SO
3
+O
2
2Na
2
SO
4
RETURN ON INVESTMENT
Payback for a pressurized deaerator verses an atmospheric boiler feed system is
based on an additional capital expenditure required divided by the yearly operating
cost savings. The differential in yearly operating costs are in the following areas:
Flash steam
Exhaust steam
Blowdown
Chemical treatment
Makeup water
Sewer
Intangibles
Flash Steam A percentage of the high-pressure condensate returns will flash to steam and be lost
in an atmospheric vessel application. This flash steam loss can be converted to an
energy loss and associated fuel cost.
Exhaust Steam Exhaust steam cannot be recovered in an atmospheric vessel application. This
exhaust steam loss can be converted to energy loss and associated fuel cost. An
example would be steam turbine exhaust.
Surface Blowdown Increased makeup water is required because of lost flash and exhaust steam. This
increase in makeup water requires an increase of surface blowdown. This is directly
related to cycles of concentration in the boiler. The additional blowdown loss can be
converted to an energy loss and associated fuel cost. The additional surface
blowdown may also result in an increase in capital expenditure for a larger
blowdown heat recovery system.
Chemical Treatment Dissolved oxygen content in an atmospheric boiler feedwater system is a function of
water temperature. Lowering the dissolved oxygen content below what is naturally
present, based on mixed water temperature at atmospheric pressure, requires the
addition of a chemical treatment program. The most common oxygen scavenger
used is sodium sulfite. Sodium sulfite reacts with dissolved oxygen as follows:
Theoretically, it takes approximately 8 ppm of sodium sulfite as Na
2
S0
3
to
scavenge 1 ppm of dissolved O
2
Makeup Water Increased make-up water is required because of lost flash steam, lost exhaust
steam, and additional surface blowdown. This additional makeup water can be
associated to a cost. Makeup water cost should be a combination of the utility
charge plus pretreatment equipment consumable costs.
Sewer Utilities often base a sewer charge on make-up water usage. Increased makeup
water usage with an associated increase in surface blowdown can affect these
costs.
Intangibles Some cost savings are difficult to calculate - in general, best practices in deaeration
will prolong the life of boiler room equipment, reducing repair and maintenance
costs.
H1-11
06-08
Section H1
Spraymaster Deaerators (Single Tank)
Deaerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-12
Make Up Valve and Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-13
Steam Pressure Reducing Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-14
Boiler Feedwater Pump And Motor Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-15
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-16
H1-12
06-08
PART 1 GENERAL 1.1 DEAERATOR SPECIFICATION
1. Provide one Cleaver-Brooks Model _________spray type,
pressurized, horizontal deaerator rated at _____pounds per
hour. The system shall be of the single tank design and shall
guarantee oxygen removal to not more than 0.005 ccs/liter in
the effluent throughout all load conditions between 5 and 100
percent. Two-compartment designs are not acceptable. The
deaerator shall be designed for operation at 5 psig, but shall be
suitable for use from 2 to 15 psig. Atmospheric operating
designs are not acceptable.
A. Deaerator
1. Feedwater and condensate shall be admitted to the deaerator
through a single spring-loaded, self-cleaning, adjustable
stainless steel spray valve, which shall provide proper internal
vent condensing and water distribution at any load between 5
and 100 percent of rated capacity. The water temperature in
the primary heating and vent concentrating section is to be
raised within 2 or 3 F of steam temperature and most of the
gases released. The water is then to be collected in a conical
water collector. From there, it is to flow to an atomizing valve
where high velocity steam strikes it, breaks it down into a fine
mist, and heats it to a full steam saturation temperature. The
mixture is to strike a deflecting baffle, which separates water
and steam. Hot, gas-free water is to then drop to the storage
compartment to complete the cycle. The steam and non-
condensables are to flow upward, through the primary heating
spray, into the internal vent concentrating section, where they
contact the cold influent water. Here, the steam is to be
condensed to continue the cycle. Released gasses are
discharged to atmosphere through the vent outlet. All internal
surfaces, which come in contact with un-deaerated water, shall
be constructed of Type 316 stainless steel.
2. Automatic vent valve shall be thermostatically controlled to
provide a fast means of venting when a sudden buildup of
gases occurs, such as seen at start up. The manual vent valve
shall have an orifice for continuous minimum venting. Venting
rate shall not exceed 0.1 of 1% of the rated deaerator capacity
at 5 psig.
H1-13
06-08
3. The deaerated water storage tank shall have _____minutes of
storage and have a capacity of
_____gallons measured to overflow. The tank shall be _____
diameter x ____long. An _____manhole shall be provided for
access. All nozzles 3" and under shall be 3000 lbs forged steel
couplings and over 3" shall be 150 lbs flat face flanges. Heads
to be ASME torispherical type constructed of ASTM A516 GR
70 carbon steel with a minimum thickness of 0.25 inches.
Shell plate to be fabricated of ASTM A36 carbon steel with a
minimum thickness of 0.25 inches. The tank shall be designed
in accordance with ASME, Section VIII of the Pressure Vessel
Code for 50 psig at 650 F and stamped accordingly.
Certification shall be required. Joint efficiencies to be 70%
circumferential per Table UW-12, which does not require
stress relieving or nondestructive examination.
4. The deaerator loads shall be as specified in the table below.
Low temperature returns are defined as condensate with a
temperature below that of the deaerator operating
temperature. High temperature returns are defined as
condensate with a temperature above that of the deaerator
operating temperature.
5. Optional - The tank shall be factory-insulated and lagged with
blanket insulation, pins, clips, and a durable steel jacket.
Block-type insulation is not acceptable. The blanket insulation
is to be fiberglass, 2" thick, 1 lb/cu-ft, and have a rating of R5.
Pins are to be located on 18" centers and holding clips
attached. The steel jacket or lagging shall have a shell
thickness of 18 gauge (0.0478") minimum and head thickness
of 18 gauge (0.0478") minimum.
6. Optional - The magnesium or sacrificial anode shall provide
cathodic protection against galvanic corrosion. This rod shall
be 1-5/16" diameter with a 1/4" steel core to assure a good
electrical contact and added strength. The design shall have a
small weep hole to signal it has been consumed. Linings shall
not be acceptable in this application.
7. Optional - The high temperature diffuser or sparge tube shall
be located beneath the normal tank water level. The tube shall
be constructed of 2-1/2 inch pipe. This tube shall provide even
distribution and blending of high-temperature condensate
returns.
8. Optional - The chemical feed quill shall be located beneath the
normal tank water level. The quill material shall be constructed
of stainless steel. The tube shall provide even distribution and
blending of chemical.
LOAD PERCENTAGE LBS/HR TEMP PRESSURE
Make up GPM 25 psig Minimum
Pumped Low Temp Returns 10 psig Minimum
High Temp Returns Not To Exceed 30%
Load Specifications
H1-14
06-08
9. Optional - The basic deaerator shall be equipped with the
following trim and accessories. Piping on packaged units shall
comply with ASME Power Piping Code B31.1.
B. Make Up Valve and Controller
1. Option (Mechanical) - ____" inlet water regulating lever valve
with ______body and _______connections. The valve Cv shall
not exceed ______and be rated for _____gpm at ______psig
inlet pressure. The pressure drop across the valve shall not
exceed a delta-P of 10 psig. This valve shall be suitable for
temperatures up to 300 F. The valve manufacture shall be
_______, Model _____. This valve shall be mechanically
controlled by an external float cage with cast iron body and 8"
stainless steel float. The float cage manufacturer shall be
__________, Model ______.
2. Option (Electronic) - ______" inlet water motorized regulating
valve with steel body and threaded NPT connections. Motor
shall be 110V bi-directional, with a permanently lubricated
gear train, and be directly coupled to the valve stem. The valve
Cv shall not exceed _____and be rated for_____gpm at
______psi inlet pressure. Valve shall not exceed a delta-P of
10 psig. This valve shall have teflon seats and be suitable for
temperatures up to 300 F. The motorized valve manufacturer
shall be __________. This valve shall be electronically
controlled by a solid state control with internally mounted
capacitance probes. The electronic solid state control shall be
able to set desired level point and acceptable deviation. The
electronic solid state control shall include a selection for
automatic and manual operating mode. The internals shall
include two additional probes for high and low water alarm.
The controller manufacturer shall be Cleaver-Brooks Model
TW82. A solenoid valve and float switch are not acceptable.
(Available only in the U.S.)
3. Option (Pneumatic) - _______" inlet water diaphragm actuated
regulating valve with cast iron body and _____connections.
The valve shall be globe type with proportional control and a
spring opposed diaphragm actuator arranged for 3 - 15 psig
operating signal. The valve shall be normally open on loss of
air. The valve Cv shall not exceed _____and be rated for
______gpm at ______psig inlet pressure. Valve shall not
exceed a delta-P of 10 psig. This valve shall have stainless
steel trim with TFE packing and be suitable for temperature up
to 410 F. The diaphragm actuated valve manufacturer shall
be ___________, Model _____. This valve shall be
pneumatically controlled by an external proportional type
sensor. The sensor shall be a 14" displacer that produces a
pneumatic output signal. The controller manufacturer shall be
_________, Model ______. A filter regulator is to be provided
to reduce 50 psig instrument air supply to 3 - 15 psig for
proper operation.
H1-15
06-08
4. Optional - The make up valve shall include a ANSI Class 125
lb three-valve bypass with inlet Y-type cast iron strainer.
Strainer screen to be removable and of stainless steel
construction.
C. Steam Pressure Reducing Station
1. Option (Mechanical) - _______" steam pressure reducing valve
with cast iron body and _____connections. The valve shall be
a self-contained unit capable of reducing ____psig saturated
steam to the operating pressure of the deaerator at a flow rate
of _____lbs/hr. The valve shall be 250 lb class with stainless
steel trim and an adjustable pilot. The valve manufacturer shall
be _____, Model _____.
2. Option (Pneumatic) - _______" diaphragm actuated steam
pressure reducing valve with cast iron body and _______
connections. The valve shall be globe type with proportional
control and a spring opposed diaphragm actuator arranged for
____psig operating signal. The valve shall be normally closed
on loss of air. The valve shall be capable of reducing _____
psig saturated steam to the operating pressure of the deaerator
at a flow rate of ____lbs/hr. This valve shall be 250 lb class
and have stainless steel trim. The diaphragm actuated valve
manufacturer shall be ________, Model _______. This valve
shall be pneumatically controlled by an external transmitter.
The transmitter set pressure shall be adjustable. The
transmitter manufacturer shall be _________________, Model
_________.
3. Optional - The steam pressure reducing valve shall include a
three valve bypass with Y-type cast iron strainer. Strainer
screen to be removable and of stainless steel construction.
4. Optional - Quantity ______, _______" relief valves sized to
relieve full capacity of the pressure reducing valve in the event
of its failure. Valves to meet Paragraph UG-125 of ASME
Unfired Pressure Vessel Code, Section VIII. Valve body to be of
bronze construction. Relieving set pressure to be 50 psig.
Relief valve manufacturer to be _______________________,
Model____________.
5. Optional - High level alarm switch. This shall be an externally
mounted float type switch. The switch shall make contact on
rise and break on fall. The float cage construction shall be cast
iron. (Not required with electronic make up controller.)
6. Optional - Low level alarm switch. This shall be an externally
fall and break on rise. The float cage construction shall be cast
7. Optional - ________" overflow drainer sized to relieve full
capacity at the operating pressure of the deaerator. The
overflow drainer shall be a float type trap. The construction is
to be a steel housing with stainless steel float ball. The
overflow drainer manufacturer shall be _______, Model
_______.
H1-16
06-08
8. Optional - Suction piping for pumps shall consist of a gate
valve, cast iron Y-type strainer with replaceable stainless steel
screen and flexible connector or hose. This piping assembly
shall be 125 lb class construction. The vortex breaker shall be
located in the tank nozzle. Manifold suction lines are not
acceptable.
D. Boiler Feedwater Pump And Motor Set
1. Option (Intermittent) - Quantity________, turbine type boiler
feedwater pump and motor set. Centrifugal type pumps are not
acceptable in this application. Pump to be rated for _____gpm
at _____feet TDH with ______feet NPSH required. Pump to
be ______materials of construction and have ______seals for
a maximum water temperature of 250 F. Pump impeller to be
hydraulically balanced. The pump shall be mounted on a steel
baseplate and flexibly coupled with an OSHA type coupling
guard to a ____hp, _____phase, ______Hz, ______Volt,
_______rpm, ________enclosure motor. Motor to be non-
overloading at the rated condition without using any portion of
the service factor. Pump and motor set to be factory aligned
prior to shipment. Pump manufacturer to be______________,
Model ________, size ____" x _______".
2. Option (Continuous) - Quantity ______, centrifugal type boiler
feedwater pump and motor set. Turbine type pumps are not
at ______feet TDH with ____feet NPSH required. Pump to be
_______materials of construction as defined by the Hydraulic
Institute and have _______seals for a maximum water
temperature of 250 F. Pump impeller to be hydraulically
balanced. The pump shall be mounted on a steel baseplate
and flexibly coupled with an OSHA type coupling guard to a
_______hp, ______phase, _________Hz, _________Volt,
_____rpm, _______enclosed motor. Motor to be non-
prior to shipment. Pump manufacturer to be _________, Model
_______, size _____" x _______". A stainless steel
recirculation orifice is to be supplied with the pump and
shipped loose for field installation to provide minimum bypass
flow.
3. Optional - The stand shall elevate the deaerator tank to provide
the net positive suction head required by the pump at the rated
condition to prevent cavitation plus a 1-1/2 foot safety factor.
The stand shall be constructed of heavy square steel tubing for
the legs and 1/4" steel plate covering the floor.
E. Control Panel
1. Optional (Base) - Control panel shall be in a NEMA 1 enclosure
and wired to the National Electric Code. The wire shall be
black number coded. The assembly is to contain individual
motor starters with 120 Volt holding coil and fuse protection.
Individual green oil-tight pump run lights shall be provided. All
switches and lights to have nameplate identification. The
assembled panel shall be given a factory continuity test prior to
shipment.
H1-17
06-08
2. Optional (Electric Components) - Audible and visual high and
low water alarm function shall be provided by a bell or horn
with silence switch and individual red oil-tight lights.Control
circuit transformer to supply 110-120 Volts, single-phase
power supply. The transformer shall be mounted, wired and
fused. Auxiliary contacts shall be furnished for chemical feed
pump initiation. Contacts shall be normally open.
3. Standard - The deaerator shall have a gauge glass assembly
that covers the entire tank diameter. The gauge glass shall be
quartz, 0.625 inch diameter by 24 inch maximum length.
Each length of glass shall be furnished with a bronze gauge
cock set and protector rods. The deaerator shall be supplied
with a pressure gauge that has a 4-1/2 inch dial with a 0-60
psig range and a thermometer with a 50 to 300 F range.
Packaged units are required to have both gauges bracket-
mounted at eye level. The deaerator is to be hand cleaned with
a solvent to SSPC- SP-1 standards prior to painting. Prime
coated to not less than 1 mil thick and finish coated with an
enamel paint to not less than 1 mil thick prior to shipment.
Unit is to be knocked down for shipment. Piping is to be
matched marked. Three, bound, Operating and Maintenance
manuals to be provided. Warranty period to be twelve months
after start-up or eighteen months after shipment, whichever
comes first.
H1-18
06-08
Notes
H1b-1
03-08
CONTENTS
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-3
Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-4
Dimensions and Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-6
Return On Investment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-10
Flash Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-10
Exhaust Steam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-10
Surface Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-10
Chemical Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-10
Makeup Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-10
Sewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-10
Intangibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-10
Section H1b
SPRAYMASTER SERIES
DEAERATORS (Single Tank)
Spraymaster Signature Deaerators (Single Tank) Section H
H1b-2
03-08
ILLUSTRATIONS
Figure H1-1. Spraymaster Signature Deaerator Tank Supports and Saddles, Details and Dimensions H1b-7
Figure H1-2. Spraymaster Signature Deaerator Deaerator Dimensions and Ratings (Single Tank) - Sheet 1 of 2
H1b-8
TABLES
Table H1-1. Signature Deaerator Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-4
oxygen and other dissolved gases in boiler feed water. Thus, it is the answer to
maintaining long-lasting boiler equipment for industrial and commercial boiler
users. The Cleaver-Brooks deaerator is constructed of corrosion-resistant alloys for a
long lifetime of service. The deaerator design employs those basic principals of gas
removal that have proven to be the most effective and economical means of proper
operation. Contact your local Cleaver-Brooks authorized representative for
component sizing information.
Section H Spraymaster Signature Deaerators (Single Tank)
H1b-3
03-08
Low Profile Design:
Low elevation and small footprint allows installation in space restricted areas.
Packaged assembly for easy installation and maintenance.
requirements.
removal of these corrosive gases from boiler feedwater.
Angles associated with the water spray valve assembly and water spray pattern
allow deposit-free surfaces to be maintained.
Internal Automatic Check Valves Prevent Back Flooding:
Both the water spray valve and steam atomizing valve are in the normally closed
position under no flow conditions.
Prevents steam back-flow through the water spray valve and water back flow
through the steam atomizing valve.
Ensures a longer life of all wetted materials in intimate contact with corrosive
liquids and the released corrosive gases.
Recovery of flash steam exhaust and turbine steam.
Saves BTUs that would normally be exhausted to atmosphere. This in turn
improves overall system and plant efficiency.
Auto Vent Valve Eliminates Dissolved Gases at Start-Up:
Guaranteed to remove oxygen concentrations to 0.005 cc/liter while operating
between 5% and 100% capacity.
H1b-4
03-08
Carbon dioxide concentrations are practically reduced to zero.
Capacity Not Affected by Mixed Inlet Temperature:
Consistent performance under variable loads and conditions.
Saves BTUs by accepting condensate before cold make-up water. Maintains a
Provides flexibility for selecting a tank for specific applications, limiting the loss
of hot condensate to drain (minimum offering available is 10 minutes of
storage).
Complete packages are pre-fabricated in the manufacturing facility to ensure
piping alignment and control wiring function. The unit is partially disassembled,
and match marked for efficient field re-assembly.
Available in Horizontal Configuration:
Provides adaptability for installation in space restricted areas.
PRODUCT OFFERING
Information in this section applies directly to Cleaver- Brooks packaged
Spraymaster Signature Deaerators ranging from 7,000 to 100,000 pounds/hour.
For larger capacities contact your local Cleaver-Brooks authorized representative.
The product offering for Spraymaster Signature Series Deaerators is shown in Table
H1-1.
MODEL NO.
RATING
(LBS/H)
Typical TANK
CAPACITY
STORAGE CAP.
(MIN)
SS-15 15000 415 10
SS- 30 30000 610 10
SS- 45 45000 1105 10
SS -70 70000 1400 10
SS-100 100000 2485 10
NOTE: Model number designation (example, SM-7) is: SS =Spraymaster
Signature Signature Deaerator. 7 =7,000 lbs/hr rating.
Storage capacities greater than 10 minutes are available. Please contact
your local Cleaver-Books authorized representative.
Table H1-1. Spraymaster Signature Deaerator Product Offering
H1b-5
03-08
The Spraymaster Signature Deaerator is a pressurized low-headroom spray-type
deaerator system designed to remove dissolved oxygen in boiler feedwater to 0.005
cc per liter, or less, and eliminate carbon dioxide. A typical deaerator package
includes the deaerator tank mounted on a stand of appropriate height along with all
operating controls, feed pumps assembled and piped (typically knocked down for
shipment and field assembly). The tank conforms to section VIII of the ASME code.
The main deaerating portion is located internally and consists of a water collector
cone and steam atomizing valve. Built into a flange on top of the tank is a spring
loaded water spray nozzle which includes an automatic and manual vent valve.
Packaged Spraymaster Signature Deaerator systems offer substantial advantages
through, lower cost installation and simplified operation and maintenance.
Spraymaster Signature Spraymaster Signature Deaerators arrive on site ready for
installation and hookup to your water, steam, and electric power connections.
The deaerator stand comes with feed pump/motor set mounted on a base. The base
is specially reinforced to prevent vibration wear on vital system components. Rugged
square structural tubing combines lasting strength with generous working space for
inspection or routine servicing.
Control Panel
The control panel, complete with starters, fuse protection, switches, lights and pre-
wired terminal blocks is mounted on the stand assembly. Wiring to feed pump motor
and all controls is standard.
Deaerator Tank
ASME construction - certified to 50 psig. All tanks provided with manhole,
individual pump suction tappings and other openings as required. Legs are standard
on all sizes. Storage in the vessels is designed for a minimum of 10 minutes.
Piping
Pump and motor sets are mounted directly on the base channel.
Individual suction piping (including strainer, shutoff valve, flexible connector) is
standard and provided for all feed pumps.
Standard Equipment
Spraymaster Signature deaerator.
Deaerator steam inlet atomizing valve.
Deaerator manual and automatic vent.
Gauge glass.
Water temperature thermometer.
Required tappings.
H1b-6
03-08
Optional three valve bypass and strainer (PRV).
Optional three valve bypass and strainer (MUV).
High water alarm.
Low water alarm.
Recirculation orifice.
Suction strainer.
Optional discharge check valve.
Optional discharge shutoff valve.
Optional discharge pressure gauge.
Optional discharge manifold.
Overflow drainer.
Control panel.
Optional chemical feed quill.
Optional vacuum breaker.
Optional insulation and jacket.
Optional tank drain valve.
Optional magnesium anode.
Stand.
Packaging
Dimensions and ratings for Spraymaster Signature Deaerators are shown in Figure
H1-1 and Figure H1-2.
H1b-7
03-08
Figure H1-1. Spraymaster Signature Series Tank Supports, Details and Dimensions
260 415 610 840 1105 1400 2485
A 47 86 86 86 86 86 110
B 53 92 92 92 92 92 116
C 38 38 44.75 44.75 50 52 62
D 40.5 40.5 47.25 48.25 53 55 65.5
E 22.31 22.78 23.59 24.84 25.91 26.78 29.59
F 1.25 1.25 1.25 1.75 1.5 1.5 1.75
G 6 6 6 6 6 6 6
H 10 10 14.37 16 18.25 21.25 23.12
J 48 48 54 60 66 72 84
K 83.31 123.33 124.93 127.36 129.56 131.23 160.58
L 0.87 0.87 0.87 1.12 1.12 1.12 1.12
M 0.75 0.75 0.75 1 1 1 1
T
A
N
K

D
I
A
M
E
T
E
R
OVERALL LENGTH
FOR AN
"M"BOLT
"F"
"H"
"E"
"L"
"G"
"G/2"
"K"
"B"
"A"
"C"
"D" "J"
H1b-8
03-08
Figure H1-2. Spraymaster Signature Series Deaerator Dimensions and Ratings (Single Tank) - Sheet 1 of 2
Note:
1. Packaged units only. Mounted on side stand.
2. Suction piping includes strainer, gate valve and flexible connection.
3. All couplings are 3000# F.S.
4. All flanges are 150# F.F. except as noted.
6. Mount tank above pump at elevation necessary for static head including safe allowance for piping
friction as approved by pump manufacturer.
7. Deaerator tank is built to SAME Code.
8. Accompanying dimensions , while sufficiently accurate for layout purposes, must be confirmed for
construction by certified dimension prints.
9. Add Suffix P to Model No. for packaged units (SSP-45).
10. Dimension B will change depending on controls required - contact your local Cleaver-Brooks
11. No interconnecting piping or wiring furnished on non-packaged units unless specified, contact
your local Cleaver-Brooks representative for specific piping or wiring furnished on packaged
assemblies.
12. Weights shown are without controls or packaging - contact your local Cleaver-Brooks repre-
sentative for additions.
13. Capacities otherthan shown as standard available by proper selection of controls - contact
your local Cleaver-Brooks autherized representative.
14 Optional tank sizes and ratings available - contact your local authorized Cleaver-Brooks repre-
sentative.
15. Lifting lugs are for lifting EMPTY tanks only.
16. For zone IIB Stand dimensions - contact your local Cleaver-Brooks representatve
260 415 610 840 1105 1400 2485 SS7 0.75
48 x 75 48 x 115 54 x 117 60 x 119 66 x 121 72 x 123 84 x 152 SS15 0.75
1400 1800 2100 2400 2900 3200 4200 SS30 0.75
4500 5600 6750 7200 7600 8100 11,100 SS45 0.75
6900 9250 12050 14,450 17,100 20,000 29,700 SS70 1
SS100 1.5
Manual Vent Valve Size RATINGS
Tank Weight (Dry) (lb)
TANK SIZES
Tank Size (Dia x Length)
Package Weight (Total Flooded) (lb)
Package Weight (Total Dry)(lb)
RATINGS FOR
SPRAYMASTER MODEL
SS-7
SS-15
SS-30
SS-45
SS-70
SS-100
6"-150#FF Flg
6"-150#FF Flg
6"-150#FF Flg
6"-150#FF Flg
6"-150#FF Flg
3"-150#RF Flg
2"-150#RF Flg
2.5"-150#RF Flg
Conn. 3 Steam Inlet
1.5"-150#RF Flg
2"-150#RF Flg
Conn. 4 Water Inlet
6"-150#FF Flg 1" NPT.
H1b-9
03-08
Figure H1-2. Spraymaster Signature Deaerator Dimensions and Ratings (Single Tank) - Sheet 2 of 2
X Overall Package Width 81 81 95 98 101 99 117
Y Overall Package Height 157 157 163 169 175 181 205
Z Overall Package Length 87 123.5 125 127.5 129.5 131.5 160.5
A Overall Tank Height 73 73 80 85 91 97 109
B Overall Tank Width 70 68 70.5 76.5 82.5 88.5 100.5
C Front Head 12.31 12.31 13.13 14.37 15.44 16.31 18.81
D High Temperature Return 49 8 8 8 8 8 20
E Level Control 6 18 18 18 18 18 30
F Water Inlet 17.5 37.5 37.5 37.5 37.5 37.5 49.5
G Steam Inlet 37.5 57.5 57.5 57.5 57.5 57.5 69.5
H Relief Valve 49 70 70 70 70 70 82
J Relief Valve N/A 78 78 78 78 78 90
K Spare N/A 86 86 86 86 86 98
Spare N/A N/A N/A N/A N/A N/A 106
L Drain 46 85 85 85 85 85 97
M Overflow REAR HEAD 75 75 75 75 75 87
N Overflow 1.56 1.59 4.62 7.62 10.87 13.81 18.25
OVERALL DIMENSIONS (TANK AND STAND)
TANK DIMENSIONS
260 415 610 840 1105 1400 2485
A1 Overall Length 52 91 91 91 91 91 116
B2 C/L to C/L Bolt Holes 47 86 86 86 86 86 110
C3 Overall Width 72.75 72.75 72.75 72.75 78 80 91
D4 C/L to C/L Bolt Holes 68.25 68.25 68.25 68.25 73.5 75.5 86.5
E5 Hole Size 1.37 1.37 1.37 1.37 1.37 1.37 1.37
F6 Anchor Bolt Size 1.25 1.25 1.25 1.25 1.25 1.25 1.25
STAND DIMENSIONS -FOR ZONE IV- see note 16.
1 Relief Valve Size / Quantity
2 Overflow Size 3" NPT 3" NPT 3" NPT 3" NPT 4"-150#FF 4"-150#FF 4"-150#FF
3 Steam Inlet Size 6"-150#FF 6"-150#FF 6"-150#FF 6"-150#FF 6"-150#FF 6"-150#FF 6"-150#FF
4 Water Inlet Size 8"-150#FF 8"-150#FF 8"-150#FF 12"-150#FF 12"-150#FF 12"-150#FF 12"-150#FF
5 High Temperature Return Size 1 1/2" NPT 2" NPT 2" NPT 2" NPT 3" NPT 3" NPT 3" NPT
6 Drain Size 2" NPT 2" NPT 2" NPT 2" NPT 2" NPT 2" NPT 2" NPT
7 Suction Size 2.5" NPT 2.5" NPT 2.5" NPT 2.5" NPT 3"-150#FF 3"-150#FF 4"-150#FF
8 Thermometer 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT
9 Sample 1/2" NPT 1/2" NPT 1/2" NPT 1/2" NPT 1/2" NPT 1/2" NPT 1/2" NPT
10 Chemical Feed 1" NPT 1" NPT 1" NPT 1" NPT 1" NPT 1" NPT 1" NPT
11 Recirculation 1.5" NPT 1.5" NPT 1.5" NPT 1.5" NPT 1.5" NPT 1.5" NPT 2" NPT
13 Level Controller 1.5" NPT 1.5" NPT 1.5" NPT 1.5" NPT 1.5" NPT 1.5" NPT 1.5" NPT
14 Make-Up Valve
15 Pressure Gauge 1/4" NPT 1/4" NPT 1/4" NPT 1/4" NPT 1/4" NPT 1/4" NPT 1/4" NPT
16 Control Panel Per Design Per Design Per Design Per Design Per Design Per Design Per Design
17 Feed Pump/Motor Per Design Per Design Per Design Per Design Per Design Per Design Per Design
18 Suction Piping Per Design Per Design Per Design Per Design Per Design Per Design Per Design
19 Manway Size - SSP 15-70 12" x 16" 12" x 16" 12" x 16" 12" x 16" 12" x 16" 12" x 16" N/A
20 Manway Size - SSP 100 N/A N/A N/A N/A N/A N/A 14" x 18"
21 Level Alarms 1" NPT 1" NPT 1" NPT 1" NPT 1" NPT 1" NPT 1" NPT
22 Overflow Drainer Per Design Per Design Per Design Per Design Per Design Per Design Per Design
Contact Your Local Cleaver-Brooks Authorized Representative
H1b-
03-08
2Na
2
SO
3
+O
2
2Na
2
SO
4
Flash steam
Exhaust steam
Blowdown
Chemical treatment
Sewer
Intangibles
in an atmospheric vessel application. This flash steam loss can result in an energy
loss and associated fuel cost. Returning condensate to a pressurized vessel
decreases the amount of flash steam created and reduces losses to atmosphere.
related to cycles of concentration in the boiler. The additional blowdown loss can
result in an energy loss and associated fuel cost. The additional surface blowdown
may also result in an increase in capital expenditure for a larger blowdown heat
recovery system.
2
S0
3
to
scavenge 1 ppm of dissolved O
2
costs.
costs.
H1b-11
03-08
Section H1b
Spraymaster Signature Series Deaerators (Single Tank)
Packaged Deaerator Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-12
Deaerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-12
Deaerator Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-12
Deaerator Load Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-13
Deaerator Standard Trim and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-13
Deaerator Make-Up Valve and Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-13
Deaerator Steam Pressure Reducing Valve (PRV) Station . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-13
Deaerator Safety Relief Valve(s) (SRV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-14
Deaerator Water Level Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-14
Deaerator Overflow Drainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-14
Deaerator Suction Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-14
Boiler Feedwater Pump And Motor Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-14
Deaerator Support Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-15
Deaerator Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-15
Electric Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-15
Deaerator Preparation and Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-16
Deaerator Manuals and Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1b-16
Spraymaster Signature Series Deaerators (Single Tank) Section H
H1b-12
03-08
PART 1 GENERAL 1.1 PACKAGED DEAERATOR SPECIFICATION
A. Provide one (1) Cleaver-Brooks Model SSP_____Signature Series
spray type, pressurized, horizontal deaerator rated at _____pounds
per hour. The system shall be a single tank design. Performance is
guaranteed to remove oxygen to not more than 0.005 ccs/liter in the
effluent throughout all load conditions between 5 and 100 percent
with a 20:1 turndown ratio. The deaerator shall be designed for
operation at 5 PSIG, but shall be suitable for use from 2 to 15 PSIG.
Feedwater, low and medium temperature condensate shall be
admitted to the deaerator through a single spring-loaded, self-
cleaning, adjustable stainless steel spray valve, which shall provide
proper internal vent condensing and water distribution at any load
between 5 and 100 percent of rated capacity.
PART 2 PRODUCTS 2.1 DEAERATOR
A. The water temperature in the primary heating and vent
concentrating section is to be raised within 2 to 3 F of steam
saturation temperature causing the majority of non-condensable
gases to be released. The water is then to be collected in a stainless
steel conical water collector. From the collector, it shall flow to an
atomizing valve where high velocity steam shall contact the water
stream and break it into a fine mist. At this stage, the water shall be
heated to full steam saturation temperature. The mixture is to strike
a deflecting baffle, which separates water and steam. Hot, gas-free
water shall then drop to the storage compartment of the pressure
vessel to complete the deaeration process. The non-condensable
gases released during the process and steam shall flow upward,
through the primary heating spray portion, into the internal vent
concentrating section, where they contact the cold influent water.
Here, the steam is to be condensed to continue the cycle. Released
gasses are discharged to atmosphere through the vent outlet.
B. All internal surfaces, which come in contact with un-deaerated
water, shall be constructed of Type 316 stainless steel. An automatic
vent valve shall be thermostatically controlled to provide a swift
means of venting during a sudden buildup of gases. This condition is
most typically seen at start up. The manual vent valve shall contain
a fixed orifice for continuous venting. Venting rate shall not exceed
0.1 of 1% of the rated deaerator capacity at 5 PSIG.
2.02 DEAERATOR VESSEL
A. The deaerated water storage tank shall have a minimum of 10
minutes of storage and have a capacity of _____gallons measured to
overflow. The tank shall be _____diameter x _____long. A 12 x 16
inch elliptical manway shall be provided for access to the deaerator.
All nozzles 3" and under shall be 3000 lbs. forged steel couplings.
All nozzles over 3" shall be 150 lbs. flat face flanges. Heads to be
ASME torispherical type constructed of ASTM A516 GR 70 carbon
steel with a minimum thickness of 0.25 inches. Shell plate to be
fabricated of ASTM A36 carbon steel with a minimum thickness of
0.25 inches. The tank shall be designed in accordance with ASME,
Section VIII of the Pressure Vessel Code for 50 PSIG at 650 ?F and
stamped accordingly. Certification shall be required. Joint
efficiencies to be 70% circumferential per Table UW-12, which does
not require stress relieving or nondestructive examination.
Section H Spraymaster Signature Series Deaerators (Single Tank)
H1b-13
03-08
B. A quantity of two (2) , inch tappings for water sampling and
chemical injection shall be provided under the water line.
2.03 DEAERATOR LOAD SPECIFICATION
2.04 DEAERATOR STANDARD TRIM AND ACCESSORIES
A. The basic deaerator shall be equipped with the following trim and
accessories. Piping on packaged units shall comply with ASME
Power Piping Code B31.1.
2.05 DEAERATOR MAKE-UP VALVE AND CONTROLLER
A. A _____" inlet make-up water regulating valve with bronze body and
threaded NPT connections that is electronically actuated. The valve
shall be a globe style Siemens Flowrite VF 599 Series two-way
valve designed to operate with an electronic actuator with a 3/4-
inch (20 mm) stroke. The electronic actuator shall be the Siemens
Flowrite EA 599 Series SKB/C Electronic Valve Actuator. The
actuator shall receive a 0 to 10 Vdc or a 4 to 20 mA control signal
to proportionally control the valve. The valve shall be rated for
_____GPM at _____PSIG inlet pressure. The valve shall meet ANSI
leakage class IV (0.01% of Cv) shutoff standards. The valve shall be
normally closed, with stainless steel trim, linear control, include
Teflon V-ring packing and be suitable for temperatures up to 330F.
B. A McDonnell & Miller 93-7B level controller shall electronically
control the make-up valve.
C. The make-up valve shall optionally be included in an assembly
using an ANSI Class 125 LB three-valve bypass with inlet Y-type
cast iron strainer. Strainer screen to be removable and of stainless
steel construction.
2.06 DEAERATOR STEAM PRESSURE REDUCING VALVE (PRV) STATION
A. A _____" steam pressure reducing valve with cast iron body and
______connections. The valve shall be a self-contained unit
capable of reducing _____PSIG saturated steam to the operating
pressure of the deaerator at a flow rate of _____LBS./HR. The valve
shall be 250 lb. class with stainless steel trim and an adjustable
pilot. The valve manufacturer shall be Spence, Model _____.
Raw Make up GPM 25 psig Minimum
Low Temperature Returns
(Less than 200 F
10 psig Minimum
Med. Temp Returns
(200 - 230 F)
10 psig Minimum
High Temp Returns
(greater than 230 F)
Not To Exceed 25%
Load Specifications
H1b-14
03-08
B. The steam pressure reducing valve shall optionally be included in
an assembly using a three valve bypass with Y-type cast iron
strainer. Strainer screen to be removable and of stainless steel
construction.
2.07 DEAERATOR SAFETY RELIEF VALVE(S) (SRV)
A. Include a quantity of _____, _____" relief valves sized to relieve full
capacity of the pressure reducing valve in the event of its failure.
Valves to meet Paragraph UG-125 of ASME Unfired Pressure Vessel
Code, Section VIII. Valve body to be of _____construction. Relieving
set pressure to be 50 PSIG. Relief valve manufacturer to be Kunkle,
Model _____.
2.08 DEAERATOR WATER LEVEL ALARMS
A. A NEMA 1 high water alarm shall be an externally mounted float
type switch. The switch shall make contact on rise and break on
fall. The float cage construction shall be cast iron.
B. A NEMA 1 low water alarm shall be an externally mounted float
type switch. The switch shall make contact on fall and break on
rise. The float cage construction shall be cast iron.
C. A NEMA 1 low-water cutout alarm and switch shall be an externally
mounted float type switch. The switch shall make contact on fall
and break on rise. The float cage construction shall be cast iron. The
cutout will protect the pumps from a dry-run condition.
2.09 DEAERATOR OVERFLOW DRAINER
A. A _____ overflow drainer sized to relieve full capacity at the
operating pressure of the deaerator. The overflow drainer shall be a
float type trap. The construction is to be a steel housing with
stainless steel float ball. The overflow drainer manufacturer shall be
B. Warren Model _____.
2.010 DEAERATOR SUCTION PIPING
A. Suction piping for pumps shall consist of a _____gate valve, cast
iron Y-type strainer with replaceable stainless steel screen and
flexible connector or hose. This piping assembly shall be 125 LB
class construction. The vortex breaker shall be located in the tank
nozzle.
2.011 BOILER FEEDWATER PUMP AND MOTOR SET
Pumps may be selected to run either on/off or intermittent.
Intermittent
A. Quantity _____, vertically oriented, multistage centrifugal type boiler
feedwater pump and motor set. Pump to be rated for _____GPM at
_____feet TDH with _____feet NPSH required. Pump to be _____
materials of construction and have mechanical seals for a maximum
water temperature of 250 F. Pump impeller to be hydraulically
balanced. The pump shall be mounted on a steel baseplate channel
and flexibly coupled with an OSHA type coupling guard to a _____
HP, _____phase, _____Hz, _____Volt, _____RPM, _____
enclosure motor. Motor to be non-overloading at the rated condition
without using any portion of the service factor. Pump and motor set
Section H Spraymaster Signature Series Deaerators (Single Tank)
H1b-15
03-08
to be factory aligned prior to shipment. Pump manufacturer to be
Grundfos Model _____k
Continuous
B. Quantity _____, vertically oriented, multistage centrifugal type boiler
_____feet TDH with _____feet NPSH required. Pump to be _____
materials of construction and have mechanical seals for a maximum
balanced. The pump shall be mounted on a steel baseplate channel
and flexibly coupled with an OSHA type coupling guard to a _____
HP, _____phase, _____Hz, _____Volt, _____RPM, _____
enclosure motor. Motor to be non-overloading at the rated condition
without using any portion of the service factor. Pump and motor set
to be factory aligned prior to shipment. Pump manufacturer to be
Grundfos Model _____k A stainless steel recirculation orifice is to be
supplied with the pump and shipped loose for field installation to
provide minimum bypass flow.
2.012 DEAERATOR SUPPORT STAND
A. The _____feet high stand shall elevate the deaerator tank to provide
condition to prevent cavitation plus a 2 foot safety factor. The stand
shall be constructed of heavy square steel tubing.
B. The stand shall be designed for Seismic Zone 2B.
C. Calculations for Seismic Zone 2B or a design upgrade to Seismic
Zone 4 may be provided optionally.
2.013 DEAERATOR CONTROL PANEL
A. Control panel shall be in a NEMA 1 enclosure and wired to the
National Electric Code. The wire shall be black number coded. The
assembly is to contain individual motor starters with 120 Volt
holding coil and fuse protection. Individual oil-tight pump run lights
shall be provided. All switches and lights to have nameplate
identification. The assembled panel shall be given a factory
continuity test prior to shipment.
2.014 ELECTRIC COMPONENTS
A. Audible and visual high, low-water and low-water cutout alarm
functions shall be provided by a bell, horn or electronic sounder
with silence switch and individual oil-tight lights. Control circuit
transformer to supply 110-120 Volts, single-phase power supply.
The transformer shall be mounted, wired and fused. Auxiliary
contacts shall be optionally furnished per customers requirements.
Contacts shall be normally open.
B. The deaerator shall have a gauge glass assembly that covers the
operating range of the unit. The gauge glass shall be quartz, 0.625
inch diameter by 24 inch maximum length. Each length of glass
shall be furnished with a bronze gauge cock set and protector rods.
The deaerator shall be supplied with a pressure gauge that has a 4-
1/2 inch dial with a 0-60 PSIG range and a thermometer with a 50
to 300 ?F range.
H1b-16
03-08
2.015 DEAERATOR PREPARATION AND PACKAGING
A. The deaerator is to be hand cleaned with a solvent to SSPC- SP-1
standards prior to painting. Prime coated to not less than 1 mil thick
and finish coated with enamel paint to not less than 1 mil thick
prior to shipment.
B. The deaerator vessel, stand, controls and piping shall be packaged
together as a complete system. The unit is to be disassembled for
shipment. Piping is to be matched marked for ease of reassembly.
PART 3 EXECUTION 3.1 DEAERATOR MANUALS AND WARRANTY
A. All units shall include three (3) bound, Operating and Maintenance
manuals. The warranty period to be not less than twelve months
after start-up or eighteen months after shipment, whichever comes
first.
B. Deaerator Options for Trim and Accessories
1. The tank shall be optionally factory-insulated and lagged with
blanket insulation, pins, clips, and a durable steel jacket. The
blanket insulation is to be fiberglass, 2" thick, 1 LB/CU-FT, and
have a rating of R3.85. Pins are to be located on 18" centers
and holding clips attached. The steel jacket or lagging shall
have a shell thickness of 22 gauge (0.299") minimum and
head thickness of 12 gauge (0.1046") minimum.
2. The optional magnesium or sacrificial anode shall provide
cathodic protection against galvanic corrosion. This rod shall
be 1-5/16" diameter with a 1/4" steel core to assure a good
small weep hole to signal it has been consumed.
3. The optional chemical feed quill shall be located beneath the
4. Additional discharge piping, manifold piping and recirculation
piping may be provided optionally.
H2-1
03-08
CONTENTS
ILLUSTRATIONS
Figure H2-1. Spraymaster Duo-Tank Supports and Saddles, Details and Dimensions . . . . . . . . . . H2-4
Figure H2-2. Spraymaster Deaerator (Duo-Tank) Dimensions and Ratings - Sheet 1 of 3 . . . . . . . . H2-5
TABLES
Table H2-1. Spraymaster Deaerator Duo-Tank Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-4
Section H2
SPRAYMASTER DEAERATORS (Duo-Tank)
Spraymaster Deaerators (Duo-Tank) Section H
H2-2
03-08
The Duo Tank product combines a surge tank with a Spraymaster deaerator into a single combined vessel,
providing a complete engineered and packaged system.
The Cleaver-Brooks designed deaerator assures high purity effluent by removing oxygen and other dissolved
gases in boiler feed. Thus, it is the answer to long-lasting boiler equipment for industrial and commercial boiler
users. Built of corrosion- resistant alloys for lifetime service, the deaerator employs those basic principles of gas
removal proven most effective and economical to every boiler owner. Contact your local Cleaver-Brooks
authorized representative for component sizing information.
Section H Spraymaster Deaerators (Duo-Tank)
H2-3
03-08
The Duo Tank product combines a surge tank with a Spraymaster deaerator in to a
single combined vessel, providing the following features and benefits in addition to
the benefits of the deaerator and surge tank independently.
Double Inner Head Separates the Deaerator Pressure Vessel From Surge
Tank:
Ensures the deaerator and surge tank are two separate vessels while structurally
attached for space considerations. This also limits heat transfer from the
deaerator pressure vessel to the surge atmospheric vessel, preventing energy
loss due to surge tank water boiling.
Vented and Insulated Gap Between the Deaerator and Surge Tank:
Insulation is placed between the double inner head to further limit heat transfer
from the deaerator pressure vessel to the surge atmospheric vessel. A vent is
placed between the double inner head to allow moisture evaporation eliminating
corrosion potential.
Low Profile Design:
Low head room allows for installation in space restricted areas.
Complete packages are pre-fabricated in the Cleaver-Brooks manufacturing
facility to ensure piping alignment and control wiring function. The unit is
disassembled, match marked for efficient field re-assembly.
PRODUCT OFFERING
Information in this section applies directly to Cleaver-Brooks packaged Spraymaster
Deaerators in duo-tank arrangement ranging from 7000 to 280,000 lbs/hr.
The product offering for Duo-Tank packaging is a combination of the product offering
for the Spraymaster Deaerator and the Surge Tank. The combined package product
offering for Duo-Tank products is shown in Table H2-1
Dimensions and ratings are shown in Figure H2-1 and Figure H2-2
H2-4
03-08
230 300 600 900 1400 2000 2800 4000 5600
AA 81-1/2 108-1/2 N/A N/A N/A N/A N/A N/A N/A
AB 875-1/2 114-1/2 N/A N/A N/A N/A N/A N/A N/A
AC 31-3/4 40-1/4 N/A N/A N/A N/A N/A N/A N/A
AD 29-1/2 38 N/A N/A N/A N/A N/A N/A N/A
AE 6-1/8 7-3/8 N/A N/A N/A N/A N/A N/A N/A
AF 2 3 N/A N/A N/A N/A N/A N/A N/A
AG 4 6 N/A N/A N/A N/A N/A N/A N/A
AH 1-1/8 1-1/4 M/A N/A N/A N/A N/A N/A N/A
AJ 12-1/2 16-1/2 N/A N/A N/A N/A N/A N/A N/A
AK 7/8 7/8 N/A N/A N/A N/A N/A N/A N/A
AL 3/4 3/4 N/A N/A N/A N/A N/A N/A N/A
AM N/A N/A 148 169-1/2 231-1/2 270 257 245-1/2 281
AN N/A N/A 154 175-1/2 237-1/2 276 263 251-1/2 287
AP N/A N/A 51-1/2 57 62 67 77-1/2 88 98-3/4
AR N/A N/A 44-3/4 44-3/4 50 52 62 72 83
AS N/A N/A 3-3/8 6-18 6 7-1/2 7-3/4 8 7-7/8
AT N/A N/A 16-1/2 18-3/4 20 25 22-1/2 31-5/8 34
Figure H2-1. Spraymaster Duo-Tank Supports and Saddles, Details and Dimensions
MODEL NO. SD-7 SD-15 SD-30 SD-45 SD-70 SD-100 SD-40 SD-200 SD-280
Rating (lbs/hr) 7000 15000 30000 45000 70000 100000 140000 200000 280000
Deaerator Gallons
to Overflow
230 300 600 900 1400 2000 2800 4000 5600
Deaerator Storage
Capacity (min)
16 10 10 10 10 10 10 10 10
Surge Gallons to
Flooded
160 300 600 900 1400 2000 2800 4000 5600
Surge Storage
Capacity (Min)
11.5 10 10 10 10 10 10 10 10
NOTE: Model designation (example SD-7) is: S =Spraymaster Deaerator, D =Duo-tank, 7 =7,000 lbs/h rating,
combined deaerator and surge tank package.
Table H2-1. Spraymaster Deaerator Duo-Tank Offering
H2-5
03-08
NOTES:
1. Mounted at dim. "H" (top of tank) on non-packaged units.
2. Tank mounted on non-packaged unit.
3. Packaged units only. Mounted on left end, right side of stand on 48" dia. 450 gal, 66" dia. 1400 gal & 72" dia. 2000 gal units as shown.
5. Discharge piping includes gate valve, check valve, control valve, by-pass orifice, and pressure gauge.
6. All couplings are 3000#F.S.
7. All flanges are 150#F.F. except as noted.
8. Two water and steam inlets used, one shown.
10. Mount tank above pump at elevation necessary for static head including safe allowance for piping friction as approved by pump manufacturer.
11. Deaerator section of tank is built to ASME Code.
13. Add suffix "P" to Model no. for packaged units (SDP-45).
14. Optional tanks available for 5 minutes storage (except SDP-7 & SDP-15), other combinations of capacities as required - contact your local Cleaver-Brooks
15. Using Warren #377 float cage (except SM7 which uses MCD-M #51), dimension "B" may change with other controls - contact your local Cleaver-Brooks au-
thorized representative.
16. No interconnecting piping or wiring furnished on non-packaged units unless specified, contact your local Cleaver-Brooks authorized representative for specific
piping or wiring furnished on packaged assemblies.
17. Weights shown are without controls or packaging - contact your local Cleaver-Brooks authorized representative for additions.
18. Capacities other than shown as standard available by proper selection of controls - contact your local Cleaver-Brooks authorized representative.
19. Optional tank sizes and ratings available - contact your local Cleaver-Brooks authorized representative.
21. Raw water make-up should first pass through a water softener if hardness is present.
22. All dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimensional prints.
Figure H2-2. Spraymaster Deaerator (Duo-Tank) Dimensions and Ratings - Sheet 1 of 3
H2-6
03-08
STORAGE TANK DETAIL AND DIMENSIONS
SPRAYMASTER
MODEL NO.
SM-7D SM-15D SM-30D SM-45D SM-70D SM-100D SM-140D
SM-200D
8
SM-280D
8
Ratings (lb/h) 7000 15000 30000 45000 70000 100000 140000 200000 280000
Tank Weight (lbs) 1530 2500 3650 4500 6770 8810 10760 12975 18735
Tank Weight Flooded
(lbs)
5165 10835 17720 24440 38450 52310 68045 80290 106475
Tank Cap-Deaerator
(Gal to Overflow)
230 300 600 900 1400 2000 2800 4000 5600
Storage Cap (Min) 16 10 10 10 10 10 10 10 10
Tank Cap-Rec Section
(Gal to Flooded)
160 300 600 900 1400 2000 2800 4000 5600
Storage Cap (Min) 11.5 10 10 10 10 10 10 10 10
Tank Size (Dia x Length) 36 x 106-1/2 48 x 141-1/2 54 x 181 60 x 207 66 x 270-1/2 72 x 302 84 x 302-1/4 96 x 308-3/4 108 x 349
A Overall Height 58 66-1/2 74-1/2 80-1/2 88 96-1/2 109 120-1/2 133
B Overall Width 51 62 68 75 80 87 99 111 123
C 8-1/2 10-1/2 11-1/2 12-1/2 13-1/2 14-1/2 16-1/2 18-5/8 20-3/4
D 28-1/2 72-1/2 92-1/2 101 146 164 146 4 136 4 153
E 43 54-1/2 74 83 124 142 124 24 116 24 133
F 48-1/2 34-1/2 54 63 104 122 104 44 96 48 109
G 11 16 31 42 68 68 73 60 59
H 21 26 45 54 80 104 86 82 98
J Contact Your Local Cleaver-Brooks Authorized Representative
K Contact Your Local Cleaver-Brooks Authorized Representative
L Contact Your Local Cleaver-Brooks Authorized Representative
M Contact Your Local Cleaver-Brooks Authorized Representative
N 52 56 90 102 144 164 147 130 144
P N/A 31 50 32 35 36 28 35 28
R N/A 47 65 74 115 132 126 106 123
S Consult Your Local Cleaver-Brooks Authorized Representative
T 38 60 90 27 27 32 27 36 27
W 64 90 109 126 169 224 205 160 186
X Consult Your Local Cleaver-Brooks Authorized Representative
Y 69 95 120 145 198 192 177 196 196
z 85 115 155 171 230 266 258 258 249
KK 2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-3/4 2-3/4
LL 1/2 3/4 3/4 3/4 1 1-1/2 2 2 @ 1-1/2 2 @ 2
MM 3 6 6 10 6 6 8 12 12
NN 10 C
L
4 7 6-1/2 8 14-1/2 26-1/2 27-1/2
PP 68 94 112 127 180 197 173 175 191
RR 74 101 120 133 200 227 205 201-1/2 211
SS 72 95 126 138 188 214 183 190 229
TT 82 109 144 160 218 243 232 213 249
W
W
75 108 132 153 208 267 249 206 279
XX Consult Your Local Cleaver-Brooks Authorized Representative
YY 12 16 19 22 24 27 31 36 40
ZZ 10 12-1/2 16 19-1/2 22 25 30 34-1/2 40
H2-7
03-08
STAND BASE DIMENSIONS
TANK CAPACITY (GAL) 230 300 600 900 1400 2000 2800 4000 5600
A1 Outside Length 87 115 154 175-1/2 237-1/2 276 268 144 297
B2 C
L
to C
L
Anchor Bolt
Holes
82 110 148 169-1/2 230-1/2 269 265 137 294
C3 Outside Width 49 62 66 71 76 81 86-1/2 102 112
D4 C
L
to C
L
Anchor Bolt
Holes
46 59 63 68 73 78 79-1/2 99 101
E5 3/4 1 1 1 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8
F6 5/6 7/8 7/8 7/8 1 1 1 1 1
TANK CONNECTION SIZES
1 Relief-Valve(s) Contact Your Local Cleaver-brooks Authorized Represaentative
2 Overflow (Dea) 1-1/4 NPT 3 NPT 3 NPT 3 NPT 4 FLG 4 FLG 4 FLG 6 FLG 6 FLG
3 Pump Suction (Optional) Contact Your Local Cleaver-Brooks Authorized Representative
4 Steam Inlet (Dea Flg) 3 6 6 6 6 6 8 2 @ 6 2 @ 8
5 High Temp Return 1-1/4 NPT 1-1/2 NPT 2 NPT 2 NPT 3 NPT 3 NPT 3 NPT 2 @ 3 NPT 2 @ 3 NPT
6 Water Inlet (150#RF Flg) 1 NPT 1-1/2 2 2 2-1/2 3 4 2 @ 3 2 @ 4
7 Drain (Dea) 1-1/4 NPT 2 NPT 2 NPT 2 NPT 2 NPT 2 NPT 2 NPT 2 NPT 2 NPT
8 Overflow (Rec) 2 NPT 2 NPT 2 NPT 3 NPT 3 NP 3 NPT 4 NPT 4 NPT 6 NPT
9 Pump Suction (Optional) Contact Your Local Cleaver-Brooks Authorized Representative
10 Vent (Rec) 3 NPT 3 NPT 3 NPT 3 NPT 4 NPT 4 NPT 4 NPT 4 NPT 6 NPT
11 Low Pressure Return
(Rec)
2 NPT 2 NPT 3 NPT 3 NPT 3 NPT 3 NPT 4NPT 4 NPT 6 NPT
12 Cold Water Inlet (Rec) 2 NPT 2 NPT 2 NPT 2 NPT 2 NPT 2 NPT 2 NPT 2 NPT 3 NPT
13 Drain (Rec) 1-1/4 NPT 2 NPT 2 NPT 2 NPT 2 NPT 2 NPT 2 NPT 2 NPT 2 NPT
ITEM LIST
14 Suction Pump, (optional) (For each pump) (Note 4)
15 Pump/Motor, (optional)
16 Control Panel, (optional)
17 Manway 11 x 15
18 Overflow Drainer, (optional)
19 Make-Up Valve, (optional)
21 Pressure Gauge
22 Thermometer (3/4 NPT)
Sizes listed for items 22 thru 29
are for tank connections only.
23 Level Alarms (1 NPT), (optional)
24 Level Control (1-1/2 NPT), (optional)
25 Sample Connection (1/2 NPT)
26 Recirculation Connection (1 NPT), (optional) (For each pump)
27 High Temp Return Connection-Rec (3 NPT)
28 Diffuser Tube (2-1/2 NPT, (optional)
29 Breather Connection (1/2 NPT -Do Not Plug)
30 Discharge Piping, (optional) (For each pump) (NOTE 5)
H2-8
03-08
Notes
H2-9
03-08
Section H2
Spraymaster Deaerators (Duo-Tank)
Deaerator and Surge Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-10
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-12
Boiler Feedwater Pump and Motor Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-14
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-16
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2-17
H2-10
03-08
PART 1 GENERAL The following sample specifications are provided by Cleaver-Brooks to assist you in
specifying your customers specific needs and application.
1.1 DEAERATOR AND SURGE TANK
A. Cleaver-Brooks Model _________spray type, pressurized, horizontal
deaerator is rated at _____pounds per hour. The system shall be
guarantee oxygen removal to not more than 0.005 CCS/liter in the
effluent throughout all load conditions between 5 and 100 percent.
The deaerator shall be designed for operation at 5 psig, but shall be
suitable for use from 2 to 15 psig.
B. The surge tank shall receive returning condensate and supplement
make up water to maintain the desired operating level. Condensate
and make up water mix into a blended temperature, as determined
by the percentage of each. The surge tank shall be vented to
atmosphere. The collected water is then transferred to the deaerator.
C. The collected water shall be admitted to the deaerator through a
single spring-loaded, self-cleaning, adjustable stainless steel spray
valve, which shall provide proper internal vent condensing and water
distribution at any load between 5 and 100 percent of rated
capacity. The water temperature in the primary heating and vent
concentrating section is to be raised within 2 or 3 F of steam
temperature and most of the gases released. The water is then to be
collected in a conical water collector. From there, it is to flow to an
atomizing valve where high velocity steam strikes it, breaks it down
into a fine mist, and heats it to a full steam saturation temperature.
The mixture is to strike a deflecting baffle, which separates water
and steam. Hot, gas-free water is to then drop to the storage
condensables are to flow upward, through the primary heating spray,
into the internal vent concentrating section, where they contact the
cold influent water. Here, the steam is to be condensed to continue
the cycle. Released gasses are discharged to atmosphere through
the vent outlet. All internal surfaces, which come in contact with un-
deaerated water, shall be constructed of Type 316 stainless steel.
D. Automatic vent valve shall be thermostatically controlled to provide
a fast means of venting when a sudden buildup of gases occurs,
such as seen at start up. The manual vent valve shall have an orifice
for continuous minimum venting. Venting rate shall not exceed 0.1
of 1% of the rated deaerator capacity at 5 psig.
E. The duo tank shall be divided into two separate sections. The
deaerator water storage and condensate surge section shall be
divided by a double inner head. The dead air space between the two
inner heads shall be packed with a fiberglass insulation and have a
breather and drain connection. The duo tank shall be _____"
diameter and _____" long.
H2-11
03-08
F. The deaerated water storage tank section shall have _____minutes
of storage and have a capacity of _______gallons measured to
overflow. An _________manhole shall be provided for access. All
nozzles 3" and under shall be 3000 lbs forged steel couplings and
over 3" shall be 150 lbs flat face flanges. Heads to be ASME
torispherical type constructed of ASTM A516 GR 70 carbon steel
with a minimum thickness of 0.25 inches. Shell plate to be
0.25 inches. The tank shall be designed in accordance with ASME,
Section VIII of the Pressure Vessel Code for 50 psig at 650 delta-F
and stamped accordingly. Certification shall be required. Joint
G. The surge tank section shall have __________minutes of storage
and have a capacity of _______gallons flooded. An _________
manhole shall be provided for access. All nozzles shall be 3000 lbs
forged steel couplings. Heads to be ASME torispherical type (flat
heads are not acceptable) constructed of ASTM A516 GR 70 carbon
steel with a minimum thickness of 0.25 inches. Shell plate to be
0.25 inches.
H. The loads shall be as specified in the table above. Low temperature
returns are defined as condensate with a temperature below that of
the deaerator operating temperature. High temperature returns are
defined as condensate with a temperature above that of the
deaerator operating temperature.
I. Optional - The surge tank section shall be designed in accordance
with Section VIII of the ASME Pressure Vessel Code for ________
psig, and stamped accordingly. Certification shall be required. Joint
J. Optional - The duo tank shall be factory-insulated and lagged with
blanket insulation, pins, clips, and a durable steel jacket. Block-type
insulation is not acceptable. The blanket insulation is to be
fiberglass, 2" thick, 1 lb/cu-ft, and have a rating of R3.85. Pins are
to be located on 18" centers and holding clips attached. The steel
jacket or lagging shall have a shell thickness of 18 gauge (0.0478")
minimum and head thickness of 18 gauge (0.0478") minimum.
K. Optional - The magnesium or sacrificial anode shall provide cathodic
protection against galvanic corrosion. This rod shall be 1-5/16"
diameter with a 1/4" steel core to assure a good electrical contact
and added strength. The design shall have a small weep hole to
signal it has been consumed. Linings shall not be acceptable in this
application.
L. Optional - The high temperature diffuser or sparge tube shall be
located beneath the normal tank water level. The tube shall be
constructed of 2 inch pipe. This tube shall provide even distribution
and blending of high-temperature condensate returns.
M. Optional - The chemical feed quill shall be located beneath the
normal tank water level. The quill material shall be constructed of
stainless steel. The tube shall provide even distribution and blending
of chemical.
H2-12
03-08
N. Optional - The basic deaerator section shall be equipped with the
A. Make Up Valve and Controller
not exceed ______and be rated for _____gpm at ______psi
___________, Model _____. This valve shall be mechanically
___________________, Model ______.
shall be 110V bi-directional type with a permanently
lubricated gear train, and be directly coupled to the valve stem.
The valve Cv shall not exceed _____and be rated for_____
gpm at ______psig inlet pressure. Valve shall not exceed a
delta-P of 10 psig. This valve shall have teflon seats and be
suitable for temperatures up to 300 F. The motorized valve
manufacturer shall be ____. This valve shall be electronically
exceed a delta-P of 10 psig.This valve shall have stainless
be ___________, Model _____. This valve shall be
_________, Model ______. A filter regulator is to be provided
to reduce 50 psig instrument air supply to 3 - 15 psig for
proper operation.
H2-13
03-08
4. Optional - The make up valve shall include an ANSI Class 125
construction.
A. Steam Pressure Reducing Station
be ____________, Model _____.
______psig operating signal. The valve shall be normally
closed on loss of air. The valve shall be capable of reducing
_____psig saturated steam to the operating pressure of the
deaerator at a flow rate of ____lbs/hr. This valve shall be 250
lb class and have stainless steel trim. The diaphragm actuated
valve manufacturer shall be __________, Model ____. This
valve shall be pneumatically controlled by an external
transmitter. The transmitter set pressure shall be adjustable.
The transmitter manufacturer shall be ______________, Model
____.
bronze construction. Relieving set pressure to be 50 psig. Relief
valve manufacturer to be ________________, Model _______.
overflow drainer manufacturer shall be _______, Model
_______.
H2-14
03-08
acceptable.
B. Boiler Feedwater Pump and Motor Set
1. Option - Intermittent - Quantity________, turbine type boiler
prior to shipment. Pump manufacturer to be_____________,
Model ________, size ____" x _______".
at ________feet TDH with ____feet NPSH required. Pump to
be _______materials of construction as defined by the
Hydraulic Institute and have _______seals for a maximum
______hp, ______phase, _______Hz, ______Volt, _____
rpm, _______enclosure motor. Motor to be non-overloading at
the rated condition without using any portion of the service
factor. Pump and motor set to be factory aligned prior to
shipment. Pump manufacturer to be _________, Model
flow.
3. Optional - The basic surge tank shall be equipped with the
C. Make Up Valve and Controller
not exceed ______, and shall be rated for _____gpm at ______
psi inlet pressure. The pressure drop across the valve shall not
____________, Model _______. This valve shall be
mechanically controlled by an external float cage with cast iron
body and 8" stainless steel float. The float cage manufacturer
shall be _______________, Model __________.
H2-15
03-08
1) Option (Electronic) - ______" inlet water motorized
regulating valve with steel body and threaded NPT
connections. Motor shall be 110V bi-directional
type, with a permanently lubricated gear train, and
directly coupled to the valve stem. The valve Cv shall
not exceed _____and be rated for_______gpm at
________psi inlet pressure. Valve shall not exceed a
delta-P of 10 psig. This valve shall have teflon seats
and be suitable for temperatures up to 300 F. The
motorized valve manufacturer shall be _________.
This valve shall be electronically controlled by a solid
state control with internally mounted capacitance
probes. The electronic solid state control shall be
able to set desired level point and acceptable
deviation. The electronic solid state control shall
include a selection for automatic and manual
operating mode. The internals shall include two
additional probes for high and low water alarm. The
controller manufacturer shall be Cleaver-Brooks,
Model TW82. A solenoid valve and float switch are
not acceptable. (Available only in the U.S.)
2) Option (Pneumatic) - _______" inlet water diaphragm
actuated regulating valve with cast iron body and
_____connections. The valve shall be globe-type
with proportional control and a spring-opposed
diaphragm actuator arranged for 3 - 15 psig
operating signal. The valve shall be normally open on
loss of air. The valve Cv shall not exceed _____and
be rated for ________gpm at ______psi inlet
pressure. Valve shall not exceed a delta-P of 10 psig.
This valve shall have stainless steel trim with TFE
packing and be suitable for temperature up to 410
F. The diaphragm actuated valve manufacturer shall
be ___________, Model _______. This valve shall be
pneumatically controlled by an external proportional
type sensor. The sensor shall be a 14" displacer that
produces a pneumatic output signal. The controller
manufacturer shall be _____________, Model
__________. A filter regulator is to be provided to
reduce 50 psig instrument air supply to 3 - 15 psig
for proper operation.
2. Optional - The make up valve shall include a ANSI Class 125 lb
three-valve bypass with inlet Y-type cast iron strainer. Strainer
3. Optional - High-level alarm switch. This shall be an externally
mounted float-type switch. The switch shall make contact on
4. Optional - Low-level alarm switch. This shall be an externally
H2-16
03-08
acceptable.
6. Transfer Pump and Motor Set - Quantity ______, centrifugal
type transfer pump and motor set. Turbine type pumps are not
acceptable in this application. Pump to be rated for _______
gpm at ________feet TDH with ______feet NPSH required.
Pump to be _______materials of construction as defined by
the Hydraulic Institute, and have _______seals for a maximum
______hp, ______phase, _______Hz, ______Volt, _____
rpm, _______enclosure motor. Motor to be non-overloading at
the rated condition without using any portion of the service
factor. Pump and motor set to be factory aligned prior to
shipment. Pump manufacturer to be _________, Model
flow.
7. Optional - The duo stand shall elevate the deaerator and surge
tank sections to provide the net positive suction head required
by the pump at the rated condition to prevent cavitation. The
stand shall be constructed of heavy square steel tubing for the
legs and 1/4" steel plate covering the floor.
D. Control Panel
shipment.
with silence switch and individual red oil-tight lights.
a. Control circuit transformer to supply 110-120 Volts,
single-phase power supply. The transformer shall be
mounted, wired and fused.
b. Auxiliary contacts shall be furnished for chemical feed
E. Standard
1. The deaerator and surge section shall have a gauge glass
assembly that covers the entire tank diameter. The gauge glass
shall be quartz 0.625 inch diameter by 24 inch maximum
length. Each length of glass shall be furnished with a bronze
H2-17
03-08
gauge cock set and protector rods.
a. The deaerator section shall be supplied with a pressure
gauge that has a 4-1/2 inch dial with a 0-60 psig range
and a thermometer with a 50 to 300 F range. Packaged
units are required to have both gauges bracket-mounted
at eye level.
b. The surge tank section shall be supplied with a
thermometer with a 50 to 300 F range.
c. The duo tank is to be hand cleaned with a solvent to
SSPC- SP-1 standards prior to painting. Prime coated to
not less than 1 mil thick and finish coated with an enamel
paint to not less than 1 mil thick prior to shipment.
d. Unit is to be knocked down for shipment. Piping is to be
matched marked. Three, bound, Operating and
Maintenance manuals to be provided. Warranty period to
be twelve months after start-up or eighteen months after
Load Specifications
Make up to Deaerator GPM 25 psig Min.
Make up to Surge Tank GPM
Pumped Low Temp Returns
Gravity Feed Low Temp
Returns
High Temp Returns
H2-18
03-08
Notes
H3-1
05-08
CONTENTS
ILLUSTRATIONS
Figure H3-1. Cleaver-Brooks Traymaster Deaerator Dimension Diagram . . . . . . . . . . . . . . . . . . . . H3-7
Figure H3-2. Traymaster Deaerator Dimensions and Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-8
Figure H3-3. Traymaster Tank Supports and Saddles, Details and Dimensions . . . . . . . . . . . . . . . H3-10
Section H3
TRAYMASTER DEAERATORS
Traymaster Deaerators Section H
H3-2
05-08
Section H Traymaster Deaerators
H3-3
05-08
The following features and benefits apply to the Traymaster Deaerator product line.
Less Mechanical Movement of Deaerator Components:
The water spray valve is the only internal moving component within the
deaerator vessel.
requirements.
Maintains deposit-free surface.
Internal Automatic-Check Valve Prevents Steam Back-Flow:
The water spray valve is normally closed at no flow.
Prevents steam back flow through the water spray valve at no flow conditions.
Pressurized Tank Reduces Flashing and Minimizes Venting:
Saves BTUs that would normally be exhausted to atmosphere.
Improves plant efficiency.
Auto Vent Valve Eliminates Gases at Start-Up:
Cleaver-Brooks deaerator is guaranteed to remove oxygen concentrations to
0.005 cc/liter while operating between 5 and 100% capacity.
Carbon dioxide concentration is practically reduced to zero.
H3-4
05-08
Saves BTUs by accepting condensate before cold make-up water. Maintains a
Provides flexibility for selecting a tank for specific applications to limit the loss
Complete packages are pre-fabricated in the Cleaver- Brooks manufacturing
partially disassembled, match marked for efficient field re-assembly.
PRODUCT OFFERING
Information in this section applies directly to Cleaver-Brooks packaged Traymaster
deaerators ranging from 30,000 lbs/hr to 500,000 lbs/hr at 50 F makeup.
The Traymaster deaerator is a pressurized low maintenance system designed to
remove dissolved oxygen in boiler feed water to 0.005 cc per liter or less and
eliminate carbon dioxide. A typical deaerator package includes the tray column and
storage tank mounted on a stand of appropriate height along with all operating
controls, feed pumps assembled and piped (typically knocked down for shipment
and field assembly). The tank conforms to Section VIII of the ASME code.
The tray column design is best for handling high-temperature returns. The column
is constructed of carbon steel. Built into the top of the tray box is a spring loaded
self-cleaning water spray nozzle. Automatic and manual vent valves are built into
the top of the vent condenser.
From experience, large industrial plants and utilities have learned that the most
practical and economical way to remove oxygen from feedwater is through
mechanical deaeration. The Traymaster deaerator economically effects oxygen
removal through a design that is trouble free in performance.
Raw water, untreated and not deaerated, contains as much as ten cubic
centimeters of corrosion-causing oxygen per liter. Oxygen in water corrodes and
shortens the life of boiler feed lines, boilers and condensate return lines.
oxygen and other dissolved gases in boiler feed. Thus, it is the answer to long-
lasting boiler equipment for industrial and commercial boiler users. Built of
corrosion-resistant alloys for lifetime service, the deaerator employs those basic
principals of gas removal proved to most effective and economical to every boiler
owner. Contact your local Cleaver-Brooks authorized representative for component
and sizing information.
H3-5
05-08
The design of the Traymaster deaerator offers simplicity in both operation and
service. The tray section, the heart of the deaerator, requires no maintenance. There
are no moving parts to adjust or maintain. Installation is simple and quick.
Standard Equipment
Tray column.
Stainless steel trays of riveted construction.
Gauge glass.
Deaerator manual and automatic vent valve.
Feed water thermometer.
Required tappings.
Optional Equipment
High water alarm.
Low water alarm.
High-temperature condensate diffuser tube (over 227 F).
Recirculation orifice or relief valve.
Suction strainer.
Discharge manifold.
Overflow drainer.
Control panel.
Vacuum breaker.
Tank drain valve.
H3-6
05-08
Magnesium anode.
Stand.
Packaging
Half packaged, suitable for field erection with interconnecting piping and
wiring by others.
Dimensions and ratings for Traymaster Deaerators are shown in the following
figures and tables.
H3-7
05-08
Figure H3-1. Traymaster Deaerator Dimension Diagram
H3-8
05-08
Table H31. Dimensions, TM030-TM125
TM030 TM045 TM070 TM100 TM125
A HEIGHT ABOVE STAND 143 154 169 179-1/2 197-1/2
B OVERALL LENGTH 120-1/2 133 137 160 168
C OVERALL WIDTH 75 78 85 91 97
D COLUMN DIAMETER 36 36 48 54 54
E STORAGE TANK DIA. 42 48 60 66 72
F C/L TO C/L BOLT HOLES 79-1/2 95 95 112-1/2 112-1/2
G STAND LENGTH 84-1/2 101 101 119-1/2 119-1/2
H C/L TO C/L BOLT HOLES 55 59 68 73 80
J STAND WIDTH 58 62 71 76 83
K TEMP./PRESS. SENSOR 15-5/8 15-5/8 18 23-7/8 18-7/8
L HIGH TEMP. RETURN 41-5/8 39-5/8 40 40-7/8 52-3/4
M STEAM INLET 54-5/8 52-5/8 55 55-7/8 67-3/4
N DAVITED MANWAY 54-5/8 52-5/8 55 55-7/8 67-3/4
P WATER INLET SEE "A" 81-3/8 84-1/4 87-1/8 99-1/8
Q TRAY CLEARANCE 18 24 36 36 36
20 20 20 30 36
1600 1800 2300 3000 3300
600 900 1400 2000 2500
1500 1800 2400 3800 4300
6500 9300 14000 20500 25100
TM030 TM045 TM070 TM100 TM125
A1 TEMP./PRESS. SENSOR 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT
B1 HIGH TEMP. RETURN 2" NPT 2" NPT 2-1/2" NPT 3" NPT 3" NPT
C1 STEAM INLET 6"-150#" RFSO 8"-150#RFSO 8"-150#RFSO 10"-150#RFSO 10"-150#RFSO
D1 WATER INLET 2-1/2"-150#RFSO 3"-150#RFSO 3"-150#RFSO 4"-150#RFSO 4"-150#RFSO
E1 DOWNCOMER 10"-150#FFSO 12"-150#FFSO 14"-150#FFSO 16"-150#FFSO 16"-150#FFSO
F1 MANWAY 16" 18" 18" 20" 20"
G1 VENT PIPE 3/4" NPT 1-1/2" NPT 1-1/2" NPT 2" NPT 2" NPT
STORAGE TANK WEIGHT (DRY) (LB)
MODEL NUMBER
STORAGE TANK WEIGHT (FLOODED) (LB)
COLUMN WEIGHT (LB)
TRAYMASTER DETAILS AND DIMENSIONS
COLUMN CONNECTIONS
MODEL NUMBER
STORAGE TANK CAPACITY (GAL.)
TRAY QTY.
TM140 TM175 TM200 TM225 TM250
A HEIGHT ABOVE STAND 200 218-1/2 218-1/2 232 232
B OVERALL LENGTH 186 188 197 190-1/2 195-1/2
C OVERALL WIDTH 97 107-1/2 107-1/2 119 119
F C/L TO C/L BOLT HOLES 137 135-1/2 137 127-1/2 137
G STAND LENGTH 144 142-1/2 144 134-1/2 144
H C/L TO C/L BOLT HOLES 80 88-1/2 88-1/2 99 99
J STAND WIDTH 83 91-1/2 91-1/2 102 102
K TEMP./PRESS. SENSOR 20 21-7/8 21-7/8 21-7/8 24-3/8
L HIGH TEMP. RETURN 45 44-7/8 44-7/8 44-7/8 47-3/8
M STEAM INLET 69-1/2 69-7/8 69-7/8 69-7/8 72-3/8
N DAVITED MANWAY 69-1/2 69-7/8 69-7/8 69-7/8 72-3/8
P WATER INLET 103-1/4 107-1/8 107-1/8 108-1/8 109-5/8
42 42 56 65 70
3700 3700 5600 5800 6000
2800 3500 4000 4500 5000
4700 6600 6900 7900 8100
28000 35800 40200 45400 49800
TM140 TM175 TM200 TM225 TM250
B1 HIGH TEMP. RETURN 4"-150#RFSO 6"-150#RFSO 6"-150#RFSO 6"-150#RFSO 8"-150#RFSO
C1 STEAM INLET 12"-150#RFSO 14"-150#RFSO 14"-150#RFSO 16"-150#RFSO 16"-150#RFSO
D1 WATER INLET 6"-150#RFSO 6"-150#RFSO 6"-150#RFSO 6"-150#RFSO 6"-150#RFSO
F1 MANWAY 20" 24" 24" 24" 24"
G1 VENT PIPE 2" NPT 2-1/2" NPT 2-1/2" NPT 3" NPT 3" NPT
MODEL NUMBER
COLUMN CONNECTIONS
MODEL NUMBER
TRAY QTY.
COLUMN WEIGHT (LB)
H3-9
05-08
Table H34. Connections and Trim
TM300 TM350 TM400 TM450 TM500
A HEIGHT ABOVE STAND 252 259 260-1/2 262-1/2 262-1/2
B OVERALL LENGTH 198 205-1/2 246 258-1/2 304
C OVERALL WIDTH 130 130 130 130 130
F C/L TO C/L BOLT HOLES 137 144 185 197 243
G STAND LENGTH 144 151 192 204 250
H C/L TO C/L BOLT HOLES 110 110 110 110 110
J STAND WIDTH 113 113 113 113 113
K TEMP./PRESS. SENSOR 24-1/4 27-1/2 28-3/4 28-3/4 28-3/4
L HIGH TEMP. RETURN 41-1/4 43 44-1/4 40-1/4 40-1/4
M STEAM INLET 68-1/4 70 71-1/8 71-1/4 71-1/8
N DAVITED MANWAY 68-1/4 70 69-1/4 69-1/4 69-1/4
P WATER INLET 112-3/8 119-3/8 102-5/8 120-5/8 119-5/8
84 98 120 132 144
7300 8500 10700 10900 11100
6000 7000 8000 9000 10000
11000 11400 13200 13700 15700
61000 69700 79900 88700 99000
TM300 TM350 TM400 TM450 TM500
B1 HIGH TEMP. RETURN 8"-150#RFSO 8"-150#RFSO 10"-150#RFSO 10"-150#RFSO 10"-150#RFSO
C1 STEAM INLET 18"-150#RFSO 18"-150#RFSO 20"-150#RFSO 20"-150#RFSO 22"-150#RFSO
D1 WATER INLET 8"-150#RFSO 8"-150#RFSO 8"-150#RFSO 8"-150#RFSO 10"-150#RFSO
F1 MANWAY 28" 28" 36" 36" 36"
G1 VENT PIPE 3" NPT 3" NPT 3" NPT 4" NPT 4" NPT
MODEL NUMBER
COLUMN CONNECTIONS
TRAY QTY.
COLUMN WEIGHT (LB)
MODEL NUMBER
1 RELIEF VALVE SIZE
2 OVERFLOW SIZE
3 DRAIN SIZE
4 SUCTION SIZE
5 RECIRC.
6 THERMOMETER (3/4" NPT)
7 SAMPLE (1/2" NPT)
8 CHEM. FEED (1" NPT)
9 GAUGE GLASS ASSEMBLY
10 LEVEL CONTROLLER
11 OVERFLOW DRAINER (OPT)
12 CONTROL PANEL (OPT)
13 FEED PUMP/MOTOR (OPT)
14 SUCTION PIPING (OPT)
15 MANWAY 12" X 16"
16 LEVEL ALARMS (OPT)
17 VACUUM BREAKER
CONTACT YOUR LOCAL CLEAVER-BROOKS AUTHORIZED REPRESENTATIVE
MODEL NUMBER TM030 - TM500
H3-10
05-08
Figure H3-2. Storage Tank Saddle Footprint
600 900 1400 2000 2500 2800 3500 4000 4500 5000 6000 7000 8000 9000 10000
TANK DIA. 42 48 60 66 72 72 84 84 96 96 108 108 108 108 108
A 79 94 95 113-1/2 113-1/2 138 136-1/2 138 128 138 138 145 186 198 244
B 84-1/2 100 101 119-1/2 119-1/2 144 142-1/2 144 134 144 144 151 192 204 250
C 34-1/2 38 44-3/4 50 70 70 62 62 72 72 83 83 83 83 83
D 46 48 57 66 52 52 82 82 92 92 104 104 104 104 104
E 5-3/4 5 6-1/8 8 9 9 10 10 10 10 10-1/2 10-1/2 10-1/2 10-1/2 10-1/2
F 7/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8
TANK CAPACITY (GAL.)
H3-11
05-08
Payback for a pressurized deaerator versus an atmospheric boiler feed system is
Flash steam
Exhaust steam
Blowdown
Chemical treatment
Makeup water
Sewer
Intangibles
2
S0
3
to scavenge
1 ppm of dissolved O
2
costs.
costs.
2Na
2
SO
3
+O
2
2Na
2
SO
4
H3-12
05-08
NOTES
H3-13
05-08
Section H3
Traymaster Series Deaerators
Packaged Deaerator Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-14
Deaerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-14
Deaerator Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-14
Deaerator Load Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-15
Deaerator Standard Trim and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-15
Deaerator Make-Up Valve and Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-15
Deaerator Steam Pressure Reducing Valve (PRV) Station . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-16
Deaerator Safety Relief Valve(s) (SRV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-17
Deaerator Water Level Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-17
Deaerator Overflow Drainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-17
Deaerator Suction Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-17
Boiler Feedwater Pump And Motor Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-17
Deaerator Support Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-18
Deaerator Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-18
Electric Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-18
Deaerator Preparation and Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-18
Deaerator Manuals and Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-19
H3-14
05-08
PART 1 GENERAL 1.1 PACKAGED DEAERATOR SPECIFICATION
A. Provide one Cleaver-Brooks Model TM _________tray type,
pressurized, deaerator rated at _____pounds per hour. The system
shall be of the two tank design and shall guarantee oxygen removal
to not more than 0.005 ccs/liter (7 ppb) in the effluent throughout
all load conditions between 5 and 100 percent. The deaerator shall
be designed for operation at 5 PSIG, but shall be suitable for use
from 2 to 15 PSIG.
PART 2 PRODUCTS 2.1 DEAERATOR
A. A vertically oriented deaerator section shall be Y ft. -Y.1 in. x Z ft. -
Z.1 in. shell length. The deaerator shall be of the counter flow
design. Undeaearated water shall enter through the top of the
column into a true Internal Direct Contact Vent Condenser. Units not
implementing a True Internal Direct Contact Vent Condenser shall
not be accepted. The water shall be evenly sprayed through a
spring-loaded, self-cleaning, adjustable stainless steel spray valve(s)
over the trays. The valves shall be constructed of type 304 stainless
steel material. Trays shall be all riveted construction using 16 gauge
type 430 Stainless Steel material. Welded trays shall not be
accepted. Trays shall be stacked within a stainless steel tray box
with a minimum thickness of 1/4". The tray box shall be constructed
using type 304 Stainless Steel material. The tray box shall include a
wear plate at the saturated steam inlet area to ensure durability. The
tray box shall have an access door for ease of inspection of the trays.
This access area to the tray box shall be through a X in. round
davited manhole located on the shell of the deaerator. The tank shall
be designed in accordance with ASME, Section VIII of the Pressure
Vessel Code for 50 PSIG at 650 F and stamped accordingly.
Connections shall include steam inlet, vent, water inlet, high
temperature return, and downcomer to the storage vessel. Unit shall
provide proper internal vent condensing and water distribution at
any load between 5 and 100 percent of rated capacity.
B. All internal surfaces, which come in contact with un-deaerated
water, shall be constructed of stainless steel. Automatic vent valve
shall be thermostatically controlled to provide a fast means of
venting when a sudden buildup of gases occurs, such as seen at
start up. The manual vent valve shall have an orifice for continuous
minimum venting. Venting rate shall not exceed 0.1 of 1% of the
rated deaerator capacity at 5 PSIG.
2.2 DEAERATOR VESSEL
A. The deaerated water storage tank shall have _____minutes of
storage and have a capacity of_____ gallons measured to overflow.
The tank shall be _____diameter x ____long. An 12 x 16 elliptical
manhole shall be provided for access. All nozzles 3" and under shall
be 3000 lbs forged steel couplings and over 3" shall be 150 LB. flat
face flanges. Heads to be ASME torispherical type constructed of
ASTM A516 GR 70 carbon steel with a minimum thickness of 0.25
inches. Shell plate to be fabricated of ASTM A36 carbon steel with a
minimum thickness of 0.25 inches. The tank shall be designed in
accordance with ASME, Section VIII of the Pressure Vessel Code for
50 PSIG at 650 F and stamped accordingly. Certification shall be
required. Joint efficiencies to be 70% circumferential per Table UW-
H3-15
05-08
12, which does not require stress relieving or nondestructive
examination.
The tank shall be factory-insulated and lagged with blanket insulation, pins, clips,
and a durable steel jacket. The blanket insulation is to be fiberglass, 2" thick, 1 LB/
CU-FT, and have a rating of R3.85. Pins are to be located on 18" centers and
holding clips attached. The steel jacket or lagging shall have a shell thickness of 22
gauge (0.299") minimum and head thickness of 12 gauge (0.1046") minimum.
The magnesium or sacrificial anode shall provide cathodic protection against
galvanic corrosion. This rod shall be 1-5/16" diameter with a 1/4" steel core to
assure a good electrical contact and added strength. The design shall have a small
weep hole to signal it has been consumed.
The high temperature diffuser or sparge tube shall be located beneath the normal
tank water level. The tube shall be constructed of 2-1/2 inch pipe. This tube shall
provide even distribution and blending of high-temperature condensate returns.
The chemical feed quill shall be located beneath the normal tank water level. The
quill material shall be constructed of stainless steel. The tube shall provide even
distribution and blending of chemical.
2.3 DEAERATOR LOAD SPECIFICATION
The surge tank loads shall be as specified in the following table.
2.4 DEAERATOR STANDARD TRIM AND ACCESSORIES
A. The basic deaerator shall be equipped with the following trim and
accessories. Piping on packaged units shall comply with ASME
Power Piping Code B31.1.
2.5 DEAERATOR MAKE-UP VALVE AND CONTROLLER
A. ____" inlet water regulating lever valve with ______body and
_______connections. Rated for _____GPM at ______PSIG inlet
pressure. This valve shall be suitable for temperatures up to 300 F.
The valve manufacture shall be _______, Model _____. This valve
shall be mechanically controlled by an external float cage with cast
iron body and 8" stainless steel float. The float cage manufacturer
shall be __________, Model ______.A McDonnell & Miller 93-7B
level controller shall electronically control the make-up valve.
Make up
Low Temp Returns
(<210 F)
Medium Temp
Returns (211
230F)
High Temp Returns
(>230F)
H3-16
05-08
B. ______" inlet water motorized regulating valve with steel body and
threaded NPT connections. Motor shall be 110V bi-directional, with
a permanently lubricated gear train, and be directly coupled to the
valve stem. Rated for_____GPM at ______PSIG inlet pressure.
This valve shall have teflon seats and be suitable for temperatures
up to 300 F. The motorized valve manufacturer shall be
__________. This valve shall be electronically controlled by a solid
state control with internally mounted capacitance probes. The
electronic solid state control shall be able to set desired level point
and acceptable deviation. The electronic solid state control shall
include a selection for automatic and manual operating mode. The
internals shall include two additional probes for high and low water
alarm. The controller manufacturer shall be Model TW82.
C. _______" inlet water diaphragm actuated regulating valve with cast
iron body and _____connections. The valve shall be globe type with
proportional control and a spring opposed diaphragm actuator
arranged for 3 - 15 PSIG operating signal. The valve shall be
normally open on loss of air. Rated for ______GPM at ______PSIG
inlet pressure This valve shall have stainless steel trim with TFE
packing and be suitable for temperature up to 410 F. The
diaphragm actuated valve manufacturer shall be ___________,
Model _____. This valve shall be pneumatically controlled by an
external proportional type sensor. The sensor shall be a 14"
displacer that produces a pneumatic output signal. The controller
manufacturer shall be _________, Model ______. A filter regulator is
to be provided to reduce 50 PSIG instrument air supply to 3 - 15
PSIG for proper operation.
D. The make up valve shall include a ANSI Class 125 LB three-valve
bypass with inlet Y-type cast iron strainer. Strainer screen to be
removable and of stainless steel construction.
2.6 DEAERATOR STEAM PRESSURE REDUCING VALVE (PRV) STATION
A. _______" steam pressure reducing valve with cast iron body and
_____connections. The valve shall be a self-contained unit capable
of reducing ____PSIG saturated steam to the operating pressure of
the deaerator at a flow rate of _____LB./HR. The valve shall be 250
lb class with stainless steel trim and an adjustable pilot. The valve
manufacturer shall be _____, Model _____.
B. _______" diaphragm actuated steam pressure reducing valve with
cast iron body and _______connections. The valve shall be globe
type with proportional control and a spring opposed diaphragm
actuator arranged for ____PSIG operating signal. The valve shall be
normally closed on loss of air. The valve shall be capable of reducing
_____PSIG saturated steam to the operating pressure of the
deaerator at a flow rate of ____LB./HR. This valve shall be 250 LB
class and have stainless steel trim. The diaphragm actuated valve
manufacturer shall be ________, Model _______. This valve shall be
pneumatically controlled by an external transmitter. The transmitter
set pressure shall be adjustable. The transmitter manufacturer shall
be _________________, Model _________.
C. The steam pressure reducing valve shall include a three valve
bypass with Y-type cast iron strainer. Strainer screen to be
removable and of stainless steel construction.
H3-17
05-08
2.7 DEAERATOR SAFETY RELIEF VALVE(S) (SRV)
A. Quantity ______, _______" relief valves sized to relieve full capacity
of the pressure reducing valve in the event of its failure. Valves to
meet Paragraph UG-125 of ASME Unfired Pressure Vessel Code,
Section VIII. Valve body to be of __________construction. Relieving
set pressure to be 50 PSIG. Relief valve manufacturer to be
_______________________, Model ____________.
2.8 DEAERATOR WATER LEVEL ALARMS
A. High Level Alarm - NEMA 1 This shall be an externally mounted
float type switch. The switch shall make contact on rise and break
on fall. The float cage construction shall be cast iron.
B. Low Level Alarm - NEMA 1 This shall be an externally mounted
float type switch. The switch shall make contact on fall and break
on rise. The float cage construction shall be cast iron.
2.9 DEAERATOR OVERFLOW DRAINER
A. ________" overflow drainer sized to relieve full capacity at the
operating pressure of the deaerator. The overflow drainer shall be a
float type trap. The construction is to be a steel housing with
stainless steel float ball. The overflow drainer manufacturer shall be
_______, Model _______.
2.10 DEAERATOR SUCTION PIPING
A. Suction piping for pumps shall consist of a __ gate valve, cast iron
Y-type strainer with replaceable stainless steel screen and flexible
connector or hose. This piping assembly shall be 125 LB class
construction. The vortex breaker shall be located in the tank nozzle.
2.11 BOILER FEEDWATER PUMP AND MOTOR SET
A. Intermittent - Intermittent Quantity ________, turbine type boiler
_____feet TDH with ______feet NPSH required. Pump to be
______materials of construction and have ______seals for a
maximum water temperature of 250 F. Pump impeller to be
baseplate and flexibly coupled with an OSHA type coupling guard to
a ____HP, _____phase, ______Hz, ______Volt, _______RPM,
________enclosure motor. Motor to be non-overloading at the rated
condition without using any portion of the service factor. Pump and
motor set to be factory aligned prior to shipment. Pump
manufacturer to be ______________, Model ________, size ____" x
_______".
H3-18
05-08
B. Continuous - Continuous Quantity ______, centrifugal type boiler
______feet TDH with ____feet NPSH required. Pump to be
Institute and have _______seals for a maximum water temperature
of 250 F. Pump impeller to be hydraulically balanced. The pump
shall be mounted on a steel baseplate and flexibly coupled with an
OSHA type coupling guard to a _______HP, ______phase,
_________Hz, _________Volt, _____RPM, _______enclosed
motor. Motor to be non-overloading at the rated condition without
using any portion of the service factor. Pump and motor set to be
factory aligned prior to shipment. Pump manufacturer to be
_________, Model _______, size _____" x _______".
A stainless steel recirculation orifice is to be supplied with the pump and shipped
loose for field installation to provide minimum bypass flow.
2.12 DEAERATOR SUPPORT STAND
A. The ___feet high stand shall elevate the deaerator tank to provide
condition to prevent cavitation plus a 1-1/2 foot safety factor. The
stand shall be constructed of heavy square steel tubing for the legs
and 1/4" steel plate covering the floor.
2.13 DEAERATOR CONTROL PANEL
A. Control panel shall be in a NEMA 1 enclosure and wired to the
National Electric Code. The wire shall be black number coded. The
assembly is to contain individual motor starters with 120 Volt
holding coil and fuse protection. Individual green oil-tight pump run
lights shall be provided. All switches and lights to have nameplate
identification. The assembled panel shall be given a factory
continuity test prior to shipment.
2.14 ELECTRIC COMPONENTS
A. Audible and visual high and low water alarm function shall be
provided by a bell or horn with silence switch and individual red oil-
tight lights. Control circuit transformer to supply 110-120 Volts,
single-phase power supply. The transformer shall be mounted,
wired and fused. Auxiliary contacts shall be furnished for chemical
feed pump initiation. Contacts shall be normally open.
B. The deaerator shall have a gauge glass assembly that covers the
entire tank diameter. The gauge glass shall be quartz, 0.625 inch
diameter by 24 inch maximum length. Each length of glass shall be
furnished with a bronze gauge cock set and protector rods. The
deaerator shall be supplied with a pressure gauge that has a 4-1/2
inch dial with a 0-60 PSIG range and a thermometer with a 50 to
300 F range. Packaged units are required to have both gauges
bracket-mounted at eye level.
2.15 DEAERATOR PREPARATION AND PACKAGING
A. The deaerator is to be hand cleaned with a solvent to SSPC- SP-1
standards prior to painting. Prime coated to not less than 1 mil thick
and finish coated with an enamel paint to not less than 1 mil thick
prior to shipment.
H3-19
05-08
B. Unit is to be knocked down for shipment. Piping is to be matched
marked.
2.16 DEAERATOR MANUALS AND WARRANTY
A. Three, bound, Operating and Maintenance manuals to be provided.
Warranty period to be twelve months after start-up or eighteen
months after shipment, whichever comes first.
Notes
H4-1
03-08
CONTENTS
ILLUSTRATIONS
Figure H4-1. Cleaver-Brooks Boilermate Deaerator Selection Guide . . . . . . . . . . . . . . . . . . . . . . . H4-7
Figure H4-2. Boilermate Deaerator Dimensions and Ratings - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . H4-8
Figure H4-3. Boilermate Tank Supports and Saddles, Details and Dimensions . . . . . . . . . . . . . . . H4-10
Section H4
BOILERMATE DEAERATORS
Boilermate Deaerators Section H
H4-2
03-08
The Cleaver-Brooks designed deaerator assures high purity effluent by removing oxygen and other dissolved
gases in boiler feed. Thus, it is the answer to long-lasting boiler equipment for industrial and commercial boiler
users. Built of corrosion-resistant alloys for lifetime service, the deaerator employs those basic principals of gas
removal proven most effective and economical to every boiler owner. Contact your local Cleaver-Brooks
authorized representative for component and sizing information.
Section H Boilermate Deaerators
H4-3
03-08
The following features and benefits apply to the Boilermate Deaerator product line.
The Boilermate design uses a packed column to deaerate the water.
Less Mechanical Movement of Deaerator Components:
The water spray valve is the only internal moving component within the
deaerator vessel.
requirements.
Maintains deposit-free surface.
Internal Automatic-Check Valve Prevents Steam Back-Flow:
The water spray valve is normally closed at no flow.
Prevents steam back flow through the water spray valve at no flow conditions.
Saves Btus that would normally be exhausted to atmosphere.
Improves plant efficiency.
Auto Vent Valve Eliminates Gases at Start-Up:
H4-4
03-08
Cleaver-Brooks deaerator is guaranteed to remove oxygen concentrations to
0.005 cc/liter while operating between 5 and 100%capacity.
Carbon dioxide concentration is practically reduced to a zero.
Saves Btus by accepting condensate before cold make-up water. Maintains a
Provides flexibility for selecting a tank for specific applications to limit the loss
Complete packages are pre-fabricated in the Cleaver- Brooks manufacturing
partially disassembled, match marked for efficient field re-assembly.
PRODUCT OFFERING
Information in this section applies directly to Cleaver-Brooks packaged boilermate
deaerators ranging from 1,500 lbs/hr at 50 F makeup to 135,000 lbs/hr at 200 F
make-up. Larger capacities can be obtained by using two columns. The Boilermate
deaerator product offering is shown in Figure H4-1.
The Boilermate deaerator is a pressurized packed column, low maintenance system
designed to remove dissolved oxygen in boiler feed water to 0.005 cc per liter or
less and eliminate carbon dioxide. A typical deaerator package includes the packed
column and storage tank mounted on a stand of appropriate height along with all
operating controls, feed pumps assembled and piped (typically knocked down for
shipment and field assembly). The tank conforms to Section VIII of the ASME Code.
The packed column design is best for handling high-temperature returns. The
column is constructed of a carbon steel casing with a stainless steel liner. Built into
a flange on top of the column is a spring loaded self-cleaning water spray nozzle
and an automatic and manual vent valve.
From experience, large industrial plants and utilities have learned that the most
practical and economical way to remove oxygen from feedwater is through
mechanical deaeration. The Boilermate deaerator economically effects oxygen
removal through a design that is trouble free in performance.
Raw water, untreated and not deaerated, contains as much as ten cubic
centimeters of corrosion-causing oxygen per liter. Oxygen in water corrodes and
shortens the life of boiler feed lines, boilers and condensate return lines.
H4-5
03-08
oxygen and other dissolved gases in boiler feed. Thus, it is the answer to long-lasting
boiler equipment for industrial and commercial boiler users. Built of corrosion-
resistant alloys for lifetime service, the deaerator employs those basic principals of
gas removal proved to most effective and economical to every boiler owner. Contact
your local Cleaver-Brooks authorized representative for component and sizing
information.
The design of the Boilermate deaerator offers simplicity in both operation and
service. The exchange packing, the heart of the deaerator, requires no maintenance.
There are no moving parts to adjust or maintain. Installation is simple and quick.
Standard Equipment
Boilermate column.
Stainless steel exchange packing.
Gauge glass.
Deaerator manual and automatic vent valve.
Feed water thermometer.
Required tappings.
Optional Equipment
High water alarm.
Low water alarm.
High-temperature condensate diffuser tube (over 227 F).
Suction strainer.
Discharge manifold.
Overflow drainer.
Control panel.
H4-6
03-08
Vacuum breaker.
Tank drain valve.
Stand.
Packaging
wiring by others.
Dimensions and ratings for Boilermate Deaerators are shown in Figure H4-2 and
Figure H4-3.
H4-7
03-08
MODEL NO
*DEARERATOR CAPACITY LBS/HR
BM-8 BM-12 BM-16 BM-20 BM-24 BM-30 BM-36 BM-42
50F 1,500 3,500 6,000 10,000 15,000 23,000 33,000 45,000
100F 2,000 4,500 8,000 12,500 18,000 28,000 40,000 54,000
150F 2,700 6,000 11,000 17,000 24,000 38,000 55,000 75,000
200F 5,000 11,000 20,000 30,000 44,000 69,000 100,000 135,000
Weight (lbs)
Including Packing
250 350 410 560 960 1,275 1,810 2,390
NOTE: Model Designation (example BM-8) is: BM =Boilermate Deaerator. 8 =size of packed column.
Ratings for each column size vary with makeup water temperature.
* Capacities may be doubled by using two columns.
140
120
100
80
60
40
20
140
120
100
80
60
40
20
50 70 90 110 130 150 170 190
42
36
30
24
20
16
12
8
FEEDWATER MIX TEMPERATURE - F
M
O
D
E
L
I
N
L
E
T

C
A
P
A
C
I
T
Y

-

L
B
S
/
H
R

X

1
0
0
0

W
A
T
E
R
Figure H4-1. Cleaver-Brooks Boilermate Deaerator Selection Guide
H4-8
03-08
1. Mounted at dim. "M" (top of tank) on non-packaged units.
2. Tank mounted on non-packaged unit.
3. Packaged units only. Mounted on left end, right side of stand on 48" dia. 1070 gal 54" dia. 1500 gal as shown.
8. Mount tank above pump at elevation necessary for static head including safe allowance for piping friction as approved by pump manufac-
turer.
9. Tank is built to ASME Code.
prints.
11. Add suffix "P" to Model no. for packaged units (BMP-24).
12. Dimension "R" will change depending on controls required- contact your local Cleaver-Brooks authorized representative.
13. No interconnecting piping or wiring furnished on non-packaged units unless specified, contact your local Cleaver-Brooks authorized rep-
resentative for specific piping or wiring furnished on packaged assemblies.
15. Capacities other than shown as standard available by using two columns - contact your local Cleaver-Brooks authorized representative.
16. Optional tank sizes available - contact your local Cleaver-Brooks authorized representative.
18. Manway is standard. Manufacturing may require a larger manway for fabrication. See dimensional diagram for actual size.
COLUMN DETAILS AND DIMENSIONS
BOILERMATE MODEL NO. 8 12 16 20 24 30 36 42
A Height 46 48.5 58 62 64 71.5 78.5 80
B Water Inlet (150#RF Flg) 1.25 1.5 1.5 2 2 2.5 3 4
C Column Outside Diameter 8.63 12.8 16 20 24 30 36 42
D Manual Vent Valve Size .5" NPT .5" NPT .75" NPT .75" NPT .75" NPT 1" NPT 1.5" NPT 2" NPT
Column Weight (lb) 250 350 450 600 750 850 1050 1300
Volume Packing (Cu ft) 0.7 1.6 3.0 5.0 8.0 12.0 18.0 29.0
Packing Weight (lb) 25 50 150 200 300 450 650 1050
Figure H4-2. Boilermate Deaerator Dimensions and Ratings - Sheet 1 of 2
" B2" " D4"
" C3" " A1"
FRONT VIEW SIDE VIEW

(4) "E5" E HOLES
FOR "F6" E BOLTS
STAND HEIGHT
VARIES PER
PROJECT
REQUIREMENTS
3 5
"D" NPT. MANUAL
6
2 DIA. HOLE
IN LIFTING LUGS
TANK
DIA.
0 "T" " E" " G"
5
"P"
" S"
"A"
"R"
(NOTE 12)
" F"
2
B
"H"
1
"J" "K"
1
" L"
1
"M"
6
8 9 10
20
21
12
13
15 11
17
18
19
(NOTE 2)
(NOTE 1)
(NOTE 3)
(NOTE 4)
4 7
16
14
PORT (PLUGGED)
(1.5" NPT. FOR
.5" NPT AUTO.
B
(9" FOR MODEL 8 & 16)
2" NPT. INSPECTION
MODELS 8 & 12)
" C"
VENT VALVE
VENT VALVE
(NOTE 18)
H4-9
03-08
Figure H4-2. Boilermate Deaerator Dimensions and Ratings - Sheet 2 of 2
RATINGS
Cap (Gal to Overflow) 110 330 430 800 1070 1500
Tank Weight (Dry) (lb) 750 1200 1400 1900 2500 2750
Tank Weight (Flooded) (lb) 1850 4250 5300 9100 12700 15600
Tank Size (Dia x Length) 24 x 70 36 x 86 36 x 110 48 x 114 54x 127 60 x 129
TANK DIMENSIONS
E Steam Inlet 29 33 53 60
F Level Alarm 23 26 45 50
G High Temp Return 35 21 39 43
H Level Control 42 41 61 69
J Relief Valve 48 50 69 77
K Relief Valve N/A 60 79 86
L Relief Valve N/A N/A N/A 95
M Drain 36 47 76 93
P Overflow Rear Hd 60 10 10
R Overall Width 39 51 51 63 69 75
S Front Head 6 8 8 10 11
T Column 8.5 8.5 22 12
STANDARD DIMENSIONS
A1 Overall Length 54 61 86 101
B2 C/L to C/L Bolt Holes 49 56 80 95
C3 Overall Width 42 49 64 71
D4 C/L to C/L Bolt Holes 39 46 61 68
E5 Hole Size 0.75 1 1 1.125
F6 Anchor Bolt Size 0.625 0.875 0.875 1
CONNECTIONS & TRIM
1 Relief Valve Size Contact your local Cleaver-Brooks authorized representative
2 Overflow Size 1.25" NPT 2" NPT 3" NPT 3" NPT
3 Steam Inlet Size 2" NPT 3" NPT 4"-150#FF 6"-150#FF 6"-150#FF
4 Suction Size 3" NPT 3" NPT 3" NPT 4"-150#FF
5 High Temp Return Size 1" NPT 1.5" NPT 2" NPT 3" NPT
6 Drain Size 2" NPT 2" NPT 2" NPT 2" NPT
7 Recirc (1" NPT)
8 Thermometer (.75" NPT)
9 Sample (.5" NPT)
10 Chem Feed (1" NPT)
11 Thermometer
12 Gauge Glass Assy
13 Level Controller
14 Make-Up Valve
15 Pressure Gauge
16 Overflow Drainer (Opt)
17 Control Panel (Opt)
18 Feed Pump/Motor (Opt)
19 Suction Piping, (Opt)
20 Manway, 12 x 16
21 Level Alarms (Opt)
H4-10
03-08
Figure H4-3. Boilermate Tank Supports and Saddles, Details and Dimensions
TANK CAPACITY (GAL.)
MODEL
110 330 430 800 1070 1500
LEGS SADDLES
A 48.5 55.5 80 95
B 54 61 85.5 86.5 101
C 22.5 29.5 29.5 38 44.75
D 24.25 31.25 31.25 40 51.5 57
E 11 15 15 17 16 17
F 0.875 0.875 0.875 1 3.38 6.13
G 5.5 5.5 5.5 6.5 N/A
H 7 7 7 9.75 N/A
" C" " D"
" B"
" A"
" F" " G" /2
" G"
" H"

(4) .875" E HOLES
FOR .75" E BOLTS
TANK SUPPORT LEGS
STANDARD ON 110, 330,
430 & 800 GALLON TANKS
" E"
SADDLES
" D" " C"
" B"
" A"
(4) 1.125" E HOLES
FOR .75" E BOLTS
6
" F"
" E"
FRONT HEAD FRONT HEAD
STANDARD ON 1070 &
1500 GALLON TANKS
H4-11
03-08
Flash steam
Exhaust steam
Blowdown
Chemical treatment
Makeup water
Sewer
Intangibles
2
S0
3
to scavenge
1 ppm of dissolved O
2
costs.
costs.
2Na
2
SO
3
+O
2
2Na
2
SO
4
H4-12
03-08
NOTES
H4-13
03-08
Section H4
Boilermate Deaerators
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-14
Deaerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-14
Boiler Feedwater Pump and Motor Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-17
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-18
H4-14
03-08
The following sample specifications are provided by Cleaver-Brooks to assist you in
specifying your customers specific needs and application
A. Deaerator
1. Cleaver-Brooks Model _________packed column type,
pressurized, horizontal deaerator is rated at _____pounds per
hour at ____F mixed inlet water temperature. The system
shall be of the single tank design and guarantee oxygen
removal to not more than 0.005 CCS/liter in the effluent
throughout all load conditions between 5 and 100 percent.
Tray-type designs are not acceptable. The deaerator shall be
designed for operation at 5 psig, but shall be suitable for use
from 2 to 15 psig. Atmospheric operating designs are not
acceptable.
2. Feedwater and condensate shall be admitted to the deaerator
through a single spring-loaded, self-cleaning, adjustable
stainless steel spray valve, which shall provide proper internal
vent condensing and water distribution at any load between 5
and 100 percent of rated capacity. The water temperature in
the primary heating and vent concentrating section is to be
raised within 2 or 3 F of steam temperature and most of the
gases released. The water is then to drop down through the
columns stainless steel exchange packing counterflow to the
steam, which enters at the top of the storage tank and rises up
through the column. The column is to be ____" in length and
____" in diameter. The column shall have a stainless liner and
grid support. Hot, gas-free water is to then drop to the storage
condensables are to flow upward, through the primary heating
spray, into the internal vent concentrating section, where they
contact the cold influent water. Here, the steam is to be
condensed to continue the cycle. Released gases are
discharged to atmosphere through the vent outlet. All internal
surfaces, which come in contact with un-deaerated water,
shall be constructed of Type 316 stainless steel.
3. Automatic vent valve shall be thermostatically controlled to
provide a fast means of venting when a sudden buildup of
gases occurs, such as seen at start up. The manual vent valve
shall have an orifice for continuous minimum venting. Venting
rate shall not exceed 0.1 of 1% of the rated deaerator capacity
at 5 psig.
Make up 25 psig Minimum
Pumped Low Temp Returns 10 psig Minimum
High Temp Returns Not To Exceed 30%
Load Specifications
H4-15
03-08
4. The deaerated water storage tank shall have _____minutes of
storage and have a capacity of _____gallons measured to
overflow. The tank shall be _____diameter x _____long. An
11" x 15" elliptical manhole shall be provided for access. All
nozzles 3" and under shall be 3000 lbs forged steel couplings
and over 3" shall be 150 lbs flat face flanges. Heads to be
ASME torispherical type constructed of ASTM A516 GR 70
carbon steel with a minimum thickness of 0.25 inches. Shell
plate to be fabricated of ASTM A36 carbon steel with a
minimum thickness of 0.25 inches. The tank and column shall
be designed in accordance with ASME, Section VIII of the
Pressure Vessel Code for 50 psig at 650 F and stamped
accordingly. Certification shall be required. Joint efficiencies to
be 70% circumferential per table UW-12, which does not
require stress relieving or nondestructive examination.
5. The deaerator loads shall be as specified in the table below.
Low temperature returns are defined as condensate with a
temperature below that of the deaerator operating temperature.
High temperature returns are defined as condensate with a
temperature above that of the deaerator operating temperature.
6. Optional - The tank and column shall be factory-insulated and
lagged with blanket insulation, pins, clips, and a durable steel
jacket. Block-type insulation is not acceptable. The blanket
insulation is to be fiberglass, 2" thick, 1 lb/cubic foot, and have
a rating of R3.85. Pins are to be located on 18" centers and
holding clips attached. The steel jacket or lagging shall have a
shell thickness of 22 gauge (0.299") minimum and head
thickness of 12 gauge (0.1046") minimum.
cathodic protection against galvanic corrosion. This rod shall be
1-5/16" diameter with a 1/4" steel core to assure a good
8. Optional - The high temperature diffuser or sparge tube shall be
constructed of 2 inch pipe. This tube shall provide even
distribution and blending of high-temperature condensate
returns.
10. Optional - The basic deaerator shall be equipped with the
1. Option (Mechanical) - ___" inlet water regulating lever valve
not exceed ______and be rated for _____gpm at ______psig
H4-16
03-08
__________Model _____. This valve shall be mechanically
_______________, Model ______.
shall be 110V bi-directional type with a permanently
lubricated gear train, and be directly coupled to the valve stem.
The valve Cv shall not exceed _____and be rated for_____
gpm at ______psig inlet pressure. Valve shall not exceed a
manufacturer shall be ____. This valve shall be electronically
be ________, Model _____. This valve shall be pneumatically
controlled by an external proportional type sensor. The sensor
shall be a 14" displacer that produces a pneumatic output
signal. The controller manufacturer shall be _________, Model
______. A filter regulator is to be provided to reduce 50 psig
instrument air supply to 3 - 15 psig for proper operation.
construction.
C. Steam Pressure Reducing Station
be _____Model _____.
H4-17
03-08
____psig operating signal. The valve shall be normally closed
on loss of air. The valve shall be capable of reducing _____psig
saturated steam to the operating pressure of the deaerator at a
flow rate of ____lbs/hr. This valve shall be 250 lb class and
have stainless steel trim. The diaphragm actuated valve
manufacturer shall be _________Model ____. This valve shall
be pneumatically controlled by an external transmitter. The
transmitter set pressure shall be adjustable. The transmitter
manufacturer shall be __________________, Model _______.
bronze construction. Relieving set pressure to be 50 psig. Relief
valve manufacturer to be ___________________, Model
______.
overflow drainer manufacturer shall be ____________, Model
_______.
acceptable.
D. Boiler Feedwater Pump and Motor Set
1. Option (Intermittent) - Quantity________, turbine type boiler
H4-18
03-08
prior to shipment. Pump manufacturer to be_____________,
Model ________, size ____" x _______".
at ______feet TDH with ____feet NPSH required. Pump to be
Institute and have _______seals for a maximum water
temperature of 250 F. Pump impeller to be hydraulically
_____hp, ______phase, _______Hz, ______Volt, _____rpm,
_______enclosure motor. Motor to be non-overloading at the
rated condition without using any portion of the service factor.
Pump and motor set to be factory aligned prior to shipment.
Pump manufacturer to be _________, Model _______, size
_____" x _______". A stainless steel recirculation orifice is to
be supplied with the pump and shipped loose for field
installation to provide minimum bypass flow.
3. Optional - The stand shall elevate the deaerator tank to provide
condition to prevent cavitation plus a 1-1/2 foot safety factor.
The stand shall be constructed of heavy square steel tubing for
the legs and 1/4" steel plate covering the floor.
E. Control Panel
shipment.
a. Control circuit transformer to supply 110-120 volts,
3. Standard
a. The deaerator shall have a gauge glass assembly that
covers the entire tank diameter. The gauge glass shall be
quartz 0.625 inch diameter by 24 inch maximum length.
Each length of glass shall be furnished with a bronze
H4-19
03-08
b. The deaerator shall be supplied with a pressure gauge
that has a 4-1/2 inch dial with a 0-60 psig range and a
thermometer with a 50 to 300 F range. Packaged units
are required to have both gauges bracket-mounted at eye
level.
c. The deaerator is to be hand cleaned with a solvent to
matched marked. Three bound Operating and
Maintenance manuals to be provided. Warranty period to
be twelve months after start-up or eighteen months after
H4-20
03-08
Notes
H5-1
03-08
CONTENTS
ILLUSTRATIONS
Figure H5-1. Surge Tank Dimensions and Ratings - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . H5-5
Figure H5-2. Surge Tank Supports and Saddles, Details and Dimensions . . . . . . . . . . . . . . . . . . H5-7
TABLES
Table H5-1. Surge Tank Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-3
Section H5
SURGE TANKS
Surge Tanks Section H
H5-2
03-08
This section contains information on the complete line of surge tanks ranging in sizes from 300 to 3000 gallon
capacities.
The Cleaver-Brooks Surge Tank products provide additional storage time and handle volume swings in
condensate returns. Because condensate return volume is largely unpredictable, a surge tank provides a means
to collect intermittent condensate returns and supply water at a relatively constant volume, while limiting
discharge to drain. Contact your local Cleaver-Brooks authorized representative for component sizing
information.
Section H Surge Tanks
H5-3
03-08
The following features and benefits apply to Cleaver-Brooks Surge Tank Products.
ASME Heads:
Assures vessel quality in materials and fabrication.
1/4" Thick (Minimum) Shell:
Quality construction.
Longer material life.
Boosts Condensate Return Pressure:
Acts as a collecting point for low pressure and gravity returns.
Allows pumping of returns to a pressurized vessel.
Accepts Gravity Returns:
Vessels are vented to atmosphere, therefore providing no pressure resistance
that would inhibit gravity return.
PRODUCT OFFERING
Information in this section applies directly to Cleaver- Brooks package surge tanks
ranging from 300 to 3,000 gallon capacity. Contact your local Cleaver-Brooks
authorized representative for larger capacities. The product offering for surge tanks
is shown in Table H5-1.
Surge tanks can reduce dependance on cold, untreated raw water to replace boiler
system losses, by collecting condensate for re-use in the boiler. Dedicated surge
tanks are required when intermittent peak loads of condensate can exceed the surge
capacity of the deaerator.
The surge tank receives returning condensate and is supplemented by raw make-up
water to maintain the desired operating level. Condensate and make-up water mix
into a blend temperature as determined by the percentage of each. The surge tank is
vented to atmosphere.
Surge tanks are designed to work with the deaerator. They can be packaged with
transfer pumps, stand and controls of the same sturdy construction as the deaerator.
MODEL NO. FLOODED CAPACITY (GAL.)
SRG-300 300
SRG-450 450
SRG-600 600
SRG-900 900
SRG-1200 1200
SRG-1400 1400
SRG-1600 1600
SRG-2000 2000
SRG-2500 2500
SRG-3000 3000
NOTE: Model number (example, SRG-300) is: SRG =surge tank.
300 =300 gal. capacity.
Table H5-1. Surge Tank Product Offering
H5-4
03-08
Custom arrangements are also available. Contact local Cleaver-Brooks authorized
representative for component and sizing information.
Surge tanks provide additional storage time and handle volume swings in
condensate return. Surge tanks are used when gravity or pumped condensate
returns do not have enough pressure to enter the deaerator on their own. Water and
treatment costs are reduced by recycling condensate that has already been treated.
Integral control automatically introduces cold water makeup to supplement
condensate only when necessary to meet boiler demand. This translates into
reduced fuel costs for heating boiler feedwater.
Standard Equipment
Surge tank.
Thermometer.
Gauge glass.
Required tappings, and manway.
Optional Equipment
ASME code tank.
Three valve bypass and strainer.
Suction strainer.
Discharge manifold.
High water alarm.
Low water alarm.
Condensate diffuser tube.
Control panel.
Transfer pump and motor.
Drain valve.
Stand.
Packaging
wiring by others.
H5-5
03-08
Dimensions and ratings for surge tanks are shown in Figure H5-1 and Figure H5-2.
STAND BASE DIMENSIONS
Tank Capacity (gal) 300 450 600 900 1200 1400 1600 2000 2500 3000
A1 Outside Length 61 60-1/2 84-1/2 100 121-3/4 94 108-1/2 95-1/2 119-1/2 105-1/2
B2 C
L
to C
L
Anchor Bolt Holes 56 55-1/2 79-1/2 95 115-3/4 88 102-1/2 89-1/2 112-1/2 102-1/2
C3 Outside Width 49 58 58 62 60-1/2 71 71 81 83 86-1/2
D4 C
L
to C
L
Anchor Bolt Holes 46 55 55 59 57-1/2 68 68 78 80 79-1/2
E5 1 1 1 1 1 1 1 1 1-1/8 1-1/8
FZ 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 1 1
NOTES:
1. Mounted on packaged units only.
6. Mount tank above pump at elevation necessary for static head including safe allowance for piping friction as approved by pump manufac-
turer.
prints.
8. Add suffix Pto Model no. for packaged units (SRG45-P).
9. Using Warren #377 float cage - dimension Nmay change with other controls - contact your local Cleaver-Brooks authorized represen-
tative.
10. No interconnecting piping or wiring furnished on non-packaged units unless specified, contact your local Cleaver-Brooks authorized rep-
resentative for specific piping or wiring furnished on packaged assemblies.
12. Optional tank sizes available - contact your local Cleaver-Brooks authorized representative.
14. Raw water make-up should first pass through a water softener if hardness is present.
Figure H5-1. Surge Tank Dimensions and Ratings - Sheet 1 of 2
H5-6
03-08
Figure H5-1. Surge Tank Dimensions and Ratings - Sheet 2 of 2
STORAGE TANK DETAIL AND DIMENSIONS
Tank Weight (b) 935 1095 1330 1690 2420 2625 2765 3255 3680 4370
Flooded Weight (lb) 3605 4905 6360 9195 12480 14595 16235 20610 24505 29240
Tank Size (Dia X Length) 36x80 42x84 42x109 48x124 48x164 60x125 60x143 72x131 72x155 84x138
A 6 6 8 12 20 12 14 15 15 15
B 23-1/2 23 30 34 52 34 43 37 41 36
C 32 32-1/2 45 52 68 50 55 51 59 52-1/2
D 40 42 60 69-1/2 91-1/2 66 75 64-1/2 84-1/2 70-1/2
E 57-1/2 59 82 91-1/2 123-1/2 88 104 86-1/2 110-1/2 91-1/2
F 8-1/2 9-1/2 9-1/2 10-1/2 10-1/2 12-1/2 12-1/2 14-1/2 14-1/2 16-1/2
G 9-1/2 11 14 14 28 14 21 17 19 16
H Contact Your Local Cleaver-Brooks Authorized Representative
J Contact Your Local Cleaver-Brooks Authorized Representative
K 54 54 76 89-1/2 115-1/2 86 97 84-1/2 106-1/2 90-1/2
L 11 14 14 16 15 20-1/2 20-1/2 25-1/2 29-1/2 31
M 10 10 10 12-1/2 12-1/2 19-1/2 19-1/2 25 25 30
N 51 57 57 63 63 75 75 87 87 99
TANK CONNECTION SIZES
1 Low Pressure Return (2) 3 NPT 3 NPT 3 NPT 3 NPT 4 NPT 4 NPT 4 NPT 4 NPT 4 NPT 4 NPT
2 Vent 3 NPT 3 NPT 3 NPT 3 NPT 4 NPT 4 NPT 4 NPT 4 NPT 4 NPT 4 NPT
3 Cold Water Inlet 1-1/4
NPT
1-1/4
NPT
1-1/4
NPT
1-1/4
NPT
1-1/4
NPT
1-1/4
NPT
1-1/4
NPT
1-1/4
NPT
1-1/4
NPT
1-1/2
NPT
4 Overflow Connection 3 NPT 3 NPT 3 NPT 3 NPT 4 NPT 4 NPT 4 NPT 4 NPT 4 NPT 4 NPT
5 Pump Suction (For Each Pump) Contact Your Local Cleaver-Brooks Authorized Representative
ITEM LIST
6 High Temperature Return (3 NPT)
7 Suction Piping (Optional) (For Each Pump) (Note 2)
8 Pump/motor (Optional)
9 Manway (11 X 15)
10 Diffuser Tube (2-1/2 NPT) (Optional)
11 Makeup Valve (Optional)
13 Control Panel (Optional)
14 Drain (2 NPT)
15 Thermometer (3/4 NPT)
Sizes Listed for items15 thru 18
are for Tank Connections Only.
16 Level Alarms (1 NPT (Optional)
17 Level Control (1-1/2 NPT) (Optional)
18 Recirculating Connection (1 NPT) (For Each Pump)
H5-7
03-08
300 450 600 900 1200 1400 1600 2000 2500 3000
AA 55-1/2 55 79 93-1/2 N/A N/A N/A N/A N/A N/A
AB 59-1/2 59 83 99-1/2 N/A N/A N/A N/A N/A N/A
AC 31-3/4 36-3/4 36-3/4 40-1/2 N/A N/A N/A N/A N/A N/A
AD 29-1/2 34-1/2 34-1/2 38 N/A N/A N/A N/A N/A N/A
AE 5 6-1/8 6-1/8 7-1/4 N/A N/A N/A N/A N/A N/A
AF 2 2 2 3 N/A N/A N/A N/A N/A N/A
AG 4 4 4 6 N/A N/A N/A N/A N/A N/A
AH 5/8 3/4 3/4 3/4 N/A N/A N/A N/A N/A N/A
AJ 12-1/2 14-1/2 15 15-1/2 N/A N/A N/A N/A N/A N/A
AK 3/4 7/8 7/8 7/8 N/A N/A N/A N/A N/A N/A
AL N/A N/A N/A N/A 4-1/4 6-1/8 6-1/8 7-1/2 7-1/2 7-3/4
AM N/A N/A N/A N/A 115-3/4 88 102-1/2 89-1/2 113-1/2 94-1/2
AN N/A N/A N/A N/A 121-3/4 94 108-1/2 95-1/2 119-1/2 100-1/2
AP N/A N/A N/A N/A 46-1/2 57 57 67 67 77-1/2
AR N/A N/A N/A N/A 38 44-3/4 44-3/4 52 52 62
AS N/A N/A N/A N/A 24-1/2 18-1/2 20-1/4 20-1/2 20-1/2 21-7/8
VENT CAPACITY CHART
SIZE (NPT)
CAPACITY
(lbs/hr)
1 175
1-1/4 350
1-1/2 525
2 1000
2-1/2 1600
3 2800
4 4800
5 10500
6 17000
8 35000
Values given based on:
1) 50 ft. equivalent pipe length.
2) Schedule 40 pipe
3) 2 psi back pressure
4) Vent capacities should be com-
pared with anticipated venting
needs. Oversized vents are avail-
able.
Figure H5-2. Surge Tank Supports and Saddles, Details and Dimensions
H5-8
03-08
Notes
H5-9
Section H5
Surge Tanks
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-10
Surge Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-10
Transfer Pump and Motor Set (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-12
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-12
specific needs and application
H5-10
03-08
PART 1 GENERAL The following sample specifications are provided by Cleaver-Brooks to assist you in
specifying your customers specific needs and application
A. Surge Tank
1. Cleaver-Brooks Model _________________shall be an
atmospheric, horizontal Surge Tank.
2. The surge tank shall receive returning condensate and
supplement make up water to maintain the desired operating
level. Condensate and make up water mix into a blended
temperature, as determined by the percentage of each. The
surge tank shall be vented to atmosphere. The collected water
is then transferred to the deaerator.
3. The surge tank shall have _______minutes of storage and
have a capacity of _______gallons flooded. The tank shall be
____" diameter x ______" long. An 11" x 15" elliptical manhole
shall be provided for access. All nozzles shall be 3000 lbs
forged steel couplings. Heads shall be ASME torispherical type
(flat heads are not acceptable) constructed of ASTM A516 GR
70 carbon steel with a minimum thickness of 0.25". Shell
plate to be fabricated of ASTM A36 carbon steel with a
minimum thickness of 0.25".
4. The surge tank loads shall be as specified in the following
table.
5. Optional - The tank shall be designed in accordance with
Section VIII of the ASME Pressure Vessel Code for ______psig,
and stamped accordingly. Certification shall be required. Joint
efficiencies to be 70% circumferential per table UW-12, which
does not require stress relieving or nondestructive examination.
6. Optional - The tank shall be factory-insulated and lagged with
blanket insulation, pins, clips, and a durable steel jacket.
Block-type insulation is not acceptable. The blanket insulation
is to be fiberglass, 2" thick, 1 lb/cu-ft, and have a rating of
R3.85. Pins are to be located on 18" centers and holding clips
attached. The steel jacket or lagging shall have a shell
thickness of 22 gauge (0.299") minimum and head thickness
of 12 gauge (0.1046") minimum.
Make up 20 psig Minimum
Low Temp Returns
High Temp Returns
Load Specifications
H5-11
03-08
cathodic protection against galvanic corrosion. This rod shall be
1-5/16" diameter with a 1/4" steel core to assure a good
8. Optional - The high-temperature diffuser or sparge tube shall be
constructed of 2" pipe. This tube shall provide even distribution
and blending of high-temperature condensate returns.
10. Optional - The basic surge tank shall be equipped with the
not exceed ______, and shall be rated for _____gpm at ______
psig inlet pressure. The pressure drop across the valve shall not
_________, Model _______. This valve shall be mechanically
____________, Model __________.
shall be 110V bi-directional type, with a permanently
lubricated gear train, and directly coupled to the valve stem.
The valve Cv shall not exceed _____and be rated for_______
gpm at ________psig inlet pressure. Valve shall not exceed a
manufacturer shall be _________. This valve shall be
electronically controlled by a solid state control with internally
mounted capacitance probes. The electronic solid state control
shall be able to set desired level point and acceptable
deviation. The electronic solid state control shall include a
selection for automatic and manual operating mode. The
internals shall include two additional probes for high and low
water alarm. The controller manufacturer shall be Cleaver-
Brooks, Model TW82. A solenoid valve and float switch is not
acceptable. (Available only in the U.S.)
H5-12
03-08
The valve shall be globe-type with proportional control and a
spring-opposed diaphragm actuator arranged for 3 - 15 psig
________gpm at ______psig inlet pressure. Valve shall not
be ___________, Model _______. This valve shall be
_____________, Model __________. A filter regulator is to be
provided to reduce 50 psig instrument air supply to 3 - 15 psig
for proper operation.
construction.
rise and break on fall. Float cage construction shall be cast
fall and break on rise. Float cage construction shall be cast
acceptable.
C. Transfer Pump and Motor Set (Optional)
1. Quantity ______, centrifugal type transfer pump and motor set.
Turbine type pumps are not acceptable in this application.
Pump to be rated for _______gpm at ________feet TDH with
______feet NPSH required. Pump to be _______materials of
construction as defined by the Hydraulic Institute, and have
_______seals for a maximum water temperature of 212 F.
Pump impeller to be hydraulically balanced. The pump shall
be mounted on a steel baseplate and flexibly coupled with an
OSHA type coupling guard to a ________hp, ________phase,
_______Hz, ________Volt, _____rpm, _______enclosure
motor. Motor to be non-overloading at the rated condition
without using any portion of the service factor. Pump and
motor set to be factory aligned prior to shipment. Pump
manufacturer to be _________, Model _______, size _____" x
_______". A stainless steel recirculation orifice is to be
supplied with the pump and shipped loose for field installation
to provide minimum bypass flow.
H5-13
03-08
2. Optional - The stand shall elevate the surge tank to provide the
net positive suction head required by the pump at the rated
condition to prevent cavitation. The stand shall be constructed
of heavy square steel tubing for the legs and 1/4" steel plate
covering the floor.
D. Control Panel
and wired to the National Electric Code. The wire shall be black
number coded. The assembly is to contain individual motor
starters with 120 Volt holding coil and fuse protection.
shipment.
a. Control circuit transformer to supply 110-120 Volts,
3. Standard
a. The surge tank shall have a gauge glass assembly that
covers the entire tank diameter. The gauge glass shall be
quartz 0.625 inch diameter by 24-inch maximum length.
Each length of glass shall be furnished with a bronze
b. The surge tank shall be supplied with a thermometer with
a 50 to 300 F range.
c. The surge tank is to be hand cleaned with a solvent to
matched marked. Warranty period to be twelve months
after start-up or eighteen months after shipment,
whichever comes first.
H5-14
03-08
Notes
H6-1
03-08
CONTENTS
FEATURES AND BENEFITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-3
Simplex Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-4
Duplex Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-4
Dual Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-4
Triplex Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-4
Boiler Feedwater Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-4
SELECTION GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-5
Optional Steam Preheating Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-5
PACKAGE CONCEPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-11
Intermittent (On-Off) Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-11
Pump Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-11
Pump Total Dynamic Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-12
Pump Material of Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-12
Receiver Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-12
Receiver Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-12
Optional Steam Preheater Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-12
Preheater Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-13
Make-up Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-13
Section H6
BOILER FEED SYSTEMS
Boiler Feed Systems Section H
H6-2
03-08
ILLUSTRATIONS
Figure H6-1. Dimensions and Ratings for Boiler Feed Systems . . . . . . . . . . . . . . . . . . . . . . . . . . .H6-6
TABLES
Table H6-1. Boiler Feedwater Systems Tank Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-4
Table H6-2. Simplex and Duplex System Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-7
Table H6-3. Dual System Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-8
Table H6-4. Triplex System Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-9
Table H6-5. Internal Steam Heater Assemblies for High Pressure System (30-250 psig Steam),
Thermostatic Regulating Valve with Pressure Reducing Attachment . . . . . . . . . . . . . . . . . H6-10
Table H6-6. Internal Steam Heater Assemblies for Low Pressure System (10-15 psig Steam),
Thermostatic Regulating Valve without Pressure Reducing Attachment . . . . . . . . . . . . . . . H6-11
Cleaver-Brooks boiler feed systems help maintain peak efficiency and prolong the life of boilers where investment
in a deaerator cannot be justified. Consisting of one or more feed pumps and a corrosion resistant receiver tank,
the system automatically supplements condensate with makeup water to replace system losses. Cold water is
heated by mixing with hot condensate and pumped to the boiler on demand.
Information in this section addresses tank size and typical offering of Boiler Feed Systems.
Section H Boiler Feed Systems
H6-3
03-08
The following features and benefits apply to Cleaver-Brooks Boiler Feed system
products.
All Pumps Deliver the Required Capacity at 210 F:
Guaranteed pump performance.
All Pumps Have Mechanical Seals (Standard):
Reduces maintenance when compared to packing type seals.
Tank Includes a Protective Lining:
The vessel is lined with an epoxy coating, deterring corrosion of vessel steel due
to dissolved gases.
Specifically Designed for Compatibility With Cleaver-Brooks Boilers:
Quick, accurate equipment selection.
Single source responsibility.
Proven performance.
Provides Additional Storage Time and Handles Volume-Swings in Condensate
Return:
Feedwater tank collects intermittent condensate returns and supplies water at a
relative constant volume.
Minimizes problem from unpredictable condensate flow rates.
Boosts Condensate Return Pressure:
Acts as a collecting point for low pressure and gravity returns.
Allows the introduction of returns to a high pressure vessel.
Accepts Gravity Returns:
Vessels are vented to atmosphere, providing no pressure resistance that would
inhibit gravity return.
PRODUCT OFFERING
Information in this section applies directly to Cleaver- Brooks Feed Systems for low
and high pressure (15 - 300 psig) boilers (15 - 800 horsepower). Selection of Boiler
Feed Systems is based on boiler size, pump requirements (flow, pressure, hp), and
water storage requirements (tank size). Contact your local Cleaver-Brooks authorized
representative for detailed component sizing information.
Table H6-1 shows available tank sizes for boiler feedwater systems.
H6-4
03-08
When equipped with an automatic steam preheater, feedwater temperature can be
maintained at 210 F. At this higher temperature, oxygen and carbon dioxide are
released, reducing corrosion problems in the boiler. Pre-heating is recommended if
return condensate constitutes 50% or less of the feedwater required.
Cleaver-Brooks Packaged Feedwater Systems include pumps, control panel with
magnetic starters, and necessary switches. Systems are available in simplex,
duplex, dual and triplex arrangements. Custom arrangements are also available.
Accessories include high temperature diffuser tube, automatic preheater, make-up
valves, electrolytic corrosion inhibitor, and ASME tanks.
Contact your local Cleaver-Brooks authorized representative for information on
alternate Cleaver-Brooks/Aurora Pump Feed Systems.
Simplex Units
Simplex units include one pump set complete with open drip-roof motor on steel
channel base with flexible coupling between pump and motor, one large receiver
mounted on structural steel stand, complete with make-up valve, gauge glass with
shutoff valves, thermometer, and suction piping from receiver to pump with Y-type
strainer, flexible hose and gate valve.
Duplex Units
Duplex units are similar to simplex units, but with two pumps and one receiver.
Magnetic starters (where required) are mounted in a NEMA I enclosure, with
manual transfer switch for standby pump.
Dual Unit
Dual units are similar to duplex units, except that receiver tank is sized for two
boiler operation. Transfer switch is not required.
Triplex Units
Triplex units are similar to Dual units but with three pumps and one receiver.
Boiler Feedwater Systems
Standard equipment includes the following:
Lined tank.
Stand.
CAPACITY (GAL.)
45
75
100
200
270
340
500
750
1000
Table H6-1. Boiler Feedwater Systems Tank Capacities
H6-5
03-08
Boiler feed pump and motor.
Magnetic starter.
Suction strainer.
Suction flexible fittings.
Gauge glass.
Internal float make-up valve.
Thermometer.
Required tappings.
Optional equipment
Preheating systems.
High temperature diffuser tube.
Manhole.
External float make-up valve.
Electric alternator.
Special electrical requirements.
ASME Code tank.
Magnesium anode.
Dimensions and ratings for boiler feed systems are shown in Figure H6-1.
SELECTION GUIDE
Refer to Table H6-2, Table H6-3, and Table H6-4 for basic feed system selection.
Optional Steam Preheating Equipment
All standard tanks are supplied with extra openings for preheating equipment.
Preheating systems are provided with thermostatically controlled steam pressure
regulators connected to the perforated tube installed in the tank by means of a
special bushing. Feed systems with optional steam preheat also include a sentinel
valve installed on the tank.
On standard high pressure units (30 through 250 psi) the following equipment is
furnished (refer to Table H6-5):
1. Perforated heater tube with special bushing.
2. Pressure/temperature regulating valve.
3. Strainer for regulating valve.
4. Pressure gauge.
5. Sentinel valve on tank.
On standard low pressure units (10 through 15 psi) the following equipment is
furnished (refer to Table H6-2):
H6-6
03-08
VENT CAPACITY CHART
SIZE (NPT)
CAPACITY
(#/hr)
4 4800
5 10,500
6 17,000
8 35,000
Values given based on:
1) 50 ft. equivalent pipe
length
2) Schedule 40 pipe
3) 2 psi back pressure
4) Vent capacities should be
compared with anticipated
venting needs. Oversized
vents are available.
45 75 100 200 270 340 500 750 1000
A 18 24 24 30 36 36 42 48 48
B 69 75 75 89 95 95 109 115 115
C 64 70 70 84 90 90 104 110 110
D 55 58 58 69 72 72 83 86 86
E 35-1/2 33 47-1/2 58-1/2 54-1/2 69-1/2 73 85 117
F 26-1/2 26-1/2 26-1/2 39-1/2 39-1/2 39-1/2 44 44 44
G 43 40 55 67 63 78 84 96 128
H 34 34 34 43-1/2 43-1/2 43-1/2 49 49 49
J 2 2 2 3 3 3 3 3 3
K* 4 4 4 4 4 4 4 4 4
L 1-1/4 1-1/4 1-1/4 2 2 2 2 2 2
M 3/4 3/4 3/4 1 1 1 1-1/2 1-1/2 1-1/2
N 6-1/4 9 9 11-1/2 14 14 17 19 19
P 6-1/4 9 9 11-1/2 14 14 17 19 19
R 11-3/4 11-1/2 16-1/4 14-1/2 13-1/2 17-1/4 19-1/2 22-1/2 30-1/2
S 33-1/4 30 42-3/4 55 51-1/2 64-3/4 68-3/4 79-1/4 107-1/4
T 33-1/4 30 42-3/4 55 51-1/2 64-3/4 68-3/4 79-1/4 107-1/4
W 5-1/2 7 7 10-1/2 13 13 16 19 19
X 3/4 3/4 3/4 3/4 3/4 1 1 1 1
Y 5/8 5/8 5/8 5/8 5/8 7/8 7/8 7/8 7/8
Z 2 2 2 3 3 3 3 3 3
* See Vent Capacity Chart
NOTE:
1. Control panel not furnished with single phase motor.
2. Dim. Hmay not reflect overall unit width. Overall width may be greater due to pump/motor bases extending past stand posts and varying control panel depths,
3. All above dimensions while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension prints.
Figure H6-1. Dimensions and Ratings for Boiler Feed Systems
1" NPT SENTINAL
VALVE CONNETION
H6-7
03-08
BOILER
HR
EVAP
RATE
TANK
CAP.
TANK
SIZE
DIA. X
LENGTH
ACTUAL PUMP DISCHARGE PRESSURE (PSI)
30 105 130 155 205 255 305
BOILER OPERATING PRESSURE (PSI) MAKE-UP
VALVE
(IN.) 15 100 125 150 200 250 300
15 1.0 45 18 x 43 P-D-1/2
5.0
P-2D-1
2.4
P-2E-1-1/2
2.3
P-2F-2
3.0
P-3E-3
2.0
2-3F-3
2.1
P-4F-5
3.2
3/4
20 1.4 45 18 x 43 P-D-1/2
5.0
P-2E-1
4.1
P-2F-2
5.0
P-2F-2
3.0
P-3F-2
4.5
P-4E-3
2.8
P-4F-5
3.2
3/4
25 1.7 45 18 x 43 P-D-1/2
5.0
P-2E-1
4.1
P-2F-2
5.0
P-3E-3
4.1
P-3F-3
4.5
P-4F-5
4.8
P-4G-7-1/2
4.0
3/4
30 2.1 45 18 x 43 P-D-1/2
5.0
P-2E-1
4.1
P-2F-2
5.0
P-3E-3
4.1
P-3F-3
4.5
P-4F-5
4.8
P-4G-7-1/2
4.0
3/4
40 2.8 45 18 x 43 P-E-1/2
7.0
P-2F-2
6.9
P-2G-3
5.6
P-3F-3
6.9
P-4F-3
6.7
P-4G-5
5.8
P-5I-7-1/2
7.0
3/4
50 3.5 45 18 x 43 P-E-1/2
7.0
P-2F-2
6.9
P-3F-3
7.9
P-3F-3
6.9
P-4G-5
8.5
P-4I-7-1/2
6.9
P-5I-7-1/2
7.0
3/4
60 4.1 75 24 x 40 R-F-1/2
10
R-2G-2
8.3
R-3G-3
10
R-3G-3
8.3
R-4G-5
8.5
R-4IA-7-1/2
8.3
R-5IA-10
10
3/4
70 4.8 75 24 x 40 R-F-1/2
10
R-2I-3
11
R-3G-3
10
R-3I-5
11
R-4I-5
11.3
R-5I-7-1/2
12
R-5IA-10
10
3/4
80 5.5 75 24 x 40 R-G-1/2
12
R-2I-3
11
R-3I-3
15
R-3I-5
11
R-4I-5
11.3
R-2II-15
17
R-2II-15
14
3/4
100 6.9 100 24 x 55 S-H-3/4
17
S-2IA-3
15
S-3I-3
15
S-3IA-5
14
S-4IA-7-1/2
14
S-2II-15
17
S-2II-15
14
3/4
125 8.6 100 24 x 55 S-H-3/4
17
S-3I-3
18
S-3IA-5
18
S-L-10
21
S-2II-15
22
S-2II-15
17
S-2EE-20
17
3/4
150 10 100 24 x 55 S-I-3/4
20
S-3IA-5
25
S-K-7-1/2
21
S-L-10
21
S-2II-15
22
S-2K-15
20
S-2L-20
20
3/4
200 14 200 30 x 67 T-IA-1
28
T-K-7-1/2
28
T-L-10
28
T-2II-15
26
T-2K-15
27
T-2L-20
28
T-3K-20
27
1
250 17 200 30 x 67 T-P-1-1/2
45
T-L-7-1/2
37
T-2K-15
36
T-2K-15
34
T-2EE-15
32
T-3K-20
32
T-3EE-25
32
1
300 21 270 36 x 63 V-P-1-1/2
45
V-L-7-1/2
37
V-2EE-15
41
V-2EE-15
38
V-2L-15
38
V-3L-25
42
V-3L-25
38
1
350 24 270 36 x 63 V-R-2
50
V-2EE-10
45
V-2L-15
50
V-2L-15
45
V-3L-25
47
V-3GG-25
48
V-4L-25
45
1
400 28 340 36 x 78 W-R-2
50
W-2FF-10
50
V-2L-15
50
W-2GG-15
52
W-3GG-25
56
W-4GG-30
58
W-4GG-30
52
1
500 35 340 36 x 78 W-GG-3
68
W-2GG-15
65
W-2GG-15
61
W-2J J -15
66
W-4GG-30
66
W-3KK-30
70
1
600 41 500 42 x 84 X-HH-5
75
X-2J J -15
81
X-2J J -15
72
X-2KK-20
81
X-3KK-30
83
1-1/2
700 48 500 42 x 84 X-HH-5
75
X-2J J -15
81
X-2KK-20
83
X-2KK-20
81
X-3KK-30
83
1-1/2
800 55 750 48 x 96 Y-KK-7-1/2
83
X-2J J -15
81
Y-2KK-20
83
Y-2KK-20
81
Y-3KK-30
83
1-1/2
NOTE:
1. Selection for intermittent operation through boiler level switches for 60 Hz applications only.
2. Prefix Model number with SSimplex or Dfor Duplex.
3. Example
V-R-2: V-size tank is 260 gal, R-Model Pump, 2 hp motor.
50: 50 gpm capacity at rated discharge capacity on 210F water.
4. Contact your local Cleaver-Brooks authorized representative for information on 50 Hz applications.
Table H6-2. Simplex and Duplex System Selection
H6-8
03-08
BOILER
HR
EVAP
RATE
TANK
CAP.
TANK
SIZE
DIA. X
LENGTH
30 105 130 155 205 255 305
BOILER OPERATING PRESSURE (PSI) MAKE-UP
VALVE
(IN.) 15 100 125 150 200 250 300
15 1.0 45 18 x 43 P-D-1/2
5.0
P-2D-1
2.4
P-2E-1-1/2
2.3
P-2F-2
3.0
P-3E-3
2.0
2-3F-3
2.1
P-4F-5
3.2
3/4
20 1.4 45 18 x 43 P-D-1/2
5.0
P-2E-1
4.1
P-2F-2
5.0
P-2F-2
3.0
P-3F-2
4.5
P-4E-3
2.8
P-4F-5
3.2
3/4
25 1.7 45 18 x 43 P-D-1/2
5.0
P-2E-1
4.1
P-2F-2
5.0
P-3E-3
4.1
P-3F-3
4.5
P-4F-5
4.8
P-4G-7-1/2
4.0
3/4
30 2.1 45 18 x 43 P-D-1/2
5.0
P-2E-1
4.1
P-2F-2
5.0
P-3E-3
4.1
P-3F-3
4.5
P-4F-5
4.8
P-4G-7-1/2
4.0
3/4
40 2.8 75 24 x 40 R-E-1/2
7.0
R-2F-2
6.9
R-2G-3
5.6
R-3F-3
6.9
R-4F-3
6.7
R-4G-5
5.8
R-5I-7-1/2
7.0
3/4
50 3.5 75 24x 40 R-E-1/2
7.0
R-2F-2
6.9
R-3F-3
7.9
R-3F-3
6.9
R-4G-5
8.5
R-4I-7-1/2
6.9
R-5I-7-1/2
7.0
3/4
60 4.1 100 24 x 55 S-F-1/2
10
S-2G-2
8.3
S-3G-3
10
S-3G-3
8.3
S-4G-5
8.5
S-4IA-7-1/2
8.3
S-5IA-10
10
3/4
70 4.8 100 24 - 55 S-F-1/2
10
S-2I-3
11
S-3G-3
10
S-3I-5
11
S-4I-5
11.3
S-5I-7-1/2
12
S-5IA-10
10
3/4
80 5.5 200 30 x 67 T-G-1/2
12
T-2I-3
11
T-3I-3
15
T-3I-5
11
T-4I-5
11.3
T-2II-15
17
T-2II-15
14
1
100 6.9 200 30 x 67 T-H-3/4
17
T-2IA-3
15
T-3I-3
15
T-3IA-5
14
T-4IA-7-1/2
14
T-2II-15
17
T-2II-15
14
1
125 8.6 270 36 x 63 V-H-3/4
17
V-3I-3
18
V-3IA-5
18
V-L-10
21
V-2II-15
22
V-2II-15
17
V-2EE-20
17
1
150 10 270 36 x 63 V-I-3/4
20
V-3IA-5
25
V-K-7-1/2
21
V-L-10
21
V-2II-15
22
V-2K-15
20
V-2L-20
20
1
200 14 340 36 x 78 W-IA-1
28
W-K-7-1/2
28
W-L-10
28
W-2II-15
26
W-2K-15
27
W-2L-20
28
W-3K-20
27
1
250 17 340 36 x 78 W-P-1-1/2
45
W--L-7-1/2
37
W-2K-15
36
W-2K-15
34
W-2EE-15
32
W-3K-20
32
W-3EE-25
32
1
300 21 500 42 x 84 X-P-1-1/2
45
X-L-7-1/2
37
X-2EE-15
41
X-2EE-15
38
X-2L-15
38
X-3L-25
42
X-3L-25
38
1-1/2
350 24 500 42 x 84 X-R-2
50
X-2EE-10
45
X-2L-15
50
X-2L-15
45
X-3L-25
47
X-3GG-25
48
X-4L-25
45
1-1/2
400 28 750 48 x 96 Y-R-2
50
Y-2FF-10
50
Y-2L-15
50
Y-2GG-15
52
Y-3GG-25
56
Y-4GG-30
58
Y-4GG-30
52
1-1/2
500 35 750 48 x 96 Y-GG-3
68
Y-2GG-15
65
Y-2GG-15
61
Y-2J J -15
66
Y-4GG-30
66
Y-3KK-30
70
1-1/2
600 41 1000 48 x 128 Z-HH-5
75
Z-2J J -15
81
Z-2J J -15
72
Z-2KK-20
81
Z-3KK-30
83
1-1/2
700 48 1000 48 x 128 Z-HH-5
75
Z-2J J -15
81
Z-2KK-20
83
Z-2KK-20
81
Z-3KK-30
83
1-1/2
NOTE:
2. Prefix Model number with U for Dual.
3. Example
X-R-2: X-size tank is 500 gal, R-Model Pump, 2 hp motor.
Table H6-3. Dual System Selection
H6-9
03-08
BOILER
HR
EVAP
RATE
TANK
CAP.
TANK
SIZE
DIA. X
LENGTH
30 105 130 155 205 255 305
MAKE-UP
VALVE
(IN.)
BOILER OPERATING PRESSURE (PSI)
15 100 125 150 200 250
300
50 3.5 200 30 x 67 T-E-1/2
7.0
T-2F-2
6.9
T-3F-3
7.9
T-3F-3
6.9
T-4G-5
8.5
T-4I-7-1/2
6.9
T-5I-7-1/2
7.0
1
60 4.1 200 30 x 67 T-F-1/2
10
T-2G-2
8.3
T-3G-3
10
T-3G-3
8.3
T-4G-5
8.5
T-4IA-7-1/2
8.3
T-5IA-10
10
1
70 4.8 200 30 x 67 T-F-1/2
10
T-2I-3
11
T-3G-3
10
T-3I-5
11
T-4I-5
11.3
T-5I-7-1/2
12
T-5IA-10
10
1
80 5.5 200 30 x 67 T-G-1/2
12
T-2I-3
11
T-3I-3
15
T-3I-5
11
T-4I-5
11.3
T-2II-15
17
T-2II-15
14
1
100 6.9 200 30 x 67 T-H-3/4
17
T-2IA-3
15
T-3I-3
15
T-3IA-5
14
T-4IA-7-1/2
14
T-2II-15
17
T-2II-15
14
1
125 8.6 270 36 x 63 V-H-3/4
17
V-3I-3
18
V-3IA-5
18
V-L-10
21
V-2II-15
22
V-2II-15
17
V-2EE-20
17
1
150 10 270 36 x 63 V-I-3/4
20
V-3IA-5
25
V-K-7-1/2
21
V-L-10
21
V-2II-15
22
V-2K-15
20
V-2L-20
20
1
200 14 340 36 x 78 W-IA-1
28
W-K-7-1/2
28
W-L-10
28
W-2II-15
26
W-2K-15
27
W-2L-20
28
W-3K-20
27
1
250 17 340 36 x 78 W-P-1-1/2
45
W-L-7-1/2
37
W-2K-15
36
W-2K-15
34
W-2EE-15
32
W-3K-20
32
W-3EE-25
32
1
300 21 500 42 x 84 X-P-1-1/2
45
X-L-7-1/2
37
X-2EE-15
41
X-2EE-15
38
X-2L-15
38
X-3L-25
42
X-3L-25
38
1-1/2
350 24 500 42 x 84 X-R-2
50
X-2EE-10
45
X-2L-15
50
X-2L-15
45
X-3L-25
47
X-3GG-25
48
X-4L-25
45
1-1/2
400 28 750 48 x 96 Y-R-2
50
Y-2FF-10
50
Y-2L-15
50
Y-2GG-15
52
Y-3GG-25
56
Y-4GG-30
58
Y-4GG-30
52
1-1/2
500 35 750 48 x 96 Y-GG-3
68
Y-2GG-15
65
Y-2GG-15
61
Y-2J J -15
66
Y-4GG-30
66
Y-3KK-30
70
1-1/2
600 41 1000 48 x 128 Z-HH-5
75
Z-2J J -15
81
Z-2J J -15
72
Z-2KK-20
81
Z-3KK-30
83
1-1/2
700 48 1000 48 x 128 Z-HH-5
75
Z-2J J -15
81
Z-2KK-20
83
Z-2KK-20
81
Z-3KK-30
83
1-1/2
NOTE:
2. Prefix Model number with T for Triplex
3. Example
Y-R-2: Y-size tank is 750 gal, R-Model Pump, 2 hp motor.
Table H6-4. Triplex System Selection
H6-10
03-08
MODEL
NUMBER
HEATING RATE (GPM)
SIZE OF STEAM
CONTROL VALVE
& STRAINER
(INCHES)
MINIMUM STEAM
SUPPLY LINE
(INCHES)
MINIMUM
STEAM
SUPPLY
PRESSURE
MAXIMUM
STEAM
SUPPLY
PRESSURE
50F
TEMP
RISE
100F
TEMP
RISE
150F
TEMP
RISE
25PT-5-.75 17 9 6 3/4 1 30 50
25PT-5-.75 3/4 1 50 100
25PT-5-.5 1/2 3/4 100 125
25PT-5-.5 1/2 3/4 125 150
25PT-5-.5 1/2 3/4 150 200
25PT-5-.5S 1/2 3/4 200 250
25PT-5-.1 28 13 9 1 1-1/4 30 50
25PT-5-.75 3/4 1 50 100
25PT-5-.75 3/4 1 100 125
25PT-5-.5 1/2 3/4 125 150
25PT-5-.5 1/2 3/4 150 200
25PT-5-.5 1/2 3/4 200 250
25PT-5-1.25 37 18 12 1-1/4 1-1/2 30 50
25PT-5-.1 1 1-1/4 50 100
25PT-5-.75 3/4 1 100 125
25PT-5-.75 3/4 1 125 150
25PT-5-.5 3/4 1 150 200
25PT-5-.5 3/4 1 200 250
25PT-5-1.5 53 26 18 1-1/2 2 30 50
25PT-5-1.25 1-1/4 1-1/2 50 100
25PT-5-1 1 1-1/4 100 125
25PT-5-.75 3/4 1 125 150
25PT-5-.75 3/4 1 150 200
25PT-5-.75 3/4 1 200 250
25PT-5-2 92 42 28 2 2-1/2 30 50
25PT-5-2 2 2-1/2 50 100
25PT-5-1.25 1-1/4 1-1/2 100 125
25PR-5-1 1 1-1/4 125 150
25PR-5-1 1 1-1/4 150 200
25PT-5-.75 3/4 1 200 250
25PT-5-2.5 140 68 45 2-1/2 3 30 50
25PT-5-2 2 2-1/2 50 100
25PT-5-1.5 1-1/2 2 100 125
25PT-5-1.5 1-1/2 2 125 150
25PT-5-1.25 1-1/4 1-1/2 150 200
25PT-5-1 1 1-1/4 200 250
25PT-5-3 190 90 60 3 4 30 50
25PT-5-2.5 2-1/2 3 50 100
25PT-5-2 2 2-1/2 100 125
25PT-5-2 2 2-1/2 125 150
25PT-5-1.5 1-1/2 2 150 200
25PT-5-1.25 1-1/4 1-1/2 200 250
NOTE: Not applicable for steam pressure over 250 psi, if available steam pressure is over 250 psi, contact your local Cleaver-
Table H6-5. Internal Steam Heater Assemblies for High Pressure System (30-250 psig Steam),
Thermostatic Regulating Valve with Pressure Reducing Attachment
H6-11
03-08
1. Perforated heater tube with special bushing.
2. Temperature regulating valve.
3. Strainer for temperature regulating valve.
4. Pressure gauge.
5. Sentinel valve on tank.
PACKAGE CONCEPT
Cleaver-Brooks line of packaged catalog feed systems is based on the following
parameters.
Intermittent (On-Off)
Pump Operation
As the water level in the boiler falls to a certain level, contacts close in the float
switch on the boiler and the pump starts. As the water level in the boiler rises to a
certain level, the contacts open in the float switch on the boiler and the pump
stops. The operation repeats as the water levels drop again.
The intermittent operation, normally used on Cleaver-Brooks firetube boilers, is well
suited to the regenerative turbine pump, for the following reasons:
The pump covers a broad range of pressures, which covers a wide boiler
pressure range.
Comparatively low capacities are ideal for the small and medium range boilers.
The pump is allowed to operate at a nearly constant head-capacity point and
not over the entire pump curve as with continuous operation using a modulating
feedwater valve, normally used on large industrial watertube boilers.
The pump can obtain rated flow and head at a relatively low speed. The pumps
are run at 1750 rpm, which gives a longer desired life.
The pump is flexibly coupled to the motor, which reduces the possibility of heat
transfer from the liquid being pumped to the driver.
MODEL
NUMBER
HEATING RATE (GPM)
SIZE OF STEAM
CONTROL VALVE &
STRAINER
(INCHES)
MINIMUM STEAM
SUPPLY LINE
(INCHES)
50F
TEMP RISE
100F
TEMP RISE
150F
TEMP RISE
25T-5-1 13 6.5 4.2 1 1-1/4
25T-1.25 18 8.7 5.9 1-1/4 1-1/2
25T-5-1.5 25 12.6 8.4 1-1/2 2
25T-5-2 44 22 14.6 2 2-1/2
25T-5-2.5 70 35 23 2-1/2 FLG 3
25T-5-3 92 46 31 3 FLG 4
NOTE:
1. For operation on steam supply pressure less than 10 psig, consult your local Cleaver-Brooks authorized representative.
2. Specify available steam pressure when ordering.
Table H6-6. Internal Steam Heater Assemblies for Low Pressure System (10-15 psig Steam),
Thermostatic Regulating Valve without Pressure Reducing Attachment
H6-12
03-08
Pump Flow One Boiler Horsepower is equal to an evaporation rate of 34.5 pounds of water
per hour at 212 F. To convert the value to gallons per minute, divide by the weight
of one gallon water, or 8.33 lbs, to obtain gallons per hour. Divide this value by 60
to determine the number of gallons per minute. The result of this calculation is
0.069 gallons per minute, which is the theoretical evaporation rate for each boiler
horsepower. When selecting the boiler feed pump flow, it is necessary to provide for
excess capacity to take care of the boiler load without running the pump
continuously. For this reason, selections for intermittent boiler feed pumps are
based on a value of 1-1/2 to 2 times the theoretical evaporation rate.
Pump Total Dynamic
Head
The pump head to be developed by a boiler feed pump that is returning water
directly to the boiler must be equal to the boiler pressure, plus static head
differences, plus friction losses in the piping, valves and any other equipment
between the pump and the boiler.
EXAMPLE: Boiler operating at 100 psig.
CALCULATION: 100 psig (oper) + 5 psig (loss) x 2.31 (constant) 0.96 (specific
gravity) = 252 TDH.
Pump Material of
Construction
Material of construction for a boiler feed pump should be carefully selected for
compatibility of the liquid being pumped. In general, the Cleaver-Brooks bronze-
fitted pump is best suited for most applications. Factors that will affect this decision
are water quality and treatment. An example: In situations when alkalinity is higher
than a pH of 8.5, do not use a bronze-fitted pump. There is no substitute for
experience in selecting materials for pump construction. Previous experience in
handling a particular application should be the main criteria.
Receiver Size The receiver should be sized for a capacity sufficient to allow feed water for a
minimum of 10 to 15 minutes of boiler operation at rated horsepower.
The run time is essential because of unpredictable surges of condensate returns.
Since 0.069 gpm is the theoretical rate of evaporation per boiler horsepower, the
maximum tank size should be approximately 0.069 boiler hp x 10 minutes.
If it is known that the receiver will see 100% make-up with no returns, a five
minute capacity tank can be substituted. The reduced storage capacity is
acceptable, since the receiver will have a steady predictable load.
Receiver
Construction
Standardly, tanks are protected by three coats of a two-part, air cured, epoxy lining
or by an optional hot-dipped galvanization process.
The receivers are manufactured as a non-code tank for venting to atmosphere. As
an option, Cleaver-Brooks offers receivers constructed for ASME Section VIII,
Division 1 of the ASME Pressure Vessel Code. When an ASME Code receiver is
required, contact your local Cleaver-Brooks authorized representative for additional
factors to be considered in this application. Coded tanks supplied will normally be
furnished unlined because of possible increased operating temperature limitations.
Optional Steam
Preheater Size
Three basic factors are considered when sizing a preheater:
1. The heating rate in gallons per minute. It is generally assumed the same as the
total evaporation rate of the boilers being supplied with water, unless otherwise
specified.
2. The temperature rise required to raise the temperature in the tank based on
condensate returns and make-up water mixed inlet temperature to 212 F.
H6-13
03-08
3. The available steam supply pressure at the regulating valve is generally
assumed the same as the operating pressure of the boiler from which the steam
is being tapped, unless otherwise specified.
Two basic benefits are gained by supplying a preheat package.
1. The risk of damage to the boiler caused by thermal shock is reduced.
2. The dissolved oxygen content can be reduced, slowing corrosion and showing a
savings in the chemical treatment program of the boiler. Oxygen in 212 F
feedwater is roughly 1.8 cc/liter as opposed to 50 F feedwater, which is 5.9
cc/liter. The American Society of Engineers, in a paper called Consensus On
Operating Practices For The Control of Feedwater and Boiler Water Quality in
Modern Industrial Boilers , suggests dissolved oxygen limits that should be
considered. A preheater by no means deaerates water to an acceptable level by
itself.
Preheater
Components
Preheater Components include the following:
1. Perforated heater tube, also referred to as a diffuser or sparge tube. The tube is
located under the water level in the tank, and its purpose is steam distribution.
2. Regulating valve to control the incoming steam supply. When the steam supply
pressure is between 10-15 psi, a one-element regulating valve (temperature
sensor) is used. On higher pressure packages, when the steam supply is
between 30-250 psi, a two-element regulating valve, sensing pressure and
temperature, is used. The two-element regulating valve is furnished and
packaged with higher steam supply pressures, instead of one element regulating
valve for added safety, even through the receiver is vented and pressurization
should not occur.
3. Strainer for arresting any dirt or scale carried over with the supply steam. For its
protection, the strainer is located upstream of the regulating valve.
4. Pressure gauge for monitoring down stream steam pressure from the regulating
valve.
5. Sentinel valve to warn if the receiver is pressurized, if the regulating valve fails,
or a vent becomes plugged. The valve is not required by a code, but is added
for safe operation.
Make-up Valve Size The valves are sized for the maximum theoretical evaporation rate of the boiler, with
no condensate return as a supplement. The sizing criteria makes the water level in
the receiver self-adjusting for any loss of condensate return.
These parameters are based on more than 60 years experience at Cleaver-Brooks in
the packaged boiler room equipment market, and should not be ignored.
H6-14
03-08
Notes
H6-15
03-08
A. The following sample specifications are provided by Cleaver-Brooks to
assist you in specifying your customers specific needs and
application
B. Boiler Feed System shall be Cleaver-Brooks Model
_______________________(Specify simplex, duplex, dual, or triplex)
packaged boiler system suitable for ______gpm, at a discharge
pressure of ___________psig. (Refer to Table H5-4, Table H5-5, and
Table H5-6.)
PART 2 PRODUCTS 2.1 SYSTEM COMPONENTS
A. The unit shall consist of the following components:
1. One (substitute two for duplex or dual; three for triplex) bronze-
ringed, pump(s) certified by Cleaver-Brooks for a minimum of
________________gpm or 212 F water at __________psig.
The pump(s) shall be guaranteed for one year against defects in
workmanship and material. The pump(s) shall be equipped with
mechanical seals for temperatures up to 225 F.
2. One non-code welded receiver made of structural grade steel
with epoxy resin lining applied to a clean surface to resist
corrosion while in service. The tank shall be furnished with
integral supports and connections for inlet, outlet drain, makeup
valve, thermometer and gauge glass.
3. Tank size shall be __________inches diameter with _______
gallon capacity.
4. One fresh water makeup valve consisting of a ____________
inch float type mechanical valve suitable for tight shutoff against
100 psig inlet pressure.
5.
Section H6
Boiler Feed Systems
H6-16
03-08
Notes
H7-1
03-08
CONTENTS
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-4
ILLUSTRATIONS
Figure H7-1. Manual System Dimensions (By-Pass Feeders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-5
Figure H7-2. Manual System Dimensions (Shot Feeders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-5
Figure H7-3. Automatic System Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-6
TABLES
Table H7-1. Automatic Chemical Feed System Pump Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-4
Section H7
CHEMICAL FEED SYSTEMS AND METERING PUMPS
Chemical Feed Systems and Metering Pumps Section H
H7-2
03-08
This section contains information on a complete line of manual and automatic chemical feed systems and
associated metering pumps. These products are used to treat boiler feed water and condition blowdown sludge
to protect the boiler against corrosion and scaling.
Section H Chemical Feed Systems and Metering Pumps
H7-3
03-08
Complete Standard Packaging Provides:
Lower installation costs.
Easy installation.
Alternative Materials of Construction:
Product selection to match system requirements.
Custom Pump Selection:
Piston or diaphragm.
Direct Drive, Clamp Mounted Agitator:
Ability to mix and dilute powdered materials.
Ease of maintenance.
Adjustable Pump Parameters:
Ability to adjust pump output based upon system requirements.
Controls chemical cost.
Standard 6" Funnel on Manual Chemical Feed Systems:
Less product loss due to spillage.
PRODUCT OFFERING
Cleaver-Brooks chemical feed systems treat feedwater and condition blowdown
sludge where an extra measure of protection against corrosion and scaling is
required. Automatic systems are available for single- or multiple-boiler installations.
They are fully packaged and can be equipped with either piston or diaphragm
pump(s) capable of accurately injecting chemical from 0 to 6 gph at up to 1000
psig.
Automatic Systems
Tank materials: polyethylene, stainless steel, carbon steel or overpack (steel
tank with polyethylene liner and cover).
Tank sizes: 30 to 200 gal.
Pressures: up to 1000 psig.
Agitator included.
Manual Shot Feeders
Manual shot feeders are used for batch feeding of chemicals into closed loop or low
makeup water systems. They are completely assembled and ready for installation
for:
Pressures: 125 to 300 psig.
Capacities: 3/4 to 25 gal.
H7-4
03-08
Dimension and rating information is shown in Figure H7-1 through Figure H7-3,
and Table H7-1..
ENGINEERING DATA
The V-10 Simplex Piston Pump and V-10 Duplex Piston Pump are used in this
system.
These pumps are of the high pressure, low volume, reciprocating plunger, positive
placement type, ideal for use in feeding chemicals to hot water and steam boilers.
These pumps are designed for trouble-free operation where a controlled volume of
chemical treatment is required. Units have over 20 years of proven field
installations. All are equipped with relief valves for positive protection at all times.
Max pump discharge pressure is 1000 psig.
The stroke can be simply and quickly adjusted by loosening the nut and turning the
head screw to the desired length stroke; then, re-tighten nut against the slide. The
stroke adjustment (0 to maximum capacity) may be performed while the pump is
running or when the pump is shut down.
MODEL TYPE STROKING
RATE
PISTON
DIA
(IN.)
GPH
MAX
SIMPLEX
V-10 - 1560 (Std)
A 60 5/8 6.00
V-10 - 1530 30 5/8 3.00
V-10 - 1460 60 1/2 3.00
V-10 - 1430 30 1/2 1.50
V-10 - 1360 60 3/8 1.60
V-10 - 1330 30 3/8 0.80
V-10 - 1260 60 1/4 1.00
V-10 - 1230 30 1/4 0.50
DUPLEX
V-10 - 2560 (Std)
A 60 5/8
12.00
B
V-10 - 2530 30 5/8
6.00
B
V-10 - 2460 60 1/2
6.00
B
V-10 - 2430 30 1/2
3.00
B
V-10 - 2360 60 3/8
3.20
B
V-10 - 2330 30 3/8
1.60
B
V-10 - 2260 60 1/4
2.00
B
V-10 - 2230 30 1/4
1.00
B
A. Unless otherwise specified, Model V-10 - Type 1560 pumps will be
shipped for Simplex systems and Model V-10 - Type 2560 for Duplex sys-
tems.
B. For both pumping heads.
Specifications subject to change without notice.
Table H7-1. Automatic Chemical Feed System
Pump Ratings
Section H Chemical Feed Systems and Metering Pumps
H7-5
03-08
TANK
CAPACITY
A
WIDTH
(INCH)
B
BODY
(INCH)
C
OVER-
ALL
HEIGHT
(INCH)
CONNECTIONS
IN OUT SAMPLE
3/4 Gal
1 Gal
1-1/2 Gal
2 Gal
2-1/2 Gal
5 Gal
10 Gal
18 Gal
25 Gal
4
6
6
8
8
10
10
14
18
15
10
12
10
12
15
29
32
28
35
28
30
28
30
33
47
50
46
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
By Pass Feeders Include:
Tank
1/2" screwed inlet
3/8" screwed outlet
3/8" flow control valve
Sight glass with gauge valves and guards
1/2" sample valves
6" diameter funnel
Tanks 5 gallon capacity and larger have three 12-inch support legs.
Figure H7-1. Manual System Dimensions (By-Pass Feeders)
Figure H7-2. Manual System Dimensions (Shot Feeders)
TANK
CAPACITY
A
WIDTH
(INCH)
B BODY
(INCH)
C
OVER-
ALL
HEIGHT
(INCH)
CONNECTIONS
IN OUT SAMPLE
3/4 Gal
1 Gal
1-1/2 Gal
2 Gal
2-1/2 Gal
5 Gal
10 Gal
18 Gal
25 Gal
4"
6"
6"
8"
8"
10"
10"
14"
18
15"
10"
12"
10"
12"
15"
29"
32"
28
33"
23"
25"
23"
25"
27"
42"
45"
41
1/2"
1/2"
1/2"
1/2"
1/2"
1/2"
1/2"
1/2"
1/2
1/2"
1"
1"
1"
1"
1"
1"
1"
1
1/2"
1/2"
1/2"
1/2"
1/2"
1/2"
1/2"
1/2"
1/2
Shot Feeders Include:
Tank
1/2" screwed inlet
1/2" or 1" screwed outlet
1/2" sample valve
6" diameter funnel
Tanks 5 gallon capacity and larger have three support legs.
H7-6
03-08
Figure H7-3. Automatic System Dimensions
CAPACITY
(GAL.)
DIMENSIONS (INCHES)
A B C D E F
50 23 48 31 17 22 18
100 36 51 31 20 31 27
150 36 56 36 20 31 27
200 36 68 48 20 31 27
CAPACITY
(GAL.)
DIMENSIONS (INCHES)
A B C D
30 18 30 12 49
55 22 34 17 60
100 28 42 18 70
150 31 47 18 66
OVER PACK CHEMICAL SYSTEMS
The Over Pack chemical feed system is recommended for
almost all industrial applications. A polyethylene liner and cover
are inserted into a steel tank with welded steel frame and pump
support.
POLYETHYLENE TANKS
STAINLESS & CARBON
STEEL TANKS
SERIAL #
50-OP-1-V10
1/4"NPT
63"
POLYSUPPLY
VALVE
STRAINER
PRV
VISUAL
SLIT
(SS HINGE OPTIONAL)
REMOVABLE LID
MIXER (OPTIONAL)
34"
13"
17"
(3) 3/8"BOLTHOLES
V-10 PUMP
26"
21 3/4"
23"
20 1/4"
SERIAL #
POLYETHYLENE TANKS
POLYSUPPLY
VALVE
STRAINER
PRV
(SS HINGE OPTIONAL)
REMOVABLE LID
MIXER (OPTIONAL)
V-10 PUMP
C
B
D A
STAINLESS & CARBON STEEL TANKS
MIXER
STRAINER
VALVE
DISCHARGE
GAUGE
SERIAL #
V-10
PRV
B
F
A
E
D
C
GLASS
H7-7
03-08
Section H7
Chemical Feed Systems and Metering Pumps
The following specifications are provided by Cleaver-Brooks to assist you in specifying
your customers requirements.
Provide completely preassembled, packaged chemical feed system(s)/chemical
metering pump(s), as manufactured by _______________. Package shall be
hydraulically and electrically tested at the factory and shall be assembled to the
fullest extent possible. Package shall be furnished with all required lubricants, special
tools, and installation instructions.
A. Pump
1. Pump capacity shall be adjustable through 100% of the range
by manual micrometer dial while the pump is running or
stopped. Pump stroking speed shall not exceed 60 spm.
2. The pump shall be sized to deliver the required capacity at 85%
of maximum stroke length. Stroke adjustment shall be a variable
micrometer type mechanism, with the plunger powered through
its entire travel. Lost motion designs are not acceptable.
3. The pump shall include an automatic vent and refill mechanism
on the hydraulic side, which operates once each stroke. The
pump shall have an external hydraulic relief valve which is
adjustable.
4. Double ball check valves shall be provided on the discharge to
ensure accurate repeatable metering. The pump valves shall be
removable for cleaning or replacement without the need to
disturb suction or discharge piping.
5. The pump shall be field convertible to automatic stroke
adjustment without the use of special tools, and without the
need to replace any major frame parts.
6. The pump shall be furnished with a factory-mounted driver
suitably sized for continuous operation at the maximum relief
setting. The motor shall be (integrally mounted direct coupled
flange mounted with flexible coupling). No belts or pulleys
should be used in the drive train or for capacity adjustment.
B. Feed System
1. Complete chemical feed system(s) shall be furnished suitable for
handling ___________________. Each system will consist of
______pump(s), tank, piping, and accessories as defined below.
H7-8
03-08
Manufacturer will select all materials in contact with the
chemical and guarantee their suitability for the particular
service. Pump(s) shall be mounted below the tank.
C. Tank
1. The tank(s) shall be constructed of (polyethylene/304SS/
316SS/other) and furnished with a hinged or removable cover.
Tank shall include connections for pump suction, drain, level
gauge, chemical fill, dilution water, and relief valve return
piping. Drain connection shall be separate from pump suction
connection. Drain shall be located in the bottom of the tank for
complete emptying of contents.
2. Tank shall be furnished with (drain valve) (level switch) (level
gauge).
D. Mixer
1. An angle plate mount mixer with 304SS shaft and propeller
shall be furnished. The mixer propeller shall operate at 1750
rpm. The purpose of the mixer shall be to (mix liquids/dissolve
powder in liquid/create and maintain a suspension).
H8-1
03-08
CONTENTS
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-3
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-4
DIMENSIONS, RATINGS, AND SIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-4
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-4
Chlorine, Organics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8H8-6
Particles Down to 10-Micron Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-6
Sand, Heavy Sediment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-6
Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-6
ENGINEERING DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-7
ILLUSTRATIONS
Figure H8-1. Dimensional Data, Filter System Without Regeneration Tanks . . . . . . . . . . . . . . . . . H8-5
TABLES
Table H8-1. Model CF Activated Carbon Media Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-7
Table H8-2. Model MF Multi-Layered Media Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-8
Section H8
FILTERS
Filters Section H
H8-2
03-08
Table H8-3. Model SF Sand Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-9
Table H8-4. Model IF Iron Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-9
Table H8-5. Engineering Data (Filters) (Page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-10
This section contains information on water filters used for the removal of impurities from raw water. Filters
discussed here remove:
Chlorine and organics.
Particles down to 10-micron size.
Sand and heavy sediment.
Iron.
Section H Filters
H8-3
03-08
Complete Range of Sizes and Filter Media Available:
Precisely match customer needs (system specific).
Pre-Engineered Packaged Units Shipped From Stock:
Short lead times.
Minimum down time.
Industrial Grade Multiport Control Valve:
Long lasting.
High reliability.
Easy maintenance.
Backwash Control Actuated On a Time Clock, Pressure Differential Switch, or Water
Meter Basis:
Versatility.
Inlet and Outlet Pressure Gauges and Sample Cocks:
Easy monitoring of system performance.
Fully Assembled Manifold Piping:
Ease of installation, lower installation costs.
Heavy Duty Steel Tanks With Galvanized or Prime Coat Exterior Finish (Specialty
Linings Optional):
Corrosion resistance and longer life.
Premium Grades of Filter Media:
Optimum performance.
PRODUCT OFFERING
The need for special filter equipment for removal of impurities can be readily
determined by raw water analysis. Where filters are recommended, cost is quickly
recovered by eliminating need for frequent equipment cleaning and servicing,
inefficient performance, damage to system components, and premature equipment
failure.
Standard Equipment Automatic Units 12" - 16" Diameter:
Skirt type tanks.
Epoxy lined interior.
Painted exterior.
Locking bayonet cover.
Fine slotted tubular PVC distributor.
Automatic time clock operation.
Filters Section H
H8-4
03-08
Automatic Units 20" - 42" Diameter:
Structural steel legs.
Double hot-dipped galvanized interior and exterior.
ML and AC filters are epoxy lined with prime coat exterior.
20" - 30" have access handhole in top head and lower sideshell.
36" - 42" have 11" x 15" elliptical manhole in top head.
PVC radial distribution.
Automatic Units 48" Diameter and Larger:
Adjustable jack support legs.
Prime coat exterior.
12" x 16" elliptical manhole in top head.
Header and lateral distribution system.
Inlet and outlet pressure gauges.
Air relief valve.
Flanged tank openings.
Optional Equipment ASME code tanks.
Specialty tank linings.
Skid mounted, fully pre-piped and wired.
Automatic operation by pressure differential or water meter.
Manual backwash controls.
Backwash with water from auxiliary source.
DIMENSIONS, RATINGS, AND SIZING
Dimensions for filter systems without regenerant tanks are shown in Figure H8-1.
Sizing In addition to service flow, the selection of a filter system must take into account
the available backwash flow rate. This is the most important function in the proper
operation of a filter. A periodic backwash and rinse is required to cleanse and
reclassify the filter media.
Backwash flow rates are always higher than service flow rates and therefore limit
the filter size that can be installed. As a general rule, select the largest filter that can
be back washed with the flow rate available at the point of filter installation. Then
note the service flow rate for the filter selected. If it is not adequate for the flow to
be treated, a twin filter installed in parallel is required.
A parallel installation will increase the service flow and permit each filter to be back
washed separately with the existing water supply.
Generally, lower flows produce higher quality water and a larger volume of treated
water between backwashing.
Section H Filters
H8-5
03-08
FILTER
TANK
SIZE (IN)
A x B
SYSTEM DIMENSIONS OTHER APPLICABLE DIMENS IONS
SINGLE TWIN TRIPLE QUAD
W H C D E F G I J
L
1
L
2
L
3
L
4
20x54 20 58 96 134 28-1/2 72 38 15-1/2 43 3-1/4 5-3/8 3-9/16 4/12
24x54 24 66 108 150 33 75 42 18 43 3-1/4 5-7/8 3-9/16 4-1/2
30x54 30 78 126 174 40 78 48 21-1/8 43 4-5/8 11 4-1/2 9
36x60 36 90 144 198 46 89 54 24-1/8 43 4-5/8 11-1/4 4-1/2 9-1/2
42x60 42 102 162 222 53-1/2 91 60 27-1/8 43 6-5/8 14-1/4 6-7/16 10-7/8
48x60 48 114 180 246 64 86 66 35 36-1/2 6-5/8 14-1/2 6-7/16 11-1/4
54x60 54 126 198 270 70 87 72 38 37-1/4 6-5/8 14-1/2 6-7/16 12-7/8
60x60 60 138 216 294 76 89 78 41 38 6-5/8 14-1/2 6-7/16 12-7/8
72x60 72 162 252 342 88 93 90 47 41-1/4 6-5/8 14-1/2 6-7/16 12-7/8
84x60 84 186 288 390 100 97 102 53 43 6-5/8 53-1/4 6-7/16 17-3/4
96x60 96 210 324 438 114 101 114 41-1/4 45 6-5/8 53-1/4 6-7/16 17-3/4
NOTES:
1. All values are in inches.
2. System dimensions based on 18" space between pressure tanks.
Figure H8-1. Dimensional Data, Filter System Without Regeneration Tanks
Filters Section H
H8-6
03-08
Cleaver-Brooks rates the performance of each filter as follows:
Superior
Recommended for most applications under all operating conditions.
Best quality water.
Maximum on line time between backwashing.
Lowest pressure loss.
Recommended for influent suspended solids loads up to or greater than 300
ppm.
High
Well suited for many applications.
Very good quality water.
Moderate on line time between backwashing.
Increased pressure loss.
Recommended for influent suspended solids loads less than 300 ppm.
Utility
Flow rates listed are at peak design: operation at higher flows not
recommended.
Satisfactory water quality.
Shorter on line time.
Higher pressure loss.
Recommended for influent suspended solids loads less than 150 ppm.
Chlorine, Organics CB activated carbon filters (Table H8-11) remove free chlorine, some dissolved
organics and sediment, down to 40-micron particle size, from boiler makeup water.
By removing sediment, activated carbon filters also help control sludge buildup in
boilers. They protect pretreatment equipment by: 1) removal of free chlorine, which
is corrosive and attacks the ion exchange resin cross-linking agent in water
softeners and dealkalizers, and the membranes in reverse osmosis equipment, and
2) removing organics which promote fouling in ion exchange beds, that can
contaminate water supplies and cause foaming in boilers and heat exchange
equipment.
Periodic backwashing is required to remove collected matter from the filter bed.
Flow rates: 3 to 226 gpm.
Tank sizes: 12" to 72" dia.
Operating temperatures: 40 F to 120 F.
Particles Down to
10-Micron Size
Multilayered filters (Table H8-2) are used for finer levels of filtration and for
handling heavy flow rates. They remove sediment, suspended solids and colloidal
matter, down to 10-micron particle size, from boiler makeup water. They are highly
effective in controlling sludge buildup. Periodic backwashing is required to remove
collected matter from the filter bed.
Section H Filters
H8-7
03-08
Sand, Heavy
Sediment
Sand filters (Table H8-3) can handle heavy loads in controlling sludge buildup. They
remove heavy, large-particle sediment and suspended solids, down to 40-micron
size, from makeup water. Periodic backwashing is required to remove collected
matter from the filter bed.
Iron Cleaver-Brooks iron filters (Table H8-4) remove both soluble and insoluble iron,
suspended solids and colloidal matter down to 40-micron particle size from boiler
makeup water. They are used to control sludge buildup caused by iron precipitation.
Water pH must be at least 6.2. Occasional regeneration with potassium
permanganate may be required.
ENGINEERING DATA
Select a filter from the tables to produce the desired flow rate and pressure drop.
Check to assure the required backwash flow rate is available. Twin filters may be
required to produce maximum flow rate and still enable backwash with the existing
piping system.
MODEL
NUMBER
PIPE
SIZE
WATER QUALITY
BACK-
WASH
RATE
TANK
SIZE
DIA
x
SIDE
SHELL
FILTER
MEDIA
LOAD
FLOOR
SPACE
REQ'D
HEIGHT
OPER
WT
SUPERIOR HIGH UTILITY
CFB-
FLOW
RATE
PRESS.
LOSS
FLOW
RATE
PRESS.
LOSS
FLOW
RATE
PRESS.
LOSS
IN. GPM PSIG GPM PSIG GPM PSIG GPM IN. CU FT IN. IN. LBS
2-1 1 3 1 4.5 2 6 3 8.3 12x54 2 13x21 60 450
3-1 1 4 1 6 3 9 4 10 14x60 3 15x23 66 550
4-1 1 6 1 8 3 11 4 13.5 16x60 4 17x25 66 700
5-1/2-1 1 9 1 13 2 17 3 20 20x54 5.5 21x29 72 100
7-1-1/4 1-1/4 13 2 19 3 25 6 30 24x54 7 25x33 74 1650
12-1/2-1-1/2 1-1/2 20 3 29 4 39 7 46 30x54 12.5 31x40 79 2700
18-2 2 28 2 42 4 57 7 70 36x60 18 37x48 90 4200
25-2 2 38 3 58 6 77 9 95 42x60 25 43x56 92 5800
25-2-1/2 2-1/2 38 2 58 3 77 5 95 42x60 25 43x57 92 5900
34-3 3 50 1 75 2 100 3 115 48x60 34 49x64 86 7100
44-3 3 64 2 95 3 127 5 150 54x60 44 55x70 87 9100
54-3 3 79 2 118 4 157 7 180 60x60 54 61x76 89 11400
78-3 3 113 3 170 7 226 11 270 72x60 78 73x88 93 15700
78-4 4 113 2 170 3 226 5 270 72x60 78 73x90 93 15800
NOTES:
Filter Media Consists of Granular Activated Carbon.
For chlorine removal only use the flow rates from the utility water quality column. For sediment and organic removal use the flow rates from the
superior water quality column.
Table H8-1. Model CF Activated Carbon Media Filter
Filters Section H
H8-8
03-08
MODEL
NUMBER
PIPE
SIZE
WATER QUALITY
BACK-
WASH
RATE
TANK
SIZE
DIA
x
SIDE
SHELL
FILTER
MEDIA
LOAD
FLOOR
SPACE
REQ'D
HEIGHT
OPER
WT
MFB-
FLOW
RATE
PRESS.
LOSS
FLOW
RATE
PRESS.
LOSS
FLOW
RATE
PRESS.
LOSS
IN. GPM PSIG GPM PSIG GPM PSIG GPM IN. CU-FT IN. IN. LBS
2-1 1 8 5 12 8 16 12 11.5 12x54 2 13x21 60 500
2-1/2-1 1 11 6 16 11 21 17 15 14x60 2.5 15x23 66 690
4-1-1/4 1-1/4 14 7 21 12 28 18 20 16x60 4 17x25 66 850
5-1-1/4 1-1/4 22 6 33 12 44 19 30 20x54 5 21x29 72 1800
5-1-1/2 1-1/2 22 3 33 6 44 10 30 20x54 5 21x30 72 1850
7-1-1/4 1-1/4 31 9 47 18 63 29 45 24x54 7 25x33 74 2350
7-1-1/2 1-1/2 31 5 47 9 63 16 45 24x54 7 25x34 74 2400
10-1-1/2 1-1/2 49 10 74 19 98 26 75 30x54 10 31x40 79 3675
10-2 2 49 6 74 13 98 20 75 30x54 10 31x41 79 3700
15-2 2 71 9 106 17 141 27 105 36x60 15 37x46 90 5550
15-2-1/2 2-1/2 71 5 106 10 141 15 105 36x60 15 37x48 90 5650
21-2-1/2 2-1/2 96 7 144 13 192 20 150 42x60 21 43x53 92 8295
21-3 3 96 6 144 11 192 16 150 42x60 21 43x54 92 8350
27-3 3 126 6 188 11 251 17 180 48x60 27 49x64 86 10400
27-4 4 126 3 188 5 251 8 180 48x60 27 49x66 86 10500
34-3 3 159 8 239 15 318 22 240 54x60 34 55x70 87 12800
34-4 4 159 4 239 6 318 10 240 54x60 34 55x72 87 12900
43-3 3 197 10 295 20 393 31 300 60x60 43 61x76 89 15800
43-4 4 197 5 295 9 393 13 300 60x60 43 61x78 89 15900
NOTES:
1. Filter media consists of various size, distinctly layered sand.
2. All pressure drop data based on new filter media and 60 F water temperature
3. Backwash when pressure drop increases by 12-15 psig over pressure drop of a clean filter.
4. Consult Cleaver-Brooks for larger diameter tanks.
5. Allow a minimum of 24" above filter for access into top of tank.
Table H8-2. Model MF Multi-Layered Media Filter
Section H Filters
H8-9
03-08
MODEL
NUMBER
PIPE
SIZE
WATER QUALITY
BACK-
WASH
RATE
TANK
SIZE
DIA
x
SIDE
SHELL
FILTER
MEDIA
LOAD
FLOOR
SPACE
REQ'D
HEIGHT
OPER
WT
SFB-
FLOW
RATE
PRESS.
LOSS
FLOW
RATE
PRESS.
LOSS
FLOW
RATE
PRESS.
LOSS
2-1 1 3 2 4 3 5 5 10 12x54 2 13x21 60 490
3-1 1 3 2 5 4 6 5 13.5 14x60 3 15x23 66 650
4-1 1 4 2 6 4 8 6 15 16x60 4 17x25 66 850
6-1 1 7 2 10 3 13 5 25 20x54 6 21x29 72 1700
9-1-1/4 1-1/4 9 2 14 4 19 6 35 24x54 9 25x33 74 2250
14-1-1/2 1-1/2 15 3 22 5 29 7 60 30x54 14 31x40 79 3500
20-2 2 21 2 32 5 42 7 85 36x60 20 37x46 90 5300
28-2 2 29 3 43 6 58 9 115 42x60 28 43x53 92 7900
28-2-1/2 2-1/2 29 2 43 4 58 6 115 42x60 28 43x54 92 8000
34-3 3 38 2 57 4 75 5 150 48x60 34 49x64 86 9900
44-3 3 48 2 72 4 95 6 190 54x60 44 55x70 87 12200
54-3 3 59 3 88 5 118 7 230 60x60 54 61x76 89 15100
78-4 4 BWA 85 3 127 6 170 9 330 72x60 78 73x88 93 21700
NOTES:
1. Filter media consists of silica sand.
2. 4BWA - minimum 4" water supply required. FIlter manifold connections are 3" inlet/outlet and 3" backwash assist.
3. All pressure drop data based on new filter media and 60 F water temperature.
4. Backwash when pressure drop increases by 12-15 psig over pressure drop of a clean filer.
5. Consult Cleaver-Brooks for larger diameter tanks.
6. Allow a minimum of 24" above filter for access into top of tank.
Table H8-3. Model SF Sand Filter
MODEL
NUMBER
PIPE
SIZE
WATER QUALITY
BACK-
WASH
RATE
TANK
SIZE
DIA
x
SIDE
SHELL
FILTER
MEDIA
LOAD
FLOOR
SPACE
REQ'D
HEIGHT
OPER
WT
IFB-
FLOW
RATE
PRESS.
LOSS
FLOW
RATE
PRESS.
LOSS
FLOW
RATE
PRESS.
LOSS
2-1 1 3 3 5 5 6 7 8.3 12x54 2 13x21 60 490
3-1 1 4 3 6 5 9 8 10 14x60 3 15x23 66 660
4-1 1 6 3 8 6 11 8 13.5 16x60 4 17x25 66 850
6-1 1 9 3 13 6 17 8 20 20x54 6 21x29 72 1550
9-1-1/4 1-1/4 13 5 19 7 25 10 30 24x54 9 25x33 74 2200
13-1-1/2 1-1/2 20 3 29 6 39 9 46 30x54 13 31x40 79 3600
18-2 2 28 2 42 4 57 6 69 36x60 18 37x46 90 5200
28-2 2 38 5 58 9 77 13 90 42x60 28 43x53 92 7500
28-2-1/2 2-1/2 38 3 58 5 77 8 90 42x60 28 43x54 92 7600
34-3 3 50 3 75 5 100 7 115 48x60 34 49x64 86 9800
44-3 3 64 4 95 6 127 9 150 54x60 44 55x70 87 10800
54-3 3 79 4 118 7 157 10 190 60x60 54 61x76 89 13900
78-3 3 113 5 170 9 226 15 270 72x60 78 73x88 93 20400
78-4 4 113 3 170 6 226 9 270 72x60 78 73x90 93 20500
Note: Filter media consists of manganese greensand. It must periodically be regenerated with potassium permanganate (KMnO
4
).
Table H8-4. Model IF Iron Filter
Filters Section H
H8-10
03-08
MODEL
NUMBER
TANK SIZE
(DIA x HT)
PIPE
SIZE
(IN.)
MEDIA
(CU-FT)
FREE
BOARD
(IN.)
SUPPT
BED
(LBS)
NO.
OF
DIST
SERV
FLOW
(GPM)
PRESS.
LOSS
(PSIG)
PEAK
FLOW
GPM)
PRESS.
LOSS
(PSIG)
BACK
WASH
GPM
DRAIN
PIPE
SIZE
(IN.)
SHIP
WT
(LBS)
OP
WT
(LBS)
ACC-MFB MULTI-LAYERED
2-1 12x54 1 2 19 40 1 8 5 16 12 11.5 3/4 377 500
2-1/2-1 14x60 1 2.5 24-1/2 60 1 11 6 21 17 15 3/4 483 690
4-1-1/4 16x60 1-1/4 4 25 85 1 14 7 28 18 20 1 621 850
5-1-1/4 20x54 1-1/4 5 19 200 4 22 6 44 19 30 1-1/4 955 1800
5-1-1/2 20x54 1-1/2 5 19 200 6 22 3 44 10 30 1-1/4 982 1850
7-1-1/4 24x54 1-1/4 7 23-1/2 200 4 31 9 63 29 45 1/1/4 1283 2350
7-1-1/2 24x54 1-1/2 7 23-1/2 200 6 31 5 63 16 45 1-1/4 1314 2400
10-1-1/2 30x54 1-1/2 10 23 400 6 49 10 98 26 75 2 2046 3675
10-2 30x54 2 10 23 400 8 49 6 98 20 75 2 2066 3700
15-2 36x60 2 15 30-1/2 500 8 71 9 141 27 105 2 3180 5550
15-2-1/2 36x60 2-1/2 15 30-1/2 500 12 71 5 141 15 105 2 3391 5650
21-2-1/2 42x60 2-1/2 21 31 700 12 96 7 192 20 150 2-1/2 3741 8295
21-3 42x60 3 21 31 700 16 96 6 192 16 150 2-1/2 3761 8350
27-3 48x60 3 27 31 1000 26 126 6 251 17 180 3 5370 10400
27-4 48x60 4 27 31 1000 26 126 3 251 8 240 3 5888 10500
34-3 54x60 3 34 31 1300 36 159 8 318 22 240 3 6566 12800
34-4 54x60 4 34 31 1300 36 159 4 318 10 240 3 7087 12900
43-3 60x60 3 43 31 1800 36 197 10 393 31 300 4 8999 15800
43-4 60x60 4 43 31 1800 36 197 5 393 13 300 4 9213 15900
ACC-SFB SAND
2-1 12x54 1 2 16 40 1 3 2 5 5 10 3/4 386 490
3-1 14x60 1 3 18 60 1 3 2 6 5 13.5 3/4 534 650
4-1 16x60 1 4 17-1/2 85 1 4 2 8 6 15 1 701 850
6-1 20x54 1 6 13 200 4 7 2 13 5 25 1-1/4 1073 1700
9-1-1/4 24x54 1-1/4 9 15 200 4 9 2 19 6 35 1-1/4 1545 2250
14-1-1/2 30x54 1-1/2 14 15 400 6 15 3 29 7 60 2 2532 3500
20-2 36x60 2 20 22-1/2 500 8 21 2 42 7 85 2 3630 5300
28-2 42x60 2 28 22 700 12 29 3 58 9 115 2-1/2 4781 7900
28-2-1/2 42x60 2-1/2 28 22 700 16 29 2 58 6 115 2-1/2 5385 8000
34-3 48x60 3 34 24 1000 10 38 2 75 5 150 3 6045 9900
44-3 54x60 3 44 24 1300 16 48 2 95 6 190 3 7566 12200
54-3 60x60 3 54 24 1800 16 59 3 118 7 230 4 9623 15100
78-4 72x60 4 78 24 2600 26 85 3 170 9 330 6 14727 21700
Table H8-5. Engineering Data (Filters) (Page 1 of 2)
Section H Filters
H8-11
03-08
ACC-CFB ACTIVATED CARBON
2-1 12x54 1 2 16 40 1 3 1 6 3 8.3 3/4 206 450
3-1 14x60 1 3 18 60 1 4 1 9 4 10 3/4 324 550
4-1 16x60 1 4 17-1/2 85 1 6 1 11 4 13.5 1 421 700
5-1/2-1 20x54 1 5-1/2 16 200 4 9 1 17 3 20 1-1/4 633 1200
7-1-1/4 24x54 1-1/4 7 22-1/2 200 4 13 2 25 6 30 1-1/4 855 1650
12-1/2-1-1/2 30x54 1-1/2 12-1/2 18-1/2 400 6 20 3 39 7 46 2 1407 2700
18-2 36x60 2 18 26 500 8 28 2 57 7 70 2 2170 4200
25-2 42x60 2 25 25-1/2 700 8 38 3 77 9 95 2-1/2 2731 5800
25-2-1/2 42x60 2-1/2 25 25-1/2 700 12 38 2 77 5 95 2-1/2 3335 5900
34-3 48x60 3 34 24 1000 16 50 1 100 3 115 3 3652 7100
44-3 54x60 3 44 24 1300 16 64 2 127 5 150 3 4462 9100
54-3 60x60 3 54 24 1800 26 79 2 157 7 190 4 5856 11400
78-3 72x60 3 78 24 2600 26 113 3 226 11 270 6 8662 15700
78-4 72x60 4 78 24 2600 26 113 2 226 5 270 6 9113 15800
ACC-IFB IRON
2-1 12x54 1 2 16 40 1 3 3 6 7 8.3 3/4 356 490
3-1 14x60 1 3 18 60 1 4 3 9 8 10 3/4 489 660
4-1 16x60 1 4 17-1/2 85 1 6 3 11 8 13.5 1 633 850
6-1 20x54 1 6 13 200 4 9 3 17 8 20 1-1/4 983 1550
9-1-1/4 24x54 1-1/4 9 15-1/2 200 4 13 5 25 10 30 1-1/4 1380 2200
13-1-1/2 30x54 1-1/2 13 17-1/2 400 6 20 3 39 9 46 2 2232 3600
18-2 36x60 2 18 26 500 8 28 2 57 6 69 2 3160 5200
28-2 42x60 2 28 22 700 8 38 5 77 13 90 2-1/2 4361 7500
28-2-1/2 42x60 2-1/2 28 22 700 12 38 3 77 8 90 2-1/2 4965 7600
34-3 48x60 3 34 24 1000 16 50 3 100 7 115 3 5522 9800
44-3 54x60 3 44 24 1300 16 64 4 127 9 150 3 6882 10800
54-3 60x60 3 54 24 1800 26 79 4 157 10 190 4 8813 13900
78-3 72x60 3 78 24 2600 26 113 5 226 15 270 6 12952 20400
78-4 72x60 4 78 24 2600 26 113 3 226 9 270 6 13403 20500
MODEL
NUMBER
TANK SIZE
(DIA x HT)
PIPE
SIZE
(IN.)
MEDIA
(CU-FT)
FREE
BOARD
(IN.)
SUPPT
BED
(LBS)
NO.
OF
DIST
SERV
FLOW
(GPM)
PRESS
LOSS
PSIG)
PEAK
FLOW
(GPM)
PRESS
LOSS
(PSIG)
BACK
WASH
GPM
DRAIN
PIPE
SIZE
(IN.)
SHIP
WT
(LBS)
OP
WT
(LBS)
Table H8-5. Engineering Data (Filters) (Page 2 of 2)
Filters Section H
H8-12
03-08
NOTES
H8-13
03-08
Section H8
Filters
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-14
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-14
Mineral Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-14
Upper Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-14
Lower Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-14
Main Operating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-14
Filter Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-15
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-15
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-15
Guarantees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-15
requirements.
Filters Section H
H8-14
03-08
PART 1 GENERAL 11 GENERAL
Furnish, install, and place in service an assembled vertical, pressure type, water
filtration system of an approved design fabricated by a manufacturer regularly
engaged in the production of water conditioning equipment. It shall be a Cleaver-
Brooks Model ___having ____cubic feet of filter media in each filter tank. Service
flow rate through each filter tank shall be ____gpm at pressure loss not to exceed
____psig.
PART 2 PRODUCTS 21 HARDWARE
A. Mineral Tank
1. The mineral tank(s) shall be of welded construction of tank
quality carbon steel. It shall be _____" diameter with a _____"
straight shell with reinforced openings for pipe connections
and an 11" x 15" manhole in the top head (for tank 30"
diameter and smaller; two (2) 4" spin off handholes are
provided in the top head and lower sideshell). The mineral
tank shall be rated for 100 psig working pressure and
hydrotested to 150 psig. Support legs shall be strap type -
permanently welded to the lower tank head. Mineral tank(s)
shall have both the exterior and interior protected with a hot
dipped galvanized application prior to fabrication and
shipment.
2. Option. ASME Code 100 psig working pressure, 150 psig test
pressure stamped and certified. Cold set epoxy polyamide
internal lining 8-10 mils DFT, with external rust resistance
prime coat, 2-3 mils DFT. (For activated carbon and multilayer
filters, cold set epoxy lining must be used due to highly
corrosive effects of activated carbon.)
3. A minimum freeboard of 50% shall be provided for backwash
expansion above the normal filter media bed level.
B. Upper Distributor
a. The upper distributor system shall be of the single point
baffle type. Constructed of Schedule-40 galvanized steel
and fittings.
C. Lower Distributor
1. The lower radial distribution system shall be the hub and
radial type of Schedule-80 PVC construction with a sub-fill of
1/8" x
1/16" gravel covering the distributor system laterals with
slotted full flow non-clogging replaceable polypropylene
strainers.
D. Main Operating Valve
1. The main operating valve on the filter shall be of the automatic
multiport type, consisting of five (5) individual diaphragm
valves housed in a compact casting. These valves are to be
pressure actuated by an external pilot valve, automatically or
manually. The valve shall be manufactured by the same
manufacturer as the entire filtering system. The valve guides,
seats, and diaphragm shall be constructed of Noryl plastic.
Section H Filters
H8-15
03-08
2. Pressure gauges and sample cocks to be provided on the inlet
and outlet of the filter system.
3. An automatic backwash control shall be provided to maintain a
proper backwash and flush flows over wide variations of
operating pressure. Controller shall contain no moving parts
and require no field adjustment.
4. The regeneration sequence shall be the accepted standard,
which is backwash, fast flush, and return to service.
5. An external PVC constructed eductor is to be provided to draw
regenerant solution and rinse water to regenerate the filter
media mineral. (On iron removal filters only.)
6. The pipings shall be galvanized Schedule-40 galvanized steel
with galvanized fittings.
7. All face piping shall be preassembled to the tank in a
professional manner.
E. Filter Media
1. The filter media shall be S (No. 26 sand) for removal of sand
and heavy sediment from water.
2. The filter media shall be ML (Multi-Media) consisting of reverse
grading of fine gravel, coarse gravel, red flint sand, and
activated carbon.
3. The filter media shall be M (Manganese Greensand) that will be
periodically regenerated with potassium permanganate
(KMnO4).
4. The filter media shall be AC (Granular Activated Carbon).
F. Controls
1. Regeneration shall be controlled by a fully automatic time clock
control (TCC) which is fully adjustable or a remote manual
controller. For fully automatic operation, the regeneration shall
be initiated by a calendar clock. A pointer shall indicate the
cycle of operation at all times.
2. When two (2) filters, or more, are required, a lockout shall be
provided to allow only one (1) unit to regenerate at any one
time.
3. In the event of a power failure, a complete regeneration can be
performed by manual operation of the external pilot valve.
4. Control Options: Regeneration to be initiated by head loss
across the filter(s). A delay timer is to be provided to prevent
false backwashing due to pressure surges in the system.
PART 3 EXECUTION 31 INSTRUCTIONS
A complete set of installation and operating instructions shall be included.
3.2 GUARANTEES
A. Attrition loss of mineral is guaranteed not to exceed 3% per year for
a period of three (3) years.
B. All mechanical equipment is guaranteed for one (1) year against any
defects in workmanship or materials. Any part proving defective will
be replaced or repaired within this period.
Filters Section H
H8-16
03-08
C. The manufacturer guarantees that under actual operating
conditions, the mineral shall not be washed out of the system
during the service run or backwashing period; that the turbidity and
color of the effluent, by reason of passing through the filter system,
shall not be less than the incoming water; and that the under-drain
system, gravel, and mineral shall not become fouled, either with
turbidity or by dirt, while operating as noted on manufacturers
instructions.
H9-1
09-04
CONTENTS
MODELS SSE & FSE FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9- 3
MODELS SMR FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9- 5
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9- 6
DIMENSIONS, RATINGS AND SIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9- 7
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9- 7
Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9- 7
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9- 7
Sizing Calculations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9- 8
SAMPLE SPECIFICATIONS (SSE/FSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-19
SAMPLE SPECIFICATIONS (SMR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-27
ILLUSTRATIONS
Figure H9-1. SSE Models (Size 30-1200) Softener Dimensions - Page 1 of 2 . . . . . . . . . . . . . . . . H9-9
Figure H9-2. (1 of2) Model FSE (Size 30-600) Softener Dimensions . . . . . . . . . . . . . . . . . . . . . . H9-11
Figure H9-3. CRS Crossover Twin Dimensions (Size 30-300) . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-13
Figure H9-4. SMR Dimensions (Size 150-1050) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-14
Figure H9-5. Water Softener Sizing Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-18

Models SSE & FSE
Model SMR
Section H9
SOFTENERS
Softeners Section H
H9-2
09-04
TABLES
Table H9-1. SSE Water Softener Ratings Polybond Lined Steel . . . . . . . . . . . . . . . . . . . . . . . . . H9-15
Table H9-2. FSE Water Softener Ratings, Fiberglass Softeners . . . . . . . . . . . . . . . . . . . . . . . . . . H9-16
Table H9-3. CRS Water Softener Ratings, Fiberglass Softeners with Crossover Controls . . . . . . . . H9-16
Table H9-4. SMR Water Softener Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-17
This section contains information on Cleaver-Brooks cation, ion exchange, and water softeners available in package
designs for virtually any commercial or industrial application. Softeners should be used whenever raw water hardness
exceeds 5 ppm.
Cleaver-Brooks water softeners remove hardness, preventing scale buildup on heat transfer surfaces, while
maintaining peak boiler efficiency. Removing hardness also reduces the need for chemical treatment used to control
scale.
Section H Softeners
H9-3
09-04
MODELS SSE & FSE FEATURES AND BENEFITS
Quality Constructed Tanks:
Two types of softener resin tanks are available to meet environmental requirements.
Both rugged lined steel or fiberglass (FRP) vessels are available.
Exclusive Polybondtanks are made of industrial grade steel. The tank interior is
lined with a heat-fused virgin polyethylene lining, creating a 40-60 mil thick,
resilient, and non-corrosive tank within a tank. The lining material is Food and Drug
Administration (FDA) listed. All surfaces that contact water during system operation,
including valve flanges and openings, are covered with the lining material, so that
water never touches bare steel, providing maximum protection against rust and
corrosion. In addition, gasketed tank openings provide dry thread closures,
eliminating coated threads which can be weak spots in tank linings.
All tanks are 100% spark tested to ensure the integrity of the tank lining.
All steel tanks up to 48 in diameter are hot-quench phosphatized prior to the
application of a 4- 6 mil thick exterior epoxy coating for further protection against
rust and corrosion, providing years of good appearance on the job. Tanks over 48
diameter are coated with a zinc oxide-rich protective coating, suitable for field
painting where desired.
Fiberglass tanks are available for applications where environmental conditions or
budgetary constraints prevail. They are especially useful in providing rust and
corrosion protection. All FRP tanks are provided with a minimum of 5 year
warranties.
Electronic Demand Programmable (ED) Controls
ED controls offer precise control over water softener operation. All controls have
state-of-the-art electronics, and are microprocessor-based and completely
programmable. Operating efficiency combines with ease of use -- a 4-button
keypad and alphanumeric LCD display permit easy programming and observation of
system functions (no complicated jumper pins or dip switches to set). Simple
programming prompts the operator through set-up. Model code programming
makes set-up as easy as selecting model, pipe size, salt dosage, water hardness,
and time. Controls perform all calculations to minimize set-up errors.
An EEPROM memory retains all programmed and accumulated data, eliminating
the need to re-program the control after a power loss. A capacitor operates the
microprocessor in case of short term power loss.
An easy-to-read LCD display continuously displays system status and allows instant
access to current operating conditions, including flow rate, total treated flow,
remaining capacity, valve position and many more important features. The display is
illuminated for easy reading, even in low-light conditions. Self-diagnostic electronics
provide 24-hour per day review of the system, and stores historical data to allow
system optimization and simplify troubleshooting. A built-in speaker can transmit
this System Performance Analysis (SPA) data via regular telephone lines to a remote
service center for computerized troubleshooting, or, data can be recorded for later
transmission.
Controls have a look-ahead feature. The main memory monitors operation, tracks
data, then adjusts regenerations automatically for high- and low-water use periods.
All controls are designed for use with Fleck regeneration valves as well as
traditional valve nest operated systems. Pre-wired components with indexed cables
make installation quick and simple, and eliminate the need for complicated wiring
diagrams and wiring connection instructions. Low voltage 24-volt operation
simplifies installation and minimizes electrical hazards.
Softeners Section H
H9-4
09-04
Two models are available to meet varying needs: EDS/EDT, and VF.
EDS/EDT controls are capable of operating one or two softener tanks in single,
parallel, or alternating modes.
VF controls can operate two, three, or four softener tanks in parallel, alternating, or
variable flow mode. Each tank has its own flowmeter, so that the control knows
how much softening capacity remains in each tank. If water demand increases, the
system can be expanded by adding more softener tanks, and the control can be
reprogrammed to handle the larger system. If one softener tank is taken of-line, the
VF control adjusts the remaining tanks to maintain the same system flow rate. It
also staggers tank regeneration to prevent all tanks from being exhausted
simultaneously, thus maintaining sufficient softened water flow to the boiler or
process need.
In variable mode, the VF control monitors flow rate and switches tanks into service
to meet changes in system demand, thus making sure that sufficient softened water
is available, and that each tank is efficiently used.
Versatile Control Valve:
Each softener control valve is a low-lead brass, mechanically actuated,
hydraulically balanced, self-cleaning six (6) position type to accomplish the
regeneration steps of backwash, brine draw, slow rinse, fast rinse, and tank refill.
Separate rinse and timed refill positions are used to reduce regeneration water use.
The valve is fitted with a fixed orifice eductor nozzle and self-adjusting backwash
flow control. The bypass body, like the main control valve, is actuated by a
mechanical drive. The valve is capable of stepping through all regeneration phases
without electrical power.
Brine System and Salt Storage
Positive action brine piston eliminates the need for constant line pressure at the salt
storage tank, minimizing brine tank overflows.
Timed tank refill provides highly reliable brine levels and salt usage. Salt dosage is
easily changed from the system control, eliminating the need to empty salt tanks.
Simple protected brine well design eliminates the need for gravel subfill and
minimizes brine tank maintenance.
High density FDA approved polyethylene tank and cover provide maximum strength
and corrosion resistance.
High Quality Softener Resins
All water softeners contain a high-quality, high-capacity, solvent-free synthetic ion
exchange resin, that exchanges the hardness minerals of calcium and magnesium
ions with soluble sodium ions, a soft and non-scaling mineral that does not build
up on pipes to cause hot spots and weaknesses. All resins have a minimum
exchange capacity of 30,000 grains per cubic foot when regenerated with 15
pounds of salt per cubic foot. Resins provide efficient exchange capacity at lower
salt dosages (20,000 grains per cubic foot at 5 pounds of salt per cubic foot). In
addition to softening water, resins also provide iron and manganese removal from
the water. Softener resins are stable over the entire pH range.
They are suitable for high flow rates and high hardness waters, and are physically
stable at high temperatures. Resins feature low attrition loss, and minimum
backwash water is required.
Section H Softeners
H9-5
09-04
All resins are in solid bead form with uniform particle size, clean and free of dirt and
extraneous matter which might interfere with the ion exchange process.
All resins rest on a bed of quartz particles that have been screened not to exceed 16
mesh size by 3/16-inch particle size. The quartz bed is at least two inches in depth
and is placed above the softened water distributor mounted in the bottom of the
tank. The quartz is washed and dried to remove debris and fines.
Automatic Self-Adjusting Backwash and Rinse Controls
This feature assures maximum cleansing of the resin bed during backwash, and
prevents loss of resin across the entire operating range of 30-100 PSIG. The flow
control eliminates the need for troublesome and time-consuming field adjustments.
Availability:
All softener systems are available from stock, with short lead times.
Optional Skid Mounting:
Tanks may be ordered skid-mounted for easy handling and easier and lower-cost
field installation.
Efficient Water Distributors:
Inlet water distributors are designed to produce uniform flow through the entire
resin bed and thus ensure maximum exchange capacity with low pressure loss.
MODELS SMR FEATURES AND BENEFITS
Automatic Control Center Engineered for Efficient Trouble-Free Service Includes:
Industrial grade multi-valve with integral brine injector.
Electrically operated cycle controller with position indicator.
Automatic backwash flow control.
The exclusive multi-valve design, features five hydraulically-operated diaphragm
valve assemblies conveniently arranged. The valve seats are positioned vertically in
the valve casting, reducing the possibility of dirt or debris lodging in the seat area.
This design provides a positive shut-off with no leaking or dripping, as is often the
case with horizontally-positioned valve seats.
Single unit softeners are provided with an automatic bypass valve that provides
service water during regeneration. Cycling of the diaphragm assemblies is smooth
and entirely free of water hammer.
Automatic Self-Regulating Brine Injector:
Assures efficient brining without time-consuming field adjustments.
Automatic Brine Maker, Includes Heavy Gauge Polyethylene Brine Tank for
Maximum Strength and Corrosion Resistance:
Platform brine system allows use of pure, clean, efficient salt pellets or nuggets,
eliminating costly and time consuming brine tank cleaning.
The system eliminates need for gravel subfills, reducing shipping weight and freight
costs.
Automatic brine valve provides reliable refill of the brine system with fresh water
and is fully serviceable. All critical seal areas of the brine valve are designed to
prevent corrosion or scaling to assure trouble-free operation.
Softeners Section H
H9-6
09-04
High Capacity Resin, Adaptable to Wide Range of Applications:
High exchange capacity (30,000 grains per cubic foot at 15 lbs. salt dosage).
Efficient exchange capacity at lower salt dosages (20,000 grains per cubic foot at 6
lbs. salt).
Iron and manganese removal.
Stability over entire pH range.
Suitable for high flow rates.
Suitable for high hardness waters.
Physically stable at high temperatures.
Low attrition loss.
Minimum backwash water required.
Automatic Self-Adjusting Backwash And Flush Controls:
Assures maximum cleansing of the resin bed during backwash and prevents loss of
costly resin across the entire operating range of 30-100 psig.
Eliminates the need for troublesome and time consuming field adjustments because
the flow control is pre-sized at the factory.
Available From Stock:
Short lead time or minimum down time.
Optional Skid Mounting:
Ease of installation in the field; lower installation cost.
System of Non-Clogging Strainers Arranged in a Radial Network:
Assures uniform flow through the entire resin bed, resulting in maximum exchange
capacity from the resin with low pressure loss.
Eliminates wasted capacity in the bottom area of the resin tank.
PRODUCT OFFERING
Water softeners require periodic regeneration with salt brine.
Standard Equipment - SSE & FSE
Single, duplex, triplex, or quadraplex unit systems include resin tank(s), brine tank,
resin, piping, multi-position piston valves, flowmeters and electronic demand controller.
Single tank exchange capacities: 30,000 to 1,200,000 grains.
Tank sizes: 9 to 48 diameter standard (larger diameters available).
Operating temperatures: 40 to 100 F.
Water meter for automatic regeneration.
24 Volt operation.
Heat fused polyethylene lined steel or FRP tanks.
Standard Equipment - SMR
Single, twin, or triple unit system includes resin tank(s), brine tank, resin, face-piping,
diaphragm, valve nest and cycle controller.
Size range in capacities: 30,000 to 2,100,000 grains.
Section H Softeners
H9-7
09-04
Optional Equipment - SSE & FSE
ASME Code tank construction.
Alternating Parallel or Variable Flow operation.
Skid mounting, pre-wired and pre-piped.
High temperature operation.
Alternate linings and external coatings.
Optional Equipment - SMR
ASME Code tank construction.
Water meter for automatic regeneration.
Alternating operation.
Skid mounting, pre-wired and pre-piped.
External corrosion protection.
Operating Specifications
Pressure Range: 25 to 100 psig.
Temperature: Standard equipment suitable for water up to 100 F. Above 100 F,
special fitted valves are available. Specify water temperature when ordering.
Electrical: 120 Volt, 60 Hz is standard. Alternate voltages and frequencies
available. Specify electrical requirements when ordering. Transformers for control
operation voltage will be supplied with the SSE &FSE, SMR with MX controls.
Power: 6 Watts per cycle controller.
DIMENSIONS, RATINGS AND SIZING
Dimensions Dimensions for the SSE Model Polybond lined Steel Softeners (sizes 30 - 1200) are
shown in Figure H9-1.
Dimensions for the FSE Model FRP Softeners (sizes 30 - 600) are shown inFigure H9-
2.
Dimensions for the Model SMR Softeners (sizes 150-1050) are shown in Figure H9-4.
Ratings Softener capacity and flow ratings are shown in Table H9-1, Table H9-2,Table H9-3 and
Table H9-4.
Sizing Five things are required to size a softener:
1. Flow Rate/Pressure Loss
Softeners have two published flow rates:
Continuous - Used for sizing when actual flows are known. This rating of a softener will
generally produce a pressure loss of 15 psig.
Peak - Used to establish the absolute upper limits of a softener. This rating of a softener
will produce a pressure loss of 25 psig.
2. Time On-Line
Single softeners should be sized to stay on-line for at least one day. For continuous
usage when an alternating twin softener is used, each tank should be sized to stay on-
line for 8-12 hours.
Softeners Section H
H9-8
09-04
3. Water Hardness
To size the softener, the total water hardness must be determined in grains per gallons.
If the analysis report is in terms of parts per million or milligrams per liter (these are
equal), divide by 17.1 to convert to grains per gallon.
4. Water Usage
When the flow rate is constant, multiply the flow rate (gpm) by minutes on line. For
example, 50 gpm for 480 minutes (8 hours) = 24,000 gallons. When the flow rate is
not in constant use, use actual gallons used, or calculate gallons used based on boiler
make-up rates.
5. Exchange Capacity
Exchange rate is expressed in grains, and varies with salt dosage as follows:
15 pounds of salt per cu-ft = 30,000 grains capacity (best water quality, least
efficient).
10 pounds of salt per cu-ft. = 25,000 grains capacity (good water quality, medium
efficiency).
6 pounds of salt per cu-ft. = 20,000 grains capacity (poorest water quality, most
efficient). For boiler make-up water, the higher water quality - 15 pounds salt dosage
per cu-ft. - is recommended.
Sizing Calculations l. Single Softener. (Water usage per day x water hardness =capacity required.) For example:
10,000 gallons per day x 15 gpg hardness = 150,000 grains per day capacity
required.
Select a Model (SSE 150) from the literature. Then select the pipe size to meet flow
rate requirements.
2. Alternating Twin Softeners
Flow rate x hardness x minutes on line =capacity required. For example:
Flow rate = 40 gpm. Hardness = 15 gpg. 40 x 15 x 480 minutes on line = 288,000
grains.
Select a Model (SSE 300) from the literature. Then select pipe size based on flow rate
requirements. When the gallons of make-up is not known, use Figure H9-5 to
calculate softener capacity required per hour. When less than 6 hours is expected
between regeneration of a twin softener, two brine makers are required.
Section H Softeners
H9-9
09-04
Figure H9-1. SSE Models (Size 30-1200) Softener Dimensions - Page 1 of 2
PLAN VIEW
BRINE
F
FRONT VIEW
A
TREATED
WATER
WATER
RAW
D E
RIGHT SIDE VIEW
FRONT VIEW OF 36" TANK
A
C
B
C
B
SHOWN REDUCED
Dimensions (next page) are given in inches.
Softeners Section H
H9-10
09-04
MODEL
NUMBER
A
(in.)
B
(in.)
C
(in.)
***
D
(in.)
E
(in.)
F
(in.)
INLET/
OUT-
LET (in.)
DRAIN
SIZE
(in.).
SSE
SINGLE
TWIN
TRIPLE
QUAD
*
SINGLE
TWIN
TRIPLE
QUAD
*
SINGLE TWIN TRIPLE
QUAD
**
30-1 10 40 46 18 18 40 40 32 46 60 74 1 3/4*
60-1 12 52 58 18 18 40 40 35 75 47 83 1 3/4*
90-1
90-1
1
/
2
14 66 72 18 24 40 41* 36 54 82 100
1
1
1
/
2
3/4*
120-1
1
/
2
120-2
18 66
72
77
24 24* 41 41 46 68 90 112
1
1
/
2
2
3/4*
150-1
150-1
1
/
2
18 66
72
77
24 24 41 41 46 68 90 112
1
1
1
/
2
3/4
210-1
1
/
2
210-2
24
6
72
77
24 24 50 50 52 80 108 136
1
1
/
2
2
1*
300-1
1
/
2
300-2
24 66
72
77
24 24 50 50 52 80 108 136
1
1
/
2
2
1*
450-2
450-3
30 66
77
86
30 30* 50 50* 65 99 133 167
2
3
1 1/2*
600-2
600-3
36 71
82
86
39 39 48 48 80 120 160 200
2
3
1 1/2
900-3 42 71 86 39 39* 48 48* 85 131 177 223 3 2
1200-2 48 71 86 52 52* 60 60*
104 156 212 268 3 2
* Recommend two (2) brine tanks on quad systems.
** When using two brine tanks on quad systems, add the diameter of the brine tank plus 4 inches to the overall length.
*** Total height of the unit will increase when using ASME code tanks. All ASME tanks (18-inch diameter through 48-
inch diameter) are 70-1/2 inches in height plus the height of the control valve.
Figure H9-1. SSE Models (Size 30-1200) Softener Dimensions - Page 2 of 2
Section H Softeners
H9-11
09-04
Figure H9-2. (1 of2) Model FSE (Size 30-600) Softener Dimensions
FRONT VIEW
A
TREATED
WATER
BRINE
RAW
WATER
F
D
E
RIGHT SIDE VIEW
C
B
Softeners Section H
H9-12
09-04
Figure H9-2. (2 of 2) Model FSE (Size 130-600) Softener Dimensions
MODEL
NUMBER
A
(in.)
B
(in.)
C
(in.)
D
(in.)
E
(in.)
F
(in.)
PIPE SIZE (in.)
FSE
SINGLE
TWIN
TRIPLE
QUAD*
SINGLE
TWIN
TRIPLE
QUAD*
SINGLE TWIN TRIPLE QUAD**
INLET/
OUTLET
DRAIN
SIZE
30-1 9 48 54 18 18 40 40 31 44 57 70 1
3
/
4
60-1 12 52 59 18 18 40 40 34 50 66 82 1
3
/
4
90-1
90-1
1
/
2
14 65 71 18
24* 40 41* 36 54 82 100
1
1
1
/
2
3
/
4
120-1
1
/
2
120-2
17 72 72 24 24 41 41 45 66 87 100
1
1
/
2
2
3
/
4
150-1
150-1
1
/
2
17 72
80
84
24 24 41 41 45 66 87 100
1
1
1
/
2
3
/
4
210-1
1
/
2
210-2
24 72
82
87
24 24 50 50 52 80 108 136
1
1
/
2
2
1
300-1
1
/
2
300-2
24 72
82
87
24 24 50 50 52 80 108 136
1
1
/
2
2
1
450-2 30 72 92 30 30* 50 50 64 98 132 166 2 1
600-2
600-3
36 72
92
96
39 39* 48 48 79 119 159 199
2
3
1
1
/
2
* Recommend using two (2) brine tanks on quad systems.
** When using two (2) brine tanks on quad systems, add the diameter of the brine tank plus 4-inches to the overall
length.
Section H Softeners
H9-13
09-04
Figure H9-3. CRS Crossover Twin Dimensions (Size 30-300)
PLAN VIEW
A
RAW
WATER
TREATED
WATER
BRINE
TANK
F
D E
C
B
MODEL
NUMBER
A
(in.)
B
(in.)
C
(in.)
D
(in.)
E
(in.)
F
(in.)
PIPE SIZE (in.)
CRS
INLET/
OUTLET
DRAIN
30-1 9 48 54 18 40 46 1
3
/
4
60-1 12 52 59 18 40 52 1
3
/
4
90-1
90-1
1
/
2
14 65 71 18 40 54
1
1
1
/
2
3
/
4
120-1
1
/
2
16 65 72 24 41 67 1
1
/
2
3
/
4
150-1
1
/
2
17 72 80 24 41 68 1
1
/
2
3
/
4
210-1
1
/
2
24 72 82 24 50 80 1
1
/
2
1
300-1
1
/
2
24 72 82 24 50 80 1
1
/
2
1
Softeners Section H
H9-14
09-04
Figure H9-4. SMR Dimensions (Size 150-1050)
1
MODEL NUMBER
HEIGHT
(IN)
WIDTH
(IN)
SINGLE
LL1
TWIN
L2
TRIPLE
L3
SMR-150-1
72
29
50 88 126
SMR-150-1 1/4 30
SMR-150-1 1/2 30
SMR-150-2 34
SMR-210-1 1/4
73
32
54 96 138
SMR-210-1 1/2 32
SMR-210-2 36
SMR-210-2 1/2 37
SMR-300-1 1/2
76
38
60 108 156
SMR-300-2 42
SMR-300-2 1/2 43
SMR-300-3 44
SMR-450-1 1/2
82
38
66 114 162
SMR-450-2 42
SMR-450-2 1/2 43
SMR-450-3 44
SMR-600-1 1/2
89
44
81 135 189
SMR-600-2 48
SMR-600-2 1/2 49
SMR-600-3 50
SMR-750-2
101
48
81 135 189 SMR-750-2 1/2 49
SMR-750-3 50
SMR-900-2
94
54
90 150 218 SMR-900-2 1/2 55
SMR-900-3 56
SMR-1050-2
106
54
98 158 218 SMR-1050-2 1/2 55
SMR-1050-3 56
Section H Softeners
H9-15
09-04
Table H9-1. SSE Water Softener Ratings Polybond Lined Steel
MODEL
NUMBER
EXCHANGE
CAPACITY
RESIN
QYT
CONT
SERV
FLOW
PRESS
DROP
PEAK
SERV
FLOW
PRESS
DROP
BACK-
WASH
FLOW
TANK
DIMENSIONS
MANIF
PIPE
SIZE
(in.)
FLOW
SENSOR
SIZE
(in.)
SALT
STORAGE
CAPACITY
(lbs)
SSE MAX GR
MIN
GR
CU-FT GPM PSI GPM PSI GPM
SOFR
(in.)
BRINE
(in.)
30-1 30,000 20,000 1 8 5 12 10 2 10x40 18x40 1 1 400
60-1 60,000 40,000 2 16 10 24 20 3 12x52 18x40 1 1 400
90-1
90-1-1/2
90,000 60,000 3
21
24
15
9
29
36
25
16
5 14x66 18x40
1
1-1/2
1 400
120-1-1/2
120-2
120,000 80,000 4
32
32
12
7
48
48
22
12
7 18x66 24x41
1-1/2
2
1-1/2
2
700
150-1-1/2
150-2
150,000 100,000 5
40
40
13
6
52
60
25
11
7 18x66 24x41
1
1-1/2
1-1/2
2
700
210-1
1
/
2
210-2
210,000 140,000 7
45
56
15
8
60
84
25
15
15 24x66 24x50
1-1/2
2
1
1
/
2
2
1,000
300-1
1
/
2
300-2
300,000 200,000 10
45
77
15
15
58
107
25
25
15 24x66 24x50
1-1/2
2
1
1
/
2
2
1,000
450-2
450-3
450,000 300,000 15
87
140
15
15
118
200
25
25
20 30x66 30x50
2
3
2
3
1,500
600-2
600-3
600,000 400,000 20
94
160
15
15
125
240
25
25
25
30
36x71 39x48
2
3
2
3
2,500
900-3 900,000 600,000 30 200 15 270 25 40 42x71 39x48 3 3 2,500
1200-3 1,200,000 800,000 40 210 15 280 25 50 48x71 52x60 3 3 4,500
Flow rates and resin capacities are based on a single tank.
Softeners Section H
H9-16
09-04
Table H9-2. FSE Water Softener Ratings, Fiberglass Softeners
MODEL
NUMBER
EXCHANGE
CAPACITY
RESIN
QYT
CONT
SERV
FLOW
PRESS
DROP
PEAK
SERV
FLOW
PRESS
DROP
BACK-
WASH
FLOW
TANK
DIMENSIONS
MANIF
PIPE
SIZE
(in.)
FLOW
SENSOR
SIZE
(in.)
SALT
STORAGE
CAPACITY
(lbs)
FSE MAX GR MINGR CU-FT GPM PSI GPM PSI GPM
SOFR
(in.)
BRINE
(in.)
30-1 30,000 20,000 1 8 5 12 10 2 9X48 18x40 1 1 400
60-1 60,000 40,000 2 16 10 24 20 3 12x52 18x40 1 1 400
90-1
90-1-1/2
90,000 60,000 3
21
24
15
9
29
36
25
16
5 14x65 18x40
1
1-1/2
1
1-1/2
400
120-1-1/2
120-2
120,000 80,000 4
32
32
12
7
48
48
22
12
7 16X65 24x41
1-1/2
2
1-1/2
2
700
150-1-1/2
150-2
150,000 100,000 5
40
40
13
9
52
60
25
16
7 17X72 24x41
1-1/2
2
1-1/2
2
700
210-1
1
/
2
210-2
210,000 140,000 7
45
56
15
8
60
84
25
15
15 24x72 24x50
1-1/2
2
1-1/2
2
1,000
300-1
1
/
2
300-2
300,000 200,000 10
45
77
15
15
58
107
25
25
15 24x72 24x50
1-1/2
2
1-1/2
2
1,000
450-2 450,000 300,000 15 87 15 118 25 20 30x72 30x50 2 2 1,500
600-2
600-3
600,000 400,000 20
94
160
15
15
125
240
25
25
25
30
36x72 39x48
2
3
2
3
2,500
MODEL
NUMBER
EXCHANGE
CAPACITY
RESIN
QYT
CONT
SERV
FLOW
PRESS
DROP
PEAK
SERV
FLOW
PRESS
DROP
BACK-
WASH
FLOW
TANK
DIMENSIONS
MANIF
PIPE
SIZE
(in.)
FLOW
SENSOR
SIZE
(in.)
SALT
STORAGE
CAPACITY
(lbs)
CRS MAX GR MINGR CU-FT GPM PSI GPM PSI GPM
SOFR
(in.)
BRINE
(in.)
30-1 30,000 20,000 1 8 5 12 10 2 9x48 18x40 1 1 400
60-1 60,000 40,000 2 16 10 24 20 3 12x52 18x40 1 1 400
90-1 90,000 60,000 3 21 15 29 25 5 14x65 18x40 1 1 400
90-1
1
/
2
90,000 60,000 3 24 9 36 16 5 14x65 18x40
1
1
/
2
1
1
/
2
400
1201
1
/
2
120,000 80,000 4 32 12 48 22 7 16x65 24x41
1
1
/
2
1
1
/
2
700
150-1
1
/
2
150,000 100,000 5 40 13 52 25 7 17x72 24x41
1
1
/
2
1
1
/
2
700
210-1
1
/
2
210,000 140,000 7 45 15 60 25 15 24x72 24x50
1
1
/
2
1
1
/
2
1,000
300-1
1
/
2
300,000 200,000 10 45 15 58 25 15 24x72 24x50
1
1
/
2
1
1
/
2
1,000
(CRS Crossover Systems Are Only Available In Twin Alternating Configurations.)
Table H9-3. CRS Water Softener Ratings, Fiberglass Softeners with Crossover Controls
Section H Softeners
H9-17
09-04
Table H9-4. SMR Water Softener Ratings
MODEL
NUMBER
EXCHANGE
CAPACITY
RESIN
CU-FT
MANIF
PIPE
SIZE
IN.
CONT
SERV
FLOW
GPM
PEAK
SERV
FLOW
GPM
BACK-
WASH
FLOW
GPM
TANK
DIMENSIONS SALT
CAPACITY
BRINE MAKER
(LBS)
SALT PER
REGEN
REC
WATER
METER
SIZE
(in.)
DRAIN
PIPE SIZE
(in.)
SMR
MAX
GR
MIN
GR
SOFR
(in.)
BRINE
(in.)
MAX
LBS
MIN
LBS
150-1
150-1-1/4
150-1-1/2
150-2
150,000 100,000 5
1
1-1/4
1-1/2
2
32
43
55
69
42
57
70
97
10.0 20x54 24x50 700 75 30
1
1-1/4
1-1/2
2
1
210-1-1/4
210-1-1/2
210-2
210-2-1/2
210,000 140,000 7
1-1/4
1-1/2
2
2-1/2
41
64
80
115
57
86
110
160
15 24x54 24x50 600 105 42
1-1/4
1-1/2
2
2-1/2
1
300-1-1/2
300-2
300-2-1/2
300-3
300,000 200,000 10
1-1/2
2
2-1/2
3
65
82
140
165
92
125
190
230
20.0 30x54 24x60 600 150 60
1-1/2
2
2-1/2
3
1
450-1-1/2
450-2
450-2-1/2
450-3
450,000 300,000 15
1-1/2
2
2-1/2
3
63
82
120
140
90
115
170
190
20.0 30x60 30x60 1000 225 90
1-1/2
2
2-1/2
3
1
600-1-1/2
600-2
600-2-1/2
600-3
600,000 400,000 20
1-1/2
2
2-1/2
3
72
110
140
175
94
125
190
250
30.0 36x60 39x60 1900 300 120
1-1/2
2
2-1/2
3
1 1/2
750-2
750-2-1/2
750-3
750,000 500,000 25
2
2-1/2
3
90
140
160
116
190
230
30.0 36x72 39x60 1700 375 150
2
2-1/2
3
1 1/2
900-2
900-2-1/2
900-3
900,000 600,000 30
2
2-1/2
3
105
150
188
133
218
274
45.0 42x60 42x60 1900 450 180
2
2-1/2
3
2
1050-2
1050-2-1/2
1050-3
1050K 700K 35
2
2-1/2
3
95
145
175
124
210
259
45.0 42x72 50x60 2300 525 210
2
2-1/2
3
2
A. Continuous service flow at a pressure loss not exceeding 15 psig.
B. Peak service flow at a pressure loss not exceeding 25 psig.
T denotes turbo type water meter.
Softeners Section H
H9-18
09-04
ITEMS THAT MUST BE KNOWN
1. Capacity of generator in lbs of steam per hour.
2.% Make-up.
3. Water hardness.
4. Hours operated each day.
PROCEDURE
1. Lay a straight edge from lbs steam/hour (line A) to the% make-up (line D) and obtain the DBMS make-
up flow from line B.
2. Lay a straight edge from the gpm make-up (line B) to the water hardness (Line E) and obtain the hard-
ness removal required for each hour of generator operation from line C.
3. Calculate the hardness removal required each day by multiplying the value obtained in step 2 by the
hours operated each day.
NOTE: In situations where softened water is required for loads in addition to boiler requirements, the total
gpm flow for the softener is the total of both requirements. Then using lines B and E, the required grain
removal per hour can be determined.
EXAMPLE
10,000 lbs steam/hour
15% make-up
8 hours daily operation
Water hardness 10 grains per gallon
FROM NOMOGRAPH
Feedwater make-up is 3 gpm.
Hardness removal required is 1800 grains per hour.
Hardness removal required each day - 8 x 1800 - 14,400 grains.
SOFTENER SELECTION
Select a softener that will meet both flow rate and exchange requirements. For 24 hour operation and to
provide a continuous supply of soft water, a twin unit is required. For the above example, an SSE-60-1 Twin
could be used to provide 24 hour operation. This model would provide 1 day operation between regenera-
tion periods. To provide 8 hour a day operation, the SSE-60-1 single unit would permit 3 days between re-
generation periods.
Figure H9-5. Water Softener Sizing Chart
H9-19
09-04
Section H9
Softeners (SSE/FSE)
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-20
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-20
Tanks 10 Through 36 Diameter (Steel Polybond: Standard SSE) . . . . . . . . . . . . . . . . . . . . . H9-20
Tanks 9 Through 36 Diameter (Fiberglass Reinforced Plastic: Standard FSE) . . . . . . . . . . . . H9-21
Tanks 20 Through 42 Diameter (SMR Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-21
Distribution System - Models SSE & FSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-21
Main Operating Valve SSE /FSE 30 to 1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-22
Brine System and Salt Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-22
Resin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-22
Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-22
Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-23
Gauge and Sample Valve Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-23
Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-23
Duplex Twin Alternating Units EDT Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-23
Variable Flow Multiple Tank Systems VF Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-24
Cross Over Twin Units CSR Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-25
Time Clock Units TC Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-25
Flowsensors 1 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-25
Flowsensors 1.5 x 2 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-26
Flowsensors 3 and Larger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-26
EXECUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-26
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-26
Time Clock Units TC Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-27
Flowsensors 1 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-27
Flowsensors 1.5 x 2 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-27
Flowsensors 3 and Larger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-27
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-27
Skid Mounting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-28
Steel Softeners Model 30 to 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-28
Steel Softeners Model 450 to 600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-28
Steel Softeners Model 750 to 1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-28
Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-28
SAMPLE SPECIFICATIONS (SSE/FSE)
The following sample specifications are provided to you by Cleaver-Brooks to assist you in meeting your
customers requirements.
Softeners Section H
H9-20
09-04
PART 1 GENERAL 11 GENERAL
Furnish, install, and place in operation an Automatic Water Softener System similar
or approved equal to Cleaver-Brooks Model (SSE: lined steel tank/FSE: fiberglass
reinforced plastic tank)_______________, having ______tank(s) with ______cu-ft.
of ion exchange resin per tank. Soft water output to be ___________gallons (cu-
meters) per tank per regeneration with______lbs(kg) of salt, based on _______
grains per gallon compensated hardness. Service flow rate per tank_______gpm
(lpm) at a pressure loss through softener system not exceeding _______psig (bar).
PART 2 PRODUCTS 21 EQUIPMENT
A. Tanks 10 Through 36 Diameter (Steel Polybond: Standard SSE)
1. Softener tanks shall be made of butt-welded industrial grade
carbon steel designed for a working pressure of 125 psi
(____bar) dynamic and hydrostatically tested at 50% excess of
the working pressure. Each tank shall be _______m) diameter
with a _______m) overall tank height. Tank support(s) shall be
of a skirt-ring type welded to the tank(s) lower head. The
tank(s) shall be equipped with a resin loading port and a drain/
resin removal port (14 and larger).
2. Steel tank(s) shall be provided with a Polybondlining of inert
non-leachable virgin polyethylene material at least 40-60 mils
thick permanently bonded to the tank interior by heat fusion.
The tank lining shall meet the requirements of the United
States Food and Drug Administration (USFDA). The tank lining
shall be chemically inert so as not to react with water, media,
acids, caustic soda, chemicals or water-borne contaminants.
The tank exterior shall be degreased, pre-cleaned, and
phosphatized and shall have an exterior coating of high gloss
epoxy enamel 4 to 6 mils thick. Tank openings shall be fitted
with O-ring seals that seat firmly on the tank interior lining to
prevent holidays due to thread tapping and eliminate water to
thread contact.
3. Steel tank linings shall be tested for lining integrity by a 2,500-
volt spark test, and the test certified with the shipping papers
for the system (if requested at the time of order). The spark
test shall be capable of detecting the most minute
imperfection. The tank(s), with linings in place, shall be water
tested under pressure for leaks.
4. 2.1 Tanks 42 Through 48 Diameter (Steel Polybond:
Standard SSE)
5. Softener tanks shall be made of butt-welded industrial grade
carbon steel designed for a working pressure of 100 psi
(____bar) dynamic and hydrostatically tested at 50% excess of
the working pressure. Each tank shall be _______m) diameter
with a _______m) overall tank height. Tank support(s) shall be
strap-type steel legs permanently welded to the lower tank
head. The tank(s) shall be equipped with a resin loading port
and a drain/resin removal port.
Section H Softeners
H9-21
09-04
6. Steel tank(s) shall be provided with a Polybondlining of inert
non-leachable virgin polyethylene material at least 40-60 mils
thick permanently bonded to the tank interior by heat fusion.
The tank lining shall meet the requirements of the United
States Food and Drug Administration (USFDA). The tank lining
shall be chemically inert so as not to react with water, media,
acids, caustic soda, chemicals or water-borne contaminants.
The tank exterior shall be degreased, precleaned, and
phosphatized and shall have an exterior coating of high gloss
epoxy enamel 4 to 6 mils thick. Tank openings shall be fitted
with O-ring seals that seat firmly on the tank interior lining to
prevent holidays due to thread tapping and eliminate water to
thread contact.
7. Steel tank linings shall be tested for lining integrity by a 2,500-
volt spark test, and the test certified with the shipping papers
for the system if requested at the time of order. The spark test
shall be capable of detecting the most minute imperfection.
The tank(s), with linings in place, shall be water tested under
pressure for leaks.
B. Tanks 9 Through 36 Diameter (Fiberglass Reinforced Plastic:
Standard FSE)
1. Softener tank(s) shall be made of fiberglass reinforced ABS
plastic. The exterior sideshell shall be reinforced by a
continuous roving glass filament overwrap of the same color as
the tank shell. The tank(s) shall be supported by a molded
polypropylene structural base. Including the base, each vessel
shall have the dimensions of _______inches diameter and
_______inches height.
C. Tanks 20 Through 42 Diameter (SMR Standard)
1. Option - Pressure vessels shall be provided in accordance with
ASME Section VIII. Working pressure will be 100, 125 or 150
psig and hydrotested to 150% of stamped and certified rating.
2. Option - Provide tank with high temperature internal epoxy
lining at 8-10 mil DFT. Exterior tank surface will be cleaned
and coated with a corrosion-resistant zinc-rich primer suitable
for epoxy coating in the field.
3. Option - Provide tank with a baked phenolic internal epoxy
lining at 8-10 mil DFT. Exterior tank surface will be cleaned
and coated with a corrosion-resistant zinc-rich primer suitable
for epoxy coating in the field.
4. Option - Provide tank with an external coating of a high gloss
epoxy paint 2-4 mil DFT.
D. Distribution System - Models SSE & FSE
1. The soft water collector and backwash water distributor shall
be non-clogging design with slot size slot 0.010 inch in width.
Single point and hub radial laterals will be used to ensure
adequate distribution of flow during service, backwash and
regeneration. Laterals will be made of Schedule 80 PVC and
designed for low pressure drop-in service.
Softeners Section H
H9-22
09-04
2. The distributor system will be fully covered by a minimum of 2
inches of quartz underbedding. The quartz shall be washed
and dried to remove debris and fines, and screened not to
exceed 16 mesh size by 3/16-inch particle size.
E. Main Operating Valve SSE /FSE 30 to 1200
1. The control valve shall have _______inch _______cm) NPT
(BSP) inlet and outlet connections. It shall be a low lead brass
mechanically-actuated, hydraulically-balanced, self-cleaning
piston six-position type to accomplish the regeneration steps of
backwash, brine draw, slow rinse, fast rinse, and refill.
Separate rinse and timed refill positions will be provided to
reduce regeneration water use. The valve shall contain fixed
orifice eductor nozzle and self-adjusting backwash flow
control. The valve will be capable of being manually stepped
through regeneration without electrical power.
F. Brine System and Salt Storage
1. The brine system shall be designed to minimize possible
overflow conditions by eliminating line pressure to the salt
storage tank at all times except during refill. Timed tank refill
will be used to utilize salt and regeneration water efficiently
and the regeneration salt dosage shall be adjustable from 5 to
20 lbs _______to___kg) per cubic ft. (m) from the system
control without the need for emptying salt tanks or moving fill
plugs.
2. A combination salt storage tank with cover and brine tank well
shall be supplied as part of the system. The tank shall be
sufficient size to hold salt for at least _______regenerations
between refills. The tank(s) shall be made of corrosion-free
one-piece molded polyethylene or fiberglass reinforced plastic
material. The tank(s) shall have a nominal diameter of
_______inches (_____cm) and a height of _______inches
(_____cm) and have a storage capacity of ______lbs (kg). All
brine systems will include a float operated plastic brine pick up
designed to provide positive shut off to prevent air from
entering the system.
3. Option - A pressurized brine control system will be provided to
introduce brine into the softener vessels. A timed brine
controller, non-corrosive self-adjusting flow controls and pilot-
operated diaphragm valve will be provided for integration into
the facilities pressurized brine source. Salt dosage shall be field
adjustable through the timed brine module.
G. Resin
1. Each softener tank shall be provided with _______cubic feet of
high capacity sulphonated styrene divinylbenzene based
synthetic ion exchange resin having a minimum exchange
capacity of 30,000 grains per cubic foot when regenerated
with 15 pounds of salt per cubic foot. The resin shall be solid,
with uniform particle size, clean and free of dirt and extraneous
matter that might interfere with flow of water through the resin
or that might interfere with the ion exchange process. All resin
shall be FDA compliant under the Code of Federal Regulation
No.21 paragraph 173.25.
Section H Softeners
H9-23
09-04
H. Flow Control
1. Automatic backwash and brine refill flow control shall be
provided to maintain proper backwash, rinse and brine flow
rates over wide fluctuations of operating pressure. The
controller will contain no moving parts and require no field
adjustment. All flow controls will be connected for ease of
removal for inspection and service as needed.
I. Piping
1. Contractor shall furnish and install all interconnecting pipe and
isolation valves. Drain connections from the control valve shall
have an air gap conforming to local codes and to permit
observation and sampling of backwash and regeneration water.
J. Gauge and Sample Valve Option
1. Manufacturer shall provide two pressure gauge and sample
valve assemblies or contractor installation in the inlet and
outlet piping. Pressure gauges and sample valves will be
stainless steel or other non-corrosive design.
K. Control Options
1. Single Units EDS Control
a. The softener system will be controlled by a single
computer-based demand (meter) initiated controller. The
controller shall be capable of operating either 1 or 2 units
in single, twin alternating, or parallel configurations
allowing easy expansion as soft water demand increases
without the need for rewiring or adding additional
controllers. The control will utilize alphanumeric, self-
prompting programming for simple start up. EEPROM
memory shall store program data eliminating need for
battery back-up or configuration input after power loss.
The control shall be pre-wired and includes twist lock
electrical end connectors for installation ease.
b. The controller will constantly monitor current operating
condition and be capable of displaying instantaneous flow
rate through the system. A resettable totalizing flow
counter will be included to measure total water processed.
c. The control shall be self-diagnostic and capable of
emitting an audible signal and error specific messages if it
detects a system problem. Control diagnostics can be
transmitted over telephone lines for troubleshooting or
review of historical operational data to allow system
optimization through evaluation of actual water usage.
Valve and control operation will be 24V, 60Hz, 1ph A
suitably sized UL/CSA listed transformer(s) will be
provided to convert 120V, 60Hz, 1ph power for system
operation. Control printed wiring assemblies will be
conformally coated to MIL specifications suitable for use
in humid environments. A water-tight enclosure will be
used to house he control.
L. Duplex Twin Alternating Units EDT Control
1. The softener system will be controlled by a single computer-
based demand (meter) initiated controller. The controller shall
Softeners Section H
H9-24
09-04
be capable of operating 2 units in twin alternating, or parallel
configurations allowing the units to easily both be put on-line
to handle peak start up flows and returned to alternating
operation during normal use periods without the need for
rewiring, or extensive reprogramming or adding additional
controllers. Although the control will allow two units to be put
on-line simultaneously, a built-in lockout prevents both units
from regenerating at the same time. The control will utilize
alphanumeric, self-prompting programming for simple start up.
EEPROM memory shall store program data eliminating need
for battery back-up or configuration input after power loss. The
control shall be pre-wired and includes twist lock electrical end
connectors for installation ease.
2. The controller will constantly monitor current operating
condition and be capable of displaying instantaneous flow rate
through the system. A resettable totalizing flow counter will be
included to measure total water processed.
3. The control shall be self-diagnostic and capable of emitting an
audible signal and error-specific messages if it detects a
system problem. Control diagnostics can be transmitted over
telephone lines for trouble shooting or review of historical
operational data to allow system optimization through
evaluation of actual water usage. Valve and control operation
will be 24V, 60Hz, 1ph A suitably sized UL/CSA listed
transformer(s) will be provided to convert 120V, 60Hz, 1ph
power for system operation. Control printed wiring assemblies
will be conformally coated to MIL specifications suitable for
use in humid environments. A water-tight enclosure will be
used to house the control.
M. Variable Flow Multiple Tank Systems VF Control
1. The system will be supplied with a single computer-based
demand (meter) initiated controller capable of operating
systems with 2 to 4 units. In addition to traditional parallel or
alternating operating conditions, the control can operate in a
variable flow mode which has the ability to bring units on and
off-line depending on current service flow. The control will
utilize alphanumeric, self-prompting programming for simple
start-up. EEPROM memory shall store program data
eliminating need for battery back-up or configuration input
after power loss. It is pre-wired and includes twist lock
electrical end connectors for installation ease.
through the system. On multiple vessel systems flow and
operational data for each unit shall be independently
displayable. A resettable totalizing flow counter will be
Section H Softeners
H9-25
09-04
3. The control shall be self diagnostic and capable of emitting an
audible signal and error-specific messages if it detects a system
problem. Control diagnostics can be transmitted over telephone
lines for troubleshooting or review of historical operational data
to allow system optimization through evaluation of actual water
usage. If an error is detected the controller will be capable of
automatically readjusting the operating program to place the
maximum number of tanks on-line and recalculate regeneration
frequency to provide optimum treatment flow capacity until
service is provided. Valve and control operation will be 24V,
60Hz, 1ph A suitably sized UL/CSA listed transformer(s) will be
provided to convert 120V, 60Hz, 1ph power for system
operation. Control printed wiring assemblies will be conformally
coated to MIL specifications suitable for use in humid
environments. A water tight enclosure will be used to house the
control.
4. This meter-initiated system allows all units to be in service at
the same time. Regeneration is immediate based on a batch
count. A built in interlock does not allow more than one unit to
be in regeneration at a time.
N. Cross Over Twin Units CSR Control
1. The softener system will be supplied with a computer-based
demand (meter) initiated controller. The control will utilize
alphanumeric, self-prompting programming for simple start-up.
EEPROM memory shall store program data eliminating need for
battery back-up or configuration input after power loss.
audible signal and error specific messages if it detects a system
problem. Control diagnostics can be transmitted over telephone
lines for troubleshooting or review of historical operational data
to allow system optimization through evaluation of actual water
usage.
4. Valve and control operation will be 24V, 60Hz, 1ph A suitably
sized UL/CSA listed transformer(s) will be provided to convert
120V, 60Hz, 1ph power for system operation. Control printed
wiring assemblies will be conformally coated to MIL
specifications suitable for use in humid environments. The
control will be mounted directly in the valve cover. Electrical
installation will only require plugging in the transformer and
connecting the flowsensor cable.
O. Time Clock Units TC Control
1. The softener(s) will be provided with a 7 day timer allowing
recharge to occur at a user adjustable time of day or night. The
timer shall be capable of being set to skip one or more days
between regenerations. Electrical operation is 120V, 60Hz,
1ph.
P. Flowsensors 1 Models
1. _______Hall effect tubo flow sensor(s) will be provided. These
Softeners Section H
H9-26
09-04
sensor(s) shall be made with no packing glands or rotating
shaft seals and will be solid state proximity transducer-type
with a self-lubricated shaft riding on a sapphire bearing. The
sensor shall be made in such a way that it can be installed and
removed with simple hand tools. Pipe size of the sensor(s)
shall be 1 inch (_______cm). It shall have a minimum flow of
1 gpm (___lpm), and a peak flow of 40 gpm (____lpm). Flow
rate normal range is 1/2 to 30 gpm. The flowmeter housing
shall be brass.
Q. Flowsensors 1.5 x 2 Models
removed with simple hand tools. Pipe size of the sensor(s)
shall be 1.5 inch (_______cm) x 2 inch _______cm). It shall
have a minimum flow of 2 gpm, flow rate normal range is 1-1/
2 to 60 gpm (____lpm), and a peak flow of 125 gpm
(_____lpm). The flowmeter housing shall be brass.
R. Flowsensors 3 and Larger
1. _______Hall effect paddle wheel flow sensor(s) will be
provided. These sensor(s) shall be made with no packing
glands or rotating shaft seals and will be solid state proximity
transducer type with a self lubricated PVDF paddlewheel riding
on a titanium shaft The sensor shall be made in such a way
that it can be installed and removed with simple hand tools.
Pipe size of the sensor(s) shall be 3 inch (_______cm). It
shall have a minimum flow of 7 gpm (____lpm), and a peak
flow of 230 gpm (_____lpm) [for 3 "]. Flow rate for 3" - normal
range is 7 to 200 gpm, _____12 gpm (____lpm), 395 gpm
(_____lpm) [for 4"]. Flow rate for 4" - normal range is 12 to
350 gpm. 25 gpm (____lpm) 999 gpm (_____lpm) [for 6"].3
PART 3 EXECUTION 3.1 EXECUTION
A. Instructions
1. The softener system will be supplied with a computer-based
demand (meter) initiated controller. The control will utilize
alphanumeric, self-prompting programming for simple start-
up. EEPROM memory shall store program data eliminating
need for battery back-up or configuration input after power
loss.
audible signal and error specific messages if it detects a
system problem. Control diagnostics can be transmitted over
telephone lines for troubleshooting or review of historical
operational data to allow system optimization through
evaluation of actual water usage.
Section H Softeners
H9-27
09-04
4. Valve and control operation will be 24V, 60Hz, 1ph A suitably
sized UL/CSA listed transformer(s) will be provided to convert
120V, 60Hz, 1ph power for system operation. Control printed
wiring assemblies will be conformally coated to MIL
specifications suitable for use in humid environments. The
control will be mounted directly in the valve cover. Electrical
installation will only require plugging in the transformer and
connecting the flowsensor cable.
B. Time Clock Units TC Control
1. The softener(s) will be provided with a 7 day timer allowing
recharge to occur at a user adjustable time of day or night. The
timer shall be capable of being set to skip one or more days
between regenerations. Electrical operation is 120V, 60Hz,
1ph.
C. Flowsensors 1 Models
removed with simple hand tools. Pipe size of the sensor(s) shall
be 1 inch (_______cm). It shall have a minimum flow of 1 gpm
(___lpm), and a peak flow of 40 gpm (____lpm). Flow rate
normal range is 1/2 to 30 gpm. The flowmeter housing shall be
brass.
D. Flowsensors 1.5 x 2 Models
removed with simple hand tools. Pipe size of the sensor(s) shall
be 1.5 inch (_______cm) x 2 inch _______cm). It shall have a
minimum flow of 2 gpm, flow rate normal range is 1-1/2 to 60
gpm (____lpm), and a peak flow of 125 gpm (_____lpm). The
flowmeter housing shall be brass.
E. Flowsensors 3 and larger
1. _______Hall effect paddle wheel flow sensor(s) will be
provided. These sensor(s) shall be made with no packing
glands or rotating shaft seals and will be solid state proximity
transducer type with a self lubricated PVDF paddlewheel riding
on a titanium shaft The sensor shall be made in such a way
that it can be installed and removed with simple hand tools.
Pipe size of the sensor(s) shall be 3 inch (_______cm). It shall
have a minimum flow of 7 gpm (____lpm), and a peak flow of
230 gpm (_____lpm) [for 3 "]. Flow rate for 3" - normal range
is 7 to 200 gpm, _____12 gpm (____lpm), 395 gpm
(_____lpm) [for 4"]. Flow rate for 4" - normal range is 12 to
350 gpm. 25 gpm (____lpm) 999 gpm (_____lpm) [for 6"].3
F. Instructions
1. A complete set of instructions for installation and operation of
the softener system will be included.
Softeners Section H
H9-28
09-04
G. Skid Mounting Options
1. The softener system will be provided skid-mounted with all
units pre-piped by the manufacturer. Each unit will be
isolatable and a system bypass valve shall come installed in
the plumbing header. Inlet and outlet connections will
terminate in convenient locations near the skid edge. All
plumbing shall be supported by Unistrut or equivalent anchors
and members.
2. Inter-tank hydraulic tubing and fittings will be installed as part
of the skid package. All mineral tanks will be bolted to the skid
members to allow removal. Permanent mounting or welding is
not acceptable. All skids will be completely assembled, and
hydraulically and electrically tested before shipment. Prior to
shipping, the system will be drained before packaging. Partial
disassembly may be required for shipment. All assemblies will
be marked to allow simple reconnection.
H. Steel Softeners Model 30 to 300
1. Tanks 10 to 24 diameter will be mounted on a 4 channel
iron skid (5.4 lb. per foot, ASTM grade A-36) The skid will be
cross-braced with similar 4 channel or angle iron. All steel
surfaces will be cleaned and painted with a high gloss epoxy
top coat matching the softener vessel color.
I. Steel Softeners Model 450 to 600
cross-braced with similar 6 channel or angle iron. All steel
surfaces will be cleaned and painted with a high gloss epoxy
top coat matching the softener vessel color.
J. Steel Softeners Model 750 to 1200
cross-braced with similar 8 channel (11.5 lb. per foot)
channel or angle iron. All steel surfaces will be cleaned and
painted with a high gloss epoxy top coat matching the softener
vessel color.
K. Guarantee
1. Attrition loss of mineral is guaranteed not to exceed 3% per
year for a period of 3 years.
2. All mechanical equipment is guaranteed for 1 year against any
defects in workmanship or materials. All EDS, EDT, and VF
controls are guaranteed for 1 year against M & W. Consult
specific product warranty for mineral and brine tank
information.
3. The manufacturer guarantees that under actual operating
conditions, the mineral shall not be washed out of the system
during service or backwash cycles when operated under the
instructions and guidelines set forth in the operation manual.
H9-29
09-04
Section H9
Softeners (SMR)
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-30
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-30
Regeneration Initiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-31
SAMPLE SPECIFICATIONS (SMR)
requirements.
Softeners Section H
H9-30
09-04
Furnish, install, and place in operation an Automatic Water Softener System similar
or approved equal to Cleaver-Brooks Model SMR_______, having tank(s) with
_______cu-ft. of ion exchange resin per tank. Soft water output to be _______
gallons per tank per regeneration with _______lbs of salt, based on _______grains
per gallon compensated hardness. Service flow rate per tank _______gpm at a
pressure loss through softener system not exceeding _______psig.
PART 2 PRODUCTS 2.1 EQUIPMENT
2.1 Tanks
Softener tank(s) shall be of welded construction of tank quality carbon steel. Each
tank shall be _______ diameter with a _______ straight side shell height. The
tank(s) shall have threaded openings for pipe connections and an 11" x 15"
manhole in the top head (for tanks 30" diameter and smaller; two 4 x 6 handholes
should be provided in the top head and lower side shell). The tank(s) shall be rated
for 100 psig working pressure and 150 psig test pressure. Support legs will be the
strap-type permanently welded to the lower tank head. The tank(s) shall have their
exterior and interior protected with a hot dipped galvanized application after
fabrication. A minimum freeboard of 50% shall be provided for backwash expansion
above the normal ion exchange resin bed level.
2.2 Tank Option
Provide pressure vessel in accordance with ASME Section VIII. Working pressure to
be 100, 125 or 150 pounds, hydrotested to 150, 187.5, or 225 psig, stamped and
certified.
2.3 Tank Option
Provide cold-set epoxy internal lining 10-12 mils DFT, with rust resistant prime coat,
external coating 2-3 mils DFT.
2.4 Tank Option
Provide baked phenolic internal lining 4-5 mils DFT, with rust resistant prime coat,
external coating 2-3 mils DFT.
2.5 Tank Option
Provide Safety Blue epoxy finish paint 6-8 mils DFT over exterior tank and valve
surfaces. To be applied on channel iron surface if applicable.
2.6 Upper Distributor
The upper distribution system shall be a single point baffle constructed of Schedule-
40 galvanized steel pipe and fittings.
2.7 Lower Distributor
The lower distribution system shall be of the hub end radial type constructed of PVC
with slotted full flow non-clogging replaceable ABS strainers and covered with a
subfill of 1/8 x 1/16 washed gravel.
2.8 Main Operating Valves
The main operating valves shall be a nest of individual diaphragm valves. The valves
shall have cast iron bodies with Buna-N diaphragm and stainless steel and brass
internal parts. The valves shall be slow opening and closing, and free of water
hammer. There shall be no contact of dissimilar metals within the valves and no
special tools shall be required to service the valves. Valves can be operated either
Section H Softeners
H9-31
09-04
hydraulically or pneumatically.
2.9 Brine System
The brine system shall be platform type with dry salt storage compartment,
sufficient for at least four regenerations at full salting and a saturated brine
compartment. The tank shall be of polyethylene construction. It shall be equipped
with a float operated plastic brine valve and allow for simple adjustment of salt
dosage without removing the brine valve. It shall be _______ diameter x _______
shell height and have a storage capacity of lbs of salt.
2.10 Resin
Resin shall be of a premium grade high capacity synthetic sulfonated styrene
divinylbenzene type, to be furnished in the sodium form. It shall be stable over the
entire pH range, have good resistance to bead fracture, and be insoluble in all
common solvents. The resin shall be capable of 30,000 grains per cubic foot
capacity when regenerated with 15 lbs NaCl.
2.11 Flow Control
An automatic backwash control shall be provided to maintain a proper backwash
and fast flush flows over wide variations of operating pressure. Controller to contain
no moving parts, and requires no field adjustment.
2.12 Piping
The main operating valves and manifold piping shall be Schedule 40 galvanized
steel. Galvanized fittings shall be standard class 150 threaded malleable iron.
PART 3 EXECUTION 3.1 REGENERATION INITIATION
A. Control
1. A NEMA 12rated factory mounted and wired electrical
enclosure with all timing and sequencing controls for each
softener shall be manufactured and provided by the same
vendor providing the water treatment hardware.
2. The controls shall include an automatic regeneration sequencer
having the capability of providing site adjustable regeneration
steps of backwash brine injection, brine displacement, flush
and return to service. An indicator on the pilot stager points to
the cycle of operation at all times. Complete function and
control of all regeneration steps can be performed by manual
operation of the pilot stager.
3. The 12-Day electrical time clock controller shall be fully
adjustable to initiate regeneration at any hour of the day and
any day of the week.
B. Control Option
1. Single Automatic Reset Meter and Alternator (Twin Softeners
Only)
Softeners Section H
H9-32
09-04
2. The twin water softener shall be equipped with a single
_______ (disc) (turbo) water meter, AWWA rated, in the
common outlet header. At a pre-set gallonage the automatic
reset head of the meter will send a 120 volt signal to an
alternator that will direct the signal to regenerate the unit
presently on-stream. Upon completion of regeneration, that
softener will remain off stream in the stand-by position. This
sequence will repeat on an alternating basis each time the
preset gallonage of soft water has passed through the meter. A
lockout shall be provided to allow only one unit to regenerate
at any one time.
C. Control Option
1. MX Electronic Programmable Controls (Two or Three Tanks)
2. The system will operate with two or three media tanks each
having a dedicated paddle wheel type flow sensor and operate
in either of these modes, one of which will be on-line while the
other is regenerated and user selected modes.
a. Alternating One media tank will be in the standby or
regeneration and one (1) or two (2) media tanks will be
on-line. At a user specified volume the standby tank will
go on line and the exhausted tank will go into
regeneration. After regeneration this tank will go into
standby until its rotation to go back on-line
b. Parallel - All media tanks are on-line simultaneously. As
each media tanks user specified volume is reached it
shall immediately be taken off-line, regenerated, and
placed immediately back on-line.
c. Additive Flow - One (1) media tank, designated as the
primary, will remain on-line at all times. Variation of
treated water flow demand shall automatically cause (one
additional media tank) (up to two additional media tanks)
to change status from standby to on-line and back to
standby as needed.
3. When the primary media tank regenerates the next media tank
in sequence shall become the primary.
4. As each media tanks user set volume is reached it will
immediately be taken off-line, regenerated, and placed
immediately back on-line or standby depending on treated
water flow demand.
5. The controller shall be capable of continuously determining the
exhaustion rate of each media tank thus automatically avoiding
the possibility of a simultaneous regeneration attempt.
Simultaneous regenerations are not possible.
6. The exchange capacity of each softener can be the same or
different. Flow or peak flow rate indication shall be
continuously displayed for each unit. The continuous flow
range is 0-999 flow units per minute (gallons, cu.ft., liters, cu-
m, etc.). Cumulative volume totalization to eight (8) digits
shall be continuously displayed for each unit.
Section H Softeners
H9-33
09-04
D. Instructions - A complete set of installation instructions and
operating instructions shall be furnished.
E. Skid Mounting (Pre-pipe and Pre-wire)
1. Mineral Tank skid mount Option.
2. The softener mineral tanks shall be shall be mounted on a 4"
channel iron skid (7.25 lbs per foot, ASTM grade A-36). The
skid shall be cross-braced with a 4" channel or angle iron,. All
steel surfaces shall be prime coated. All interconnecting piping
shall be the same material as the valve nest manifold piping
and shall be assembled by the manufacturer. This shall include
inlet and outlet bronze isolation valves for each tank, and a
bronze system bypass valve. Inlet and outlet headers shall be
installed and terminate at the skid edge. All piping shall be
suitably supported by Unistrut supports anchored to the skid.
Electric wiring, where applicable, shall be complete between
all inter unit controls and require only a single power source
connection. The inter unit wiring shall be contained in Flextite
flexible, waterproof conduit. All inter-tank hydraulic or
pneumatic tubing shall be installed as part of the skid
package. The mineral tanks are to be bolted to the skid.
Permanent attachment, or welding, will not be acceptable. The
entire skid mounted system shall be both leak and electrically
tested as a unit by the manufacturer before shipment
F. Guarantee
1. Attrition loss of mineral is guaranteed not to exceed 3% per
year for a period of 3 years.
2. All mechanical equipment is guaranteed for 1 year against any
defects in workmanship or materials. Any part proving
defective will be replaced or repaired within this period.
Softeners Section H
H9-34
09-04
3. The manufacturer guarantees that under actual operating
conditions the mineral shall not be washed out of the system
during the service run or backwashing period; that the turbidity
and color of the effluent, by reason of passing through the
softener system, shall not be greater than that of the incoming
water; and that the under-drain system, gravel and mineral
shall not become fouled, either with turbidity or by dirt, rust, or
scale from the softening system, or present in the soft water,
while operating as noted on manufacturers instructions.
Notes
H10-1
03-08
CONTENTS
DIMENSIONS, RATINGS AND SIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-4
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-4
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-4
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-4
Sizing Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-5
ILLUSTRATIONS
Figure H10-1. Dealkalizer Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-6
TABLES
Table H10-1. Automatic Dealkalizer Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-4
Table H10-2. Dealkalizer Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-7
Section H10
DEALKALIZERS
Dealkalizers Section H
H10-2
03-08
Information in this section applies directly to Cleaver-Brooks dealkalizers ranging from 10,000 to 980,000 grain
capacity.
Cleaver-Brooks chloride cycle dealkalizers are similar to water softeners except that, instead of cation resin, they
use a strong anion resin to remove selective negatively charged ions from the raw water supply.
Dealkalizers require use of softened water, and are installed down stream from the water softener, and before the
deaerator. Dealkalizers remove more than 90% of the bicarbonate alkalinity from the softened water supply. This
effectively controls formation of carbon dioxide in the boiler, the major cause of condensate line corrosion.
Dealkalization reduces the need for neutralizing chemicals by as much as 90%, and cuts fuel costs by
minimizing blowdown.
Section H Dealkalizers
H10-3
03-08
Reduces Bicarbonate Alkalinity, Thereby Minimizing CO
2
Production:
Decreased chemical consumption.
Decreased condensate line corrosion.
Lower blowdown rates.
Reduces fuel consumption.
Increased cycles of concentration.
Uses a Strong Base Anion Resin With a Combination of
Salt/Caustic Soda Regeneration:
Produces a higher operating capacity and a more consistent effluent quality.
Provides some silica reduction.
Increases feed water pH.
PRODUCT OFFERING
Information in this section applies directly to Cleaver-Brooks dealkalizers ranging
from 10,000 to 980,000 grain capacity (Table H10-1).
Cleaver-Brooks chloride cycle dealkalizers are similar to water softeners except that,
instead of cation resin, they use a strong anion resin to remove negatively charged
ions from the raw water supply. Dealkalizers replace bicarbonate, sulfate, nitrate,
and silica with chloride ions.
Dealkalizers require use of softened water, and are installed down stream from the
water softener, and before the deaerator. Dealkalizers remove more than 90% of the
bicarbonate alkalinity from the softened water supply. This effectively controls
formation of carbon dioxide in the boiler, the major cause of condensate line
corrosion. Dealkalization reduces the need for neutralizing chemicals by as much as
90%, and cuts fuel cost by minimizing blowdown.
Dealkalizers offer best payback when:
1. Cycles of concentration in the boiler can be doubled.
2. Chloride content is below 120 ppm.
3. Sulfate count is below 50% of total exchangeable anions.
4. Bicarbonate alkalinity is 100 ppm or more.
Dealkalizers are regenerated with salt brine and sodium hydroxide and have an
operating temperature range of between 40 and 120 F.
Optional equipment includes:
ASME code tank construction.
Water meter for automatic or semi-automatic regeneration.
Skid mounting.
NEMA 12 or 4 control panels.
External corrosion protection.
Operating requirements include a continuous source of softened water at 30 to 100
psig, 40 F to 100 F. Electrical service, 120 Vac, 60 Hz, 5A.
H10-4
03-08
DIMENSIONS, RATINGS AND SIZING
Dimensions Dealkalizer dimensions are shown in Figure H10-1.
Ratings Dealkalizer ratings are shown in Table H10-2.
Sizing Five things are required to size a dealkalizer:
1. Flow rate/pressure loss - because of a slower rate of exchange than softeners,
dealkalizers should be operated at a flow rate not exceeding 2 gpm per cubic foot of
resin. Peak flow could exceed this for very short periods of time without affecting
capacity or water quality.
2. Time on line - Single dealkalizers should be sized to stay on line for at least one
day. For continuous usage when an alternating twin dealkalizer is used, each tank
should be sized to stay on line for 8 - 12 hours.
3. Water analysis - In addition to alkalinity, a dealkalizer will remove sulfate, nitrate,
and carbon dioxide from water and these must all be considered to determine the
total load. The alkalinity, sulfite, nitrate, and carbon dioxide should be reported as
CaCO
3
. To correct an analysis from the ion to CaCO
3
equivalents use the following
conversion factors:
Bicarbonate HCO
3
= ______x .82 = _________as CaC0
3

Sulfate SO
4
= _________x 1.04 = __________as CaCO
MODEL
NUMBER
PIPE
SIZE
RESIN CAP
A
Resin
Tank
Size
FLOW
RATE
NORM
FLOW
RATE
MAX
B

BACK-
WASH
RATE
BRINE
TANK
SIZE
SALT
CAP
BRINER
SALT
REGEN
CAUSTIC
REGEN
WATER
METER
SIZE
C
ACC-DAB- IN. CU-FT GR IN GPM GPM GPM IN. LBS LBS LBS IN.
10-3/4 3/4 1 10000 9x48 2 4 1.0 18x31 200 4 .4 3/4
20-1 1 2 20000 12x54 4 8 1.4 18x31 200 8 .8 3/4
30-1 1 3 30000 14x60 6 12 2.0 18x31 200 12 1.2 3/4
40-1-1/4 1-1/4 4 40000 16x60 8 16 2.4 22x36 375 16 1.6 1
50-1-1/4 1-1/4 5 50000 20x54 10 20 4.3 22x36 375 20 2.0 1
80-1-1/4 1-1/4 8 80000 24x54 16 32 6.5 22x36 300 32 3.2 1
140-1-1/2 1-1/2 14 140000 30x60 28 56 10.0 24x54 550 56 5.6 1-1/2
200-2 2 20 200000 36x60 40 80 15.0 24x60 700 80 8.0 1-1/2
250-2 2 25 250000 36x72 50 100 15.0 24x60 600 100 10.0 1-1/2
330-3 3 33 330000 42x72 66 132 20.0 30x60 900 132 13.2 2T
420-3 3 42 420000 48x72 88 176 25.0 39x60 1800 168 16.8 2T
550-3 3 55 550000 54x72 110 220 32.0 39x60 1500 220 22.0 2T
680-3 3 68 680000 60x72 136 272 40.0 42x60 1800 272 27.2 3T
980-4
D 4 98 980000 72x72 196 300 60.0 50x60 3000 392 39.2 3T
NOTES:
A. Capacity based on 10,000 grains/cubic foot of resin. This decreases with chloride content over 30 ppm.
B. Maximum flow reduces capacity by 20%. Pressure drop at max flow is less than 15psi.
C. T denotes turbo type water meter.
D. Valve manifold factory assembled on the tank, removed for shipment.
Table H10-1. Automatic Dealkalizer Selection Chart
H10-5
03-08
Nitrate NO
3
= __________x .81 = __________as CaCO
Carbon Dioxide CO
2
= ______x 1.14 = _______as CaCO
The total of the above is the total load on the dealkalizer. If the total is in terms of
parts per million or milligrams per liter, convert to grains per gallon by dividing by
17.1.
4. Water usage - when the flow rate is constant, multiply the flow rate in gpm x
minutes on line. For example: 50 gpm x 480 minutes (8 hours) = 24,000 gallons.
When the flow rate is not constant, use actual gallons used or calculate gallons
based on boiler make-up rates.
5. Exchange capacity - does not vary with salt usage like a water softener. Use a
capacity of 10,000 grains per cubic foot and regenerate consumption of 4 pounds
salt and 0.4 pounds caustic per cubic foot.
Sizing Calculations Single Dealkalizer - Water usage per day x total load = capacity required. For
example: 10,000 gallons per day x 20 gpg total load = 200,000 grain capacity
required. Select a Model ACC-DAB 200 from the literature. Then select the pipe size
to meet the flow rate required.
Notice
Check to assure the continuous flow rate does not exceed 2 gpm per cubic foot of
resin.
H10-6
03-08
MODEL NO. D
S
D
B
G H W L L
1
ACC-DAB-10-3/4 9 18 37 54 22 61 88
ACC-DAB-20-1 12 18 43 60 22 64 94
ACC-DAB-30-1 14 18 49 66 22 66 98
ACC-DAB-40-1-1/4 16 22 49 66 22 72 106
ACC-DAB-50-1-1/4 20 22 43 76 30 76 114
ACC-DAB-80-1-1/4 24 22 43 79 34 80 122
ACC-DAB-140-1-1/2 30 24 43 85 41 88 136
ACC-DAB-200-2 36 24 43 91 45 94 148
ACC-DAB-250-2 36 24 43 103 45 94 148
ACC-DAB-330-3 42 30 43 106 53 106 166
ACC-DAB-440-3 48 39 38 98 64 112 178
ACC-DAB-550-3 54 39 39 99 70 126 198
ACC-DAB-680-3 60 42 40 101 76 132 210
ACC-DAB-980-4 72 48 42 105 90 148 238
Figure H10-1. Dealkalizer Dimensions
H10-7
03-08
MODEL
NO
(ACC-
DAB)
RESIN TANK DATA FLOW RATES BRINE TANK DATA CAUSTIC DATA
TANK
SIZE
(DIA X HT)
PIPE
SIZE
(IN.)
RESIN
FT
3
FRRE
BOARD
(IN.)
GRAVEL
1/8X1/16
(LBS)
SERVI
(GPM)
CAPACITY
(GRAINS)
BACK
WASH
(GPM)
SLOW
RINSE
(GPM)
FAST
RINSE
(GPM)
TANK
SIZE
A
SALT
CAP.
(LBS)
SALT/
REGN
(LBS)
BRINE
RATE
(GPM)
NaOH/
REGN
(LBS)
NaOH
RATE
(GPM)
10 9x48 3/4 1 16 15 2
5
10000
8000
1.0 0.71 2.0 18x31 225 4 0.17 0.4 0.42
20 12x54 1 2 18 30 4
10
20000
16000
1.4 0.99 2.8 18x31 225 8 0.22 0.8 0.54
30 14x60 1 3 21 45 6
15
30000
24000
2.0 1.38 4.4 18x31 225 12 0.30 1.2 0.76
40 16x60 1-1/4 4 20 60 8
20
40000
32000
2.4 1.95 5.9 22x36 375 16 0.43 1.6 1.08
50 20x54 1-1/4 5 25-1/2 100 10
25
50000
40000
4.3 2.38 7.5 22x36 375 20 0.52 2.0 1.33
80 24x54 1-1/4 8 20-1/2 200 16
40
80000
64000
6.5 3.45 12.0 22x36 375 32 0.76 3.2 1.88
140 30x60 1-1/2 14 23 300 28
70
140000
112000
10 6.90 21.5 24x50 550 56 1.52 5.6 3.77
200 36x60 2 20 24-1/2 400 40
100
200000
160000
15 8.5 30 24x60 650 80 1.87 8.0 4.72
250 36x72 2 25 28 400 50
125
250000
200000
15 13.9 40 24x60 650 100 3.05 10.0 7.85
330 42x72 3 33 29 600 66
165
330000
264000
20 15.5 50 30x60 850 132 3.4 13.2 8.91
420 48x72 3 42 29 1000 88
210
420000
336000
25 21.4 65 38x60 1650 168 4.7 16.8 12.18
550 54x72 3 55 27-1/2 1300 110
275
550000
440000
32 30 85 38x60 1350 220 6.6 22.0 17.3
680 60x72 3 68 27-1/2 1800 136
340
680000
544000
40 37.5 100 42x60 1700 272 8.3 27.2 21.4
980 72x72 3 98 27-1/2 2600 196
490
980000
784000
60 53.4 150 48x60 2200 392 10.0 39.2 26.4
A. Tank size =diameter x height.
Table H10-2. Dealkalizer Ratings
H10-8
03-08
NOTES
H10-9
03-08
Section H10
Dealkalizers
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-10
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-10
Tanks 9" Through 16" Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-10
Tanks 20" Through 42" Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-10
Tanks 48" Through 72" Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-10
Tank Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-11
Tank Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-11
Tank Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-11
Upper Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-11
Lower Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-11
Main Operating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-11
Brining System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-11
Caustic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-11
Resin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-12
Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-12
Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-12
Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-12
Automatic Reset Register Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-12
Single Automatic Reset Meter and Altwinator (Twin Dealkalizers Only) . . . . . . . . . . . . . . . . . . H10-13
Two Tanks - Alternating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-13
(Two) (Three) Tanks - Parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-13
EXECUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-14
Test Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-14
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-14
Skid Mounting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-14
Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-15
requirements.
H10-10
03-08
A. Furnish, install, and place in operation an Automatic Chloride Cycle
Dealkalizer system, similar or approved equal to Cleaver-Brooks
Model ACC-DAB ________, having tank(s) with ________cu-ft of
ion exchange resin per regeneration with ________lbs of salt and
________lbs of caustic, based on grains per gallon total anion load.
B. Service flow rate per tank ________gpm at a pressure loss through
the dealkalizer system not exceeding _______psig. The dealkalizer
shall be supplied by a boiler manufacturer that will be responsible
for the total boiler room system.
A. Tanks 9" Through 16" Diameter
1. Dealkalizer tank(s) shall be of welded construction, tank
quality carbon steel. Each tank shall be _______" diameter
with a _______" straight side shell height. The tank(s) shall
have reinforced openings for pipe connections and a 4"
diameter access opening in the top head. The tank(s) shall be
rated for 100 psig working pressure and 150 psig test
pressure. Tank support(s) shall be of a skirt ring type design,
welded to the tank(s) lower head. The tank(s) shall have the
exterior protected with a finish coat of polyurethane and the
interior protected with an epoxy-polyamide coating. A
minimum freeboard of 50% shall be provided for backwash
expansion above the normal ion exchange resin bed level.
B. Tanks 20" Through 42" Diameter
quality carbon steel. Each tank shall be __________" diameter
with a ___________" straight side shell height. The tank(s)
shall have reinforced openings for pipe connections and an 11"
x 15" manhole in the top head (for tanks 30" diameter and
smaller; two 3" spin off handhole should be provided in the top
head and lower sideshell). The tank(s) shall be rated for 100
psig working pressure and 150 psig test pressure. Support legs
will be the strap type permanently welded to the lower tank
head. The tank(s) shall have the exterior prime coated and the
interior protected with an epoxy lining 4-6 mils DFT after
fabrication. A minimum freeboard of 50% shall be provided for
back wash expansion above the normal ion exchange resin bed
level.
C. Tanks 48" Through 72" Diameter
quality carbon steel. Each tank shall be _______" diameter
with a ________" straight side shell height; the tanks shall
have reinforced openings for pipe connections and 12" x 16"
manhole in the top head. The tank(s) shall be rated for 100
psig working pressure and 150 psig test pressure. Support legs
will be the adjustable jack type. The tank(s) shall have the
exterior protected with a rust inhibiting primer and the interior
shall have an epoxy lining 4-6 mils DFT, prior to shipment. A
minimum freeboard of 50% shall be provided for backwash
expansion above the normal ion exchange resin bed level.
H10-11
03-08
D. Tank Option
1. Provide pressure vessel in accordance with ASME Section VIII.
Working pressure to be 100, 125 or 150 pounds, and
hydrotested to 150, 187.5 or 225 psig, stamped and certified.
E. Tank Option
1. Provide high-temperature epoxy internal lining 10-12 mils DFT,
with rust resistant prime coat, external coating 2-3 mils DFT.
F. Tank Option
1. Provide baked phenolic internal lining 4-5 mils DFT, with rust
resistant prime coat, external coating 2-3 mils DFT.
G. Upper Distributor
1. The upper distribution system shall be a single point baffle or
four-point cross-arm type (9" through 60" diameter, single
point), (66" through 72" diameter, four point), constructed of
Schedule-40 galvanized steel pipe and fittings.
H. Lower Distributor
1. The lower distribution system shall be of a single fine slotted
PVC lateral design with a single layer of washed 1/8" x 1/16"
gravel sub-fill to support the resin bed (9" through 16"
diameter).
2. The lower distributor system be the Hub and Radial type or
header-lateral type constructed of Schedule-80 PVC with a
sub-fill 1/8" x 1/16" gravel covering the slotted full flow non-
clogging replaceable polypropylene strainers (20" through 60"
diameter, hub and radial), (66" through 72" diameter, header-
lateral).
I. Main Operating Valve
1. Each Dealkalizer shall have an automatic multiport diaphragm
type, slow opening and closing, and free of water hammer. The
valve shall consist of five (5) individual diaphragm valves
housed in a compact casing. These valves are to be pressure
actuated by an external pilot valve, automatically or manually.
The valves shall be manufactured by the same manufacturer as
the entire dealkalizer system. The valve guides, seats and
diaphragm shall be constructed of Noryl plastic. The valve shall
have inlet and outlet pressure gauges and sample cocks.
J. Brining System
1. The brining system shall be Flexi-trol type with dry salt storage
compartment, sufficient for at least six regenerations at full
salting and a saturated brine compartment. It shall be
equipped with a float operated plastic fitted brine valve and
allow for simple adjustment of salt dosage without removing
the brine valve. The tank shall be of polyethylene construction.
It shall be _______" diameter x ______" shell height, and have
storage capacity of lbs of salt.
K. Caustic System
1. The caustic system shall be designed to pump directly from
customer-purchased drums or carboys of 50% liquid caustic
soda with no caustic handling necessary.
H10-12
03-08
2. Components of the caustic system shall be as follows:
a. One (1) caustic feed metering pump
b. One (1) moveable pump stand
c. One (1) pressure switch
d. One (1) 30 minute automatic reset timer mounted in
protective box
e. One (1) blend valve for adjustment of concentration
3. The metering pump shall be of the diaphragm type for
corrosion resistance and have a capacity of _______gallons
per minute.
L. Resin
1. Resin shall be of a premium grade high capacity synthetic
quaternary ammonium devinylbenyene type, to be furnished in
the chloride form. It shall be stable over the entire pH range,
have good resistance to bead fracture, and be insoluble in all
common solvents. The resin shall be capable of 10,000 grains
per cubic foot capacity when regenerated with 4 lbs of NaCl
and 0.4 lbs of NaOH.
M. Piping
1. Manufacturer to furnish dealkalizer tank, with assembled valve
manifold piping. Contractor shall furnish and install
interconnecting piping. Drain shall have an air gap conforming
to local codes to permit observation of discharge backwash
water and manufacturer shall provide a valved drain at the
lowest point of the dealkalizer system.
N. Flow Control
1. An automatic backwash control shall be provided to maintain a
proper backwash and fast flush flows over wide variations of
operating pressure. Controller to contain no moving parts and
requires no field adjustment. The flow controls shall be
manufactured by the same manufacturer as the entire
dealkalizer system.
2.2 CONTROL OPTIONS
A. Regeneration shall be controlled by a fully automatic time clock
control which is fully adjustable or can be controlled by a remote
manual controller. For fully automatic operating the regeneration
shall be initiated by calendar clock. A pointer indicates the cycle of
operation at all times.
1. Standard Gallon Register Meter - Each Dealkalizer tank shall
be equipped with a ______" (disc), or (turbo), standard gallon
register meter to record the amount of dealkalized water
produced. The time clock will initiate the regeneration
sequence.
H10-13
03-08
2. Signal Register Meter - Each dealkalizer tank shall be equipped
with a _________" (disc), or (turbo) meter with a signal register
head. The head shall send a ___volt electrical signal to an
audible alarm upon reaching the hand set gallonage. The signal
will continue until reset by the operator. Regeneration will be
initiated by a push-button on the cycle controller of the
exhausted unit.
B. Automatic Reset Register Meters
1. Each dealkalizer tank shall be equipped with a _____" (disc),
or (turbo) meter with automatic reset head. The head shall
send a 120 volt signal to the dealkalizer cycle controller to
initiate regeneration at a preset gallonage. The head will
automatically reset to this gallonage.
C. Single Automatic Reset Meter and Altwinator (Twin Dealkalizers
Only)
1. The twin chloride cycle dealkalizer shall be equipped with a
single _____" (disc), or (turbo) water meter in the common
outlet header. At a preset gallonage the automatic reset head of
the meter will send a 120 volt signal to an altwinator that will
direct the signal to regenerate the unit presently on stream.
Upon completion of regeneration, that dealkalizer will remain
off stream in the standby position. This sequence will repeat on
an alternating basis each time the preset gallonage of
dealkalized water has passed through the meter.
D. Two Tanks - Alternating
1. The system will operate with two media tanks each having a
dedicated flow sensor, one of which will be on-line while the
other is regenerated and standing by. Each tank can regenerate
several times per day. The on-line media tank shall regenerate
immediately upon reaching a user specified volume of treated
water. Simultaneous regenerations are not possible.
2. The exchange capacity of each dealkalizer can be the same or
different.
3. Flow rate indication shall be continuously displayed for each
unit. The flow range is 0-999 flow units per minute (gallons,
cu-ft, liters, cu-m, etc.).
4. Cumulative volume totalization to eight (8) digits shall be
continuously displayed for each unit.
E. (Two) (Three) Tanks - Parallel
1. The system shall consist of (two) (three) media tanks each
having a dedicated flow sensor, configured for parallel flow and
operate in either of these user selected modes:
a. All media tanks are on-line simultaneously. As each media
tank s user specified volume is reached it shall
immediately be taken off-line, regenerated, and placed
immediately back on-line.
b. One (1) media tank, designated as the primary, will
remain on-line at all times. Variation of treated water flow
demand shall automatically cause (one additional media
tank) (up to two additional media tanks) to change status
from standby to on-line and back to standby as needed.
H10-14
03-08
2. When the primary media tank regenerates the next media tank
in sequence shall become the primary. As each media tank
user set volume is reached it will immediately be taken off-line,
regenerated, and placed immediately back on-line or standby
depending on the treated water flow demand.
3. The networked controls shall be capable of continuously
determining the exhaustion rate of each media tank, thus
automatically avoiding the possibility of a simultaneous
regeneration attempt. Simultaneous regenerations are not
possible.
4. The exchange capacity of each dealkalizer can be the same or
different.
5. Flow rate indication shall be continuously displayed for each
unit. The flow range is 0-999 flow units per minute (gallons,
cu-ft, liters, cu-m, etc.). Cumulative volume totalization to
eight (8) digits shall be continuously displayed for each unit.
6. A regeneration start delay time interval can be user
programmed for 0 to 16 hours to allow for brine make-up or
regeneration feedwater recovery.
PART 3 EXECUTION 3.1 EXECUTION
A. Test Kit
1. A test kit shall be furnished to measure the dealkalizer
performance. It shall be of the methylorange type to detect
alkalinity.
B. Instructions
1. A complete set of installation instructions and operating
instruction shall be furnished.
C. Skid Mounting Options
1. The dealkalizer system shall be completely skid mounted.
Tanks 9" through 16" diameter shall be mounted on a 3"
channel iron skid (9 lbs per foot, ASTM Grade A-36). The skid
shall be cross-braced with 3" channel or angle iron, and the
entire skid covered with a 1/4" steel plate. All steel surfaces
shall be prime coated.
2. Tanks 20" through 30" diameter shall be mounted on a 3"
channel iron skid (9 lbs per foot, ASTM Grade A-36). The skid
shall be cross-braced with a 3" channel or angel iron, and the
entire area under the polyethylene briner shall be covered with
a 1/4" steel plate. All steel surfaces shall be prime coated.
channel iron skid (13.8 lbs per foot, ASTM Grade A-36). The
skid shall be cross-braced with 4" channel or angel iron, and
the entire area under the polyethylene briner shall be covered
with a 1/4" steel plate. All steel surfaces shall be prime coated.
channel iron skid (15.3 lbs per foot, ASTM Grade A-36). The
skid shall be cross-braced with 6" channel or angle iron, and
the entire area under the polyethylene briner shall be covered
with 1/4" steel plate. All steel surfaces shall be prime coated.
H10-15
03-08
5. All interconnecting piping shall be assembled by the
manufacturer. This shall include inlet and outlet isolation valves
for each tank and a system bypass valve. Inlet and outlet
headers shall be installed and terminate at the skid edge. All
piping shall be suitably supported by Unistrut supports
anchored to the skid. Electric wiring, where applicable, shall be
complete between all inter unit controls and require only a
single power source connection. The inter unit wiring shall be
contained in Flextite, flexible, waterproof conduit.
6. All inter tank hydraulic or pneumatic tubing shall be installed
as part of the skid package.
7. All polyethylene briners shall be supported on the skid by a 12"
high steel band welded to the skid.
8. The mineral tanks are to be bolted to the skid. Permanent
attachment, or welding, will not be acceptable.
9. Lifting lugs, rings, etc., will be suitably located for single point
lifting of the entire skid mounted system.
10. The entire skid mounted system shall be both hydro and
electrically tested as a unit by the manufacturer before
shipment. The system shall be completely drained after hydro
testing.
D. Guarantee
1. The manufacturer of the dealkalizer equipment shall guarantee
his equipment as follows:
a. All parts found defective in material or workmanship
within a period of one year after installation shall be
repaired or replaced.
b. The dealkalizer shall reduce the alkalinity of the water to
10 ppm or to 10% of the influent alkalinity.
c. Loss of resin by attrition shall not exceed 3% per year for
3 years.
2. The manufacturer of the dealkalizer equipment must have been
engaged in the manufacturing of this size equipment for a
period of not less than five (5) years and be able to furnish
locations of like-sized equipment installed and operating in the
general area of this job. A complete set of operating
instructions covering the installation, care and operation of the
dealkalizer system shall be furnished in bound booklet form.
H10-16
03-08
Notes
H11-1
06-08
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H11-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H11-3
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H11-11
ILLUSTRATIONS
Figure H11-1. Blowdown Separator Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H11-4
Figure H11-2. Automatic Drain Water Aftercooler (18DF) Dimensions . . . . . . . . . . . . . . . . . . . . .H11-7
Figure H11-3. Automatic Drain Water Aftercooler (20AO) Dimensions . . . . . . . . . . . . . . . . . . . . .H11-7
Figure H11-4. Model 5D Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H11-8
Figure H11-5. Separator Floor Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H11-9
Figure H11-6. Separator Wall Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H11-10
TABLES
Table H11-1. Boiler Blowdown Separator Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H11-4
Table H11-2. Cooling Water Line and Valve Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H11-8
This section contains information on blowdown separators, which are used to provide safe and economical flash
purification to enhance blowdown effectiveness.
Section H11
BLOWDOWN SEPARATORS
Blowdown Separators Section H
H11-2
06-08
Notes
Section H Blowdown Separators
H11-3
06-08
Fast, Safe, Low-Cost Way to Separate Steam and Water and Remove Harmful
Dissolved Solids.
Protects boiler surfaces from severe scaling or corrosion problems.
Economical Flash Purification Process for Enhancing Blowdown Effectiveness.
Reduce drain water temperature to meet state and local requirements.
The Design is Quiet, with Noise Levels Held Below 90 dBA, so no Exhaust Head is
Required.
CB Blowdown Separators are Compact, and Can Be Quickly Installed with Few
Connections.
Stainless steel striking plate greatly extends separator life.
Momentum of Water is Speeded by Spiral Baffle Centerwise to Drain. Drain is
Completely Filled - No Center Void.
Tangential inlet and small diameter prompt high velocity spinning for release of
steam.
All Interior Surfaces Slant Toward Drain, Making Unit Self- Draining, Self-Drying for
Longer Life.
Proven Performance.
Demonstrated Durability.
Universal Adaptability.
PRODUCT OFFERING
Boilers that supply steam for power, process or heating applications require periodic
and more often, frequent, blowdowns to prevent buildup of harmful solids.
Blowdown protects boiler surfaces from severe scaling or corrosion problems that
would otherwise result.
Cleaver-Brooks blowdown separators use a safe, economical flash purification
process for enhancing blowdown effectiveness. Steam is rapidly separated from
blowdown water and vented out the top of the blowdown separator in a cyclonic
spinning action. Water and dissolved solids are flushed out the bottom drain.
The design is quiet, with noise levels held below 90 dBA, so no exhaust head is
required. Internal pressures do not exceed 5 psig. Blowdown water is cooled to 120
F by a drain tempering device, designed to meet state and local codes.
Cleaver-Brooks blowdown separators are compact, and can be quickly installed with
few connections. Accessories include leg or wall brackets, drain tempering fitting,
strainer, temperature regulating valve, thermometer, pressure gauge and flanges.
Pressure ranges:
0 to 300 psig, standard.
301 to 1600 psig, special.
Available with ASME U stamp.
H11-4
06-08
SS Wear Plate
9"
14"
Section A-A
Model No. ________MAWP
250 PSIG at 450 F
"V"Vent
"A"+/- 1/4"
"I"Inlet
"PL"
A
"D"Drain
"H"+/- 1/2"
Inspection Port
MODEL NO. A20B A34B A56B
H Dimension 22 34 56
A Dimension 10 10-1/4 11
I Inlet size Determined by blowdown valve size.
:V Vent size Select from Table H11-1.
D Drain size Select from Table H11-4.
PL Plate size 5/16 or 3/8 . May be determined by
codes.
Figure H11-1. Blowdown Separator Dimensions
VALVE
SIZE
1" 1-1/4" 1-1/2" 2" 2-1/2"
Separator
Dim.
M
o
d
e
l

H
I D V
M
o
d
e
l

H
I D V
M
o
d
e
l

H
I D V
M
o
d
e
l

H
I D V
M
o
d
e
l

H
I D V
Generator
Op psig
0-15
16-50
51-100
101-125
126-150
151-175
176-200
201-225
226-300
14
20
20
34
34
34
34
34
56
1
1
1
1
1
1
1
1
1
2
2
3
3
3
3
3
4
4
2-1/2
2-1/2
2-1/2
3
3
4
4
4
4
20
20
34
34
34
34
34
56
56
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
3
3
4
4
4
4
4
4
4
4
4
4
4
4
4
5
5
5
20
34
34
34
34
34
56
56
56
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
3
3
4
4
4
4
5
5
5
4
4
4
4
5
5
5
5
6
20
34
34
34
56
56
56
56
56
2
2
2
2
2
2
2
2
2
4
4
5
5
5
5
6
6
6
5
5
5
5
6
6
6
6
8
34
34
34
56
56
56
56
56
56
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
5
5
6
6
6
6
6
8
8
6
6
6
6
6
8
8
8
8
251-300 psig U. Symbol Construction and Stamping is required.
To use this chart:
1.Select separator size from this table by matching operating pressure and blow-down valve size.
2.Select Plate Thickness (PL) as local regulations require or as desired for maximum pressure stamped on Separator 3/16", 150 psig,
5/16", 225 psig, 3/8", 250 psig.
3.If local regulations require, indicate ASME or Standard. Separator size is now determined and discharge piping may follow these sizes with
no calculation necessary. Separators are designed to exhaust at less than 5 psig.
Table H11-1. Boiler Blowdown Separator Sizing
HEADS SA 516-70
SHELL SA 53B
COUPLINGS SA 105
WEAR PLATE SA 240-304
BAFFLES SA 240-304
NOZZLES SA 53B, SA 106-B
FINISH RED OXIDE PRIMER
H11-5
06-08
Standard and
Optional Equipment
Selection
For dimensions and sizing of blowdown separators, refer to Figure H11-1 and Table
H11-1
For manual drain water tempering, use Aftercooler model 5D and specify drain
diameter.
For automatic control of drain water temperature, use 18DF___ or 20AO___
Aftercooler. 20AO Aftercooler is required in some areas to automatically regulate the
temperature of the water to the drain. Check local codes to ascertain if it is required
in your area.
A temperature regulating valve should be used when the blowdown temperature
going to the drain needs to be less than 212 F. (See Table H11-2 to select cooling
water line and valve size.)
Use a solenoid valve and thermostat when the cooling water pressure exceeds 80
psig.
1. Model 18 DF Aftercooler (Figure H11-2). Nonclogging automatic drain tempering
fitting with stainless steel mixing tongue (on 4" and larger) to provide thorough
mixing of influent cold water with drain water. The middle flange permits rotation for
various pipe fitting requirements and also serves as a dismantling flange. Two bulb-
wells for mounting control valve and thermometer are furnished. When ordering,
state cold water inlet size.
2. Model 20AO Jacket Type After Cooler (Figure H11-3). Required in some areas.
Has mixing holes corresponding to the cold water inlet size. The lower portion is
designed with wells to accommodate automatic control bulb and thermometer.
When ordering state cold water inlet size.
3. Temperature Regulator Valves Figure H11-2 and Figure H11-3). Automatically
control the flow of cold water by responding to temperature changes at the
thermostatic bulb. The 6" capillary tube allows installation in the cold water line
while the 11" bulb is mounted in the lower portion of the aftercooler. The valve size
should correspond to the cold water inlet.
4. Thermometer. Bi-metal, drawn steel case, rust resistant and finished in oven
baked enamel. Six inch brass stem with 1/4" NPT bushing provided for use with
Model 18 DF and Model 20 AO Aftercoolers.
5. Solenoid Valve. Automatically controls cooling water to aftercooler. Non-magnetic
stainless steel body; micro-finished, hardened pilot valve ball. Has two-wire control
circuit (120/60). Well immersion hot water control provided for actuating solenoid
valve.
6. The Model 5D Drain Tempering Fitting (Figure H11-4). Simple type of aftercooler
for adding cooling water with manual control. It has cold water inlet for adding
cooling water to drain for tempering to 120 F. Inlet is sized for minimum influent
water conditions of 60 F water at 40 psig pressure with 100 sq-ft of supply. When
ordering, state Model 5 D (Drain Diameter); i.e. for 4" drain use Model 5D 4.
7. Armstrong Strainer. Cast iron with .045 stainless steel screen. Install in cold
water line to protect temperature regulator valve or solenoid valve shown in adjacent
column.
8. Separator Floor Stand (Figure H11-5). Provides and excellent means for
supporting separators. Constructed of sturdy angle iron. They come attached to the
H11-6
06-08
separator to provide an easy and expedient means of installation. Standard height
raises separator 18 inches from floor, or when aftercoolers are provided, additional
height is provided.
9.Separator Wall Brackets (Figure H11-6). For wall mounting where floor space is
limited, or where desired installation is at a level higher than leg height of 18
inches.
H11-7
06-08
Figure H11-2. Automatic Drain Water Aftercooler (18DF) Dimensions
A
B
C
C
CWI - COLD WATER INLET - NPTF
STAINLESS STEEL MIXING
TONGUE SUPPLIED ON
MODELS 18DF4 AND LARGER
1/4 NPTF CONNECTION TO
ACCOMODATE BIMETALLIC
THERMOMETER
1/2 , 3/4 , OR 1 NPTF
CONNECTION TO ACOMODATE
REGULATOR VALVE SENSING
BULB
NOTES:
1. Temperature regulator valve bulb is installed in lower
section of the aftercooler so that the bulb senses mixed
water temperature. Valve is modulating so that the right
amount of cold water is added to cool the drain water to
the desired temperature set on the valve. Valve range
is 115 to 180 F.
2. Regulator Valve has composition seat to ensure tight
shut-off when not blowing down. Valve should be
protected with C.1. Strainer with .045 mesh.
3. CWI =cold water inlet size.
D
1
D
2
CWI
2
2
2-1/2
3
3
4
4
5
5
6
6
3
3
4
4
4
5
5
6
6
8
8
1/2
3/4
3/4
3/4
1
1
1-1/4
1-1/4
1-1/2
1-1/2
2
Figure H11-3. Automatic Drain Water Aftercooler (20AO) Dimensions
CWI COLD WATER INLET NPTF
1/4 NPTF CONNECTION TO
ACCOMODATE BIMETALLIC
THERMOMETER
5-1/4 D2
20
D1
D
2
1/2 , 3/4 , OR 1 NPTF
CONNECTION TO ACOMODATE
REGULATOR VALVE SENSING
BULB
NOTES:
1. Temperature regulator valve bulb is installed in
lower section of the aftercooler so that the bulb
senses mixed water temperature. Valve is modulat-
ing
so that the right amount of cold water is added to
cool the drain water to the desired temperature set
on the valve. Valve range is 115 to 180 F.
2. Regulator Valve has composition seat to ensure
tight shut-off when not blowing down. Valve should
be protected with C.1. Strainer with .045 mesh.
A B C CWI
2
2
2-1/2
3
3
4
4
5
5
6
6
20
20
20
20
20
20
20
20
20
20
20
3
3
3
3-1/2
3-1/2
3-1/2
3-1/2
3-1/2
3-1/2
4
4
1/2
3/4
3/4
3/4
1
1
1-1/4
1-1/4
1-1/2
1-1/2
2
H11-8
06-08
SEPARATOR

INLET SIZE
1 1-1/4" 1-1/2 2" 2-1/2"
COOLING
WATER
PRESS. (PSIG)
40 50 60 40 50 60 40 50 60 40 50 60 40 50 60
GENERATOR OPERATING PRESSURE (50 TO 70 F COOLING WATER TEMPERATURE)
0-50
51-100
101-125
126-175
176-225
226-250
251-300
1/2
1
1
1
1
1-1/4
1-1/4
1/2
3/4
3/4
1
1
1-1/4
1-1/4
1/2
3/4
3/4
1
1
1-1/4
1-1/4
1
1
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1
1
1
1-1/4
1-1/4
1-1/4
1-1/4
1
1
1
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
1
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
1
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/2
2
2
2
2
2
1-1/4
1-1/2
2
2
2
2
2
1-1/4
1-1/4
1-1/2
2
2
2
2
1-1/2
2
2
2-1/2
2-1/2
2-1/2
2-1/2
1-1/2
2
2
2-1/2
2-1/2
2-1/2
2-1/2
1-1/2
2
2
2
2
2
2-1/2
GENERATOR OPERATING PRESSURE (71 TO 80 F COOLING WATER TEMPERATURE)
0-50
51-100
101-125
126-175
176-225
226-250
251-300
3/4
1
1
1
1
1-1/4
1-1/4
1/2
3/4
1
1
1
1-1/4
1-1/4
1/2
3/4
3/4
1
1
1-1/4
1-1/4
1
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/2
1
1
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1
1
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
2
1
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
2
1
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/2
1-1/4
2
2
2
2
2-1/2
2-1/2
1-1/4
2
2
2
2
2-1/2
2-1/2
1-1/4
1-1/2
2
2
2
2
2
2
2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
2
2
2-1/2
2-1/2
2-1/2
2-1/2
2-1/2
1-1/2
2
2
2
2-1/2
2-1/2
2-1/2
Use the chart as follows:
1. Depending upon the temperature of the cooling water used, locate the section of the chart which applies, 50-70 F or
71 - 80 F.
2. At the top of chart locate Separator inlet size and in left column under the section selected in step one, locate Boiler
Operating pressure. You now have a selection of three valve sizes.
3. From the top of chart select the cooling water line pressure either 40, 50 or 60 and read the desired valve and line size.
Table H11-2. Cooling Water Line and Valve Sizing

Furnish and install a manual drain water aftercooler Model 5D ____ and with a ____ cold water con-
nection.
NOTE:
1. Temperature regulator valve bulb is installed in lower section of the aftercooler so that the bulb
senses mixed water temperature. Valve is modulating so that the right amount of cold water is add-
ed to cool the drain water to the desired temperature set on the valve. Valve range is 115 to 180 F.
2. Regulator Valve has composition seat to ensure tight shut-off when not blowing down. Valve
should be protected with C.1. Strainer with .045 mesh.
4. 16DS Same as 18DF Without Flanges.
A B C CWl
6 3 2 3/4
6 3 2-1/2 3/4
7 3-1/2 3 1
7 3-1/2 4 1-1/4
7 3-1/2 5 1-1/2
8 4 6 2
Figure H11-4. Model 5D Dimensions
COLD WATER
INLET - NPTF
H11-9
06-08
For Screwed or Beveled Connections, Factory Fabricated 2" x 2" x 1/4" Angle Permissible Load 6000 lbs
If 18DF, 16DS, or 20AO Aftercooler is furnished with separator, see dimension chart for separator height A. A di-
mension is determined by separator drain size D. This provides adequate height for the aftercooler and elbow when
required.
A dimension will always be 18" when separator is furnished without an aftercooler.
For Flanged Connections Factory Fabricated 2" x 2" x 1/4" Angle Permissible Load 6000 lbs.
If 18DF, 16DS, or 20AO Aftercooler is furnished with flanged connections on both ends, use dimension chart to
determine separator height "A".
"A" dimension will always be 18" when separator is furnished without an aftercooler.
D A
2 22
2-1/2 23
3 24
4 25
5 30
6 34
D A
2 28
2-1/2 30
3 31
4 32
5 33
6 35
Figure H11-5. Separator Floor Stand
H11-10
06-08
SEPARATOR WALL BRACKET 2 X 2 X 1/4" ANGLE
USE MODEL 20 W/20" SEPARATOR
NOTE:
1. DIMENSION C IS FOR MODEL 56 ONLY.
2. DIMENSION D IS FOR MODEL 20 ONLY.
MODEL A B C D
20 20 14 - 13
34 20 14 - -
56 35 28 14 -
Figure H11-6. Separator Wall Bracket
1 STRAP
12-1/2
13
TYPICAL
H11-11
03-08
Section H11
Blowdown Separators
The following sample specification is provided by Cleaver-Brooks to assist you in meeting
A. Blowdown Separaator
1. Furnish and install Cleaver-Brooks Model _____blowdown
separator with I=______, D= _____, V=______, and _______
plate thickness.
2. The separator shall be manufactured in accordance with ASME
Code for 250 psig design and tested to 375 psig.
3. Provide separator with National Board stamping and "U"
symbol. (Necessary in Michigan and Utah, optional elsewhere.)
4. The separator shall be furnished with ______________
(screwed, weld bevel, 150# flanged or 300# flanged)
connections.
5. The separator shall include a stainless steel striking plate at the
point of inlet impingement and shall be furnished by Cleaver-
Brooks.
B. Accessories
1. Provide a ________solenoid valve to automatically control the
flow of cold water by responding to temperature changes
sensed at the thermostatic bulb in the aftercooler fitting.
2. Furnish a bi-metal thermometer with necessary adaptor
bushing for use with _________(18DF or 20AO) aftercooler.
3. Furnish a ______cast iron strainer with .045 stainless steel
screen ahead of the ________(TRV or solenoid valve) to
protect said valve against foreign matter.
4. Furnish and install an automatic drain water aftercooler, Model
________(18DF or 20AO) with a ______cold water
connection for a _________________(TRV or solenoid valve
and thermostat) (See Figure H10-2 or Figure H10-3).
5. Provide a ___________temperature regulator valve to
automatically control the flow of cold water by responding to
temperature changes sensed at the thermostatic bulb in the
aftercooler fitting.
6. The accessory separator floor stand and wall mounting bracket
are shown in Figure H10-5 and Figure H10-6.
H11-12
03-08
NOTES
H12-1
03-08
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-3
BHR-S and BHR-M Series (High Pressure Steam Applications) . . . . . . . . . . . . . . . . . . . . . . . H12-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-3
BHR-S and BHR-M Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-3
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-13
ILLUSTRATIONS
Figure H12-1. Blowdown Heat Recovery System Selection and Payback (Sheet 1 of 3) . . . . . . . . H12-5
Figure H12-2. Model BHR-S Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-8
Figure H12-3. Model BHR-S Ratings/Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-9
Figure H12-4. Model BHR-M Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-10
Figure H12-5. Model BHR-M Ratings/Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-11
Section H12
BLOWDOWN HEAT RECOVERY SYSTEMS
Blowdown Heat Recovery Systems Section H
H12-2
03-08
This section contains information on Cleaver-Brooks Blowdown Heat Recovery Systems used to recover energy
from blowdown water and use the energy to preheat make-up water. Cleaver-Brooks heat recovery systems
encompass the following models:
Model BHR-S Series for single boiler applications.
Model BHR-M Series for multiple boiler applications.
Section H Blowdown Heat Recovery Systems
H12-3
03-08
BHR-S and BHR-M Series (High Pressure Steam Applications)
Integrated System Automatically Adjusts to Changing Demands:
Recovers 90% of heat normally lost.
Automatically controls surface blowdown flow to maintain the desired
concentration of dissolved solids within the boiler.
Automatically controls boiler dissolved solids.
Compact Size for Convenient Placement:
Removable Shell for Easy Inspection and Cleaning:
Significant Fuel Savings for Any Size Boiler:
It transfers the blowdown heat to the make-up, thereby decreasing fuel costs.
Saves chemical costs by reducing blowdown.
Blowdown is Cooled Before Discharging Into the Sewer:
Complies with discharge water codes.
PRODUCT OFFERING
BHR-S and BHR-M Series
Continuous boiler surface blowdown is the most effective method of purging
destructive solids from any steam boiler system. However, this protective procedure
also results in a constant and costly heat loss, unless a blowdown heat recovery
system is used.
Cleaver-Brooks blowdown/heat recovery systems adjust automatically to changing
system demands, and recover 90% or more of the heat normally lost during boiler
surface blowdown operation.
The blowdown/heat recovery systems will usually result in a payback in a few short
months from fuel savings alone. Refer to Figure H12-1 for selection and payback
calculations.
The Cleaver-Brooks Packaged Blowdown Heat Recovery System serves two primary
functions.
1. It automatically controls the surface blowdown to maintain the desired level of
total dissolved solids (TDS) in the boiler, reducing the amount of blowdown to a
minimum.
2. It recovers the heat from the high temperature blowdown, and transfers it to the
incoming cold make-up water, maximizing boiler efficiency. Use of BHR also
improves deaerator efficiency by reducing surges caused by adding large amounts of
cold make-up water to the system.
The control valve within the unit performs two functions. The valve senses the flow
of make-up, and positions itself to maintain the desired ratio of blowdown and
H12-4
03-08
make-up flows. As a result, the dissolved solids concentration within the boiler is
maintained automatically.
The proportioning control also provides for very effective heat recovery since hot
blowdown flows only when there is a corresponding flow of cold water (make-up).
Model BHR-M Systems for multiple boiler installations include a flow control valve
for each boiler. This allows for proportioning the overall system blowdown between
different boilers, which may be operating at different loads. A strainer and sampling
valve are also provided for each boiler, with a sample cooler mounted on the
system. Thus, all boilers can be sampled at one convenient location.
The heavy duty blowdown heat exchangers are uniquely designed to handle the
blowdown on the tube side. This allows many tube side passes, which ensures
maximum heat transfer, and maintains high fluid velocities preventing scaling and
fouling. Due to the severe service, tubes are stainless steel, and because of the
abrasive nature of the fluid, return bends are fabricated of extra thick material.
Since vibration is a common problem with blowdown exchangers, hold down
devices are provided to clamp the tube bundle in place.
Each system is equipped with a blowdown outlet thermometer so that performance
can be monitored. By logging data regularly, a cleaning schedule can be established
for each exchanger.
Dimensions and ratings for Model BHR-S are shown in
Figures H12-2 and H12-3.
Dimensions and ratings for Model BHR-M are shown in
Figures H12-4 and H12-5.
.
H12-5
03-08
Notes:
H12-6
03-08
Figure H12-1. Blowdown Heat Recovery System Selection and Payback (Sheet 1 of 3)
H12-7
03-08
H12-8
03-08
H12-9
03-08
MODEL BHR-S SERIES DIMENSIONS
MODEL NO. BHR-2S BHR-4S BHR-9S BHR-14S BHR-22S
A REF 54-1/2 81-1/2 84 127 128
B 20-1/2 20-1/2 23-1/2 23-1/2 33
C REF 8 8 10 10 12-1/2
D
REF
28 64 64 100 100
E REF 7 7 9-1/8 9-1/8 11-1/8
F EF 5-1/2 5-1/2 5-1/2 5-1/2 6
G 7-1/2 7-1/2 8 8 9-1/2
H + 1/8 16-1/2 38-1/2 38-1/2 64-1/2 64-1/2
J REF 9 22-3/4 22-3/4 33-1/2 31-1/2
K 35-3/4 62-5/8 62-5/8 107-1/2 105
L 33 60 60 105 96-1/2
M 4-1/2 4-1/2 4-3/8 4-3/8 4
N 16-1/2 16-1/2 19-1/2 19-1/2 24-1/2
P 7 7 7 7 7-1/2
R 1/2 1/2 * * 3/4
S +1/8 5 5 7-1/8 7-1/8 9-1/8
CONNECTIONS
1 1-1/2 FPT 1-1/2 FPT 2 FPT 2 FPT 3FLG
2 1-1/2 FPT 1-1/2 FPT 2 FPT 2 FPT 3 FPT
3 3/4 FPT 3/4 FPT 3/4 FPT 3/4 FPT 1 FPT
Figure H12-2. Model BHR-S Dimensions
H12-10
03-08
MAXIMUM CAPACITIES (GPM)
Model No. Blowdown Make up
BHR-2S 2 48
BHR-4S 4 48
BHR-9S 9 130
BHR-14S 14 130
BHR-22S 22 180
Figure H12-3. Model BHR-S Ratings/Capacities
H12-11
03-08
MODEL BHR-M SERIES DIMENSIONS
MODEL BHR-2M BHR-4M BHR-9M BHR-14M BHR-22M
MAX NO.OF BOILERS 4 4 5 5 6
A REF 54-1/2 81-1/2 84 127 128
B REF 22 22 24 24 28
C REF 19-1/4 17-1/4 18-1/2 18-1/2 19-1/2
D REF 28 64 64 100 100
E EF 7 7 9-1/8 9-1/8 11-1/8
F REF 5-1/2 5-1/2 5-1/2 5-1/2 6
G 7-1/2 7-1/2 8 8 9-1/2
H +1/8 16-1/2 38-1/2 38-1/2 64-1/2 64-1/2
J REF 9 22-3/4 22-3/4 33-1/2 31-1/2
K 35-3/4 62-5/8 62-5/8 107-1/2 105
L 33 60 60 105 96-1/2
M 4-1/2 4-1/2 4-3/8 4-3/8 4
N 14 14 16 16 20
P 13-1/2 13-1/2 15-1/2 15-1/2 21
R 11-1/2 11-1/2 11-1/2 11-1/2 11-1/2
S 20-1/2 20-1/2 23-1/2 23-1/2 33
T +1/8 5 5 7-1/8 7-1/8 9-1/8
V 25-1/2 61-1/4 61-1/4 92-1/4 95-3/4
W 15-1/2 15-1/2 18 18 22-1/2
CONNECTIONS
1 1-1/2 FPT 1/1/2 FPT 2 FPT 2 FPT 3 FPT
2 1-1/2 FPT 1-1/2 FPT 2 FPT 2 FPT 3 FPT
3 3/4 FPT 3/4 FPT 3/4 FPT 3/4 FPT 3/4 FPT
6 1/4 FPT 1/4 FPT 1/4 FPT 1/4 FPT 1/4 FPT
Figure H12-4. Model BHR-M Dimensions
H12-12
03-08
MAXIMUM CAPACITIES (GPM)
MODEL BLOWDOWN MAKE-UP
BHR-2M 2 48
BHR-4M 4 48
BHR-9M 9 130
BHR-14M 14 130
BHR-22M 22 180
Figure H12-5. Model BHR-M Ratings/Capacities
H12-13
03-08
Section H12
Blowdown Heat Recovery Systems
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-14
BHR-S Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-14
BHR-M Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-14
H12-14
03-08
The following sample specifications are provided by Cleaver-Brooks to assist you in
specifying your customers requirements.
PART 2 PRODUCTS 2.1 BHR-S SERIES
A. Furnish ______Cleaver-Brooks Model BHR-S Package blowdown
heat recovery system designed to handle a maximum blowdown
rate of _______gpm (2 to 22) and a maximum make-up rate of
_______gpm (48 to 180).
B. The heat recovery system shall be designed for a boiler of _______
hp (150 - 1500), hp operating at _______psig (35 to 250). The
unit shall be designed to cool the blowdown to within 30 F of the
make-up water temperature. The unit shall have a 250 psig rating
at 400 F.
C. The heat recovery system shall consist of a differential temperature
control valve that shall automatically regulate the blowdown of
make-up flow. The flow of blowdown shall be regulated by the
thermal expansion of the inner brass tube pressing against a valve
seat. The inner tube will contract only when cold make-up water
passes through the brass jacketed steel outer tube shell, allowing
the blowdown to cool and go out the exchanger.
D. The system shall also have a heat exchanger, including a removable
U-tube bundle manufactured of 19 gauge, 304 stainless steel tubes
and steel sideshell with hold down clamps to stop tube bundle
vibration. The vessel shall be ASME code stamped for 250 psig at
400 F. The system shall have interconnecting piping of steel and
stainless steel. The exchanger shall have a minimum sq-ft of surface
area. The flow of the blowdown make-up shall flow in opposite
directions for a maximum heat transfer efficiency of _______
percent.
E. A heat treated stainless steel valve seat and plunger shall manually
control the blowdown flow by a handwheel.
F. A blowdown thermometer Weksler Type 152 shall be furnished at
the blowdown outlet.
G. The entire system shall be supported by steel channel legs with 3/4"
diameter holes for customer-supplied 5/8" diameter anchor bolts.
H. The system will be painted with a hard enamel coating.
2.2 BHR-M SERIES
A. The following sample specifications are provided by Cleaver-Brooks
to assist you in specifying your customers requirements.
B. Furnish ______Cleaver-Brooks Model BHR-M package blowdown
heat recovery system designed to handle a maximum blowdown
rate of _______gpm (2 to 22) and a maximum make-up rate of
_______gpm (48 to 180).
C. The heat recovery system shall be designed for boilers of ______hp
(250 - 1500), hp operating at _______psig (35 to 250). The unit
shall be designed to cool the blowdown to within 30 F of the make-
up water temperature. The unit shall have a 250 psig rating at 400
F
H12-15
03-08
D. The heat recovery system shall consist of a differential temperature
control valve that shall automatically regulate the blowdown and
make-up flow. The flow of blowdown shall be regulated by the
thermal expansion of the inner brass tube pressing against a valve
seat. The inner tube will contract only when cold make-up water
passes through the brass jacketed steel outer tube shell allowing the
blowdown to cool and go out the exchanger.
E. The system shall also have a heat exchanger, including a removable
U-tube bundle manufactured of 19 gauge, 304 stainless steel tubes
and steel sideshell with hold down clamps to stop tube bundle
vibration. The vessel shall be ASME code stamped for 250 psig at
400 F. The system shall have interconnecting piping of steel and
stainless steel. The exchanger shall have a minimum sq-ft of surface
area. The flow of the blowdown make-up shall flow in opposite
directions for a maximum heat transfer efficiency of _____percent.
F. A heat treated stainless steel valve seat and plunger shall manually
control, the blowdown flow by means of a handwheel. A blowdown
outlet thermometer Weksler Type 152 shall be furnished at the
blowdown outlet.
G. A flow control assembly shall be furnished for each boiler. The
assembly shall consist of a _____inch Hancock #4595 flow control
valve rated at 300 psig, bronze construction and a _____inch cast
steel strainer with a stainless steel screen and have a 250 psig
pressure rating.
H. A SC-22 sample cooler with isolation valves and interconnecting
piping will be supplied.
I. The entire system shall be supported by steel channel legs with 3/4"
diameter holes for customer-supplied 5/8" diameter anchor bolts.
J. The system will be painted with a hard enamel finish coating.
H13-1
06-08
CONTENT
ILLUSTRATIONS
Figure H13-1. Model AHR Flash Tank Heat Exchanger Dimensions . . . . . . . . . . . . . . . . . . . . . . H13-4
This section contains information on Cleaver-Brooks Flash Tank Heat Exchangers. Flash tank heat exchangers
are used on applications when operating pressures exceed 25 psig and continuous blowdown heat recovery is
desired.
Section H13
FLASH TANK HEAT EXCHANGERS
Flash Tank Heat Exchangers Section H
H13-2
06-08
Flashing:
Hot, high-pressure blowdown water from each boiler is piped to individual flow
control valves on the inlet manifold. Pressure drops across the flow control valve
to 5-20 psig, causing the blowdown water to flash into a mixture of steam and
water.
Separation Steam/Water:
An entrainment baffle directs the mixture around the inside of the tank in a
centrifugal motion. Efficient baffling separates the dirty blowdown water from
the clean steam.
Discharge:
Steam then rises through the top of the flash tank and is piped to the feedwater
heater, or wherever low pressure steam is required. The remaining hot, dirty
water flows out the bottom of the flash tank to a heat exchanger for additional
heat recovery, or to a blow-off tank or sewer.
Heat Recovery:
In addition to the heat recovered as flashed steam, the heat exchanger will
transfer the remaining heat normally lost during blowdown, to the cold make-up
water as it flows to the feedwater heater.
PRODUCT OFFERING
Flash tank heat exchangers are used when operating pressures exceed 25 psig and
continuous blowdown heat recovery is desired for cost savings. They consist of an
ASME approved and stamped flash tank and a blowdown heat exchanger. Water
from continuous blowdown enters the tank and separates into steam and water. The
steam, normally at 5 psig, can be returned to the deaerator to help meet heating
needs. Hot water leaves the flash tank at temperatures of 220 F, or more. It goes
into the heat exchanger, where it heats cold makeup water entering the system.
The systems quickly pay for themselves with fuel savings resulting from recycled
heat that would otherwise be wasted.
The Model AHR (Figure H13-1) is available in sizes ranging from 3 to 30 gpm
blowdown and 9 to 150 gpm makeup. The model AHR is a coil type flash tank heat
exchanger. It is a compact, low cost alternative to the shell and tube design. The
basic difference is the heat exchanger, constructed of stainless steel, is integral with
the ASME approved flash tank. The space saving system includes floor supports,
liquid level control, three indicating thermometers, and a safety valve as standard
equipment.
Standard Offering
Flash separator with stainless steel coil heat exchanger.
Floor supports.
Liquid level controller.
Section H Flash Tank Heat Exchangers
H13-3
06-08
Liquid level indicator, brass body Michigan gauge.
Temperature control panel with three indicating thermometers (drain
temperature, make-up inlet, make-up outlet).
Safety Valve.
ASME Code Construction (150# Design).
Major Components
Blowdown system.
Flashtank.
Heat exchanger.
Stand.
Optional Equipment
Drain valve and level control.
Sample coolers and assembly.
Flow control valve and assembly.
Manifold.
Safety valve.
Gauge glass.
Pressure gauge.
Gauge panel.
Level alarm.
Level alarm control panel.
Thermometers for exchanger operation.
H13-4
06-08
MODEL
BLOW-
DOWN
(GPM)
MAKEUP
(GPM)
A B C D E F G H
ACC-AHR-39
ACC-AHR-315
ACC-AHR-612
ACC-AHR-630
ACC-AHR-1020
ACC-AHR-1050
ACC-AHR-2040
ACC-AHR-3060
ACC-AHR-20100
ACC-AHR-30150
3
3
6
6
10
10
20
30
20
30
9
15
12
30
20
50
40
60
100
150
96
97
110
111
100
106
140
172
140
132-1/2
44
50
49
53
44
50
67
76
67
67
44-1/4
36
50
46
42
44
62
85
62
52-1/2
8
10
10
12
16
16
18
18
18
24
1
1
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
2-1/2
2-1/2
3
3
4
4
6
6-8
6
6-8
1
1
1
2
2
2
2
2
2
2
3/4
1
3/4
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
2
2-1/2
Figure H13-1. Model AHR Flash Tank Heat Exchanger Dimensions
NOTE: Dimensions in inches.
H13-5
06-08
Section H13
Flash Tank Heat Exchangers
Sample Specifications: Model AHR
H13-6
06-08
The following sample specification is provided by cleaver- brooks to assist you in
specifying your customers requirements.
PART 2 PRODUCTS 1.2 MODEL AHR
A. Geneal
1. Furnish Cleaver-Brooks Model ACC-AHR ____packaged flash
tank coil type heat exchanger system, designed to handle a
maximum blowdown rate of ____gpm (3 to 30) and a
maximum makeup rate of _____gpm (9 to 150).
2. The system shall be designed for boilers of (130-2200) hp
operating at (0-600) psig. The unit shall be designed to cool
the blowdown to within 30 F of the makeup water
temperature. The unit shall have a 150 psig rating at 365 F.
3. The systems flash tank shall have an ASME code design
pressure of 150 psig and an internal flash pressure of ____
psig (5 to 15). The flash tank shall be ____" diameter and
____" high and shall be complete with a ______" tangential
blowdown inlet, stainless steel wear plate, steam outlet, ball
type float trap with all working parts constructed of stainless
steel, tank stand, brass-bodied Michigan site glass, and a
safety relief valve set at 150 psig. The flash tank shall have a
flanged bottom section for quick access to the sludge area and
to the coil.
4. The system shall also have a vertical coil-type heat exchanger.
The exchanger shall be constructed of stainless steel and shall
be integral with the flash tank. The coil shall be complete with
______" threaded connections for the makeup water inlet and
outlet.
5. A gauge panel shall be furnished and shall include dial
thermometers for indicating makeup inlet temperature,
makeup outlet temperature and blowdown outlet temperature.
The gauge panel shall be prepiped and mounted on the unit.
6. The entire system shall be supported by steel legs with 3/4"
diameter holes for customer-supplied 1/2" diameter bolts.
The system will be painted with Cleaver-Brooks blue finish
paint.
B. Optional Equipment
1. A SC-325 Sample Cooler with isolation valves and
interconnecting piping shall be supplied for a single boiler
application. With each additional boiler, a sample valve
assembly shall be added and manifolded to the sample cooler.
C. Multiple Boiler Operation
1. A manifold assembly shall be necessary for multiple boiler
installations and shall consist of the necessary piping with
threaded connections for the customer-supplied continuous
blowoff valves.
H14-1
06-08
CONTENTS
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H14-4
ILLUSTRATIONS
Figure H14-1. Sample Cooler (SC-22) Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H14-5
Figure H14-2. Performance Curves for Hot Water Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H14-5
Figure H14-3. Sample Cooler (SC-42) Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H14-6
Figure H14-4. Performance Curves for Steam Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H14-6
TABLES
Table H14-1. Sample Cooler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H14-4
Section H14
SAMPLE COOLERS
Sample Coolers Section H
H14-2
06-08
This section contains information on Cleaver-Brooks sample coolers. The Model SC22 and SC42 Sample Coolers
are used to cool boiler water samples under pressure so that an accurate sampling can be made. When boiler
water samples are taken without being properly cooled (while under boiler pressure), as much as 20% of the
sample can flash to steam, causing inaccurate measurement of boiler water quality.
Section H Sample Coolers
H14-3
06-08
Heavy Duty All Stainless Steel Wetted Parts:
SC-22 cools hot water samples up to 635 F and 2000 psig.
SC-42 cools steam or water samples up to 1000 F and 5000 psig.
True Counterflow Cooling:
Effective baffling on the shell side produces full counter flow with high cooling
water flow and minimum pressure drop, vibration and scaling.
Proper temperature achieved.
Compact Design:
SC-22 3-9/16" square x 5-1/2" long compact size. Easily mounted in cooling
water piping without using brackets or special supports.
SC-42 3-9/16 square x 11-1/4 long mounted in cooling water piping without
using brackets or special supports.
Stainless Steel Coil:
Single continuous tube with no joints assures long, maintenance free operation.
Removable Shell:
Shell can be easily removed for inspection and/or cleaning without
disconnecting sample water lines.
Lowest Cost:
Largest heat transfer surface per unit of cost of any sample coolers.
PRODUCT OFFERING
The sample cooler is a low-pressure-drop system for monitoring boiler water quality
without shutting down the boiler system. The Model SC-22 sample cooler is simple,
compact and designed to cool boiler samples with minimum disturbance to system
pressure. The 316 stainless steel tubing is a continuous, jointless, coil arrangement.
The tubing is maintenance-free, rated for 635 F at 2000 psig. The shell is also 316
stainless steel, rated at 450 F, 250 psig.
The design has baffling on the shell side to achieve high cooling water flow which
minimizes pressure drop, vibration and scaling. The shell can be easily removed for
inspection and/or cleaning without disconnecting sample or water lines.
Notice
The Model SC-22 Sample Cooler is not generally recommended for steam samples.
Use SC-42 for steam sample cooler information.
H14-4
06-08
Dimensions for Model SC-22 are shown in Figure H14-1, and in Figure H14-3 for
Model SC-42. Ratings are shown in Table H14-1.
ENGINEERING DATA
Refer to Figure H14-2 (hot water) and Figure H14-4 (steam) for performance
curves. For example, the hot water samples show the relationship of outgoing
sample temperature to incoming cooling water temperature for various sample
temperatures (diagonal lines) and flow rates (Scale at left). Example: If the water
sample is 1/4 gpm (946 cc/min) at 400 F and is to be cooled to less than 100 F
and the cooling water is 95 F. Follow the dotted line at 0.25 gpm to 400 F inlet
temperature. Read 18 F temperature approach. Sample pressure drop will be
approximately 6.5 psig. Sample will cool to 88 F, (70 F coolant + 18 F
approach).
MODEL
NO.
SHELL
DESIGN
TUBE
DESIGN
TUBE
MATERIAL
SHELL & HEAD
MATERIAL
AREA WEIGHT
SC-22 250 psig @
450
o
F
2000 psig @
635
o
F
1/4" OD SS
A
304 Stainless 1.2 sq-ft 9 lbs
SC-42 450 psig @
650
o
F
5000 psig @
1000
o
F
1/4 OD
316 SS
304 SS 2.4 sq-ft 12 lbs
A. Tubing is 300 series stainless steel with chemical and physical properties equal to, or better
than T304.
Table H14-1. Sample Cooler Ratings
Section H Sample Coolers
H14-5
06-08
Figure H14-1. Sample Cooler (SC-22) Dimensions
Figure H14-2. Performance Curves for Hot Water Samples
MODEL SC-22 (2.4 SQ-FT)
3 GPM COOLING WATER
1PSIG PRESSURE DROP
SAMPLE
PRESS.
DROP
APPROACH TEMPERATURE F
(PSIG)
H14-6
06-08
Figure H14-3. Sample Cooler (SC-42) Dimensions
Figure H14-4. Performance Curves for Steam Samples
MODEL SC-42
3 GPM COOLING WATER
1 PSIG PRESSURE DROP
SAMPLE DATA
GPM
LB/
SAMPLE
PRESS.
DROP
(PSIG)
APPROACH TEMPERATURE F
CC/
HR MIN
H14-7
06-08
Section H14
Sample Coolers
1.1 GENERAL
A. The following sample specifications are provided by Cleaver-Brooks to assist you in specifying
B. Furnish _______Cleaver-Brooks Model SC-22 sample cooler(s) consisting of 304 stainless
steel head and shell, jointless coiled T304 stainless steel tubing, and a carbon steel mounting
bracket.
C. The sample cooler shall be of compact bolted design and shall require no larger space than 3-
9/16" square x 5-1/2". The tubing and shell shall be removable for cleaning without
disturbing connections. The cooling water connections shall be 3/8" FPT and the sample tube
connections shall be
1/4" OD.
D. The tubing shall be rated at 2000 psig at 635 F. The surface area shall be 1.2 sq-ft.
E. Furnish _______Cleaver-Brooks Model SC-42 sample cooler(s) consisting of 304 stainless
steel head and shell, jointless coiled T304 stainless steel tubing, and a carbon steel mounting
bracket.
F. The sample cooler shall be of compact bolted design and shall require no larger space than 3-
9/16" square x 11". The tubing and shell shall be removable for cleaning without disturbing
connections. The cooling water connections shall be 3/8" FPT and the sample tube
connections shall be
1/4" OD.
G. The tubing shall be rated at 5000 psig at 1000 F. The surface area shall be 2.4 sq-ft.
H14-8
09-04
Notes
Ia
06-08
Boiler Selection Considerations
Section I
SYSTEM FUNDAMENTALS
Hot Water Systems
Steam Systems
General Engineering Data
I1
I2
I3
I4
Alternative Fuel Systems
I5
Ib
General System Fundamentals
Notes
I1-1
06-08
CONTENTS
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-2
BOILER TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4
Scotch Marine - The Classic Firetube Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4
Firebox boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-5
Commercial Watertube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-5
Industrial Watertube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-5
Flexible Watertube (Bent Tube) Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-6
Membrane Watertube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-6
Cast Iron Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-6
Electric Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-6
BOILER SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-7
Heating Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10
Process Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10
Combination Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10
Defining Load Variations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10
System Load Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-11
Load Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-11
Back-Up Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-11
Type of Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-12
Downtime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-12
Boiler Turndown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-12
Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-14
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-14
Combustion Efficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-15
Thermal Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-15
Boiler Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-15
Fuel-to-Steam Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-15
Stack Temperature and Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-15
Excess Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-16
Radiation and Convection Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-16
Heating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-16
Flue Gas Passes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-16
Integral Boiler/Burner Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-16
Replacement Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-16
PAYBACK ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-17
ILLUSTRATIONS
Figure I1-1. Annual Gas Cost as a Function of Gas Use and Unit Price . . . . . . . . . . . . . . . . . . . . I1-21
Figure I1-2. Annual Gas Cost as a Function of Gas Use and Unit Price (Expansion of Figure I1-1) . . I1-22
Figure I1-3. Annual Fuel Oil Cost as a Function of Fuel Oil Use and Unit Price . . . . . . . . . . . . . . . I1-23
Figure I1-4. Annual Fuel Oil Cost as a Function of Fuel Oil Use and Unit Price
(Expansion of Figure I1-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I1-24
Section I1
BOILER SELECTION CONSIDERATIONS
Boiler Selection Considerations Section I
I1-2
06-08
Figure I1-5. System Efficiency Improvement as a Function of Incremental Component Efficiency GainI1-25
Figure I1-6. Annual Savings as a Function of Annual Fuel Cost and System Efficiency Improvement I1-26
Figure I1-7. Annual Savings as a Function of Annual Fuel Cost and System Efficiency Improvement
(Expansion of Figure I1-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-27
TABLES
Table I1-1. Common Boiler Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4
Table I1-2. Considerations for Selecting a Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-7
Table I1-3. Load Demand Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9
Typical Firetube Boiler Fuel Consumption Rates - N0. 6 Oil (gal/hr . . . . . . . . . . . . . . . . . . . . . . . . )I1-13
Table I1-4. Typical Firetube Boiler Fuel Consumption Rates - No. 2 Oil (gal/hr) . . . . . . . . . . . . . . . I1-13
Table I1-5. Typical Firetube Boiler Fuel Consumption Rates - Natural Gas (MM/Btu/hr) . . . . . . . . . I1-14
Perhaps no other piece of equipment is more important to a facility than the boiler. Proper boiler selection, to
meet the needs of the application, is a critical factor in the design of any steam or hot water system.
This section provides information to consider when selecting a boiler. This information is divided into three main
subsections:
1. Boiler Types
Typical boiler types are defined, including: firetube, firebox, industrial watertube, and commercial watertube
boilers. General information is provided on the differences in boiler types (sizes, ranges, pressures, etc.). For
more detailed information on boiler products, refer to the specific boiler product section.
2. Boiler Selection
Provides information on codes and standards; when to use steam or hot water boilers; defines load
requirements; defines the number of boilers needed; discusses performance issues; and addresses special
requirements.
3. Payback Analysis
There are many factors that affect the decision to purchase a particular piece of boiler room equipment. This
section addresses economic considerations only, and provides a procedure that can be applied to individual
equipment selection or evaluation of alternative systems.
Definitions
To assist with understanding information in this section, it will be necessary to understand the following
definitions.
Boiler horsepower(BHP) is a measure of boiler energy output. One boiler horsepower (from and at 212 F):
BHP = 34.5 lbs/hr
BHP = 33,472 Btu/hr
BHP = 9.8 kW
BHP should not be confused with other horsepower measurements.
Boiler Trim: Accessories added to the boiler, such as auxiliary low water cutoff, special tappings, special gas
trains, etc.
Btu: Amount of energy required to raise one pound of water one F.
Input: Total amount of fuel input to the burner in Btu/hr.
Output: Total amount of energy released from a steam or hot water boiler measured in boiler horsepower, lbs/hr
of steam, or Btu/hr.
Section I Boiler Selection Considerations
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For additional definitions, refer to the glossary at the end of The Boiler Book.
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BOILER TYPES
The boilers discussed in this book are packaged boilers. This concept has been
around for more than 60 years. The packaged boiler originated with Cleaver-
Brooks, when a pre-engineered assembly was supplied to a customer to eliminate
his need to purchase separate components, and then try to make them work
together. The packaged boiler has proven to be a successful concept - with more
than 150,000 Cleaver-Brooks units around the world.
There are many types of packaged boilers available. Table I1-1 compares common
boiler types and their features.
The following is an overview of different types of boilers.
Scotch Marine - The Classic Firetube Boiler
The Scotch Marine style of boiler has become so popular in the last 40 years that it
frequently is referred to simply as a firetube boiler. Firetube boilers are available
for low or high pressure steam, or for hot water applications. Firetube boilers are
typically used for applications ranging from 15 to 1500 horsepower. A firetube
boiler is a cylindrical vessel, with the flame in the furnace and the combustion
gases inside the tubes. The furnace and tubes are within a larger vessel, which
contains the water and steam.
The firetube construction provides some characteristics that differentiate it from
other boiler types. Because of its vessel size, the firetube contains a large amount of
water, allowing it to respond to load changes with minimum variation in steam
pressure.
Steam pressure in a firetube boiler is generally limited to approximately 350 psig.
CAST
IRON
MEMBRANE
WATERTUBE
ELECTRIC FIREBOX FIRETUBE
FLEXIBLE
WATERTUBE
INDUSTRIAL
WATERTUBE
VERTICAL
FIRETUBE
Efficiency Low Medium High Medium High Medium Medium Low/Medium
Floor Space
Required
Low Very Low Very Low Medium Medium/
High
Low High Very Low
Maintenance Medium/High Medium Medium/High Low Low Medium High Low
Initial Cost Medium Low/Medium High Low Medium/
High
Low/Medium High Low
No. of Options
Available
Low Medium Medium Low/Medium High Medium High Low
Pressure
Range
HW/LPS HW/LPS HPS
to 600 psig
HW/LPS HPS
to 900 PSIG
HW/LPS HW/LPS
HPS to 350
psig
HW/LPS High Temp
HW

HPS to 900
psig
HW/LPS
HPS to 150
psig
Typical Sizes To 200 hp To 250 hp To 300 hp To 300 hp To 1500 hp To 250 hp To 100 hp
Typical
Applications
Heating/
Process
Heating/
Process
Heating/
Process
Heating Heating/
Process
Heating Process Heating/
Process
Comments Field
Erectable
Field
Erectable
Table I1-1. Common Boiler Types
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To achieve higher pressure, it would be necessary to use very thick shell and tube
sheet material. For this reason, a watertube boiler is generally used if pressure
above 350 psig design is needed.
Firetube boilers are usually built similar to a shell and tube heat exchanger. A large
quantity of tubes results in more heating surface per boiler horsepower, which
greatly improves heat transfer and efficiency.
Firetube boilers are rated in boiler horsepower (BHP), which should not be
confused with other horsepower measurements.
The furnace and the banks of tubes are used to transfer heat to the water.
Combustion occurs within the furnace and the flue gases are routed through the
tubes to the stack outlet. Firetube boilers are available in two, three and four pass
designs. A single pass is defined as the area where combustion gases travel the
length of the boiler. Generally, boiler efficiencies increase with the number of
passes.
Firetube boilers are available in either dryback or wetback design. In the dryback
boiler, a refractory-lined chamber, outside of the vessel, is used to direct the
combustion gases from the furnace to the tube banks. Easy access to all internal
areas of the boiler including tubes, burner, furnace, and refractory, is available from
either end of the boiler. This makes maintenance easier and reduces associated
costs.
The wetback boiler design has a water cooled turn around chamber used to direct
the flue gases from the furnace to the tube banks. The wetback design requires less
refractory maintenance; however, internal pressure vessel maintenance, such as
cleaning, is more difficult and costly. In addition, the wetback design is more prone
to water side sludge buildup, because of the restricted flow areas near the turn
around chamber.
For more information on specific firetube boiler products, refer to Section A.
Firebox boilers
The firebox boiler uses similar tube attachment techniques as the firetube boiler. Its
combustion chamber is not round, like the firetubes cylindrical furnace. The firebox
boiler is typically manufactured to low pressure steam or hot water applications.
The firebox boiler is a compact, economical unit and serves as a good fit for
seasonal use and when efficiency is not the driving factor. Sizes range from 12 to
337 horsepower.
Commercial Watertube Boilers
Commercial watertube boilers typically produce steam or hot water for commercial,
or modest-size applications. There are a wide variety of types, sizes, capacities, and
design pressures available. Commercial watertube boilers can be membrane type,
straight tube, modular, etc. They can be either atmospherically fired or utilize power
burners.
For more information on commercial watertube boilers, refer to Section B.
The industrial watertube boiler typically produces steam or hot water primarily for
industrial process applications, and is used less frequently for heating applications.
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In the watertube design, tubes contain steam and/or water and the products of
combustion pass around the tubes. Typically, watertube designs consist of multiple
drums. A steam drum (upper) and mud drums (lower) are connected by the tubes,
which form both the convection section and the furnace area.
Packaged industrial watertube boilers are typically rated in pounds of steam per
hour output at operating conditions and range from 10,000 to 134,000 lbs/hr.
Industrial watertube boilers are noted for their fast steaming capability. Steam is
generated very rapidly because of the relatively low water content. This allows them
to respond quickly to changing load demands.
The industrial watertube boiler design makes it capable of generating either
saturated or superheated steam. When applications dictate superheated steam
usage, large or fluctuating steam loads, or high pressures (greater than 350 psig),
an industrial watertube boiler should be considered.
For more information on industrial watertube boilers, refer to Section C.
Flexible Watertube (Bent Tube) Boilers
Flexible watertube boilers are a common type of boiler used for heating applications
because of their resistance to thermal shock. Flexible watertube boilers are
available in size ranges from 2 to 9 MMBtu/hr input. Flexible watertube boilers are
available for low pressure steam or hot water applications. Field erectable packages
are also available.
For more information on flexible watertube boilers, refer to Section B.
Membrane Watertube Boilers
The membrane watertube boiler is available for low or high pressure steam or hot
water applications. High outputs are available in a compact design and should be
considered where space is limited. Sizes range from 34 to 143 horsepower.
For more information on membrane type commercial watertube boilers, refer to
Section B.
Cast Iron Boilers
Cast iron boilers are limited to low-pressure steam or hot water applications, and
typically range in size from 25 to 200 horsepower. One advantage of the cast iron
boiler is its modular design, which includes sections for field erection.
For more information on cast iron boiler products, contact your local Cleaver-Brooks
Electric Boilers
Electric boilers are noted for being clean, quiet, easy to install, and compact.
Because there are no combustion considerations, an electric boiler has minimal
complexity (no fuels or fuel handling equipment) with easily replaceable heating
elements.
An electric boiler may be the perfect alternative to supply low or high pressure
steam or hot water where the customer is restricted by emission regulations. In
areas where the cost of electric power is minimal, the electric boiler could be the
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best choice. Sizes range from 9 kW to 3,375 kW output.
For more information on electric boilers, refer to Section B.
BOILER SELECTION
Six criteria should be considered when selecting a boiler to meet the application
needs. The criteria are:
1. Codes and standards requirements
2. Steam or Hot Water
3. Boiler load
4. Number of boilers
5. Performance considerations
6. Special considerations
Codes and
Standards
There are a number of codes and standards, laws, and regulations covering boilers
and related equipment that should be considered when designing a system.
Regulatory requirements are dictated by a variety of sources and are all focused
primarily on safety. For more information on how the various rules affect boiler
selection and operation, you may want to contact your local Cleaver-Brooks
authorized representative. Here are some key rules to consider:
The boiler industry is tightly regulated by the American Society of Mechanical
Engineers (ASME) and the ASME Codes, which governs boiler design,
inspection, and quality assurance. The boilers pressure vessel must have an
ASME stamp. (Deaerators, economizers, and other pressure vessels must also
be ASME stamped).
REQUIREMENT OR
APPLICATION
BOILER SELECTION
F
I
R
E
T
U
B
E
W
A
T
E
R
T
U
B
E
C
A
S
T

I
R
O
N
E
L
E
C
T
R
I
C
C
O
M
M
E
R
C
I
A
L

W
A
T
E
R
T
U
B
E
O
H
I
O

S
P
E
C
I
A
L
F
I
R
E
B
O
X
V
E
R
T
I
C
A
L
F
L
E
X
T
U
B
E
High Efficiency X X
Space Factor X X X
Emissions Factor X
A
X
A
X
Low Cost X X X X
Low Operating Cost X X X
Boiler Operator Factor X
Low Maintenance X X X X
High Turndown X X X
Field Erectable X X
Fuel Limitations X X X
Low Usage, No Stack X
High Pressure, Over
350 psig, or Superheat
X X
A. With Flue Gas Recirculation/ Model CB (LE) Option.
Table I1-2. Considerations for Selecting a Boiler
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06-08
The insurance company insuring the facility or boiler may dictate additional
requirements. Boiler manufacturers provide special boiler trim according to the
requirements of the major insurance companies. Special boiler trim items
usually pertain to added safety controls.
Some industries, such as food processing, brewing, or pharmaceuticals, may also
have additional regulations that have an impact on the boiler and the boiler room.
A UL, ULC, cUL, CSA or CGA listing, or Canadian Registration Number (CRN)
may be required. State, local, or provincial authorities may require data on the
boiler controls or basic design criteria.
Most areas have established a maximum temperature at which water can be
discharged to the sewer. In this case, a blowdown separator aftercooler is
required.
Most state, local or provincial authorities require a permit to install and/or
operate a boiler. Additional restrictions may apply in non-attainment areas
where air quality does not meet the national ambient air quality standards and
emission regulations are more stringent.
For all new boilers with inputs over 10 MMBtu/hr, U.S. Federal emission
standards apply, including permitting and reporting procedures.
Limits on fuel sulfur content are frequently set at 0.5% maximum.
A full-time boiler operator may be required. Operator requirement depends on
the boilers size, pressure, heating surface or volume of water. Boilers can be
selected which minimize the requirements, either by falling under the
requirements and being exempt or with special equipment that gives the
operator more freedom in the facility.
Most states or provinces require an annual boiler inspection. There may be other
requirements on piping as well.
Before beginning the selection process, refer to Table I1-2, which shows multiple
considerations for selecting a packaged boiler.
Steam or Hot Water Now that you have a general overview of the types of boilers and code and
standards requirements, its time to look at the facilitys application in order to see
how the boiler will be used. Keep in mind, the primary purpose of the boiler is to
supply energy to the facilitys operations - for heat, manufacturing process, laundry,
kitchen, etc. The nature of the facilitys operation will dictate whether a steam or hot
water boiler should be used.
Hot water is commonly used in heating applications with the boiler supplying water
to the system at 180 F to 220 F. The operating pressure for hot water heating
systems usually is 30 psig to 125 psig. Under these conditions, there is a wide
range of hot water boiler products available. If system requirements are for hot
water of more than 240 F, a high temperature water boiler should be considered.
For more information on application considerations for hot water boilers and hot
water systems, refer to Hot Water Systems, Section I2.
Steam boilers are designed for low pressure or high pressure applications. Low
pressure boilers are limited to 15 psig design, and are typically used for heating
applications. High pressure boilers are typically used for process loads and can have
an operating pressure of 75 to 700 psig. Most steam boiler systems require
saturated steam.
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06-08
Steam and hot water boilers are defined according to design pressure and operating
pressure. Design pressure is the maximum pressure used in the design of the boiler
for the purpose of calculating the minimum permissible thickness or physical
characteristics of the pressure vessel parts of the boiler. Typically, the safety valves
are set at or below design pressure. Operating pressure is the pressure of the boiler
at which it normally operates. The operating pressure usually is maintained at a
suitable level below the setting of the pressure relieving valve(s) to prevent their
frequent opening during normal operation.
Some steam applications may require superheated steam. It should be noted that
superheated steam has a high enthalpy, so there is more energy per pound of steam
and higher (drier) steam quality. One example of an application where superheated
steam may be required is with a steam turbine. The turbines blades require very
dry steam because the moisture can destroy the blades. When very high pressure or
superheated steam is required, an industrial watertube boiler should be selected.
For more information on application considerations for steam boilers and steam
systems, refer to Section I3, Steam Systems.
System Load In addition to the system load considerations provided in this section, many
excellent reference manuals are available to help further define specific load details
and characteristics. For more information, refer to the ABMA Firetube Engineering
Guide, the ASHRAE Handbook, or contact your local Cleaver-Brooks authorized
representative.
System load is measured in either Btus or pounds of steam (at a specific pressure
and temperature). When discussing the system load, we will include references to
both steam and hot water. However, not all situations or criteria apply to both. It
would be nearly impossible to size and select a boiler(s) without knowing the
system load requirements. Knowing the system load provides the following
information:
The boiler(s) capacity, taken from the maximum system load requirement.
MINIMUM WEIGHTED AVERAGE MAXIMUM
Heating Load 1
Heating Load 2
Heating Load 3
Total Heating Load
Process Load 1
Process Load 2
Process Load 3
Total Process Load
Instantaneous Load
Total Load
Utilize a load demand matrix to analyze each load and determine minimum, average, and maximum load require-
ments.
Table I1-3. Load Demand Matrix
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06-08
The boiler(s) turndown, taken from the minimum system load requirement.
Conditions for maximum efficiency, taken from the average system load
requirement.
Determining the total system load requires an understanding of the type(s) of load in
the system. There are three types of loads: heating, process, and combination.
Heating Load
A heating load is typically low pressure steam or hot water, and is relatively simple
to define because there is not a great deal of instantaneous changes to the load.
And, once a heating load is computed, the number can easily be transferred into the
equipment size requirements. A heating load is used to maintain building heat.
Cooling loads, using steam to run an absorption chiller, also are included when
computing a heating load. Characteristics of a heating load include large seasonal
variations but small instantaneous demand changes. The boiler should be sized for
the worst possible weather conditions, which means that true capacity is rarely
reached.
Process Load
A process load is usually a high pressure steam load. A process load pertains to
manufacturing operations, where heat from steam or hot water is used in the
process. A process load is further defined as either continuous or batch. In a
continuous load, the demand is fairly constant - such as in a heating load. The
batch load is characterized by short-term demands. The batch load is a key issue
when selecting equipment, because a batch-type process load can have a very large
instantaneous demand that can be several times larger than the rating of the boiler.
For example, based on its size, a heating coil can consume a large amount of steam
simply to fill and pressurize the coil. When designing a boiler room for a process
load with instantaneous demand, a more careful boiler selection process should take
place.
Combination Load
Many facilities have a mixture of loads - different types of process loads and
combinations of heating and process loads. The information just given on heating
and process loads should be taken into consideration when dealing with a
combination load.
Defining Load Variations
Loads vary and a power plant must be capable of handling the minimum load, the
maximum load, and any load variations. Boiler selection is often dictated by the
variation in load demand, rather than by the total quantity of steam or hot water
required.
There are three basic types of load variations: seasonal, daily, and instantaneous.
Seasonal Variations. For a heating system, seasonal variations can mean no demand
in the summer, light demand in the fall and spring, and heavy demand in the winter.
Manufacturing operations often have seasonal variations, because the demand for
production may vary. When selecting boiler equipment, the minimum and maximum
load for each season should be determined.
Daily Variation. Daily variation can occur due to
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variations in the work hours, or the heat required at various times of the day or
weekend. Minimum and maximum seasonal variations mentioned earlier may
already reflect these changes if they occur daily. If not, the minimum and maximum
daily loads should be included.
The seasonal and daily variations define the size of the load that the boiler(s) must
handle. Seasonal and daily variations also help define the number of boilers and
turndown requirements.
Instantaneous Demand. Instantaneous demand is a sudden peak load change that
is usually of short duration. These types of loads are sometimes hidden. Many
machines or processes are rated in pounds of steam per hour or Btu/hr as running
loads, under balanced operating conditions, and there is no recognition given to
cold startup, peak or pickup loads. The instantaneous load demand is
important to consider when selecting a boiler to ensure that these load variations
are taken into account. If the instantaneous demand is not included in the system
load calculations, the boiler(s) may be undersized.
System Load Summary
The load demand matrix shown in Table I1-3 can be used as a work sheet in
determining the minimum, maximum, and average system loads.
Load Tracking
Load tracking is the ability of a boiler to respond to changes in steam or hot water
demand. Most often associated with process loads, load tracking focuses on the
boilers ability to supply a constant volume of steam at the required pressure.
The ability of the boiler to track a variable load depends on the boiler type, burner
turndown capability, feedwater valve control, and combustion control design. If the
analysis of the load shows highly variable load conditions, a more complex control
package may be necessary. This type of control is achieved with sophisticated boiler
management systems. For more information on these types of systems, refer to
Controls, Section D, or contact your local Cleaver-Brooks authorized representative.
If the application has instantaneous load demands, whereby a large volume of
steam is required for a short period of time, a boiler with a large energy storage
reserve, such as a firetube, should be considered. If the application dictates large
variances in load demand, where the load swings frequently for long periods of
time, the best choice is probably a watertube type boiler, because it contains less
water and can respond to the variances more rapidly.
In all cases, operation of the burner should be taken into account in selecting a
boiler(s) to meet system demand. The burner will require proper operating controls
that can accurately sense the varying demands and be capable of the turndown
requirements. The boiler feedwater valve and control design are also critical if load
swings are expected.
Number of Boilers Back-Up Boilers
When selecting the boiler(s), consideration should be given to back-up equipment
to accommodate future expansion, emergency repairs, and maintenance. There are
a number of considerations for a backup boiler.
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06-08
Type of Load
Heating systems and non-critical loads that do not result in a sudden loss of
production generally have little or no backup. While this is not recommended, it is
still common practice. These types of applications rely on the ability to make repairs
quickly to reduce downtime. The risk involved in having no backup is a total loss of
heat when the boiler is not in service.
When process or heating loads use multiple boilers during peak times, and one
boiler during most other times, the availability of an additional boiler to provide full
backup during maximum demand should be considered.
In applications with critical steam or hot water requirements, laws or codes may
require a backup. Even if laws or codes do not require a backup, there are many
cases where the operation cannot tolerate downtime. For example, a hotel uses hot
water 24 hours a day, seven days a week. During periods of maintenance or in an
emergency, a backup boiler is required.
Downtime
Another way to determine whether a backup boiler is a wise decision is to compute
the cost of downtime to the owner or the user, as shown in the following three
examples:
A chemical company manufactures dry cell battery compound in a batch
process. The process temperature must be maintained within 2 degrees. The
boiler shuts down on a flame failure. They have 20 minutes to recover steam or
the batch is scrap. The value of the product is $250,000.
A Midwestern insurance company building has comfort heat supplied by one
boiler. There are over 2000 workers in the building. The boiler shuts down due
to a failed gas valve. Outside, its 11F. Inside, the temperature continues to
drop and, at 1:30 in the afternoon, all 2,000 workers are sent home.
A meat processing company makes its entire packaged ham line in a Southern
plant. It operates 24 hours a day, every day. A single boiler provides heat for
curing, sterilizing, and cleaning. The boiler goes down due to a lack of
feedwater. Each hour of steam loss results in four hours of lost production.
Boiler Turndown
Boiler turndown is the ratio between full boiler output and the boiler output when
operating at low fire. Typical boiler turndown is 4:1. For example, a 400 horsepower
boiler, with a 4:1 turndown burner, will modulate down to 100 horsepower before
cycling off. The same boiler with a 10:1 turndown burner will modulate down to 40
horsepower.
The ability of the burner to turn down reduces frequent on and off cycling. Fully
modulating burners are typically designed to operate down to 25% of rated capacity.
At a load that is 20% of the rated capacity, the boiler will turn off and cycle
frequently.
A boiler operating at low load conditions can cycle as frequently as 12 times per
hour, or 288 times per day. With each cycle, pre- and post-purge air flow removes
heat from the boiler and sends it out the stack. The energy loss can be eliminated by
keeping the boiler on at low firing rates. Every time the boiler cycles off, it must go
through a specific start-up sequence for safety
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assurance. It requires about one to two minutes to place the boiler back on line.
And, if theres a sudden load demand, the start-up sequence cannot be accelerated.
Keeping the boiler on line assures the quickest response to load changes. Frequent
cycling also accelerates wear of boiler components. Maintenance increases and,
more importantly, the chance of component failure increases.
As discussed earlier, boiler(s) capacity requirement determined by many different
types of load variations in the system. Boiler over-sizing occurs when future
AVERAGE
OUTPUT
BOILER EFFICIENCY
86% 84% 82% 80% 78% 76%
BHP
100 26 27 27 28 29 29
200 52 53 54 56 57 59
300 78 80 82 84 86 88
400 104 106 109 112 114 117
500 130 133 136 140 143 147
600 156 159 163 168 172 176
700 182 186 191 196 200 206
800 208 213 218 224 229 235
900 234 239 245 252 257 264
1000 260 266 272 280 286 294
A. Based on 150,000 Btu/gallon.
Table I1-4. Typical Firetube Boiler Fuel Consumption Rates - N0. 6 Oil (gal/hr)
A
AVERAGE
OUTPUT
BOILER EFFICIENCY
86% 84% 82% 80% 78% 76%
BHP
100 28 28 29 30 31 31
200 56 57 58 60 61 63
300 83 85 87 90 92 94
400 111 114 117 120 123 126
500 139 142 146 149 153 157
600 167 171 175 179 184 189
700 195 199 204 209 215 220
800 222 228 233 239 245 252
900 250 256 262 269 276 283
1000 278 285 292 299 307 315
A. Based on 140,000 Btu/gallon.
Table I1-5. Typical Firetube Boiler Fuel Consumption Rates - No. 2 Oil (gal/hr)
A
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06-08
AVERAGE
OUTPUT
BOILER EFFICIENCY
86% 84% 82% 80% 78% 76%
BHP
100 3.89 3.99 4.08 4.18 4.29 4.41
200 7.78 7.98 8.16 8.36 8.58 8.82
300 11.67 11.97 12.24 12.54 12.87 13.23
400 15.56 15.96 16.32 16.72 17.16 17.64
500 19.45 19.95 20.40 20.90 21.45 22.05
600 23.34 23.94 24.48 25.08 25.74 26.46
700 27.23 27.93 28.56 29.26 30.03 30.87
800 31.12 31.92 32.64 33.44 34.32 35.28
900 35.01 35.91 36.72 37.62 38.61 39.69
1000 38.90 39.90 40.80 41.80 42.90 44.10
Table I1-6. Typical Firetube Boiler Fuel Consumption Rates - Natural Gas (MM/Btu/hr)
expansion and safety factors are added to assure that the boiler is large enough for
the application. If the boiler is oversized, the ability of the boiler to handle minimum
loads without cycling is reduced. Therefore, capacity and turndown should be
considered together for proper boiler selection to meet overall system load
requirements.
Performance
Considerations
Three important considerations pertain to fuels, emissions, and efficiency. All three
have important impact on boiler performance, and can affect long-term boiler
operating costs.
Fuels
Remember, from an operating perspective, fuel costs typically account for
approximately 10% of a facilitys total operating budget. Therefore, fuel is an
important consideration. Normally, the fuels of choice are natural gas, propane, or
light oil. Increasingly stringent emission standards have greatly reduced the use of
heavy oil and solid fuels such as coal and wood. Of the fossil fuels, natural gas
burns cleanest and leaves less residue; therefore less maintenance is required.
It can be advantageous to supply a boiler with a combination burner that can burn
two fuels independently - for example, oil or natural gas. A combination burner
allows the customer to take advantage of peak time rates, which substantially
reduces the costs of a therm of gas when operating off peak by merely switching
to the back up fuel. Dual fuel capability also is beneficial if the primary fuel supply
must be shut down for safety or maintenance reasons.
Some waste streams can be used as fuel in the boiler. In addition to reducing fuel
costs, firing an alternate fuel in a boiler can greatly reduce disposal costs. Waste
streams are typically used in combination with standard fuels to ensure safe
operation and to provide additional operating flexibility.
Emissions
Emission standards for boilers have become very
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stringent in many areas, because of the new clean air regulations. The ability of the
boiler to meet emission regulations depends on the type of boiler and burner
options. For more information, refer to Emissions, Section E.
Efficiency Efficiency is used in the measure of economic performance of any piece of
equipment. In the boiler industry, there are four common definitions of efficiency,
but only one true measurement. Following are the definitions and how to measure
efficiency.
Combustion Efficiency
Combustion efficiency is the effectiveness of the burner only and relates to its ability
to completely burn the fuel. The boiler has little bearing on combustion efficiency. A
well- designed burner will operate with as little as 15 to 20% excess air, while
converting all combustibles in the fuel to thermal energy.
Thermal Efficiency
Thermal efficiency is the effectiveness of the heat transfer in a boiler. It does not
take into account boiler radiation and convection losses - for example, from the
boiler shell, water column piping, etc.
Boiler Efficiency
The term boiler efficiency is often substituted for combustion or thermal
efficiency. True boiler efficiency is the measure of fuel-to-steam efficiency.
Fuel-to-Steam Efficiency
Cleaver-Brooks guaranteed boiler efficiencies are fuel-to- steam efficiencies.
Fuel-to-steam efficiency is the correct definition to use when determining boiler
efficiency. Fuel-to-steam efficiency is calculated using either of two methods, as
prescribed by the ASME Power Test Code, PTC 4.1. The first method is input-
output. This is the ratio of Btu output divided by Btu input x 100.
The second method is heat balance. This method considers stack temperature and
losses, excess air levels, and radiation and convection losses. Therefore, the heat
balance calculation for fuel-to-steam efficiency is 100 minus the total percent stack
loss and minus the percent radiation and convection losses.
Stack Temperature and Losses
Stack temperature is the temperature of the combustion gases (dry and water
vapor) leaving the boiler. A well-designed boiler removes as much heat as possible
from the combustion gases. Thus, lower stack temperature represents more
effective heat transfer and lower heat loss up the stack. The stack temperature
reflects the energy that did not transfer from the fuel to steam or hot water. Stack
temperature is a visible indicator of boiler efficiency. Any time efficiency is
guaranteed, predicted stack temperatures should be verified.
Stack loss is a measure of the amount of heat carried away by dry flue gases
(unused heat) and the moisture loss (product of combustion), based on the fuel
analysis of the specific fuel being used, moisture in the combustion air, etc.
I1-16
06-08
Excess Air
Excess air provides safe operation above stoichiometric conditions. A burner is
typically set up with 15 to 20% excess air. Higher excess air levels result in fuel
being used to heat the air instead of transferring it to usable energy, increasing stack
losses.
Radiation and Convection Losses
Radiation and convection losses will vary with boiler type, size, and operating
pressure. The losses are typically considered constant in Btu/hr, but become a larger
percentage loss as the firing rate decreases.
Boiler design factors that also impact efficiencies of the boiler are heating surface,
flue gas passes, and design of the boiler and burner package.
Heating Surface
Heating surface is one criterion used when comparing boilers. Boilers with higher
heating surface per boiler horsepower tend to be more efficient and operate with
less thermal stress. Many packaged boilers are offered with five square feet of
heating surface per boiler horsepower as an optimum design for peak efficiency.
Flue Gas Passes
The number of passes that the flue gas travels before exiting the boiler is also a good
criterion when comparing boilers. As the flue gas travels through the boiler it cools
and, therefore, changes volume. Multiple pass boilers increase efficiency because
the passes are designed to maximize flue gas velocities as the flue gas cools.
Integral Boiler/Burner Package
Ultimately, the performance of the boiler is based on the ability of the burner, the
boiler, and the controls to work together. When specifying performance, efficiency,
emissions, turndown, capacity, and excess air all must be evaluated together. The
efficiency of the boiler is based, in part, on the burner being capable of operating at
optimum excess air levels. Burners not properly designed will produce CO or soot at
these excess air levels, foul the boiler, and substantially reduce efficiency. In
addition to the boiler and burner, the controls included on the boiler (flame
safeguard, oxygen trim, etc.) can enhance efficiency and reduce overall operating
costs for the customer. A true packaged boiler design includes the burner, boiler, and
controls as a single, engineered unit.
Special
Considerations
Replacement Boilers
If the boiler is to be placed in an existing facility, there are a number of
considerations:
Floor space required.
Total space requirements.
Access space for maintenance.
Size and characteristics of the boiler to be replaced, including location of
existing piping, the boiler stack and utilities.
Boiler weight limitations.
I1-17
06-08
With little or no access to the boiler room, the cast iron boiler and some bent-
tube type boilers can be carried into the boiler room in sections or pieces and
easily assembled, with no welding required.
Electric boilers should also be considered, especially since they do not require a
stack.
Vertical firetube boilers have a small floor space requirement.
PAYBACK ANALYSIS
There are many factors that affect the decision to purchase a particular piece of
boiler room equipment. This subsection addresses some of the economic
considerations in the decision process. The procedure presented can be applied to
equipment selection and the economic evaluation of alternative systems.
The effect of a single piece of equipment can be a significant part of the overall
transfer of energy from the fuel burned to the thermal energy of the steam or hot
water delivered. The performance of equipment, such as the boiler, stack gas
recovery systems (economizers), condensate recovery systems (deaerators, etc.),
oxygen trim systems, and blowdown heat recovery systems, should be considered.
Efficiency gains from each piece of equipment need to be evaluated individually in
the context of the overall system to determine the incremental fuel cost savings.
Savings from efficiency gains are used to evaluate the payback potential of the
equipment. Payback simply refers to the time period that will elapse before the
cumulative cost savings will equal the incremental capital cost of the equipment
selected.
In summary, this section provides a procedure and a set of tables and figures to
assist in assessing the economic justification of purchasing higher performance
equipment or additional energy savings equipment (e.g., economizers, oxygen trim
controls, etc.). This procedure may also be used to evaluate the operating cost
impact of different system configurations.
The tables and figures provided are not unique to Cleaver- Brook products.
Therefore, the procedures may be applied to any thermal energy consuming system.
Before proceeding, product related information (e.g., efficiency and fuel
consumption rates) should be obtained for each specific product.
Having defined a basic system configuration, and having identified equipment that
would yield incremental performance improvement (and investment), the payback
analysis sequence is straight forward and can be summarized as follows:
1. Estimate boiler fuel consumption rate.
2. Estimate annual fuel use.
3. Estimate annual fuel cost.
4. Determine potential incremental efficiency improvement.
5. Estimate potential annual fuel savings.
6. Determine the payback period for the investment.
7. Refine the analysis.
The remainder of this section outlines the step-by-step procedure to be used in
conjunction with the figures and tables.
I1-18
06-08
Remember, the lowest cost product is not necessarily the most economic choice. In
fact, most often it is not the best choice!
Step 1: Boiler Fuel Consumption Rate
Use Table I1-4,Table I1-5, andTable I1-6 to compare the fuel consumption rates of
two boiler configurations with different fuel-to-steam efficiency or, as a base fuel
rate for a given boiler configuration. Find the appropriate boiler size and the
efficiency on the table to find the associated fuel consumption.
Step 2: Annual Fuel Usage
Multiply the hourly fuel consumption rates by the annual hours of operation to
determine the annual fuel usage rate.
Step 3: Annual Fuel Cost
Figure I1-1 and Figure I1-2 are used to determine annual fuel cost for natural gas
based on annual gas use (billion Btu/yr) and gas cost ($/MMBtu). Figure I1-2
provides a more detailed graph for lower gas usage applications. Save the annual
fuel cost value for Step 5.
(Note that the figures referenced in this discussion are located at the end of this
section.)
Figure I1-3 and Figure I1-4 are used to determine annual fuel cost for oil fuels
based on annual oil use (thousand gal/yr) and oil cost ($/gal). Figure I1-4 provides
a more detailed graph for lower oil usage application. Save the annual fuel cost
value for Step 5.
Step 4: Incremental Efficiency Improvement
If an improvement is being added to a boiler (economizer, oxygen trim, etc.) that is
designed to improve the efficiency of the boiler by x percent (incremental
efficiency gain). Use Figure I1-4 to take the base system efficiency (bottom) and the
incremental efficiency gain (right side) to determine the actual improvement in the
system efficiency to be used for the cost savings in Step 5.
Step 5: Annual Fuel Savings
Use Figure I1-6 to determine the annual fuel savings based on the annual fuel cost
and system efficiency improvement (right side of graph). Figure I1-7 provides for a
more detailed graph for lower fuel cost applications.
Step 6: Payback Period
The payback period is the years required to recover the capital investment. To
determine payback simply divide the capital cost of the equipment by the annual
savings.
To determine the amount of capital available based on a known payback period,
multiply the annual savings by the payback period required.
Step 7: Refine the Analysis
It should be recognized that the tools provided herein are intended to provide a
quick mechanism to focus on an appropriate equipment configuration and scope.
The graphs provided should permit you to quickly identify candidate equipment
options that economically qualify and, therefore, merit more serious evaluation.
I1-19
06-08
Additional economic issues (maintenance, necessity of equipment, etc.) should be
considered by final conclusions are reached.
Contact your local Cleaver-Brooks authorized representative for additional
information.
Example Consider the following payback analysis example. Assume that a project requires a
three-year payback for any incremental capital investment. Also assume that an
800 hp firetube boiler firing No. 2 oil and operating at 85% efficiency has a cost of
$1/gal. Assume the average load is 50% of rated capacity for the anticipated 5000
hours per year of operation. The questions are:
What is the yearly savings attributable to adding an oxygen trim control system
designed to improve efficiency 1.3% to the boiler?
How much capital may be allocated to purchase this equipment and fall within the
three-year payback guideline?
Step 1: Estimate Boiler Fuel Consumption Rate
Using Figure I1-4, an average output of 400 hp at 85% efficiency will use
approximately 112.5 gal/hr (interpolated between 86% at 111 gal/hr and 84% at
114 gal/hr) of No. 2 fuel oil.
Step 2: Estimate Annual Fuel Use
112.5 gal/hr x 5000 hr/yr = 562,500 gal/yr annual fuel consumption or
approximately 560,000 gal/yr
Step 3: Estimate Annual Fuel Cost
Refer to Figure I1-5 and find the intersection of 560,000 gal/yr (bottom scale) and
the $1.40/gal fuel price line (right scale). Looking to the left, the annual fuel cost
(left scale) is shown to be $784,000.
Step 4: Determine Potential Incremental Efficiency Improvement
Based on an average efficiency improvement attributable to the trim control of 1.3%
for No. 2 oil. Refer to Figure I1-3and find the intersection of the boiler system base
efficiency of (85%) and the 1.3% incremental efficiency gain curve (right scale).
Referring to the left scale, the system efficiency improvement is shown to be 1.6%.
Step 5: Estimate Potential Annual Fuel Savings
Refer to Figure I1-7and find the intersection of $784,000 annual fuel cost (bottom
scale) and the 1.6% system efficiency improvement (right scale) identified in Step
4. Looking across to the left scale, annual savings are shown to be approximately
$12,000.
Step 6: Determine the Payback Period for the investment (or the Allowable
Incremental Capital)
Multiply $12,000 times the three years required to get $36,000.
Step 7: Refine the Analysis
If there are other economic factors to be considered as a result of adding oxygen trim
controls, add these savings (or costs) to the $12,000 annual fuel savings
determined in Step 5. Then repeat Step 6 with the combined savings figure.
I1-20
06-08
Assuming there are no other economic factors to be considered, the analysis has
shown that the project payback criteria can be met provided the installed oxygen
trim control will cost no more than $36,000. Clearly, purchase of the added control
is this example would be a good investment. The equipment purchase cost would
be recouped in less than three years and the customer would enjoy $12,000
annual savings thereafter that will grow with fuel price increases and escalation.
I1-21
06-08
Figure I1-1. Annual Gas Cost as a Function of Gas Use and Unit Price
$15.00/MM Btu
$13.50/MM Btu
$12.00/MM Btu
$4.50/MM Btu
$10.50/MM Btu
$9.00/MM Btu
$7.50/MM Btu
$6.00/MM Btu
ANNUAL GAS USE - Billion Btu/Yr.
A
N
N
U
A
L
G
A
S
C
O
S
T
-
D
o
l
l
a
r
s
/
Y
e
a
r
0 100 200 300 400 500 600 700 800 900 1000
$0
$1,500,000
$3,000,000
$4,500,000
$6,000,000
$7,500,000
$9,000,000
$10,500,000
$12,000,000
$13,500,000
$15,000,000
I1-22
06-08
ANNUAL GAS USE - Billion Btu/Yr.
A
N
N
U
A
L
G
A
S
C
O
S
T
-
D
o
l
l
a
r
s
/
Y
e
a
r
0 100 200 300
$600,000
$1,200,000
$1,800,000
$2,400,000
$3,000,000
$4,200,000
$4,800,000
$3,600,000
$0
$15.00/MM Btu
$12.00/MM Btu
$9.00/MM Btu
$6.00/MM Btu
Figure I1-2. Annual Gas Cost as a Function of Gas Use and Unit Price (Expansion of Figure I1-1)
I1-23
06-08
A
N
N
U
A
L
F
U
E
L
O
I
L
C
O
S
T
S
-
D
o
l
l
a
r
s
/
Y
e
a
r
$0
$4,000,000
$8,000,000
$12,000,000
$16,000,000
$20,000,000
$24,000,000
$28,000,000
$30,000,000
FUEL OIL CONSUMPTION - Thousands of Gallons/Year
0 4,000 2,000 6,000 8,000 10,000 12,000
$2.40/Gal
$2.00/Gal
$1.60/Gal
$1.20/Gal
$0.80/Gal
$0.40/Gal
Figure I1-3. Annual Fuel Oil Cost as a Function of Fuel Oil Use and Unit Price
I1-24
06-08
ANNUAL FUEL OIL CONSUMPTION - Thousands of Gallons/Year
0 1.000 2,000 3,000
$1,000,000
$2,000,000
$3,000,000
$4,000,000
$5,000,000
$7,000,000
$8,000,000
$6,000,000
$0
$2.40/MM Btu
$2.00/MM Btu
$1.60/MM Btu
$0.80/MM Btu
A
N
N
U
A
L
F
U
E
L
O
I
L
C
O
S
T
-
D
o
l
l
a
r
s
/
Y
e
a
r
$1.20/MM Btu
$0.40/MM Btu
Figure I1-4. Annual Fuel Oil Cost as a Function of Fuel Oil Use and Unit Price (Expansion of Figure I1-3)
I1-25
06-08
0.00%
1.00%
2.00%
3.00%
4.00%
5.00%
6.00%
7.00%
8.00%
9.00%
10.00%
5%
4%
3%
2%
1%
REFERENCE BASE SYSTEM EFFICIENCY - PERCENT
50% 55% 60% 65% 70% 75% 80% 85% 90% 95% 100%
S
Y
S
T
E
M

E
F
F
I
C
I
E
N
C
Y

I
M
P
R
O
V
E
M
E
N
T

-

P
E
R
C
E
N
T
Incremental
Efficiency
Gain
Figure I1-5. System Efficiency Improvement as a Function of Incremental Component Efficiency Gain
I1-26
06-08
A
N
N
U
A
L
S
A
V
I
N
G
S
-
D
o
l
l
a
r
s
$0
$150,000
$300,000
$450,000
$600,000
ANNUAL FUEL COST - $MM
0 1.5 3.0 4.5 6.0 7.5 9.0 10.5 12.0 13.5 15.0
5.00%
4.50%
4.00%
3.50%
3.00%
2.50%
2.00%
1.50%
1.00%
0.50%
$750,000
I1-27
06-08
ANNUAL FUEL COST - $MM
0 1.5 3.0 4.5
$30,000
$60,000
$90,000
$120,000
$150,000
$210,000
$240,000
$180,000
$0
5.00%
4.00%
3.00%
1.00%
A
N
N
U
A
L
S
A
V
I
N
G
S
-
D
o
l
l
a
r
s
2.00%
(Expansion of Figure I1-6)
I1-28
06-08
Notes
I2-1
06-08
CONTENTS
MECHANICAL CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-3
Code Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-3
Boiler Selection Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-3
Air Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4
Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4
Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-8
Domestic Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-8
Heating/Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2- 1 0
Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2- 1 1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-11
High Temperature Water Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-11
CONTROL CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-12
Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-12
Lead/Lag Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-13
Temperature Setbacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-16
Heat Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-17
WATER CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-19
Water Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-19
Chemical Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-20
Make-up Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-20
Ethylene Glycol as Heat Transfer Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-20
SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-22
ILLUSTRATIONS
Figure I2-1. Typical Expansion Tank Piping Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-5
Figure I2-2. Typical Pump Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-5
Figure I2-3. Pressure Temperature Chart for Firetube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-7
Figure I2-4. Plug Cock or Gate Valve (Manual Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-15
Figure I2-5. Two-Position Valve (Electric or Pneumatic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-15
Figure I2-6. Throttling or Modulating Valve (Electric or Pneumatic) . . . . . . . . . . . . . . . . . . . . . . . I2-15
Figure I2-7. Three-Way Mixing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-15
Figure I2-8. Three-Way Mixing Valve (By-Pass Arrangement) . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-16
Figure I2-9. Three-Way Diverting Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-16
Figure I2-10. Intermittent Secondary Pump Operation (On-Off) . . . . . . . . . . . . . . . . . . . . . . . . . . I2-16
Figure I2-11. Water Temperature Constant Thru Zone Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-16
Figure I2-12. Continuous Secondary Pump Operation with Two-Position Valve (Valve Open) . . . . . . I2-17
Section I2
HOT WATER SYSTEMS
Hot Water Systems Section I
I2-2
06-08
Figure I2-13. Continuous Pump Operation with Two-Position Valve (Valve Closed) . . . . . . . . . . . . I2-17
Figure I2-14. Primary Loop Circuit, Constant Speed Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-23
Figure I2-15. Primary Loop Circuit with Secondary Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-24
Figure I2-16. Individual Zone Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-25
Figure I2-17. Primary Loop Circuit with Three-Way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-26
Figure I2-18. Four-Way Valve System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-27
Figure I2-19. Multiple Boiler Lead/Lag, Primary/Secondary Pumping . . . . . . . . . . . . . . . . . . . . . I2-28
TABLES
Table I2-1. Circulation Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-6
Table I2-2. Pressure drop across firetube hot water boilers (standard size nozzles) . . . . . . . . . . . . I2-9
This section provides design considerations for boiler applications in hot water systems. The information
provided is intended to create an awareness of the various considerations that should be evaluated to ensure a
successful installation and long boiler life.
Section I Hot Water Systems
I2-3
06-08
MECHANICAL CONSIDERATIONS
Code
Considerations
Boilers constructed in accordance with Section IV, Heating Boilers, of the ASME
Boiler and Pressure Vessel Code can be operated with water temperature up to 250
F with a maximum design pressure of 160 psig.
Boilers for operation over 250 F or 160 psig must be constructed in accordance
with Section I, Power Boilers, of the ASME Boiler and Pressure Vessel Code.
Due to limitations of control and safety settings, desired operating temperatures
between 240 F and 250 F may require the use of a Section I boiler. System
operating pressure must not exceed 90% of the relief valve pressure setting.
Consideration should be given to system piping to ensure it meets all applicable
codes. For example, when Section I boilers are used, the piping must be in
accordance with B31.1 ASME Power Piping Code.
Boiler Selection
Considerations
When a hot water system is laid out, all of the components must be selected to
work together to achieve the design intent. The design intent could include criteria
such as: system flexibility, maximum efficiency, heating/cooling, domestic hot water,
heat storage, fuel capability, etc. Selection and operation of the boiler(s) in relation
to the other system components, and in support of the design intent, are important
considerations.
Selection of a boiler to support the design intent of the hot water system is
dependent on several site-specific variables, such as those just listed. In addition,
one of the most important selection factors is the maximum continuous rating of the
boilers, which is dependent on the load imposed by the heat users and the nature
of the load. For example, consider an installation with a maximum load of
10,300,900 Btu/hr. Of this, 9,300,900 Btu/hr are the peak winter heating load
and 1,000,000 Btu/hr are domestic hot water load, which are provided through
means of a heat exchanger.
Based on the maximum load conditions just described, consideration might be given
to a 310 horsepower firetube boiler (1 boiler horsepower = 33,472 Btu/hr).
However, to ensure system flexibility, and to provide some degree of stand-by for
unscheduled outage, common practice would dictate the installation of two units,
each with a capacity of 65% of the maximum load. That is; two 200 horsepower
units, or 6,695,000 Btu/hr each.
Based on the example just mentioned, it is apparent that boiler capacity selection,
based on peak loading, is fairly straight forward.
Specific load mix, often caused by early fall or late spring heating loads, can require
additional considerations. When the minimum heating load is 10% of the maximum
heating load, the heating load is: 9,300,900Btu/hr.
Heating Load @ 10% = 930,090Btu/hr
Domestic Water = 1,000,000Btu/hr
TOTAL LOAD = 1,930,090Btu/hr
When the light heating load only is imposed, the demand on the boiler is only 14%
of its rated capacity. A third, smaller unit should be considered for light load
conditions, unless the boiler has a burner with a 10:1 turndown ratio.
When multiple boilers are used, care must be taken to assure proper proportional
flow through each of the units. If flow is not properly balanced, wide variations in
I2-4
06-08
boiler firing rates can occur and, in extreme cases, the resulting outlet water
temperatures may not be at the desired point.
In summary, the seasonal and daily variations define the size of the load that the
boilers must handle. The maximum load will be used, along with backup
requirements, to set the plant capacity. Seasonal and daily variations are used to
help select the number of boilers and turndown requirements. In some applications,
there is a mixture of loads. These may be different types of process loads or
combinations of heating and process loads. It is usually best to analyze them
individually, and then combine them for each season.
Air Removal Air removal in a hot water boiler is important for two main reasons. Air contains
oxygen, which can cause corrosion of metal surfaces. And, air acts as an insulator
and can affect heat transfer as well the operation of temperature controls.
All Cleaver-Brooks hot water outlet connections include a dip tube, which extends 2
to 3 inches into the boiler. The dip tube does not allow any air, which may be
trapped at the top of the drum, to get back into the system.
Because any oxygen or air which is released in the boiler will collect or be trapped
at the top of the boiler drum, the air vent tapping on the top center line of the boiler
should be piped into the expansion or compression tank or fitted with an automatic
air vent valve. Any air that is trapped at the top of the boiler will find its way out of
the boiler through this tapping.
Dip tube assemblies furnished for external mounting into the boiler return
connection, or system air separators, may also be equipped with an air vent
tapping. These devices will remove air from the system, however, they do not
remove air from the top of the boiler. To avoid trapped air at the top of the boiler
drum, it is still necessary to pipe the boiler air vent into the expansion or
compression tank or into an automatic air vent valve.
Expansion Tank An expansion tank serves one primary function in a hot water system. It provides a
means for the system water to expand, as it is heated, without significantly
increasing system pressure.
Expansion tanks are also often used as the receiver for the air removed from the
boiler. This is convenient if the expansion tank does not have a bladder or
diaphragm. If the expansion tank has a bladder or diaphragm, the air from the
boiler must be removed by an automatic type air vent piped directly to the air vent
tapping on the top of the boiler.
Proper expansion tank design will account for the desired system pressure and
changes in the specific volume of water from 60 F (ambient temperature) to the
maximum operating temperature of the boiler and related system. To design the
expansion tank, you must first know the total volume of water in the flooded boiler
and system. For flooded values for a Cleaver-Brooks boiler, refer to the boiler
products section. You will need to estimate the water volume in the system by
considering the diameter and length of system piping and including the volume of
water contained in system heat exchangers.
Expansion tanks are usually charged with air or an inert gas such as nitrogen.
Nitrogen is often used in high temperature water applications due to its low
corrosive nature. Regardless of the charging media, expansion tanks are charged at
a pressure slightly higher than the static pressure on the tank with the system at
ambient temperature. As the water in the system is heated, the air or gas cushion in
I2-5
06-08
Figure I2-1. Typical Expansion Tank Piping Arrangement
Figure I2-2. Typical Pump Curve
I2-6
06-08
the expansion tank compresses, allowing the water to expand without significant
variations to the system pressure.
For more information on sizing expansion tanks, refer to the ASHRAE Guide Book,
or contact your local Cleaver-Brooks authorized representative.
A typical expansion tank piping arrangement is shown in Figure I2-1.
Pumping Equipment
Pump Type
Centrifugal type pumps are typically used for system circulating pumps, because of
their proven durability, efficiency, and ability to pump the required flow and
pressure.
Although there are many types of centrifugal pumps available with varying
characteristics, most applications use a pump with a curve similar to Figure I2-2.
When using this type of pump curve, draw a horizontal line at the feet-of-head
requirement for the system (2.31 feet of water at 60 F = 1 psig). At the point
where the line intersects the pump curve, draw a vertical line to determine the
gallon per minute flow the pump will pump at the given feet-of-head. Select a pump
that meets both the flow and feet of head requirements for the system. The
operating or design point of the pump is the point at which the vertical and
horizontal lines intersect the pump curve. This point is also commonly referred to as
the duty point.
Table I2-1. Circulation Rates
BOILER
HP
BOILER
OUTPUT
(X 1000)
BTU/HR
SYSTEM TEMPERATURE DROP - DEGREES F
10 20 30 40 50 60 70 80 90 100
15 500 100 50 33 25 20 17 14 12 11 10
20 670 134 67 45 33 27 22 19 17 15 13
30 1005 200 100 67 50 40 33 29 25 22 20
40 1340 268 134 89 67 54 45 38 33 30 27
50 1675 335 168 112 84 67 56 48 42 37 33
60 2010 402 201 134 101 80 67 58 50 45 40
70 2345 470 235 157 118 94 78 67 59 52 47
80 2680 536 268 179 134 107 90 77 67 60 54
100 3350 670 335 223 168 134 112 96 84 75 67
125 4185 836 418 279 209 168 140 120 105 93 84
150 5025 1005 503 335 251 201 168 144 126 112 100
200 6695 1340 670 447 335 268 224 192 168 149 134
250 8370 1675 838 558 419 335 280 240 210 186 167
300 10045 2010 1005 670 503 402 335 287 251 223 201
350 11720 2350 1175 784 587 470 392 336 294 261 236
400 13400 2680 1340 895 670 535 447 383 335 298 268
500 16740 3350 1675 1120 838 670 558 479 419 372 335
600 20080 4020 2010 1340 1005 805 670 575 502 448 402
700 23450 4690 2345 1565 1175 940 785 670 585 520 470
800 26780 5360 2680 1785 1340 1075 895 765 670 595 535
Note: Applications with design temperature drops over 50 degrees F require review by Cleaver-Brooks.
I2-7
06-08
Pump Location
It is recommended that the system circulating pumps take suction from the outlet
connection on the boiler and that they discharge to the system load in order to put
the boiler and the expansion tank on the suction side of the pump. This location is
preferred because it decreases potential for air entry into the system and does not
impose the system head on the boiler.
It is common practice to install a standby system circulating pump, to
accommodate scheduled pump maintenance without shutting the system down.
Usually, both the main and standby circulating pumps are located adjacent to the
boilers in the boiler room.
Pump Operation
Pumps are normally started and stopped by manual switches. It is also desirable to
interlock the pump with the burner so that the burner cannot operate unless the
circulating pump is running.
Pump Capacity
Table I2-1 can be used to determine the maximum gpm circulating rate in relation
to full boiler output and system temperature drop. Knowing the boiler size and
expected system temperature drop, the maximum circulation rate can be selected.
Circulation
The system should be piped and the controls configured to ensure continuous flow
of system water through the boiler under all operating conditions. Constant
Figure I2-3. Pressure Temperature Chart for Firetube Boilers
I2-8
06-08
circulation through the boiler results in a more even water temperature and
eliminates the possibility of stratification within the boiler and system. Constant
circulation reduces the possibility of thermal stresses to the boiler and subsequent
pressure vessel failure.
Minimum Circulation
As a rule of thumb, the minimum continuous circulation rate through the boiler
under operating conditions is one gallon per minute per boiler horsepower.
Maximum Circulation
The maximum circulation in gallons per minute through the boiler is based on
system design temperature drop, and maximum Btu output rating of the boiler.
Table I2-1 shows the maximum circulation rates for firetube boilers. For information
on specific boiler circulation rates, refer to the boiler products section.
Pressure Drop When sizing the system circulating pump, it is necessary to account for the system
line losses. Proper sizing will allow the pump to overcome the system pressures in
order to deliver the proper flow through the system. The boiler is part of the system
pressure drop calculation. As a rule of thumb, there is a pressure drop of less than
3 feet of head (1 psi = 2.31 feet of head) through Cleaver-Brooks boilers.
Table I2-2 shows pressure drop curves for firetube boilers with standard size
nozzles. To determine the pressure drop for a particular application, find the flow
rate in GPM on the y-axis and read across the graph to the boiler HP. The resulting
x value will be the head loss in feet of water (note: scale is log-log).
Pressure Requirements
In a hot water boiler, the pressure/temperature relationship is critical. Unlike a
steam boiler, where the pressure and temperature relationship corresponds to the
laws of nature, a hot water boiler design purposely prevents the water from turning
to steam. To prevent steaming, a certain amount of over pressure is required to
keep the water from flashing to steam. Figure I2-3 shows a typical pressure/
temperature relationship for Firetube and Model 4 hot water boilers. Similar charts
are provided in the specific boiler product sections. To use the chart, locate the
maximum system operating temperature (High Limit Control Setting) on the bottom
line. Draw a straight line to the minimum recommended boiler operating pressure
curve. At the point where the lines intersect, draw a horizontal line to the left of the
chart and find the necessary pressure.
Domestic Hot Water Hot water systems are often used as the energy source to provide domestic hot
water. The hot water for personal washing (showers, laundry, etc.) and, in some
cases, light industrial process, is often provided through the incorporation of a heat
exchanger in the system.
Physically, the heat exchanger provides a separation of the hot water system water
from the domestic water which, in turn, allows the fluids to be of different chemical
make-up. This provides integrity and proper water treatment for the hot water
system, and proper water treatment, while providing potable water in the secondary
loop.
Space requirements for the domestic water heat exchanger vary considerably based
on specific application. However, typically, the required space is quite small. For
I2-9
06-08
Table I2-2. Pressure drop across firetube hot water boilers (standard size nozzles)
2
.
0
3
.
0
4
.
0
5
.
0
6
.
0
7
.
0
8
.
0
9
.
0
1
0
.
0
I2-10
06-08
example, Cleaver-Brooks can provide domestic water coils integral to the boiler that
require no additional floor space, and only need room for the associated domestic
water loop piping. In this type of system, typically, there is a low volume of domestic
water stored. The heat exchanger system must be sized to maintain minimum
desired temperature at maximum load conditions. This is an excellent application
for fairly continuous domestic water loads.
In many cases, domestic hot water can, and should, be provided by including a
shell and tube (or plate and frame) heat exchanger as part of the hot water system.
Isolation and services of the heat exchanger can be performed without removing the
hot water heating system from service.
When it is apparent that large domestic water demands are required for a short
period of time, consideration should be given to incorporating a storage tank in the
domestic water loop. In most applications of this type, the heat exchanger is
incorporated into the storage tank and the hot water system fluid is pumped through
the tube side of the exchanger and the domestic hot water is on the shell side.
Domestic water heat exchangers provide physical separation of the two media and,
therefore, considerable flexibility with respect to flow and temperature. Such
systems, however, are not trouble free. Scaling or fouling of the heat exchanger
surface can occur, process controls can fail, etc. To maintain optimum operating
efficiency of the domestic water circuit, serviceability of the equipment should
always be considered during system design.
Heating/Cooling Heating/cooling systems are often called single pipe systems. In a single pipe
system, the water is either heated by a boiler or cooled by a chiller to meet the
comfort demand.
Special care and consideration must be given to system design when the heating
(hot water) and cooling (chilled water) systems share common distribution piping.
The type of boilers selected; control systems for both heating and cooling; and type
of load - heat in the morning, cooling in the afternoon - are critical issues of design
consideration that will dictate success or failure of the installation.
The overall system design intent must be the comfort heating, or cooling, of the
individuals who occupy the building. However, if either the boiler or chiller cannot
be used because they are being repaired, the system intent has failed.
Why would a boiler or chiller fail? With respect to the boiler, consider a scenario
where heating is required in the early morning and early evening. During the day,
cooling is required. To meet the demand, the boiler is maintained in a hot stand-by
mode. When the system demands heat, the pumps and control valves shift to send
boiler water to the system. What comes back to the boiler is the chilled water
(relatively cold) from the system. The result - THERMAL SHOCK. It is assumed that
a similar, but opposite, phenomenon exists within the chiller.
What can the system designer do to minimize the potential problem when single
pipe systems are designed?
Provide slow acting valves that slowly bleed the system water into the boiler
during the cooling/heating mode changeover.
Specify boilers that minimize problems resulting from Thermal Shock. Refer to
the Cleaver-Brooks Flextube Boiler product section, Section B1.
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06-08
Select and specify boiler operating controls and system controls that maximize
equipment protection without sacrificing the heating/cooling comfort needs of
the individuals.
Possibly include accumulator tanks into the system.
Accumulators Hot water systems inherently have considerable energy capacity. Once the heating
system is on-line, the flywheel affect has a tendency to smooth out the minor
spikes and valleys that occur during the typical heating load. However, some
systems dictate the requirement for load, or heat shedding, to maximize operating
efficiency or the availability of additional heat to satisfy load demand peaks. When
load shedding or heat storage needs exist within the same system, an accumulator
tank or heat accumulator, is an ideal fit.
When hot water systems include large demand heat users that are brought into
service quickly through controls and valving, the increased load demand is
immediately realized by the boiler. To minimize the impact of the condition and to
add to the total available energy for the system, accumulators or storage tanks can
be used. Proper sizing of accumulator tanks requires careful analysis of the load
peaks that are to be addressed and the minimum/maximum temperature swings
that can be tolerated in the system.
The control system, including circulating pumps, will be dependant on the specific
application of the accumulator and the design of the storage tank, such as
stratification tanks and baffle tanks.
Although accumulators are not common in most heating systems, they do provide
heat storage capacity and equipment protection and should be considered in
complex hydronic system designs.
Safety The highest level of consideration in any system design should be the safety of
personnel. Good safety practices are essential in hot water, as well as in steam
systems. For example, consideration for safe discharge of water from the relief
valves is important. For hot water heating boilers (ASME Section IV; 160 psig/250
F maximum) a flexible connection between the safety valve and the discharge pipe
is recommended. The discharge piping must be properly arranged and supported so
that its weight does not bear upon the valve.
High Temperature
Water Boilers
As required by ASME Boiler and Pressure Vessel Code, boilers for operation over
250 F or 160 psig must be constructed in accordance with ASME Section I, Power
Boilers. Due to limitations of control and safety settings, an operating temperature
above 240 F will require the use of a Section I boiler.
Design pressures above 125 psig will require Cleaver-Brooks review, regardless of
operating temperature. Use Figure I2-3 for the operating temperature and
recommended minimum boiler operating pressure. Also, please ensure that there is
continuous water flow trough the boiler.
Depending on horsepower requirements, operating temperature, design pressure,
and water flow rate, there could be some limitations that affect recommended boiler
size or maximum Btu rating. Cleaver-Brooks is in a better position to review and
comment on the design criteria if the evaluation is performed at the design stage of
the project. Contact your local Cleaver-Brooks authorized representative on any high
temperature water applications. Provide the following details for review:
Supply and return temperatures.
I2-12
06-08
Flow rate (is it constant or variable?).
Operating pressure.
Describe load characteristics.
Provide detail of system and sequence of operation.
If a system schematic is available, forward a copy to your local Cleaver-
CONTROL CONSIDERATIONS
Temperature Control Boiler Water Temperature Control
As with all pieces of mechanical equipment, rapid changes in temperature will
cause thermal stress to a boiler pressure vessel. The degree of stress and
subsequent failure is directly related to the frequency and degree at which the
thermal stresses are applied. Also, in hot water applications, too low of a boiler
water outlet temperature can cause condensation of flue gases and subsequent
fireside corrosion. In order to avoid these types of problems, certain parameters
must be considered when designing a hot water control system.
1. Minimum Outlet Temperature
Fireside corrosion occurs when flue gases are cooled below the dew point.
Cooling of the flue gases occurs when hot flue gases come in contact with cool
pressure vessel surfaces. To prevent this, minimum operating temperatures
must be maintained to keep the flue gases above the dew point. The minimum
water outlet temperature is typically 170 F. The minimum return water
temperature is typically 150 F. For exact temperatures refer to the specific
boiler section. Maintaining minimum outlet temperatures will help prevent
harmful condensing of flue gases.
2. Maximum Outlet Temperature
The maximum temperature rating for all Cleaver-Brooks ASME Section IV
boilers is 250 F. Due to limitations of control and safety settings, desired
operating temperatures above 240 F may require the use of a Section I boiler
and a high temperature hot water system. For high temperature water, ASME
Section I, the boilers maximum outlet temperature depends upon its design
pressure. For information on high temperature water applications, contact your
local Cleaver-Brooks authorized representative for further information.
3. Temperature Drop Across the Boiler
The maximum temperature drop from supply to return is directly related to the
circulation rate through the boiler and boiler capacity. These factors must be
evaluated to ensure they meet the intent of the system design. Refer to Table I2-
1 for flow rate versus temperature drop charts.
Even though design temperature drops can be up to 100 F, care must be taken
when applying boilers into these systems. At no time should the system
temperature drop provide return water at a temperature that could cause flue
gas condensation and subsequent fireside corrosion.
4. Boiler Warm-up
The controls that maintain the boiler water temperature should be designed and
set in such a way as to allow a slow warm-up of a cold boiler. To prevent
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06-08
damage to the pressure vessel and refractory, a warm-up from a cold (ambient)
boiler to operating temperature is normally accomplished through manual
operation at the low-fire rate. Automatic operation from a cold start is not
recommended without proper control sequencing, as is available with the CB-
HAWK control.
In multiple boiler installations when a second cold boiler is being brought into
the system, a means should be provided to slowly introduce flow of system
water into the return. The boilers temperature should not be increased any
quicker than 1 F per minute. Even when the boiler has reached return water
temperature, a means must be provided for a slow warm-up of the boiler from a
stand-by to an operational condition. This will provide proper warm-up of the
refractory within the boiler as well as ensure that the pressure vessel is at
operating temperature. Under these conditions, a means should be provided to
hold the burner in the low-fire position a minimum of 30 minutes if the burner
has not operated within the last 4 hours.
5. Rapid Replacement of Boiler Water
The most common causes of cold water slugs returning to a boiler are: 1) cycling
of individual zone pumps and, 2) the main circulating pump cycling off, allowing the
boiler to continue to operate. These situations cause a boiler that is operating
between 170 and 250 F to experience high flow rates of possibly ambient
temperature water, thus causing excessive thermal stress. To determine the rate at
which cold water can be introduced into an operating boiler, refer to the specific
boilers temperature drop/flow rate charts.
6. One additional item that must be considered when deciding upon boiler outlet
water temperatures is boiler auxiliaries, which may require certain temperatures. For
example, a hot water boiler firing a No. 6 fuel oil may require temperatures in
excess of 200 F, when heating the oil in an oil preheater with boiler water. The
operating temperatures needed will depend upon the fuel oil temperatures required
for proper atomization of the fuel. If water temperatures cannot be maintained at the
required levels, an electric preheater must be sized accordingly to provide the
additional heat.
System Temperature Control
Since the minimum outlet temperature for a boiler is limited, it is sometimes
desirable to regulate the water temperature going to the heat users. This is normally
done by regulating the temperature of the main supply and/or the water temperature
at the heat users.
The most common way to vary the system supply temperature is through the use of
a three- or four-way control valve. These control valves will blend a portion of return
water with boiler supply water to maintain the desired system supply temperature.
When applying these types of valves, care must be taken to ensure that the
minimum flow requirements for the boiler will be met at all times. These valves
must be slow moving to ensure that rapid temperature changes are not taking place
in the boiler return water temperature.
Temperature control at the heat users is normally accomplished through diverting or
two-position valves controlled by a room or duct thermostat. Temperature control of
heat users will be discussed in more detail later in this section.
I2-14
06-08
Lead/Lag Systems A Lead/Lag system sequences the on-off firing and modulation of multiple boilers to
meet the system load demand.
The key to the design of a lead/lag control in a hot water system is the realization
that temperature changes in a hot water system are inherently slow. This also
means that a change in boiler output does not result in immediate changes in
overall system temperature. The control system must be designed to take into
account the lag times and allow for fine tuning.
Lead/lag systems are available in two basic types. Lead/lag start - unison
modulation and lead/lag start - lead/lag modulation. Please refer to Controls, Section
8, for a more detailed description of these two systems.
In general, with hot water systems, lead/lag start - unison modulation would be the
most practical system. This is due to the fact that with hot water boilers, the load
imposed on a particular boiler is directly related to the rate of water flow through it.
If the flow rate through two boilers is equal, they must have the same Btu output to
maintain a constant supply header temperature. The following example illustrates
the problem associated with not having unison modulation with two equally sized
boilers in a lead/lag sequence.
Boiler #1 Boiler #2
200hp 200hp
Flow = 500gpm Flow = 500gpm
Firing rate = 100% Firing rate = 25%
Return temperature = 160 F
Required header temperature = 190 F
The Btu output of a 200hp boiler at 100% firing rate is 6,695,000 Btu/hr. The
same boilers output at 25% is 1,673,750 Btu/hr. Each boiler has a flow of 500
gpm or 4071 lb/min. Since it takes 1 Btu to change 1 pound of water 1 F, we can
determine the outlet temperature of each boiler.
Boiler #1
6,695,000 Btu/hr 60 min/hr = 111,583 Btu/min
111,583 Btu/min output divided by the 4071 lbs/min flow rate yields a
temperature rise of 27.4 F.
Boiler #2
1,673,750 Btu/hr 60 min/hr = 27,895 Btu/min
27,895 Btu/min output divided by the 4071 lbs/min flow rate yields a temperature
rise of 6.9 F.
With a return temperature to both boilers at 160 F, it can be seen that the outlet
temperature of boiler #1 would be approximately 187 F and the outlet temperature
of boiler #2 would be almost 167 F. Since the flow through both boilers is equal,
the mixed temperature to the header would be approximately
177 F.
This scenario becomes even further complicated when more than two boilers are in
a system, and when they are of varying sizes. When the boilers are different sizes,
the flow through the boilers must be proportional to the capacity and firing rate of
the boilers. For example, the load on a smaller boiler
may exceed rated capacity while the larger boiler is
I2-15
06-08
cycling off, resulting in inefficiencies and potential thermal shock damage to the
pressure vessel and refractory. To ensure the flow through a particular boiler is
proportional to its size and firing rate, controls and motorized valves should be
incorporated. The control system required to perform this can become quite
sophisticated; however, reliable operation and a savings in repair and maintenance
costs will be realized.
The stand-by boiler must be kept in mind when designing a system with lead/lag
operation. If there is continuous flow through all boilers, regardless of whether or
not they are firing, the stand-by boiler will have an outlet temperature equal to the
return temperature. This, again, will create a situation where a blended temperature
is getting to the common supply header. This is normally avoided by installing a
motorized valve at the outlet or return to each boiler. The position of the valve is
dictated by the status of the boiler. The valve will generally have two positions.
When the boiler is at header temperature and supplying hot water to the system,
the valve would be at its position for maximum design flow through the boiler.
When the boiler is in stand-by, the valve would be positioned for the minimum flow
rate required by the boiler. Maintaining the minimum flow rate will prevent
stratification of temperatures within the boiler. The valve positions become more
Figure I2-4. Plug Cock or Gate Valve
(Manual Operation)
Figure I2-5. Two-Position Valve
(Electric or Pneumatic)
Figure I2-6. Throttling or Modulating Valve
(Electric or Pneumatic)
Figure I2-7. Three-Way Mixing Valve
I2-16
06-08
complicated and numerous when boilers of unequal sizes are applied in the same
system. Keep in mind, flow through the boilers must be proportional to the output of
the boilers.
Provisions should be made in the lead/lag control system to maintain a boiler in a
hot standby condition. This normally requires intermittent firing at low fire to
maintain a set point slightly lower than the main supply set point.
To ensure that refractory as well as the pressure vessel are at a proper operating
temperature, all lead/lag controls must ensure that the burners return to low fire
prior to turning the burners off. It is recommended that once a boiler is brought into
the system after being off for a period of time (standby hot condition), that it be
operated at its lowest firing rate for a minimum of 30 minutes.
Temperature
Setbacks
In the interest of conserving energy, it is sometimes desirable to set back the system
supply temperatures based on time of day, day of week, or outdoor air temperature.
Since the boiler water temperature requires that a minimum outlet temperature be
maintained, resetting the boiler temperature is normally not practical. Resetting the
supply water temperature is normally accomplished through a three- or four-way
control valve. One important item to keep in mind when setting back temperatures,
is how the control valve reacts when returning the system to the higher temperature.
Figure I2-8. Three-Way Mixing Valve (By-Pass
Arrangement)
Figure I2-9. Three-Way Diverting Valve
Figure I2-10. Intermittent Secondary Pump Operation
(On-Off)
Figure I2-11. Water Temperature Constant Thru Zone
Bypass
I2-17
06-08
Control valve operation should not be instantaneous. It is extremely important to
ensure that the valve does not travel from a fully closed to a fully open position
instantaneously. This would cause high flow rates of relatively cold water to return
to the boiler, causing thermal stress and possible pressure vessel damage.
Individual zones should not normally be set back by turning off individual
circulating pumps. In determining whether or not this practice would be acceptable,
the flow rate of the zone versus the entire system flow rate must be considered. If
the zone has a high flow rate compared to other zones, cycling of pumps can cause
serious problems with cold slugs of water being returned to the boiler, resulting in
thermal stress and subsequent pressure vessel failure.
Heat Users Selection of the type, size, quantity and location of heat users is job specific, and is
usually determined by the project design engineer.
Typical load groupings are shown on the hot water system layouts shown in Figure
I2-14 thru Figure I2-19. The groupings will naturally be varied, depending on
actual job layout and the individual load and temperature requirements.
The following heat users are most commonly used in hot water heating systems:
1. Radiators
2. Convectors
3. Coils in Ducts
4. Fin Coils
5. Blast Coils
6. Unit Heaters
7. Unit Ventilators
8. Unit Ventilators with Face and Bypass Dampers
9. Radiant Panel - Inside
10. Process Heating
Figure I2-12. Continuous Secondary Pump
Operation with Two-Position Valve (Valve Open)
Figure I2-13. Continuous Pump Operation with Two-
Position Valve (Valve Closed)
I2-18
06-08
Manufacturers installation recommendations should be closely followed to avoid
special problems such as coil freeze- up, water hammer, and noise factors.
Control of Water Flow Through Heat Users
Common methods of controlling water flow through heat users are shown on the hot
water layouts found later in this section and are described later.
Plug Cock or Gate Valve (Manual Operation)
Figure I2-4 is the simplest form of control and is directly related to physical comfort
in the area adjacent to the heat user. It is commonly used on radiators, convectors,
unit heaters or ventilators, and blast coils. It is sometimes used on coils and unit
ventilators with face and by-pass dampers.
Sometimes an orificed gate valve is used in a non-critical area. The orificed gate
valve is recommended to ensure flow to the heat user, because it allows flow back to
the boiler under all system conditions.
Two-position Valve (Electric or Pneumatic)
Two-position (fully open or fully closed) valves are commonly used to control water
flow to all types of heat users. See Figure I2-5. The electric or pneumatic signal to
the valve is usually controlled by a room thermostat or manual on-off switch in the
area adjacent to the heat user.
The room thermostat or manual on-off switch in the area adjacent to the heat user
will also start the fan on devices such as unit heaters.
Throttling or Modulating Valve (Electric or
Pneumatic)
Throttling or modulating valves are used to control water flow to heat users such as:
blast coils, unit heaters, and unit ventilators. See Figure I2-6. Throttling or
modulating valves are preferred to two-position valves since they provide more
uniform heating and a relatively constant flow of return water.
Three-way Mixing Valve
Three-way mixing valves (two inlets, one outlet) are used to control water
temperatures going to inside radiant panels or process loads. See Figure I2-7. If a
pump is used, its capacity governs the quantity of water flowing through the heat
user. The pump usually operates (on-off) in response to a high limit room thermostat
(without heat anticipation feature).
When used on inside radiant panels, the three-way valve is usually controlled by a
room thermostat or by the temperature of the water going to the panel.
When used on process loads, the three-way valve is usually controlled by the
temperature of the process itself.
Three-way Mixing Valve (By-pass Arrangement)
The three-way mixing valve with bypass arrangement (Figure I2-8) is commonly
used on fin coils, coils, panels, and process loads and is preferred to the three-way
mixing valve arrangement, since it assures a flow of return water. When fin coils or
coils are controlled by a three-way valve, a room or duct thermostat usually operates
the valve.
I2-19
06-08
Three-way Diverting Valve
A three-way diverting valve (one inlet, two outlets) arrangement can be used in the
same manner as the three-way mixing valve (by-pass arrangement). See Figure I2-
9. In either case, the position of the valve allows more or less water to flow through
the coil or through the by-pass. Either position of the valve assures return water
flow to the boiler.
Primary-Secondary Pumping
1. Intermittent Secondary Pump Operation (on-off)
The secondary pump operates in response to a high limit room thermostat (without
heat anticipation feature), a duct thermostat, or actual temperature of the water
entering or leaving the heat user. See Figure I2-10.
A tee can actually be used as a mixing valve with this system. Also, wide ranges
and good control of temperature drops are available to the designer. (In the example
just given, there is a 60 degree drop from supply to return, but only a 20 degree
drop across the heat user). When the pump is off, there is no flow in the secondary
zone. The amount of water entering the zone by-pass flows through the zone by-
pass to the return header.
In Figure I2-11, the 5 gpm at 250 degrees entering the zone by-pass leaves the
zone by-pass at approximately the same temperature. If desired, the supply water
temperature could be varied with an indoor-outdoor system.
2. Continuous Secondary Pump Operation (with 2-position valve)
In Figure I2-12, when the 2-position valve is open (admits 250 F water), the 5
gpm at 250 F mixes with the 10 gpm at 190 F to supply 15 gpm at 210 F to the
pump and the heat users.
Notice
There is 0 gpm in the common piping and the return water (5 gpm) is at 190 F.
Thus, there is a 60 degree drop from supply to return, and a 20 degree drop across
the heat user.
The 2-position valve could be controlled by a room thermostat or by the
temperature of the water entering or leaving the heat user.
When the 2-position valve is closed, (Figure I2-13) the continuously operating
secondary pump is circulating 15 gpm at approximately 210 F. As long as this
satisfies the load requirements, the valve remains closed.
The 5 gpm at 250 F entering the zone by-pass line leaves the zone by-pass at
approximately the same temperature.
Continuous secondary pump operation provides continuous controlled heat input
into each zone.
WATER CONSIDERATIONS
Water Conditioning Boiling Out: Initial Cleaning
Every new system will have certain harmful substances which remain in the boiler
and piping after construction. It is common to find oils, greases, weld slag, and
I2-20
06-08
other contaminates within the system. If the foreign materials remain, the boiler
could be affected by loss of heat transfer on heat exchanger surfaces and/or an
acidic water condition. Boiler life may be reduced as a result of an unclean system.
Your authorized Cleaver-Brooks representative or water treatment company will be
able to recommend a chemical cleaning or boil-out procedure. Also, refer to the
boiler operating and instruction manual for more details.
Chemical Treatment It is recommended that chemical treatment be provided for the initial fill of the
system. Generally, chemicals will be required to prevent scale formation, promote
elimination of dissolved gases and control pH.
Most hot water boilers operate in a closed system and are considered to require
little attention for water treatment. Experience has shown, however, few systems
can be considered completely closed. Loss of water can occur from pump packing,
glands, air venting devices, and threaded or flanged pipe connections. A means
must be provided to chemically treat the raw water make-up. This is generally
accomplished through the use of a shot-type chemical feeder. For information on
shot type chemical feeders refer to Section 19.
Make-up Water It has been generally accepted in system design that hot water boilers are in a
closed system and, therefore, no make-up water is needed. This is not always the
case. Untreated make-up water is a leading cause for failures of hot water boilers.
In the design stage of a hot water system, provisions must be made for properly
introducing, metering, and treating make-up water.
Introducing Make-up Water
A recommended means for introducing make-up water to a hot water system is
shown in Figure I2-1. This method ensures all air is removed from the make-up
water. It also ensures the water temperature is tempered prior to being introduced
to the boiler, thus reducing the risk of thermal shock.
Metering Make-up Water
The purpose of metering the make-up water to a hot water system is to prevent
potential problems that can tend to damage an otherwise well planned installation.
Figure I2-1 shows the recommended location for a water meter, which is used to
measure the amount of make-up water used by the system. The meter is necessary,
as it may be the only means to identify a system loss of water. Knowledge of make-
up water usage will alert the operator to investigate the cause of the system water
loss. This allows the operator to fix the problem and properly treat the make-up
water prior to experiencing any additional problems.
In some cases, depending on the preference of the customer, no automatic means
for make-up water is provided. Instead, a low water alarm is used in the expansion
tank to alert the operator of a loss in system water and a need for system make-up.
The operator can then diagnose the system loss and properly treat the make-up
water. A low water alarm is only practical where full- time operators are employed.
Ethylene Glycol as
Heat Transfer
Medium
1
on applications requiring freeze protection, a mixture of ethylene glycol and water
is commonly used.
When using ethylene glycol certain design limitations are important, due to the
characteristics of the fluid versus the characteristics of water. These characteristics
I2-21
06-08
are: Elevated saturation temperature, decreased thermal conductivity and specific
heat, and increased viscosity and density. In addition, ethylene glycol degrades
when it is heated above the manufacturers specified maximum film temperature.
The following design parameters must be considered when operating with ethylene
glycol solutions. For industrial watertube boiler parameters, or for conditions not
covered in the following, contact your local Cleaver-Brooks authorized
representative.
1. Maximum Glycol Concentration
Firetube:60%
Flexible Watertube: 60%
Model 4 Watertube: 50%
2. Maximum Outlet Temperature
Firetube: up to 300 F
Flexible Watertube: 200 F
Model 4 Watertube: 200 F
3. Internal Circulation
A. For firetube boilers, the size of the supply and return connections are decreased
based on the design temperature drop and the system pump gpm.
B. A minimum continuous gpm flow rate through the boiler corresponding to a 40 F
system drop is recommended. For firetube boilers operating between 250 -
300 F, use a flow rate based on a 30 F system drop.
4. Expansion Tank
a. An inert gas pressurizing blanket is preferred due to the over-pressure
requirements.
5. Over-Pressure Required:
A. Firetube
170 - 250 F operating temperature - recommend 40 psig minimum operating
pressure.
250 - 300 F operating temperature - recommend 100 psig minimum operating
pressure.
B. Flexible Watertube - recommend 50 psig minimum operating pressure.
C. Model 4 Watertube - recommend 50 psig minimum operating pressure.
6. Depending upon the application, process boilers may need to be sized to limit
continuous duty to 80% of maximum boiler rating. As a general rule, fireside boilers
up to 350 horsepower and a maximum operating temperature of 200 degrees F, can
be operated without consideration of Btu de-rating.
Notice
Generally, Firetube boilers up to 350 horsepower and a maximum operating
temperature of 200 F can be operated without consideration of Btu de-rating.
1. On applications requiring freeze protection, a mixture of ethylene glycol and water is
commonly used.
I2-22
06-08
7. A means should be provided to routinely monitor the condition of the system
fluid. Frequent analysis during the first six months of operation and semi-annual
checks thereafter are recommended.
8. Excessive use of inhibitors can create precipitation of solids causing reduced
circulation and reduced heat transfer.
9. Always alert your local Cleaver-Brooks authorized representative of a system to
be designed for glycol mix. Additional product modifications may be necessary,
based on size, boiler model and operating temperature.
10. The temperature rating of the glycol is also important. In general, use a product
with a minimum temperature rating of 175 degree F above the boiler operating
temperature.
SYSTEM DIAGRAMS
Hot Water System Layout Schematics:
The system layouts (Figure I2-14 through Figure I2-19) are intended to be used
as a general guide for use with Cleaver- Brooks products. Many system layout
combinations have not been shown.
Typical load groupings have been shown and will naturally vary, depending on
actual job layout and individual load temperature requirements.
Reverse returns are shown, since they help equalize the paths of water flow and
simplify balancing of the circuits.
Centrifugal system circulating pumps are shown. It is assumed that these
pumps are manually started and stopped and that they are electrically
interlocked with the burner control circuit. The boiler cannot fire unless the
circulating pumps are running.
Balancing cocks are shown in the supply lines from each boiler to the pumps in
order to help equalize or proportion flow through the boilers.
The number and location of balancing cocks, shutoff valves, etc., to be used in
the system will vary with the particular application.
A make-up water meter must be installed in any raw water feed to the system.
A means for introducing chemicals to the system water must be provided.
Individual expansion tanks are shown for clarity. One expansion tank for
multiple boilers is typically sufficient when sized properly.
Notice
When working with individual zone circuits, where one zone may have a large
quantity of water, and where the zone circulating pump has a high gpm compared
to other zones, cooling down of the water can cause a serious problem in rapid
replacement of boiler water when the pump is started. For this reason, it is
recommended that all circulating pumps run continuously to permit constant
circulation through the relief or bypass device.
I2-23
06-08
Figure I2-14. Primary Loop Circuit, Constant Speed Pumps
I2-24
06-08
Figure I2-15. Primary Loop Circuit with Secondary Pumping
I2-25
06-08
Figure I2-16. Individual Zone Circuits
I2-26
06-08
Figure I2-17. Primary Loop Circuit with Three-Way Valve
I2-27
06-08
Figure I2-18. Four-Way Valve System
I2-28
06-08
Figure I2-19. Multiple Boiler Lead/Lag, Primary/Secondary Pumping
I3-1
CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-3
THE STEAM-GENERATING FACILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-3
Type of Application/Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-5
Operating Conditions, Requirements and Constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-5
Codes and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-7
Other Federal, State, Provincial and Local Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-7
EQUIPMENT CONSIDERATIONS AND HARDWARE DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-7
Steam Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-8
Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-10
Boiler Piping and Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-13
Boiler Feed Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-16
Water Treatment Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-21
Economizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-24
Blowdown Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-24
SYSTEM INTEGRATION AND
OPTIMIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-26
EXAMPLE - STEAM SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-26
Boiler Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-29
Condensate Return And Feedwater System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-30
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-31
Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-31
Efficiency Enhancement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-31
System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-31
ILLUSTRATIONS
Figure I3-1. Typical Steam System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-4
Figure I3-2. Schematic Diagram of a Generic Steam-Generating Facility . . . . . . . . . . . . . . . . . . . . I3-4
Figure I3-3. Summary of Application/Energy-Use Audit Items . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-6
Figure I3-4. Recommended Safety Valve Discharge Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-13
Figure I3-5. Example of System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-32
TABLES
Table I3-1. Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-11
Table I3-2. Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-11
Table I3-3. Recommended Non-Return Valve Size (High Turndown). . . . . . . . . . . . . . . . . . . . . . . I3-12
Table I3-4. Removal of Harmful Elements with Various Types of Equipment . . . . . . . . . . . . . . . . . I3-15
Table I3-5. Makeup Water Impurities, Limits and Treatment Methods . . . . . . . . . . . . . . . . . . . . . I3-15
Table I3-6. Recommended Limits for Total Suspended Solids . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-20
Table I3-7. Water Test Results and Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-26
Section I3
STEAM SYSTEMS
08-08
Steam Systems Section I
I3-2
08-08
Notes
Section I Steam Systems
I3-3
08-08
INTRODUCTION
A steam system consists of a steam-supply/generating facility, a steam and
condensate return/water piping system, and a steam-use facility (Figure I3-1). In
this section, the discussion is focused on the integration of the various equipment
within the steam-generating facility. Information is offered which need be
considered when designing a steam-supply system. A general guideline is provided
which identifies major issues to be addressed, leading to the evaluation of system
solutions and ultimately to equipment considerations for selection and design.
Finally, an example of an audit and system design are provided for demonstration
purposes.
The reader is encouraged to review the specific product sections for additional
information. The discussion in this section applies primarily to new systems and
new boiler installations. When modifying existing systems, other considerations
may apply.
THE STEAM-GENERATING FACILITY
The steam-generating facility, located in the boiler room, consists of boilers,
feedwater systems, heat exchangers (e.g., economizers), boiler and system controls,
fuel and gas handling equipment (e.g., fuel trains, stacks), and steam/water
treatment equipment and piping (Figure I3-2). The purpose of the steam-generating
facility is to provide energy (in the form of thermal energy of the steam) to drive
other processes in the steam-use facility. In turn, typical steam-use facilities are
designed to meet various industrial and commercial needs such as comfort heating,
food processing, paper corrugation, etc.
Steam-generating facility design is unique to the specific application and it is
dictated by good engineering practice, the ASME code, applicable national, state,
provincial and local codes, and utility and insurance requirements. System design
and selection depend on job specific operating requirements, boiler room structure
and venting, fuel storage, and utility service considerations. There is therefore no
simple mathematical expression to correlate steam boiler room design and
application. However, there are several characteristics which help define the
application and its relevant requirements. For a steam-generating facility, these
characteristics include:
Type of Application/Load
Operating Conditions, Requirements and Constraints
Facility Requirements and Limitations
Codes and Standards
Other Federal, State, Provincial and Local Requirements
Many of these characteristics have been thoroughly discussed in other sections of
The Boiler Book. The objective here is to draw from that information in order to
address design of integrated steam systems. Ultimately, the objective is to design a
steam-generating facility which is economically optimal for the demands of the
steam-use facility.
The following is a step-by-step procedure which assists in the design of steam-
generating facilities for industrial and commercial use. These items are typically
addressed during an application/energy-use audit of the facility.
I3-4
08-08
Figure I3-1. Typical Steam System
Figure I3-2. Schematic Diagram of a Generic Steam-Generating Facility
BOILERS
CONTROLS
STACKS
ECONOMIZERS
FUEL TRAINS
HEAT EXCHANGERS
FEEDWATER SYSTEMS
SEPARATORS
BLOWDOWN SYSTEMS
WATER TREATMENT
PUMPS
PIPING
STEAM TRAPS
PUMPS
COMMERCIAL
AND INDUS-
TRIAL HEATING,
PROCESS, AND
COMBINATION
APPLICATIONS
STACK GASES
MAKE-UP WATER
STEAM
CONDENSATE
RETURN
FUEL AND
COMBUSTION
AIR
STEAM-SUPPLY/GENERATING FACILITY
STEAM AND CONDENSATE
RETURN PIPING SYSTEM
STEAM-USE
FACILITY
WATER
TREATMENT
SYSTEM
FEEDWATER
SYSTEM
CONTROLS
BOILER(S)
STEAM-USE
FACILITY
BLOWDOWN
SYSTEM
ECONOMIZER
MAKE-UP WATER
STACK GAS
STEAM
BOILER FEEDWATER
TO SEWER
CONDENSATE RETURN
I3-5
08-08
Type of Application/
Load
1. Categorize the application and load as heating/cooling, process or combination
(see Section I1, System Load). There are a number of institutional applications
which demand not only heating/cooling, but other steam or hot water
requirements for the purpose of cooking, washing, etc. Generally speaking,
these institutional loads are classified as heating applications since the
requirement typically deals with heating and cooling of air and potable-water.
2. At this juncture, a determination is made whether the boiler should be steam-
or hot water-generating (see Section I1). For the remainder of this section, it is
assumed that a steam- generating facility is appropriately chosen. (For more
information on application considerations for hot water boilers and hot water
systems, please refer to Section I2, Hot Water Systems.)
Operating
Conditions,
Requirements and
Constraints
Steam
1. Determine the desired operating pressure. For existing steam-use facilities, the
operating pressure has typically been set in the past and now acts as a
constraint on the system design at hand. For new facilities, slightly more
flexibility exists and yet operating characteristics of equipment in the steam-use
facility either set or limit the range of operating pressure of the boiler.
2. Determine the steam load characteristics and ultimately the profile of the
steam-use facility in its entirety (see Section I1). It is important to understand
both the steady-state load profile as well as the transient and instantaneous
demands.
3. Determine the desired or necessary steam quality (dryness) or degree of
superheat. Steam quality ranges from 0 to 100% and is defined as the ratio of
the amount of saturated steam vapor to the total steam amount (which may
consist of both saturated steam vapor and liquid). A 100% steam quality
translates to zero amount of saturated steam liquid and, in this condition, the
steam is termed to be dry.
4. The degree of superheat refers to the amount of thermal energy (heat) added to
the steam relative to the saturated steam vapor point of reference, typically
expressed in units of degrees Fahrenheit. For example, a degree of superheat of
50
o
F means that an additional amount of heat has been added to the steam so
that the final steam temperature is 50
o
F greater than the saturation
temperature of the steam at the given operating pressure.
Condensate Return/Make-up Water
1. Determine the condensate return conditions, primarily focusing on temperature,
pressure and flow rate (% return).
2. Calculate the make-up water requirement based on the percentage of
condensate return.
3. Determine the water charges for the specific facility under analysis.
Water Discharge
1. Determine the maximum temperature for water discharge, which is usually
mandated by the local environmental governing authorities.
2. Determine the sewer charges for the specific facility under analysis.
Fuel
1. Determine the type(s) of fuel to be combusted within the boiler. Generally
speaking, the fuels are limited to natural gas, propane, and fuel oil (although
some other alternate fuels may be used).
I3-6
08-08
2. Obtain a composition analysis for each fuel, which will be necessary for
calculating fuel usage for a given load.
3. Determine the fuel costs; this is necessary for the economical optimization of
boiler room design. For new boiler(s) installation into an existing system, a two-
three year history of fuel billing data would be helpful in the eventual design of
the steam-generating facility.
Combustion Air
1. Determine the ambient air conditions in the boiler area and determine current
fresh air supply (e.g., louvre area). Primarily, the intention is to understand
typical air temperatures and humidity and their variance during the necessary
time of boiler operation.
Stack Gas
1. Determine any temperature limitations imposed on the stack gas.
2. Understand the local emission requirements, which will affect the allowable
stack gas composition.
3. Determine the physical lengths and flow areas of stack/breeching, most
importantly any constraints imposed in this area. These physical attributes will
affect the stack gas pressure which can, in turn, have an impact on combustion
characteristics and firing rates.
Electrical Power
1. Understand the electrical power overall demand and seasonal profiles.
2. Determine the electrical power costs for the facility. A review of 2-3 year
historical data of electric power billing from the local power company will assist
in this area. It is important to understand the demand charges separate from
the actual electrical energy charges.
Figure I3-3. Summary of Application/Energy-Use Audit Items
FUEL
COMBUSTION AIR
WATER DISCHARGE
STACK GAS
STEAM-GENERATING
FACILITY
STEAM
CONDENSATE RETURN
MAKE-UP WATER
STEAM-USE
FACILITY
1. TYPE OF APPLICATION/LOAD
2. OPERATING PRESSURE
3. LOAD PROFILE
4. QUALITY/DEGREE OF SUPERHEAT
5. TEMPERATURE
6. PERCENT MAKE-UP
7. WATER CHARGES
8. MAXIMUM TEMPERATURE
9. SEWER CHARGES
10. TYPE(S) OF FUEL
11. COMPOSITION ANALYSIS
12. FUEL COSTS
13. TEMPERATURE
14. TEMPERATURE LIMITATIONS
15. EMISSION REQUIREMENTS
16. STACK/BREECHING PHYSICAL ATTRIBUTES
17. ELECTRICAL POWER DEMANDS
18. ELECTRICAL COSTS
19. PHYSICAL LIMITATIONS
20. NOISE LEVEL REQUIREMENTS
PRESSURE
PERCENT RETURN
HUMIDITY
VARIANCE
AND PROFILE
I3-7
08-08
Facility Requirements and Limitations
1. In regard to boiler room design, understand the physical limitations of the
facility. This understanding should include floor space or footprint for both
installation and maintenance considerations as well as height limitations for
equipment sizing.
2. Determine noise level requirements.
These twenty audit items are summarized in Figure I3-3.
Codes and
Standards
Various Codes and Standards govern the design, fabrication and installation of many
of the boiler room components. Of primary importance is the American Society of
Mechanical Engineers' (ASME) Boiler and Pressure Vessel Code. The different
sections of this Code specify the rules by which steam boilers, pressure vessels and
connecting piping are to be designed, constructed and installed.
Section I of the ASME Code contains rules for Power Boilers which, for the case of
steam boilers, are boilers designed for a maximum allowable operating pressure
(MAWP) greater than 15 psig. Section IV of the ASME Code would provide rules for
steam boilers with a MAWP of 15 psig or lower. B31.1 Power Piping Code provides
rules for most of the piping systems involved in a typical steam plant, but has
special significance relative to Section I in that it contains Certification and
Stamping requirements for boiler external piping (BEP). BEP is defined as piping
from the first circumferential joint leaving the boiler up to and including the required
stop valve or valves. Most, if not all, of the piping included with a packaged boiler
is within the scope of BEP. This generally includes steam, feedwater, blowdown,
water column and instrument piping. Section VIII of the ASME Code contains rules
for unfired pressure vessels, which may apply to deaerators, blowdown separators,
etc.
Other Federal, State,
Provincial and Local
Requirements
There are many other Codes and Standards which apply to other aspects of the
design and installation of steam room equipment. For a listing of standards
organizations of relevance to the design of steam systems, please refer to Section I4.
Local jurisdictions, insurance companies and individual contracts often impose
special requirements above and beyond Code requirements, or may require
compliance with special Codes and Standards. It is essential that those responsible
for the planning of a boiler room installation be familiar with such requirements.
EQUIPMENT CONSIDERATIONS AND HARDWARE DESIGN
Having defined the application and obtained an understanding of the requirements
and constraints of the steam system, it is now important to consider basic
equipment needs and hardware design. Here the concern deals with potential
equipment problems of the steam-generating facility in terms of performance and
life. Specifically, the issues to be addressed when designing and integrating
equipment into a workable system are: (1) equipment capacity, (2) operating
characteristics and constraints of equipment, (3) maintenance issues and the
tradeoff with design/initial cost, and (4) the operational effects of each piece of
hardware on the overall system operation.
The following is a discussion concerning considerations given to each subsection of
the overall system, categorized as: steam boilers, boiler piping and valves,
feedwater systems, water treatment systems, heat exchangers and economizers,
and blowdown systems. Stacks and controls are not discussed since the intention
here is to concentrate on the steam side of the system. For information concerning
I3-8
08-08
controls and stacks, please refer to sections D and F, respectively. Considerations
concerning sizing of piping, steam traps, etc. are also not covered in this section;
those items are considered as a part of the steam/condensate return handling and
piping system design and many references concerning these issues are available.
Steam Boilers The boiler selection process is based on an evaluation of the system and load
requirements as described above, and a comparison with the different boiler types
that are available. This section defines a process and the considerations that can
be used to select a boiler for a steam system application, based on the
requirements discussed in Section I1.
The steam-use facility will have certain operating requirements that are used to
establish the boiler design pressure. For example, heating systems often operate at
low pressure (a steam pressure of 8 - 10 psig), and would use a boiler that is
designed for 15 psig. The boiler design pressure must be higher than the operating
pressure, and is usually based on common design pressures. Steam quality, or the
moisture content in the steam, may also be a requirement of the facility.
The first step in determining the required boiler size is to determine the number of
boilers. Multiple boilers can be used to divide a seasonal load into more
manageable segments, even using different boiler sizes to better match the load.
Additional boilers can be used to provide backup and minimize potential down
time. Hospitals usually require a substantial amount of backup capability.
Increasing the number of boilers also adds to the initial cost, on-going maintenance
costs and complexity of the system.
Once the number of boilers have been selected, the capacity of the boilers can be
determined. This task should not be limited to matching the peak load and the
total capacity of the boilers. For example, the base capacity or number of boilers
should be increased if there can be a high instantaneous demand. Some
consideration should also be given to how multiple boilers are cycled to minimize
the cycling and number of units in use at any one time.
Increasing the number of boilers will:
Minimize down time and maximize reliability.
Provide the highest efficiency by matching load to boiler capacity.
Increase the total installed cost of the boiler room.
Allow the use of smaller boilers and support components.
Increase maintenance cost.
Increase the size and complexity of the boiler room.
Minimizing the number of boilers will:
Decrease total installed cost.
Reduce overall efficiency because of low-load operation.
Minimize maintenance costs.
Provide a less complex and smaller boiler room.
Different sized boilers can be used for the large variation in seasonal loads.
Total boiler capacity should include future expansion considerations.
Emission regulations may require special controls above a certain total capacity.
I3-9
08-08
At this stage of the selection process, some boiler types can be eliminated based on
the operating pressure and capacity requirements. (Table I1-1 in Section I1 can be
used as a guide in this process). In addition, the load type may also impact the
selection process. For example, watertube boilers are better suited to swing loads
while firetube boilers are better for loads with upset conditions. Also, bent tube
boilers can be used when quick warm up is required.
Watertube boilers are the preferred choice for pressures above 350 psig.
Higher turndown rates improve the boiler load response because the boiler
remains on line at low loads.
Bent tube and electric boilers can provide quick warm-up without thermal
shock.
Steam superheat is generally only available on the IWT boiler.
There are numerous regulatory requirements in the boiler industry. Many boilers are
listed by Underwriters Laboratories or a similar agency, which has tested the
product to ensure that it meets their minimum standards for safety and
performance. Emission regulations have become more common in recent years.
Finally, there may be other organizations that will mandate requirements for an
installation, such as the city, state or insurance carrier. These requirements may
prevent the use of some boiler types.
Check insurance carrier for requirements.
A Package listing helps insure boiler/burner compatibility.
Construction and operating permits are usually required by local authorities.
Federal NSPS regulations, permits and recording applies over 200 hp.
The final stage in the selection process will be the consideration of the operating
features and efficiency of the boilers. Initial cost is always a factor, but it should not
be the only factor. For example, the boiler efficiency, turndown and maintenance
requirements can result in much higher or lower operating costs, and can easily
change the cost analysis. Some common considerations that impact overall
efficiency and fuel costs are:
Multiple fuel capabilities, including future conversions.
More flue gas passes in a firetube boiler will increase heat transfer.
Heating surface area, usually 5 square feet per boiler hp in a firetube boiler.
Higher turndown increases boiler efficiency and provides quicker load response.
Lower excess air operation increases boiler efficiency.
Economizers can be added to most boilers, which will increase efficiency.
Maintenance and down time can be important considerations in the boiler selection.
Using multiple boilers helps reduce the potential for loss of steam generating
capability.
Higher turndown reduces component wear and failure due to on-off cycling.
Critical operations should include controls to keep the standby boiler hot.
Always use duplex pumps and filters to allow maintenance without shut down.
Consider rental boilers as potential backup, and include required piping in the
plant.
Generally boilers with large water volumes and surface areas are more tolerant
of feedwater treatment variations and load surges.
I3-10
08-08
The moisture content in steam from a steam generator is normally very small.
There are conditions that can upset the normal operation and result in some
relatively high amounts of water carry-over. In addition, there are some
applications which require extremely dry steam for proper operation. There are
some guidelines for maintaining high quality steam, and methods to improve the
steam quality.
Feedwater quality is the single most important element in steam quality. General
feedwater guidelines are given in this book and others. Special considerations need
to be given to the type of boiler. There may be additional requirements based on the
boiler type and the conditions of the local water supply. A water specialist should
be consulted for specific requirements of an installation.
The steam quality from a boiler can be improved by adding an external separator or
an equalizing line similar to a Hartford Loop. Such special steam piping
arrangements are sometimes used on low pressure steam boilers with small steam
chambers.
The industrial watertube boiler offers some additional options for improving the
steam quality. One option uses special drum components to further remove solids,
resulting in higher steam quality. The other option is to add a superheater to
provide superheated steam.
Water maintenance programs can help insure reliable steam quality.
Boiler concentrations may need to be adjusted for best steam quality.
Special steam piping can be used with some boilers (such as the cast iron
boiler) to reduce carry-over.
An external separator will typically remove 90% of the moisture in a steam line.
Superheated steam and special steam dryers are available on industrial
watertube boilers.
Steam Nozzle Size Minimum steam nozzle size is important to maintain an acceptable steam velocity
as steam exits the boiler. Standard nozzle sizes are usually based on the design
pressure of the boiler, so it is important to determine when a nozzle change is
recommended. Use Table I3-1 as a reference when selecting the steam nozzle on a
firetube boiler.
Non-Return Valves Table I3-3 gives non-return valve sizes for standard applications. Table I3-3 gives
non-return valve sizes for high turndown applications.
I3-11
08-08
Table I3-1. Recommended Steam Nozzle Size
08-08
RECOMMENDED STEAM NOZZLE SIZE WHEN
OPERATING AT VARIOUS PRESSURES
TO MAINTAIN 5000 FPM NOZZLE VELOCITY MAXIMUM.
- FIRETUBE BOILERS -
BOILER HORSEPOWER
Operating
Pressure
PSI 15 20 30 40 50 60 70 80 100 125 150 175 200 225 250 300 350 400 500 600 700 750
15 4 4 4 6 6 6 6 6 8 8 8 8 10 10 10 12 12 12 12 12 12 12
20 2 2.5 3 4 4 4 6 6 6 6 8 8 8 8 8 10 10 10 12 12 12 12
25 2 2.5 3 3 4 4 4 6 6 6 6 8 8 8 8 10 10 10 12 12 12 12
30 2 2 2.5 3 4 4 4 4 6 6 6 6 8 8 8 8 10 10 10 12 12 12
35 2 2 2.5 3 3 4 4 4 6 6 6 6 8 8 8 8 8 10 10 12 12 12
40 2 2 2.5 3 3 4 4 4 6 6 6 6 6 8 8 8 8 10 10 10 12 12
45 1.5 2 2.5 2.5 3 3 4 4 4 6 6 6 6 6 8 8 8 8 10 10 12 12
50 1.5 2 2.5 2.5 3 3 4 4 4 6 6 6 6 6 6 8 8 8 10 10 10 12
55 1.5 2 2 2.5 3 3 3 4 4 4 6 6 6 6 6 8 8 8 10 10 10 10
60 1.5 2 2 2.5 3 3 3 4 4 4 6 6 6 6 6 8 8 8 8 10 10 10
65 1.5 2 2 2.5 3 3 3 3 4 4 6 6 6 6 6 6 8 8 8 10 10 10
70 1.5 2 2 2.5 3 3 3 3 4 4 4 6 6 6 6 6 8 8 8 10 10 10
75 1.5 2 2 2.5 3 3 3 3 4 4 4 6 6 6 6 6 8 8 8 8 10 10
80 1.5 1.5 2 2 3 3 3 3 4 4 4 6 6 6 6 6 6 8 8 8 10 10
85 1.5 1.5 2 2 3 3 3 3 4 4 4 4 6 6 6 6 6 8 8 8 10 10
90 1.5 1.5 2 2 3 3 3 3 4 4 4 4 6 6 6 6 6 6 8 8 8 10
95 1.5 1.5 2 2 3 3 3 3 4 4 4 4 6 6 6 6 6 6 8 8 8 8
100 1.5 1.5 2 2 3 3 3 3 4 4 4 4 6 6 6 6 6 6 8 8 8 8
105 1.5 1.5 2 2 3 3 3 3 4 4 4 4 4 6 6 6 6 6 8 8 8 8
110 1.5 1.5 2 2 3 3 3 3 4 4 4 4 4 6 6 6 6 6 8 8 8 8
115 1.5 1.5 2 2 3 3 3 3 4 4 4 4 4 4 6 6 6 6 8 8 8 8
120 1.5 1.5 2 2 3 3 3 3 4 4 4 4 4 4 6 6 6 6 8 8 8 8
125 1.5 1.5 2 2 3 3 3 3 4 4 4 4 4 4 6 6 6 6 8 8 8 8
130 1.5 1.5 2 2 2.5 2.5 2.5 2.5 3 3 4 4 4 4 6 6 6 6 6 8 8 8
135 1.5 1.5 2 2 2.5 2.5 2.5 2.5 2.5 3 4 4 4 4 4 6 6 6 6 8 8 8
140 1.5 1.5 2 2 2.5 2.5 2.5 2.5 2.5 3 3 4 4 4 4 6 6 6 6 8 8 8
145 1.5 1.5 2 2 2.5 2.5 2.5 2.5 2.5 3 3 4 4 4 4 6 6 6 6 6 8 8
150 1.5 1.5 2 2 2.5 2.5 2.5 2.5 2.5 3 3 4 4 4 4 6 6 6 6 6 8 8
175 1.5 1.5 2 2 2.5 2.5 2.5 2.5 2.5 2.5 3 3 4 4 4 4 6 6 6 6 6 8
200 1.5 1.5 2 2 2.5 2.5 2.5 2.5 2.5 2.5 3 3 4 4 4 4 4 6 6 6 6 6
225 1.5 1.5 2 2 2 2 2 2 2 2.5 3 3 3 3 4 4 4 4 6 6 6 6
250 1.5 1.5 2 2 2 2 2 2 2 2.5 3 3 3 3 4 4 4 4 6 6 6 6
Note
Shaded area denotes that special surge load baffles must be installed.
Standard nozzle sizes are listed for 15 and 125 psi operating pressures.
Request standard nozzle size to be changed per this table.
Table I3-2. Recommended Non-Return Valve Size
Valve sizes (300# flange) given in inches. Standard non-return valve selection limited to a maximum 2 to 1 turndown (50% of boiler output).
Selection based on typical valve sizing recommendations. For final valve selection contact your authorized C-B representative.
BOILER HP
BOILER CAPACITY (LBS/
HR)
OPERATING PRESSURE (PSIG)
50 75 100 125 150 175 200 250
100 3450 2-1/2 2-1/2 NA NA NA NA NA NA
125 4313 3 2-1/2 2-1/2 2-1/2 NA NA NA NA
150 5175 3 3 2-1/2 2-1/2 2-1/2 2-1/2 NA NA
200 6900 3* 3 3 3 3 2-1/2 2-1/2 2-1/2
250 8625 4 3* 3 3 3 3 3 3
300 10350 4 4 4 3* 3 3 3 3
350 12025 4 4 4 4 4 3* 3 3
400 13800 5 4 4 4 4 4 4 3*
500 17210 6 5 5 4 4 4 4 4
600 20700 6 6 5 5 5 4 4 4
700 24150 6 6 6 5 5 5 5 4
800 27600 6 6 6 6 6 5 5 5
I3-12
08-08
Table I3-3. Recommended Non-Return Valve Size - High Turndown
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I3-13
08-08
Boiler Piping and
Valves
This section contains information on boiler piping and valve requirements for low
and high pressure boilers.
Relevant highlights of the ASME Code are included. However, for complete details,
the reader should review the applicable section of the ASME Code. In addition to
the ASME Code, the reader should determine whether there are any special, local
insurance or regulatory requirements.
Low Pressure Boilers
The ASME Code contains many recommendations for low pressure steam systems.
Here are excerpts that apply to design consideration.
Steam Line Expansion - Provisions shall be made for the expansion and
contraction of steam and hot water mains connected to boilers by providing
substantial anchorage at suitable points, and by providing swing joints when boilers
are installed in batteries, so there will be no undue strain transmitted to the
boilers. para. HG-703.1
Stop Valves for Single, Multiple, and Steam Boilers
Steam Boilers - When a stop valve is used in the supply pipe connection of a single
steam boiler, there shall be one used in the return pipe connection.para. HG-
710.1
Multiple Boiler Installations - A stop valve shall be used in each supply and return
Figure I3-4. Recommended Safety Valve Discharge Piping
I3-14
08-08
pipe connection of two or more boilers connected to a common system. para. HG-
710.3
Shutoff Valves - No shutoff of any description shall be placed between the safety
relief valve and the boiler, nor on discharge pipes between such valves and the
atmosphere. para. HG-701.5
Safety and Safety Relief Valves - Safety and safety relief valves shall not be
connected to an internal pipe in the boiler. para. HG-701.4
Safety Valve Discharge Piping - A discharge pipe shall be used. Its internal cross-
sectional area shall be not less than the full area of the valve outlet or of the total of
the valve outlets discharging there into and shall be as short and straight as possible
and so arranged as to avoid undue stress on the valve or valves. When an elbow is
placed on a safety or safety-relief valve discharge pipe, it shall be located close to
the valve outlet. The discharge from safety or safety-relief valves shall be so
arranged that there will be no danger of scalding attendants. Para. HG-701.6 Refer
to Figure I3-4.
Bottom Blowoff - Each boiler shall have a bottom blowoff or drain pipe connection
fitted with a valve or cock connected with the lowest water space practicable. The
discharge piping shall be full size to the point of discharge. para. HG-715
High Pressure Boilers
The ASME Code provides many recommendations for high pressure steam boilers.
Here are some excerpts that apply to design considerations.
Steam Line Expansion - Provisions shall be made for the expansion and
contraction of steam mains connected to boilers, by providing substantial anchorage
at suitable points, so that there shall be no undue strain transmitted to the boiler.
para. PG-59.1.2
Steam Stop Valves - Each boiler discharge outlet, except safety valves or safety
relief valves, or preheater inlet and outlet connections, shall be fitted with a stop
valve located at an accessible point in the steam-delivery line and as near the boiler
nozzle as is convenient and practicable. When such outlets are over NPS2, the valve
or valves used on the connection shall be of the outside-screw-and-yoke rising-stem
type so as to indicate from a distance, by the position of its stem whether it is closed
or open, and the wheel may be carried either on the yoke or attached to the stem.
para. 122.1.7 (A.1) (ASME B31.1)
When boilers are connected to a common header, the connection from each boiler
having a manhole opening, shall be fitted with two stop valves having an ample
free-blow drain between them. The discharge of this drain shall be visible to the
operator while manipulating the valve. The stop valves shall consist preferably of
one automatic non-return valve (set next to the boiler) and a second valve of the
outside-screw-and-yoke type or two valves of the outside-screw-and-yoke type shall
be used. Para. 122.1.7 (A.2) (ASME B31.1)
Stop-Check Valves (Non-Code Recommendations) - A problem confronting the
power piping designer is the selection of the best size of stop check valve for his
service conditions. This type valve usually has a floating disc member, hence it is
important that the valve be sized to provide full disc lift under flow conditions
prevailing during the major portion of the service life of the installation. If the valve
is too large for flow conditions, the disc will float in a partially open position; this
may result in fluttering of the disc and rapid wear of
I3-15
08-08
valve parts. Conversely, if the valve is too small for flow conditions encountered,
pressure drop will be excessive.
Safety Valves - No valve of any description shall be placed between the required
safety valve or valves and the boiler, nor the discharge pipe between the safety
valve and the atmosphere. When a discharge pipe is used, the cross-sectional area
shall be not less than the full area of the valve outlet or the total of the areas of the
valve outlets discharging there into and shall be as short and straight as possible
and so arranged as to avoid undue stresses on the valve or valves. All safety valve or
relief valve discharges shall be so located or piped as to be carried clear from
running boards or platforms. Ample provision for gravity drain shall be made in the
DISSOLVED
CONSTITUENT
SOFTENER CLORIDE CYCLE
DEALKALIZER
FILTERS DEAERATORS
Calcium Ca
B
98-100% Must have soft water No Change No Change
Magnesium Mg
B
Hardness
A
Sodium Na Increases No Change No Change No Change
Bicarbonate Alkalinity HCO
3
A

No Change 90% No Change No Change
Sulfate SO
4
No Change 90-95% No Change No Change
Chloride Cl No Change Increases No Change No Change
Silica SiO
2
A
No Change 20% No Change No Change
Soluble Iron Fe 100% Must have soft water No Change No Change
Total Dissolved Solids
A
No Change No Change No Change No Change
Suspended Solids
A
Must Be Removed Must be removed Down to 10
Micron
No Change
Dissolved Gases
A
No Change Free CO
2
Only See Filter
Section
To.005 cc/liter of O
2
NOTE: All of the above packaged water systems can be readily integrated into existing Cleaver-Brooks boiler rooms. All are designed to
accommodate boilers of any make.
A. Specifically limited by ASME guidelines on boiler feedwater quality.
B. The sum of calcium and magnesium equal the hardness. Hardness has been listed as a separate item for those analyses showing
hardness only.
MAKE-UP WATER TEST TYPICAL IMPURITIES TYPICAL LIMITS TREATMENT METHOD
Oxygen 6 ppm
<.007 ppm
A
Deaeration/Chemical
Hardness 86 ppm
<1.0 ppm
A

Softener
Suspended Matter 0.1 ppm
0.15 ppm
A
Blowdown
pH 6.87
7.0-10.5
A
Chemical
Silica 10 ppm
<150 ppm
B
Blowdown
Alkalinity 100 ppm
<700 ppm
B
Blowdown/Dealkalizer
Dissolved Solids 500 -mho/cm
<7000 mho/cm
B
Blowdown
A. Limits for feedwater.
B. Limits of boiler.
Table I3-4. Removal of Harmful Elements with Various Types of Equipment
Table I3-5. Makeup Water Impurities, Limits and Treatment Methods
I3-16
08-08
discharge pipe at or near each safety valve or safety relief valve, and where water of
condensation may collect. Each valve shall have an opening gravity drain through
the casing below the level of the valve seat. For iron-and-steel bodied valves
exceeding 2-1/2 inch size, the drain hole shall be tapped not less than 3/8 inch pipe
size. Para PG-71.3 Refer toFigure I3-4, Recommended Safety Valve Discharge
Piping.
Safety Valve Mounting - When a boiler is fitted with two or more safety valves or
safety relief valves on one connection, this connection to the boiler shall have a
cross-sectional area not less than the combined area of inlet connections of all the
safety valves with which it connects and shall also meet the requirements of
Paragraph PG-71.3. Para. PG-71.5
Blowoff Valves - The blowoff valve or valves, the pipe between them, and the boiler
connection shall be of the same size except that a larger pipe for the return of
condensate may be used.
For all boilers... with allowable working pressure in excess of 100 psig, each bottom
blowoff pipe shall have two slow-opening valves, or one quick-opening valve or
cock; at the boiler nozzle followed by a slow-opening valve. A slow-opening valve is
a valve which requires at least five 360 degree turns of the operating mechanism
from fully closed to fully opened. On a boiler having multiple blowoff pipes, a single
master valve may be placed on the common blowoff pipe from the boilers, in which
case only one valve on each individual blowoff is required. In such a case, either the
master valve or the individual valves or cocks shall be of the slow-opening type.
Para. 122.1.7 (ASME B31.1)
Feedwater Valves - The feedwater piping for all [steam] boilers ... shall be provided
with a check valve... between the check valve and the boiler. Para 122.1 (B1)
(ASME B31.1)
When two or more boilers are fed from a common source, there shall also be a
globe or regulating valve in the branch to each boiler located between the check
valve and the source of supply. Para. 122.1.7 (B.5) (ASME B31.1)
Boiler Feed Systems The transfer of heat from steam, regardless of process usage, will create
condensate. The quantity of collectable condensate varies with the type of
application. For instance, with humidification, the steam is released to the
environment and the condensate is considered uncollectible. In industrial
applications, condensate can typically be collected in large quantity.
An important factor in the condensate return and water make-up system is to ensure
that contaminated condensate does not return to the boiler room and its associated
equipment. Condensate contaminated with oil, dye, soap, etc. must be disposed of
in a safe manner. Contaminated condensate will cause problems such as foaming,
priming, unstable water level, and it will increase blowdown requirements.
The collection of clean steam condensate is desirable for several economic reasons.
Condensate generally is capable of being collected at temperatures higher than the
temperature of raw water make-up. This results in significant fuel cost savings and
improved overall system efficiency. Since condensate is formed from steam, it
contains little or no dissolved solids. Therefore, using collected condensate reduces
chemical usage and associated costs as well.
Additionally, the cost of raw water make-up will be reduced by collecting condensate
because the demand for raw water is limited. When considering installation costs,
the expected condensate return may allow for down-
I3-17
08-08
sizing of the raw water make-up supply system and other components.
Unfortunately, condensate flow from the system may be unpredictable.
Unpredictability of returning condensate causes a problem for the boiler, since it
should have a continuous and immediately available supply of water. However,
there are several ways to collect and store condensate so it is readily available.
A collection or storage tank can be incorporated to act as a reservoir. Products
which serve this purpose include boiler feedwater systems, surge tanks, and
deaerators.
The function of these products in the overall condensate return and raw water
make-up system is as follows. For further information on this equipment, refer to
the specific product sections in The Boiler Book.
Boiler Feed System
Boiler feedwater systems help maintain maximum efficiency and prolong the life of
the boiler, when investment in a deaerator cannot be justified. Consisting of one or
more feed pumps and a corrosion resistant receiver tank, the system automatically
supplements condensate with make-up water to replace system losses. When
equipped with an automatic preheater, feedwater temperatures can be maintained
at temperatures up to 210 F (maximum). At this temperature, substantial amounts
of oxygen and carbon dioxide are released, reducing the amount of chemicals
required to protect the boiler and system from corrosion. Preheating is
recommended if the return condensate constitutes 50% or less of the required
feedwater.
Boiler feed systems typically combine one or more boiler feed pumps with a tank to
store condensate and make-up water. These components are typically furnished as
a complete package with level, temperature, and pressure controls. Additional
features such as deaeration hardware and more sophisticated controls may be
considered.
The purpose of the boiler feed system is to provide a reservoir with sufficient surge
capacity to accommodate intermittent condensate flowrates, and to provide stable
suction conditions for the boiler feed pump(s). The selection of a boiler feedwater
system is primarily driven by surge capacity. For this reason, it is necessary to
accurately estimate peak condensate flowrates from the steam-use facility,
considering also factors due to transient conditions such as equipment startups,
piping hydraulics, and system interactions. Once this information is obtained and
understood, a boiler feed tank of sufficient size may be selected.
The operating characteristics of the boiler and steam-generating system have an
impact on the type of controls and features included in the boiler feed system. In
particular, those factors influencing pump selection will also have an effect on the
height of the boiler feedwater system, the level control system, and suction piping
design. The characteristics of the returning condensate should also be considered
when selecting feedwater system components, corrosion resistant linings, and
pressure/temperature controls.
There are many cost/benefit tradeoffs available when configuring a boiler feed
system. A partial list includes:
Feedwater Preheat reduces thermal shock.
Premium Lining/Galvanizing reduces corrosion.
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08-08
Premium Level Control reduces overflow losses.
Code Rated Pressure Tank reduces flash steam losses.
Deaeration Hardware reduces corrosion and thermal shock.
Each of these options has a direct benefit on the long-term operating costs of the
system. Their increased initial costs must be balanced against the overall capital
cost and the expected life of the system. For more information on boiler feed
systems, please refer to Section H5.
Surge Tanks (Condensate Receiver Tanks)
Surge tanks can greatly reduce dependence on cold, untreated raw water to replace
boiler system losses by collecting condensate by gravity return for re-use in the
boiler feed system. Surge tanks are required when no other storage exists or when
intermittent peak loads of condensate can exceed the storage capacity of the
deaerator. Integrated control automatically introduces makeup water to supplement
condensate only when necessary to meet boiler demand. Refer to Section H4 for
more detailed information.
Deaerators
Deaeration is widely recognized as the most acceptable method for removing oxygen
and carbon dioxide from makeup water and condensate. Without deaeration, the
dissolved gases can cause serious corrosion in the boiler and other system
hardware.
Deaerators are considered essential for:
All boiler plants operating at 75 psig or more.
All boiler plants with little or no standby capacity.
All boilers plants where production depends on continuous operation.
All boiler plants operating with makeup water of 25% or more.
In addition to removing oxygen and carbon dioxide, deaerators also heat boiler
feedwater. The large storage capacity provides an effective means for recovering
heat from exhaust steam and hot condensate. With a deaerator, further savings
result from the reduced need for oxygen-scavenging chemical treatment. For further
information, refer to Sections H1, H2, and H3.
Pumps
There are five design criteria that must be considered before the proper boiler feed
pump can be selected.
1. Will the pump run continuously or intermittently?
2. What is the temperature of the water being pumped?
3. What is the pump capacity requirement in gpm?
4. What is the pump discharge pressure requirement?
5. What is the NPSH (net positive suction head) required?
Continuous or Intermittent Operation - Continuous or intermittent operation of a
pump is determined by the critical nature of the desired water level control. The
water level control requirements are primarily based on the type of boiler, but are
also affected by the load, operating pressure, and feed water temperature.
Continuous operation provides better water level control, but adds cost and
components to the system.
Boiler types with a relatively low water volume, such
I3-19
08-08
as watertube boilers, require more precise water level control than boiler types with
a large water volume, such as firetubes. This is due to the relationship between
drum (vessel) size and gallons of water content. For example, a fifty gallon change
in a watertube boiler might represent a one inch change in water level, while the
same fifty gallon change in a firetube boiler might only represent a fraction of an
inch change in water level.
Frequent load swings will require more accurate water level control to ensure the
feedwater flow matches the steam flow requirement. Frequent load swings may
require continuous feedwater control to maintain proper water level.
The relationship between operating pressure and feedwater temperature can make
water level control more critical if the temperatures vary or if there is a large
differential between saturation temperature and feed water temperature. Large
temperature differentials could result in a reduction in boiler water level when feed
water is added. The reduction is caused by a quenching effect, which lowers the
boiler water temperature slightly, reducing the steam/water volume, thereby
lowering the water level. This type of water level reduction is generally more
common on smaller, low pressure boilers.
Selection of Pump Type (Centrifugal or Turbine) - Once the criteria for water level
control is determined, the type of feed pump can be selected.
Highly accurate water level control can be achieved with a centrifugal type pump,
running continuously, in conjunction with a modulating feed water valve on the
boiler.
An effective but less precise means of water level control can be provided using a
turbine type pump, with intermittent (on- off) operation. With intermittent
operation, larger swings in water level control will result.
Although not common, turbine pumps have been used in conjunction with a
modulating feedwater valve to provide water level control. In this application, a
relief device must be included to discharge water back to the feedwater tank to
protect the pump from dead head pressures. Dead head pressures can cause
overheating, cavitation, and subsequent pump damage. A concern of this design is
the use of a relief device as a control valve, and the inherent performance and
reliability factors.
Pump Water Temperature - The temperature of the pumped water must be
specified to ensure proper design and construction. Pumps use packing or
mechanical seals to seal the area between the pump shaft and the pump casing.
These seals have temperature limitations and, if misapplied, the seals will fail.
Standard pump seals are adequate up to temperatures of approximately 215 F.
Higher temperature seals are available for temperatures up to 250 F and, for
temperatures above 250 F, external water cooling is usually employed to protect
the seals. For applications above 250 F, contact your local Cleaver-Brooks
Pump Capacity Requirements - Determining pumping capacity requirements
involves slightly different criteria for centrifugal and turbine type pumps. For both
pump types, the maximum boiler capacity must be determined. The maximum
boiler capacity, or evaporation rate, is usually calculated in pounds of steam per
hour, and should be converted to gallons per minute, and have blowdown added to
I3-20
08-08
it for pump selection purposes. For assistance in this calculation, contact your local
The pump capacity for turbine pumps, with intermittent operation, should be equal
to 2 times the maximum evaporation rate of the boiler.
The pump capacity for centrifugal pumps, with continuous operation, is equal to:
evaporation rate times 1.15 (safety factor), plus by-pass flow requirement (in gpm)
for the pump. The by-pass flow is usually regulated through a fixed orifice, and is of
sufficient quantity to prevent cavitation within the pump under dead head
conditions. The by-pass orifice must be located between the pump discharge and
the modulating feedwater valve to allow water to recirculate back to the storage
tank.
Pump Discharge Pressure Requirements - Pump discharge pressure requirements
are calculated by determining the boiler operating pressure and calculating the line
losses between the pump and the boiler. The pump discharge pressure needs to
overcome the piping line losses, and boiler pressure in order to get water into the
boiler.
All calculations need to be converted to feet of head for pump selection purposes.
Therefore, convert boiler operating pressure to feet of head, and add to that value
the equivalent length (in feet of head) of the piping and associated valves between
the pump discharge and the boiler.
Net Positive Suction Head (NPSH) - Every pump design has a certain requirement
for net positive suction head. This is the amount of liquid in feet that must be above
the pump suction centerline in order to prevent cavitation and to provide proper
pump operation.
Net positive suction head required (NPSH-R) by the pump must be exceeded by the
net positive suction head available (NPSH-A) from the system.
Calculation: NPSH-A = HP + HZ - HF - HVP
NPSH-A - Available NPSH expressed in feet of fluid.
HP - Absolute pressure on the surface of the liquid at the pump suction location,
expressed in feet. This could be atmospheric pressure or vessel pressure
(pressurized tank).
HZ - Static elevation of the liquid above, or below the centerline of the impeller,
OPERATING
PRESSURE
PSIG
TOTAL
SOLIDS
PPM
SUSPENDED
SOLIDS
PPM
0-300 3500 300
301-450 3000 250
451-600 2500 150
601-750 2000 100
751-900 1500 60
901-1000 1250 40
Table I3-6. Recommended Limits for Total
Suspended Solids
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08-08
expressed in feet.
HF - Friction and entrance head loss in the suction piping, expressed in feet.
HVP- Absolute vapor pressure of the fluid at the pumping temperature, expressed in
feet.
Cleaver-Brooks makes selections that are based on pumps having the lowest
possible NPSH-R. This is done to provide the lowest stand height and the lowest
overall height of the tank. There are some sacrifices which must be accepted in
order to have low NPSH-R. Usually a selection with a low NPSH-R is a pump that
is larger and usually requires a greater horsepower drive. Generally speaking,
however, it is more important to keep the overall height to a minimum than to select
a pump with a higher NPSH-R.
Pumps (General) - The design criteria for transfer pumps (pumps which pump
water to a deaerator) is the same as the criteria just covered for boiler feed pumps.
Cleaver-Brooks and our authorized representatives provide a full line of pumps, and
pump selection services for application in both steam and hot water systems. For
assistance, contact your local Cleaver-Brooks authorized representative.
Water Treatment
Systems
Harmful elements are contained in surface and well water. Surface and well water
are also called raw water. A sample of the raw water should be analyzed early in
the equipment planning stage. The analysis provides a clear definition of the
particular threats posed by the water source. Your Cleaver-Brooks representative
can assist you in defining the harmful elements, and can help in planning a water
treatment program and in selecting the proper treatment equipment.
The following is a discussion of the elements commonly found in raw water.
Surface water usually has high suspended solids and dissolved gases and low
dissolved solids. Well water normally has high dissolved solids and low suspended
solids and dissolved gases.
Suspended solids represent the undissolved matter in water, including dirt, silt,
biological growth, vegetation, and insoluble organic matter.
When minerals dissolve in water, ions are formed. The sum of all minerals or ions in
the water is the total dissolved solids or TDS.
Iron can be soluble or insoluble. Insoluble iron can clog valves and strainers and
can cause excessive sludge build up in low lying areas of a water system. It also
leads to boiler deposits that can cause tube failures. Soluble iron can interfere in
many processes, such as printing or the dying of cloth. In domestic water systems,
porcelain fixtures can be stained by as little as 0.25 ppm of iron.
Water hardness is the measure of calcium and magnesium content as calcium
carbonate equivalents. Water hardness is the primary source of scale in boiler
equipment.
Silica in boiler feedwater can also cause hard dense scale with a high resistance to
heat transfer.
Alkalinity is a measure of the capacity of water to neutralize strong acid. In natural
waters, the capacity is attributable to bases, such as bicarbonates, carbonates, and
hydroxides; as well as silicates, borates, ammonia, phosphates, and organic bases.
I3-22
08-08
These bases, especially bicarbonates and carbonates, break down to form carbon
dioxide in steam, which is a major factor in the corrosion of condensate lines.
Alkalinity also contributes to foaming and carryover in boilers.
pH is a measure of the degree of acid or base of a solution. The pH scale is from 0
to 14, with 0 being the most acidic and 14 being the most basic or alkaline.
Dissolved oxygen is the amount of oxygen gas dissolved in the raw water and is
caused by the solubility of atmospheric oxygen. Dissolved oxygen is not related to
the combined oxygen contained in the water molecule H2O. All surface and rain
water contain dissolved oxygen, because of their contact with the atmosphere. With
enough contact, the dissolved oxygen content will reach saturation for the
corresponding temperature. The solubility of oxygen is affected by solid content.
Water with a higher solid content will contain less oxygen than distilled water.
Surface water usually contains more oxygen than well water. As the raw water
temperature rises, dissolved oxygen is released and can cause corrosion of iron and
steel. Therefore, the problem caused by dissolved oxygen in boiler systems is
corrosion in the boiler feedwater piping, economizer, boiler, and steam and
condensate return piping.
Hence, the generation of steam from naturally occurring water sources can be
complicated by the presence of various chemical constituents in the water supply.
The American Society of Mechanical Engineers has published guidelines on boiler
water and boiler feedwater quality for steam boilers. Most boiler installations will
require some form of water treatment in order to conform to these guidelines. A few
methods of treatment are depicted in Table I3-4 and ITable I3-5.
The Objectives of Feedwater Treatment
Proper boiler feedwater treatment is an absolute necessity! Unless the boiler
receives water of proper quality, the boilers life will be shortened. The water supply
for a steam system may originate from rivers, ponds, underground wells, etc. Each
water supply source requires a specific analysis. Depending upon the analysis,
various pretreatment methods may be employed to prepare make-up water for the
boiler feedwater system.
The objectives of boiler water treatment in general are as follows:
1. Prevent hard scale deposits or soft sludge type deposits which would, if present,
impair the rate of heat transfer and possibly result in overheating and damage
to the pressure vessel.
2. Prevent general corrosion or pitting to assure maximum life of the boiler at the
lowest maintenance cost.
3. Prevent intercrystalline cracking or caustic embrittlement of boiler metal.
4. Prevent carryover to assure high quality steam at an economical rate of
continuous and intermittent blowdown.
The accomplishment of these objectives will, in all cases, involve several forms of
treatment including:
Pretreatment of the make-up water before it enters the boiler feedwater
system.
Chemical treatment of the boiler water internally in the boiler.
In addition, the selection of pretreatment methods will depend upon the chemistry
of the raw water and the plant operating
I3-23
08-08
characteristics. In most cases, pretreatment becomes more critical as the
percentage of make-up to the system increases.
Raw Water Make-up
Impurities in raw water make-up can be removed and controlled either chemically
or mechanically with various equipment. Mechanical means of removing or
controlling impurities will result in less chemicals being added to the boiler and
system. However, mechanical means will not remove or control all impurities.
Chemicals will still be required to provide the desired results.
The following are descriptions of feedwater pretreatment equipment and a
discussion of their functions in the overall feedwater pretreatment cycle. For further
information on equipment, refer to the specific product sections.
Filters
The need for special filter equipment to remove impurities can be readily
determined by a raw water analysis. Filters should be considered in order to remove
sand, iron, chlorine, and some dissolved organics and sediments. Refer to Section
H7.
Water Softeners
Water softeners should be used whenever raw water hardness exceeds 5 ppm. A
softener removes calcium and magnesium and exchanges them with highly soluble
sodium ions. Removing hardness prevents scale buildup on heat transfer surfaces
and helps maintain peak boiler efficiency. A water softener also is the base for many
sophisticated pretreatment processes that require the control of water hardness for
proper operation. Refer to Section H8.
Dealkalizers
Dealkalizers use softened water and remove negatively charged ions of bicarbonate,
carbonate, sulfate nitrate, and silica. They are replaced with chloride ions. Removal
of bicarbonate alkalinity controls formation of carbon dioxide and reduces the
corrosion of condensate piping. Dealkalization reduces the need for neutralizing
chemicals by as much as 90% and cuts fuel costs by minimizing blowdown. Refer
to Section H9.
Chemical Feed Systems
Chemical feed systems treat feedwater, boiler water, and condition blowdown
sludge where an additional measure of protection against corrosion and scaling is
required. Refer to Section H6.
In summary, the benefits of water treatment equipment include improved boiler
efficiency, corrosion reduction and therefore component life, and improved steam
purity. The selection and sizing of water treatment equipment is dictated by the
capacity of the steam system, the chemical constituents in the make-up water
supply, and the operating characteristics of the overall system. Generally speaking,
the greater the treatment load (in units of lb/hr removal), the larger the equipment.
It is important when designing a water treatment system that a detailed water
analysis be available as a guide.
The design of the water treatment system is influenced by cost/benefit tradeoffs in
equipment selection. These influences may include:
Chemical Feed Systems which have low initial costs, but significant
I3-24
08-08
operating costs.
Component Duplexing which tends to ensure uninterrupted operation.
Chloride Cycle Dealkalizers which reduce blowdown losses.
Filters which also reduce blowdown losses and maintenance.
Skid Mounting which decreases installation costs.
Premium Regeneration Controls which may decrease operating costs.
These equipment selection economic tradeoffs are influenced by size, criticality, and
operating environment of the steam system.
Economizers During boiler operation in typical commercial and industrial applications,
approximately 10-20% of the heating value of fuel is expelled with the stack gases
to the atmosphere. Stack economizers are designed to recover significant amounts
of this stack gas energy loss, thereby vastly improving boiler system efficiency, as
shown in Section G, Tables G-5 and G-6.
There are several considerations when selecting an economizer:
Gas-side Pressure Drop. Added back-pressure on the boiler stack affects the
combustion air fan throughput capability. The economizer and combustion
air fan(s) must be sized properly in order to assure a suitable system
operation and capacity.
Feedwater Temperature. The feedwater to the economizer must be
deaerated and the temperature setpoint minimally at 220
o
F to prevent tube
corrosion.
Water-side Pressure Drop. Feedwater pumps must be sized to accommodate
the economizer pressure drop. Additionally, a continuous modulating
feedwater system is required to ensure proper flow rates through the
economizer.
A full product line description of Cleaver-Brooks Boilermate Economizers, including
sizing and performance information, is offered in Section G.
Blowdown Systems A number of factors determine the need for boiler blowdown. As mentioned earlier,
the amount of total dissolved solids (TDS) is one. The American Boiler
Manufacturers Association (ABMA) has developed recommended limits for total and
suspended solids for different boiler operating pressures. Refer to Table I3-6 for
recommended limits for total and suspended solids.
Other controlling factors for determining blowdown requirements are alkalinity,
suspended solids, and other chemical factors. In boilers operating over 600 psig,
silica content could be the limiting factor.
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08-08
Solids are brought into the boiler by the feedwater. Even though the water is
treated, either mechanically or chemically, neither means of treatment is capable of
removing all substances. A small amount of crystallized solids will be present in the
boiler water, which can tend to encrust surfaces.
That is, solids become less soluble in the high temperature of the boiler water and
tend to crystallize and concentrate on heating surfaces. Internal chemical treatment
is therefore required in order to keep harmful scale and sludge from forming.
Scale has a low heat transfer value and acts as an insulating barrier. Insulation
retards heat transfer, which not only results in lower operating efficiency but, more
importantly, can cause overheating of boiler metal. Overheating of boiler metal
results in tube failure or other pressure vessel metal damage.
Scale is caused primarily by calcium and magnesium salts, silica, and oil. Any
calcium and magnesium salts, along with organic materials in the boiler water, are
generally precipitated by the use of sodium phosphate in order to maintain these
precipitates or sludge in a fluid form.
Solids, such as sodium salts and suspended dirt, do not readily form scale.
However, as boiler water boils, forming relatively pure steam, the remaining water
becomes increasingly thicker with solids. If the concentration is permitted to
accumulate, foaming and priming will occur and the sludge can cause harmful
deposits that potentially result in overheating of the metal. Therefore, lowering or
removing concentrated solids requires the use of boiler water blowdown.
Types of Blowdown
There are two principal types of blowdown: manual (intermittent) bottom blowdown
and surface (continuous) blowdown.
Manual (Intermittent) Bottom Blowdown - Bottom blowdown is necessary for the
proper operation of the boiler. Bottom blowdown removes sludge and controls the
level of TDS. On a manual system, the blowdown tappings are located at the
bottom or lowest part of the boiler, so that the dissolved solids in the boiler water
are lowered, and a portion of the sludge that accumulates in the lower portion of
the boiler is removed.
Surface (Continuous) Blowdown - Surface blowdown involves a continuous, low
flow of boiler water extracted from the surface of the water level in order to skim off
sediment, oil and other impurities. The blowdown is regulated by a flow control
valve, which is adjusted as needed to control the TDS level. The surface blowdown
opening is on the top center line of the pressure vessel and is provided with an
internal collecting pipe terminating slightly below the working water level.
A controlled orifice valve is used to allow a continual, yet controlled, flow of
concentrated water. Periodic adjustments are made to the valve in order to increase
or decrease the amount of blowdown in accordance with test analysis.
There are a few considerations when designing a blowdown system:
Local Code Requirements: If necessary, a blowdown aftercooler should be
incorporated to bring the blowdown water temperature to a level acceptable
to the sewer system and local code requirements.
Blowdown Heat Recovery: Since the blowdown water is discharged at the
saturated steam temperature, a significant amount of energy may be
I3-26
08-08
expelled during blowdown. A well-designed blowdown heat recovery system
can control blowdown rates and dissolved solids concentration while
recovering heat for make-up water preheating.
When selecting a blowdown heat recovery system, two factors should be
considered: (1) tube materials and construction, and (2) blowdown flowrate
control. The high velocities and abrasive nature of blowdown water necessitates
quality construction materials such as stainless steel, as well as design for vibration
damping. Secondly, it is important to control blowdown rate so as to match makeup
water flow rates for optimal heat recovery.
In most cases, the intermittent nature of bottom blowdown will preclude recovery of
the blowdown energy losses. Moreover, the bottom blowdown can contain
suspended matter or sludge that will tend to clog a heat exchanger. With a
continuous blowdown system, heat may certainly be recovered, transferred to make-
up water, before the blowdown is cooled and sent to sewer.
Flash Tank Heat Exchangers: Flash tank heat exchangers are also designed
to recover heat from blowdown water, but provide an added feature of
producing low-pressure steam for deaeration. The portion of blowdown
water which is not flashed either enters a blowdown heat recovery system
for make-up water preheating or is discharged to sewer.
SYSTEM INTEGRATION AND
OPTIMIZATION
The purpose of this section is to provide assistance in designing and integrating
various equipment into a workable system. A workable system is one that meets
the requirements and purposes of the system, has satisfactory life and maintenance
costs, and abides by all constraints such as pressures, temperatures, footprint,
noise, emissions, etc. In summary, a workable system performs the assigned duty,
given the imposed constraints and requirements.
System optimization, on the other hand, is the process of determining system
configuration and state point conditions which provide a maximization of some
objective such as the net present value of overall life costs. Optimized design may
offer the steam-user significant savings over the life of the steam-generating facility.
It is the design which maximizes profitability for the owner over time.
For a given application, there are many workable designs, but only one optimal
design. The discussion in this section entails a search method to approaching the
SUBSTANCE TEST RESULT LIMITS
Oxygen 6 ppm <0.007 ppm
Hardness 86 ppm <5.0 ppm
Suspended Matter 0.1 ppm <0.15 ppm
pH 6.8 7.0-10.5
Silica 10 ppm <150 ppm
Total Alkalinity 100 ppm <700 ppm
Dissolved Solids 500 mho/cm <7000 mho/cm
Table I3-7. Water Test Results and Limits
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08-08
optimal design. Components/equipment are added arbitrarily and evaluated for
effect on system performance and ultimately cost/benefit to the steam system
owner. A complete discussion of optimum system design is beyond the scope of this
publication
EXAMPLE - STEAM SYSTEMS
The following is an example of a relatively simple low pressure steam heating
system. The entire steam-generating facility of an existing heating system is
evaluated for replacement. An application/energy-use audit results in the following
information.
1. Type of Application/Load: Heating
2. Nominal Steam Pressure: 10 psig
3. Steam Load Characteristics/Profile:
The steam system operates 5 months/year.
During 3 months (2160 hours)
Minimum load: 0
Maximum load: 5,600 kBtu/hr
Average load:650 kBtu/hr
During 2 months (1440 hours)
Minimum load: 0
Maximum load: 8,100 kBtu/hr
Average load: 2,500 kBtu/hr
Transient loads, instantaneous demand, and sudden load swings do not exist.
4. Steam Quality Requirements: 98% steam quality at boiler pressure vessel exit
5. Condensate Return Conditions:
Temperature: 200 F
8100
kBtu
hour
(
hp hour
33.475 kBtu
)
=241 hp
total load =

(load
i
) (hours
i
)
$4.50
MMBtu
(5,004,000 MBtu)
1
0.6
(
) =$37,530
total fuel cost =
(total load) ($/MMBtu)
total load =2160 hrs 650 kBtu/hr. +1440 2500 kBtu/hr.

=5,004,000 kBtu
=system efficiency (decimal) where
Next, approximate fuel costs are calculated using the following:
2
I3-28
08-08
Pressure: 2 psig
% Return: 90%
6. Make-up Water Requirement: 10%
7. Water Charges:
$68.04/month service charge
$0.833/ccf consumption charge
8. Water Discharge Max. Temp: 120 F
9. Sewer Charges:
$13.72/month service charge
$0.573/ccf use charge
10. Types of Fuel:
Natural Gas
Light Oil considered as a back-up
11. Fuel Analysis:
Natural Gas
Methane: 86.0% (vol.)
Ethane: 7.2% (vol.)
Nitrogen: 6.8% (vol.)
SG: 0.619
HHV: 21,100 Btu/lb (1000 Btu/scf)
No. 2 Oil
Carbon: 85.8% (wt.)
Hydrogen: 12.7% (wt.)
Sulfur: 0.2% (wt.)
HHV: 19,420 Btu/lb
12. Fuel Costs:
Natural Gas: $4.50/MMBtu ($3.50 MMBtu interruptible)
No. 2 Oil: $4.20/MMBtu
13. Combustion Air Conditions:
Avg Temp
1
: 80 F
Rel Hum: 60%
14. Stack Gas Temperature Limits: N/A
15. Emission Regulations:
There are none currently, but requirements are in the expected future. Site is
located in a non-attainment zone.
16. Stack/Breeching Physical Attributes:
A new single stack is to be designed by the boiler supplier.
17. Electrical Power Demand: Not applicable in this case
I3-29
08-08
18. Electrical Power Costs:
$0.0345/kWhr on-peak
$0.0245/kWhr off-peak
19. Physical Limitations of Facility: None
20. Noise Level Requirements: <90 dBA
When designing a steam generating facility, necessary system capacity and
approximate fuel costs need to be considered. This will for allow both qualitative
and quantitative economic analyses of different installation alternatives.
First, required system capacity should be calculated. This is the maximum load.
A total capacity of 241 horsepower is required for this application.
Boiler Selection As this steam generating facility is replacing an existing one, pressure is already set
at 10 psig. This system operating constraint allows the use of a 15 psi boiler which
falls under Section IV of the ASME code. In addition to pressure requirements,
steam quality requirements need to be met. The customers system/application
requirement is 98%. Most boilers offer 98.5% steam quality at low pressure;
therefore this is not a limitation.
The large amount of idle time and low-load firing apparently suggest a two boiler
installation (boilers operate most efficiently near their rated capacity), with a large
boiler for winter and a smaller model for spring and fall. Reviewing the fuel bill,
however, indicates that an improvement in efficiency would not justify increased
installation, maintenance and capital costs that the customer wishes to minimize.
Furthermore, there is no need for back-up in this application. Therefore, the
recommendation is to install a single boiler. However, high- turndown would be
desirable to prevent excessive cycling.
With the necessary capacity calculated, and the number of boilers to be installed
decided, several boiler types can be ruled out immediately. Neither the Vertical
Firetube nor the Model 4 Watertube Boilers are available in sufficient size for this
system. At the opposite extreme, the load is far too small for an industrial
watertube boiler. Remaining boilers include the firebox, firetube, flextube, electric
and cast iron boilers. The cast iron boiler may be ruled out because of its higher
initial cost; the electric may be ruled out because of higher operating costs. The
remaining boilers, the firebox, firetube and flextube all are good choices for heating
loads requiring low pressure steam.
Instantaneous load is not an issue with a heating load. Likewise, there are no large
load swings to consider.
An application under federal emission regulations (NSPS) needs to be submitted
because this installation is capable of using over 10 MMBTU/hr. There are no
federal emissions requirements for this boiler because of the fuels selected. Local
permits for construction and operation will also be required. Furthermore, it is
desirable that the boiler be UL listed. There are no current local emission
requirements, although they are expected to occur in the near future as the site is
located in an ozone nonattainment area.
To minimize maintenance, a boiler with 5 square feet of heating area per
horsepower should be selected. The large water chamber and surface area reduce
I3-30
08-08
the need for cleaning, and minimize upsets caused in water treatment. A turndown
capability increased from the standard 4-1 would further reduce maintenance and
prolong boiler life. A 10-1 turndown, standard on the CB and CB (LE) [low
emission] Firetube Boilers (250-800 hp), would result in significant fuel savings in
this application. In a heating system such as this, eight to twelve cycles per hour
are common. The 10-1 turndown drastically reduces such excessive cycling and
decreases purge energy losses and cycling wear on components.
Both the CB and CB (LE) Firetube Boilers guarantee steam quality above the system
requirements.
The certainty of a future tightening of emission regulations leads to a decision in
favor of the 60 ppm CB (LE) Firetube Boiler
3
. Although both the firebox and flextube
boilers may be retrofitted with low NOx burners, it is done at considerable cost. The
CB (LE) Firetube Boilers ability to meet all future emission regulations, along with
its fuel savings, 10-1 turndown, and low cost for emissions reduction, make it the
best choice.
The customer currently carries uninterruptable gas service, paying $4.50/MMBtu.
The customer has the opportunity for savings by switching to a dual fuel burner,
which would allow for interruptible service. With the gas cost reduced to $3.50/
MMBtu, and assuming that light oil at $4.20/MMBtu would be used 20% of the
time, the resultant fuel bill is $30,490, or a $7,040 savings.
The final choice in this example will be a 250 horsepower 60 ppm CB (LE) Firetube
Boiler with a dual fuel burner. As this is a heating load, and no expansion is
foreseen, the 20% oversizing used in boiler selection for some systems is not
necessary here. In this application, the CB (LE) Firetube Boiler was selected due to
high turndown capability and the ability to meet future emissions regulations. These
features compensate for the higher capital costs of other boiler choices which could
meet demand.
Condensate Return
And Feedwater
System
This system has 90% condensate return. This yields a make-up water requirement
of 10%. If we assume a constant specific heat, and a make-up water temperature
of 40 F, a direct mixing would result in a feedwater temperature of 184 F.
It must first be decided whether to use a boiler feed system or a deaerating system.
In either case, this system must consist of a water reservoir, a stand (to provide
sufficient net positive suction head for the pump) and a pump. In this system, the
percentage of make-up water is low, and the feedwater mix temperature is relatively
high. Oxygen in the system may be controlled by chemicals. These conditions,
coupled with an already low annual fuel cost, decide against additional spending for
a deaerating system.
A rule of thumb for tanks is to have a fifteen minute water supply for boiler feed
systems and a ten minute supply for deaerating systems. A larger tank may be used
for systems with high condensate return, and a smaller tank for systems with a high
percentage of make-up. In this system, a fifteen minute water supply corresponds
to 2100 lb, or 253 gallons. A 270 gallon tank will be specified, allowing for the
high percentage condensate return.
In a heating system with a firetube boiler there is neither a large load swing nor a
necessity for precise boiler water level control. Therefore, an intermittent operation
turbine style pump will be selected to minimize system cost. As the feedwater
temperature is well below 215 F, there is no need for high temperature pump seals.
I3-31
08-08
Duplex pumps will be specified to minimize maintenance downtime.
Water Treatment Water treatment options include chemical, deaeration, softening and filtering. A
test result yielded the results in Table I3-7
The limits for silica, alkalinity and dissolved solids are all limits for the boiler water
itself. These can be controlled through blowdown (described below). The decision
to control oxygen through chemicals has already been made. It will be necessary to
include a water softener in the water treatment system to remove hardness.
Blowdown Manual bottom blowdown should be specified. The low fuel bills preclude the
option of continuous blowdown with heat recovery. Additional equipment
necessary includes a bottom blowdown separator and aftercooler. These are
necessary to reduce the blowdown water temperature to the maximum 120F.
Efficiency
Enhancement
The small annual fuel bills rule out a reasonable return on investment for efficiency
enhancing equipment such as an economizer, oxygen trim or blowdown heat
recovery. On large systems selecting such options may be the wise economic
decision.
System Schematic A schematic of the resulting system in shown in Figure I3-5.
I3-32
08-08
Figure I3-5. Example of System Configuration
WATER
SOFTENER
PACKAGED
BOILER FEED
SYSTEM
CHEMICAL
FEED SYSTEM
STEAM
SEPARATOR/
BLOWDOWN
AFTERCOOLER
STEAM HANDLING, HEATING
AND CONDENSATE RETURN
SYSTEMS
250 HP
CB (LE) BOILER
MAKE-UP WATER
STACK
90% CONDENSATE RETURN
200
10 PSIG STEAM
BOTTOM BLOWDOWN
COLD WATER
SUPPLY
TO DRAIN
I4-1
06-08
CONTENTS
STEAM PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-3
WATER PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-3
NATURAL GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-4
FUEL OIL PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-4
EQUIVALENT LENGTHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-10
STACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-10
FACTORS OF EVAPORATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-13
THERMODYNAMIC PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-14
Fuel Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-14
Fuel Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-15
Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-20
Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-21
UNIT CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-32
STANDARD ASSOCIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-45
ILLUSTRATIONS
Figure I4-1. Steam Pipe Chart - Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-5
Figure I4-2. Pressure Drop for Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-6
Figure I4-3. Oil Piping Pressure Drop (Viscosity = 100 SSU and Specific Gravity = 0.94) . . . . . . I4-8
Figure I4-4. Typical Stack Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-12
Figure I4-5. Typical Stack Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-12
Figure I4-6. Rain Cap Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-12
Figure I4-7. Fuel Oil Viscosity and Temperature Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-19
TABLES
Table I4-1. Gas Line Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-7
Table I4-2. Oil Piping Pressure Drop (Viscosity = 40 SSU and Specific Gravity = 0.9) . . . . . . . . . I4-8
Table I4-3. Oil Piping Pressure Drop (Viscosity = 100 SSU and Specific Gravity = 0.94) . . . . . . . I4-8
Table I4-4. Oil Piping Pressure Drop (Viscosity = 500 SSU and Specific Gravity = 0.94) . . . . . . . I4-8
Table I4-5. Oil Piping Pressure Drop (Viscosity = 1000 SSU and Specific Gravity = 0.96) . . . . . . I4-9
Table I4-6. Oil Piping Pressure Drop (Viscosity = 5000 SSU and Specific Gravity = 0.96) . . . . . . I4-9
Table I4-7. Equivalent Length of Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-10
Table I4-8. Single Boiler Vent or Stack Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-13
Table I4-9. Multiple Boilers - Common Breeching and Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-13
Table I4-10. Pounds of Dry Saturated Steam per Boiler Horsepower . . . . . . . . . . . . . . . . . . . . . . I4-14
Table I4-11. Typical Units for Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-15
Table I4-12. Detailed Requirements for Fuel Oils - Properties of Fuel Oil . . . . . . . . . . . . . . . . . . . I4-16
Table I4-13. Detailed Requirements for Fuel Oil Grade of Fuel Oil . . . . . . . . . . . . . . . . . . . . . . I4-17
Section I4
General Engineering Data
General Engineering Data Section I
I4-2
06-08
Table I4-14. Thermal Properties of Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-20
Table I4-15. Saturated Steam Properties, Temperature Table (Sheet 1 of 7) . . . . . . . . . . . . . . . . I4-21
Table I4-16. Saturated Steam Properties, Pressure Table (Sheet 1 of 5) . . . . . . . . . . . . . . . . . . . I4-28
Table I4-17. Temperature Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-33
Table I4-18. Conversion Factors (Sheet 1 of 9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-34
Table I4-19. pH Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-42
Table I4-20. Salinity Indicating Readings Conversion Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-42
Table I4-21. Useful Physical Constants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-42
Table I4-22. Conversions Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-43
Table I4-23. Approximate Common Equivalents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-44
Table I4-24. Conversions Accurate to Parts per Million . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-44
This section consists of four primary areas. The first includes information to assist in sizing of steam, water,
natural gas, and fuel oil piping. It also provides information on stacks.
The second area, entitled Thermodynamic Properties, contains information on fuel oils, water, and steam, and
covers viscosities, thermal properties of water, and steam tables covering the saturated region.
The third area is Unit Conversion, which includes extensive unit conversion factors as well as an discussion of the
difference between absolute and gauge pressure.
Finally, the fourth area provides a list of standard associations.
Section I General Engineering Data
I4-3
06-08
STEAM PIPING
Figure I4-1 allows pressure drop to be calculated given saturated steam pressure,
flow rate and pipe diameter. Although the example covers calculating pressure
drop, it is possible to work backwards to calculate pipe size, given pressure drop.
Example for Steam Pipe Chart, Pounds per Minute to Pressure Drop
A 500 hp boiler at 125 psig has a capacity of 17210 lbs/hr. Pressure drop will be
found through 100 feet of 5" inside diameter pipe.
First, convert pounds/hr to pounds/min by dividing by 60:
17210 60 = 285
Next, convert psig to absolute pressure by adding 14.7:
125 + 14.7 = 139.7
Now, plot 140 (the pressure) on its corresponding axis. This gives point A. Draw a
line from A through B, which is the pipe diameter. Continue this line to the axis, X.
This gives point C.
A new line is plotted from point C, through the pounds of steam per minute axis
(point D). This line ends at the pressure drop axis, for a drop of slightly more than
2.5 psi per 100 feet of pipe.
Example for Steam Pipe Chart, Pounds per Minute to Feet per Minute
The same specifications will be used from the previous example.
For this chart, begin with pounds/min. This gives point A. Draw the line through
the proper point (in this case, point B) on the diameter axis to the X axis (point C).
Next, plot from the X axis through the appropriate pressure (point D) to get steam
velocity. In this example, that corresponds to 3200 feet per minute.
WATER PIPING
Figure I4-2 allows pressure drop in psi or ft. of water to be calculated for a given
flow and pipe size. Like Figure I4-1, working backwards will allow pipe size to be
calculated for a target pressure drop. This figure will work with either water flow in
a hot water system boiler or feedwater to a steam boiler. This assumes a constant
viscosity and density for water over this range of temperatures, but should not
cause significant error.
Hot Water Boiler Example
In this example, pressure drop will be calculated for a 500 hp hot water boiler with
a 20 F temperature differential. This corresponds to approximately 1700 gpm.
The system will use 10" nominal size schedule 40 pipe. These two figures are
plotted on their respective axis, giving points A and B. A line is drawn through these
two points and the remaining two axis, giving a pressure drop of.57 psig (1.3 ft. of
water) and a 6.4 feet per second velocity.
500 hp x 33475
Btu
hr x hp
x
lb x F
1 Btu
1 hr
60 min
x x
gallon
8.3 lb
=1680
gallons
m in
1
20 F
x
I4-4
06-08
Feedwater Example
Now consider a 500 hp steam boiler. This requires approximately 40 gallons per
minute of feedwater. A 2" nominal schedule 40 pipe will be used. Plotting these
figure yields points C and D. Drawing a line through the points as before gives us a
pressure drop of 2 psig, or 4.6 feet of water.
NATURAL GAS PIPING
Table I4-1 shows capacity of a natural gas line for a given initial pressure with a 5%
pressure drop. For example, consider a 500 hp boiler, which requires 20,925 cu.-
ft. / hr. A 5 psi initial pressure is available for 100 ft. of pipe. To find the correct
pipe size, go to the line for initial gas pressure reading 5 pounds. Now move to the
right, until a number larger than 20,925 appears. In this case, the first greater
number is 30,500. The number at the top of that column shows the appropriate
pipe size, in this case 4". Table I4-1 assumes gas at 60 F, 1000 Btu/cu.-ft., and a
specific gravity of 0.619.
FUEL OIL PIPING
Table I4-2 through Table I4-6 show pressure drop for liquids with specific gravities
and viscosities in the ranges found for numbers 2 through 6 fuel oils.
To use these tables, select the table with the appropriate viscosity for the oil that is
being used. (An oil viscosity chart is provided later in this section in Figure I4-6.)
Select the line corresponding to the required flow, and the column corresponding to
the nominal pipe size. The intersection will give the pressure drop in psi per 100
feet of equivalent pipe length.
For example, a typical No. 2 fuel oil has a viscosity 40 SSU. A 500 hp boiler
requires up to 115 gallons per hour of No. 2 oil. Using Table I4-2, and specifying a
1-inch nominal pipe size, gives 0.1 psi pressure drop at 100 gph, and 0.2 at 150
gph. Linear interpolation gives 0.13 psi pressure drop per 100 equivalent feet of
pipe. Note that heavy oils require a return line, which increases total flow
requirements.
I4-5
06-08
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I4-6
06-08
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I4-7
06-08
INITIAL
GAS
PRESSURE
TOTAL
PRESS
DROP
GAS LINE CAPACITIES (CU-FT/HR THROUGH 100 FT LENGTH)
DIAMETER OF PIPE IN INCHES
1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 4 5 6 8
4 water 0.2 23 52 104 230 358 724 1180 2150 4510 8210 13400 27300
5 water 0.25 26 58 117 257 400 811 1320 2410 5050 9190 14900 30600
6 water 0.30 28 64 128 282 439 889 1450 2640 5540 10100 16400 33500
7 water 0.35 31 69 139 305 475 962 1570 2860 5990 10900 17700 36300
8 water 0.40 33 74 148 327 508 1030 1680 3060 6410 11700 19000 38800
9 water 0.45 35 79 158 347 540 1090 1780 3250 6810 12400 20200 41200
10 water 0.50 37 83 166 366 569 1150 1880 3430 7180 13100 21300 43500
11 water 0.55 38 87 175 385 598 1210 1980 3600 7550 13700 22300 45700
12 water 0.6 40 91 183 402 625 1280 2060 3760 7890 14300 23300 47700
1/2 psi .025 psi 43 98 197 433 673 1360 2220 4050 8590 15400 25100 51400
3/4 psi .038 psi 53 121 243 534 831 1680 2750 5000 10500 19100 31100 63500
1 psi .050 psi 62 141 282 622 967 1960 3190 5820 12200 22200 36100 73800
1-1/4 psi .062 psi 70 159 319 702 1090 2210 3600 6570 13800 25000 40800 83300
1-1/2 psi .075 psi 77 175 351 773 1200 2440 3970 7240 15200 27600 44900 91800
1-3/4 psi .088 psi 84 191 382 842 1310 2650 4320 7870 16500 30000 48900 99900
2 psi .100 psi 91 205 412 906 1410 2850 4660 8480 17800 32300 52600 108000
2-1/2 psi .125 psi 103 233 467 1030 1600 3240 5280 9620 20200 36700 59000 122000
3 psi .150 psi 114 259 519 1140 1780 3600 5870 10700 22400 40800 66300 136000
3-1/2 psi .175 psi 125 283 568 1250 1940 3940 6420 11700 24500 44600 72600 148000
4 psi .200 psi 135 307 615 1350 2110 4270 6960 12700 26600 48300 78700 161000
4-1/2 psi .225 psi 146 330 661 1460 2260 4580 7480 13600 28500 51900 84500 173000
5 psi .250 psi 155 352 706 1550 2420 4890 7980 14500 30500 55400 90200 184000
6 psi .300 psi 174 395 792 1740 2710 5490 8960 16300 34200 62200 101000 207000
8 psi .400 psi 211 477 957 2110 3280 6640 10800 19700 41300 75200 122000 250000
10 psi .500 psi 246 556 1120 2460 3820 7730 12600 23000 48200 87600 143000 292000
For total lengths other than 100 ft, multiply the capacity shown in the table by the factor corresponding to the desired length as follows:
Length of pipe in ft 10 15 25 50 100 150 200 250 300 350 400 500
Multiplier 3.16 2.58 2.00 1.41 1.00 .817 .707 .632 .577 .535 .500 .447
For pressures and diameters not shown, consult you local Cleaver-Brooks authorized representative.
This table shows gas flow capacities of pipes from 1/2 to 8 diameter, based upon a pressure drop of 5% of the initial gas pressure for 100-ft. length of pipe. Turbulent
flow is assumed, hence the non-linear ratio of length to capacity.
Table I4-1. Gas Line Capacities
I4-8
06-08
FUEL OIL FLOW
RATE (GPH)
NOMINAL PIPE SIZE (INCHES)
0.5 0.75 1 1.5 2 2.5 3 4
25 0.3 0.1
0.0*
0.01
0.00*
0.001
0.000* 0.000*
50 0.6 0.2 0.1 0.01 0.00 0.002 0.001
0.000*
75 0.9 0.3 0.1 0.02 0.01 0.003 0.001
0.000*
100 1.1 0.4 0.1 0.03 0.01 0.005 0.002 0.001
150 3.6 0.9 0.2 0.04 0.01 0.007 0.003 0.001
200 6.0 1.6 0.5 0.05 0.02 0.009 0.004 0.001
250 8.9 2.3 0.7 0.06 0.02 0.011 0.005 0.002
300 12.3 3.2 1.0 0.13 0.03 0.014 0.006 0.002
400 20.3 5.3 1.7 0.22 0.007 0.018 0.008 0.003
500 30.5 7.9 2.5 0.32 0.10 0.042 0.010 0.003
600 42.2 11.0 3.5 0.45 0.13 0.058 0.020 0.004
700 55.6 14.5 4.6 0.59 0.18 0.076 0.027 0.007
NOTE: Pressure Drop (psig) per 100 equivalent ft of pipe for a fuel oil viscosity of 40 SSU, specific gravity of 0.9
* Negligible pressure drop.
FUEL OIL FLOW
RATE (GPH)
0.5 0.75 1 1.5 2 2.5 3 4
25 3.9 1.3 0.5 0.1 0.03 0.02 0.007 0.002
50 7.8 2.5 1.0 0.2 0.06 0.03 0.013 0.004
75 11.6 3.8 1.4 0.3 0.10 0.05 0.020 0.007
100 15.5 5.0 1.9 0.3 0.13 0.06 0.026 0.009
150 23.3 7.6 2.9 0.5 0.19 0.09 0.039 0.013
200 31.1 10.1 3.8 0.7 0.25 0.13 0.052 0.018
250 38.8 12.6 4.8 0.9 0.32 0.16 0.066 0.022
300 46.6 15.1 5.8 1.0 0.38 0.19 0.079 0.027
400 62.1 20.2 7.7 1.4 0.51 0.25 0.10 0.035
500 77.6 25.2 9.6 1.7 0.64 0.31 0.13 0.044
600 93.2 30.2 11.5 2.1 0.76 0.38 0.16 0.053
700 108.7 35.3 13.4 2.4 0.89 0.44 0.18 0.062
FUEL OIL FLOW
RATE (GPH)
0.5 0.75 1 1.5 2 2.5 3 4
25 7.8 2.5 1.0 0.2 0.06 0.03 0.013 0.004
50 15.6 5.1 1.9 0.3 0.13 0.06 0.026 0.009
75 23.5 7.6 2.9 0.5 0.19 0.019 0.040 0.013
100 31.3 10.2 3.9 0.7 0.26 0.13 0.053 0.018
150 46.9 15.2 5.8 1.0 0.38 0.19 0.079 0.027
200 62.6 20.3 7.7 1.4 0.51 0.25 0.106 0.036
250 78.2 25.4 9.7 1.7 0.64 0.32 0.132 0.045
300 93.9 30.5 11.6 2.1 0.77 0.38 0.159 0.053
400 125.1 40.6 15.5 2.8 1.03 0.50 0.21 0.071
500 156.4 50.8 19.3 3.5 1.28 0.63 0.26 0.089
600 187.7 69.9 23.2 4.2 1.54 0.76 0.32 0.107
700 219.0 71.1 27.1 4.9 1.80 0.88 0.37 0.125
Table I4-4. Oil Piping Pressure Drop (Viscosity = 500 SSU and Specific Gravity = 0.94)
Figure I4-1. Oil Piping Pressure Drop (Viscosity = 100 SSU and Specific Gravity = 0.94) Table I4-3. Oil Piping Pressure Drop (Viscosity = 100 SSU and Specific Gravity = 0.94)
I4-9
06-08
FUEL OIL FLOW
RATE (GPH)
0.5 0.75 1 1.5 2 2.5 3 4
25 16.0 5.2 2.0 0.4 0.13 0.06 0.027 0.009
50 32.0 10.4 4.0 0.7 0.26 0.13 0.054 0.018
75 48.0 15.6 5.9 1.1 0.39 0.19 0.081 0.027
100 64.0 20.8 7.9 1.4 0.52 0.26 0.108 0.036
150 96.0 31.2 11.9 2.1 0.79 0.39 0.162 0.055
200 128.0 41.6 15.8 2.9 1.05 .052 0.216 0.073
250 160.1 52.0 19.8 3.6 1.31 0.64 0.270 0.091
300 192.1 62.4 23.7 4.3 1.57 0.77 0.324 0.109
400 256.1 83.1 31.7 5.7 2.10 1.03 0.43 0.146
500 320.1 103.9 39.6 7.1 2.62 1.29 0.54 0.182
600 384.1 124.7 47.5 8.6 3.15 1.55 0.65 0.219
700 448.1 145.5 55.4 10.0 3.67 1.81 0.76 0.255
FUEL OIL FLOW
RATE (GPH)
0.5 0.75 1 1.5 2 2.5 3 4
25 80 26 10 2 1 0.3 0.1 0.05
50 160 52 20 4 1 0.6 0.3 0.09
75 240 78 30 5 2 1.0 0.4 0.14
100 320 104 40 7 3 1.3 0.5 0.18
150 480 156 59 11 4 1.9 0.8 0.27
200 641 208 79 14 5 2.6 1.1 0.36
250 801 260 99 18 7 3.2 1.4 0.46
300 961 312 119 21 8 3.9 1.6 0.55
400 1281 416 158 29 11 5.2 2.2 0.73
500 1601 520 198 36 13 6.5 2.7 0.91
600 1922 624 238 43 16 7.7 3.2 1.09
700 2242 728 277 50 18 9.0 3.8 1.28
I4-10
06-08
EQUIVALENT LENGTHS
Table I4-7 shows equivalent lengths of pipe for various plumbing fittings. Find the
nominal pipe size being used in the leftmost column. For each fitting, read the
value under the appropriate heading and add this to the length of piping. This
allows total system pressure drop to be calculated. (This is valid for any fluid.)
STACKS
Notice
For boilers over 800 hp, consult your local Cleaver-Brooks authorized representative.
Why Used
The only purpose of a vent stack on Cleaver-Brooks boilers is to conduct the
products of combustion to a point of safe discharge (atmosphere). Forced draft
design eliminates the need for a stack designed to create a draft.
Stack Draft on CB Boilers
Depending on the boiler model, draft variations of as much as 1/2 inch W.C. at the
boiler vent outlet will have no appreciable effect on the Model CB burner operation.
This is due to the high pressure drops which are taken from the burner inlet to the
boiler vent outlet. See individual boiler sections for specific limitations on stack/
breeching size criteria. Other typical pressure drops for the Model CB Boilers are as
follows:
A. A 4 inch to 12 inch WC drop is taken across the burner in order to provide
high turbulence, good mixing of fuel and air, and high CO
2
readings for most
efficient combustion,
B. A 2 inch to 6 inch WC drop is taken through the four (4) gas passes of the
boiler in order to maintain high flue gas velocities and thus increase heat
transfer.
For other boiler types, the draft variation could be similar. Consult you local Cleaver-
PIPE SIZE
EQUIVALENT LENGTH OF STRAIGHT PIPE (FEET)
STANDARD
ELBOW
STANDARD
TEE
GATE
VALV E
FULL OPEN
GLOBE
VALVE FULL
OPEN
ANGLE
VALVE FULL
OPEN
1-1/2 4 9 0.9 41 21
2 5 11 1.2 54 27
2-/1/2 6 13 1.4 64 32
3 8 16 1.6 80 40
3-1/2 9 18 2.0 91 45
4 11 21 2.2 110 55
5 13 26 2.8 140 70
6 16 32 3.4 155 81
8 20 42 4.5 210 110
10 25 55 5.5 270 140
12 30 65 6.5 320 160
14 35 75 8.0 370 190
This table contains the number of feet of straight pipe usually allowed for standard
fittings and valves.
Table I4-7. Equivalent Length of Pipe
I4-11
06-08
If the stack height is over 150 feet or if an extremely large breeching and stack
combination cause excessive draft, a simple barometric damper can be located in
the breeching close to the stack or chimney. This damper should only be considered
after burner adjustment problems have been experienced and are serious enough to
warrant corrective action.
Automatic or special draft controls are not required and are not recommended for
use with Cleaver-Brooks boilers.
Stack Location
An off-set type stack connection to the stub vent on the boiler is preferred and
recommended. A direct vertical connection can also be made, if required. A typical
stack location diagram is shown in Figure I4-3.
Stack Condensation
The amount of condensation in the stack will vary with the type of fuel and with the
stack gas temperature. Normally, the temperature of the flue gas leaving the boiler
is higher than the temperature of the steam or the water in the boiler.
Stack condensation is most likely to occur on heating boiler installations where light
loads and intermittent firing cause a cool stack condition, which results in
condensation of the water vapor in the flue gas. This condensed water accelerates
corrosion of steel stacks or breechings.
The following items should be considered when planning to keep stack
condensation to a minimum:
A. The boiler should be sized as close as possible to the true heat load.
Oversized boilers should be avoided.
B. Masonry stacks have better heat holding characteristics than steel stacks.
C. When steel stacks are used, stack insulation will help prevent heat loss.
D. An off-set stack (recommended) with bottom clean-out and drain connection
will prevent any condensed water from draining back into the boiler.
Stack Weight
Boiler vent outlets will withstand a maximum direct vertical load of 2,000 pounds.
This loading must include the effect of wind and guy wires.
Stack Construction
The stack can be terminated several feel above the top of the roof. (State and local
codes may govern the stack height above the roof.) If down drafts are unavoidable,
the stack outlet can be provided with a ventilator such as the Breidert Air-X-Hauster
or equivalent. See Figure I4-4 for typical stack construction details.
Stack Material
Minimum 12 gauge steel is recommended for stack sections. If the stack will be
inaccessible, the use of a non-corrosive material (e.g. glass lining) should be
considered.
A rain cap or hood should be used at the top of the stack to minimize the entrance
of rain or snow. See Figure I4-5 for typical rain cap details.
I4-12
06-08
BOILER HP
STACK
DIAMETER
(IN.)
A (IN.)
B
(IN.)
C
(IN.)
D
(IN.)
15-20 6 5 12 3 3
25-40, 50A 8 6 16 4 4
50-60 10 8 20 5 5
70-100A, 125A 12 9 24 6 6
125-200 16 12 32 8 8
250-350 20 15 40 10 10
400-600 24 18 48 12 12
700-800 24 21 48 12 12
VERTICAL STACK CONNECTION OFFSET STACK CONNECTION (RECOMMENDED)
STACK TIGHT-SEAL
CLEANOUT
CLEANOUT
DRAIN CONNECTION
STACK
Figure I4-5. Rain Cap Details
Figure I4-3. Typical Stack Locations
BOILER HP
STACK
DIAMETER (IN.)
A (IN.)
B
(IN.)
C
(IN.)
15-20 6 15 15 12
25-40, 50A 8 20 20 16
50-60 10 25 25 20
70-100A, 125A 12 30 30 24
125-200 16 40 40 32
250-350 20 50 50 40
400-800 24 60 60 48
RAIN CAP
AS REQUIRED
BY LOCAL CODE
STACK DIA.
TOP OR ROOF
2-0 MIN
A
B
C
Figure I4-4. Typical Stack Construction
A
B
C
D
STACK
DIA
I4-13
06-08
Stack/Breeching Size Criteria
The design of the stack and breeching system must provide a draft at the boiler
outlet(s) which is within the required limits. Consideration must be given to
operation variations (including number of boilers), purge cycles, outside wind and
air conditions, and the impact of other variables that may impact draft conditions.
Safe and reliable burner performance requires good stack design.See Table I4-8 and
further detail in the individual boiler sections.
Stack and breeching sizes should always be provided by a reputable stack supplier
who will design the stack and breeching system based on the required system
layout. Your local Cleaver-Brooks authorized representative is capable of assisting in
your evaluation of the stack/breeching design.
FACTORS OF EVAPORATION
The factor of evaporation is used to adjust rated boiler output (from and at 212 F)
to actual job or operating conditions. Available feedwater temperature and expected
boiler operating pressure (psig) affect the boiler output ratings which are based on
from and at 212 F.
Example: A boiler is to have an output of 3060 pounds of steam per hour when
operating at 10 psig with feedwater at 100 F. What should the boiler rating be on
the basis of from and at 212 F.
Referring to Table I4-10, at 100 F and 10 psig, the following factors can be
obtained: 30.6 pounds of steam per boiler horsepower. This factor is used to
convert the from and at 212 F rating basis:
3060 30.6 = 100 hp rated boiler should be selected.
BOILER HP
STACK DIAMETER
Same as Boiler Vent Outlet
Size (Inches OD)
15-20 6
25-40, 50A 8
50-60 10
70-100, 100A,
125A
12
125-200 16
250-350 20
400-800 24
Table I4-8. Single Boiler Vent or Stack Diameter
BOILER HP
MINIMUM RECOMMENDED STACK
DIAMETER
A
NUMBER OF BOILERS
2 3 4
100
FT
200
FT
100
FT
200
FT
100
FT
200
FT
15-20 9" 10" 10" 12" 11" 12"
25-40 11" 12" 13" 14" 14" 16"
50A, 50-60 13" 14" 15" 16" 17" 18"
70-100.
100A
16" 17" 19" 20" 21" 23"
125-200 21" 22" 24" 26" 28" 30"
250-350 26" 28" 32" 34" 34" 40"
400-600 32" 34" 38" 40" 421" 46"
700-800 38" 42" 44" 48" 48" 52"
Notes:
A. No barometric damper required.
Table I4-9. Multiple Boilers - Common Breeching
and Stack
I4-14
06-08
Table I4-10. Factor of Evaporation
THERMODYNAMIC PROPERTIES
Fuel Oils The purpose of this section is to provide technical information on the various grades
of fuel oils commonly used in the generation of steam and hot water. The American
Society for Testing and Materials (ASTM) has established numerous tests to identify
fuel oil properties and specifications that allow the fuel to be identified by a grade,
which can be No. 1, 2, 4, 5, or 6.
Grades No. 1 and No. 2 are considered distillate oil, while grades No. 4 through No.
6 are considered residual oils. Distillate oils have a low viscosity and are relatively
easy to burn. Residual oils have a high viscosity and often require heating to pump
and atomize. Residual oils will also have much higher emission levels, and their use
is frequently regulated because of this.
The viscosity ranges of fuel oils are shown in Figure I4-6.
30.0
33.8
I4-15
06-08
Fuel Oil
Specifications
The limits on fuel oil properties are shown in Table I4-11, Table I4-12, and Table
I4-13. Definitions of these properties are discussed next.
Ultimate Analysis - Ultimate analysis is a statement of the quantities of the various
elements of which a substance is composed. For fuel oils, this will likely state
higher heating values and specific gravity in addition to the percentages by weight
of each element.
Flash Point - The flash point of a fuel oil is an indication of the maximum
temperature at which it can be stored and handled without serious fire hazard. The
minimum permissible flash point is usually regulated by federal, state or municipal
laws and is based on accepted practice in handling and use.
Pour Point - The pour point is an indication of the lowest temperature at which a fuel oil can be
stored and still be capable of flowing under very low forces. The pour point is prescribed in
accordance with the conditions of storage and use. Higher pour point fuels are permissible
where heated storage and adequate piping facilities are provided. An increase in
pour point can occur when residual fuel oils are subjected to cyclic temperature
variations that can occur in the course of storage or when the fuel is preheated and
returned to storage tanks. To predict these properties, Test Method D 3245 may be
required.
Water and Sediment - Appreciable amounts of water and sediments in a fuel oil
tend to cause fouling of facilities for handling it, and cause trouble in burner
mechanisms. Sediment may accumulate in storage tanks and on filter screens or
burner parts, resulting in obstructions to flow of oil from the tank to the burner.
Water in distillate fuels can cause corrosion of tanks and equipment, and can cause
emulsions in residual fuels.
Carbon Residue - The carbon residue of a fuel is a measure of the carbonaceous
material left after all the volatile components are vaporized in the absence of air. It
is a rough approximation of the tendency of a fuel to form deposits in vaporizing
burners, such as pot-type and sleeve burners, where the fuel is vaporized in an air-
deficient atmosphere.
To obtain measurable values of carbon residue in the lighter distillate fuel oils, it is
necessary to distill the oil to remove 90% of it in accordance with Section 9 of Test
Method D 524, and determine the carbon residue concentrated in the remaining
10% bottoms.
Ash - The amount of ash is the quantity of noncombustible material in an oil.
Excessive amounts can indicate the presence of materials that cause high wear of
burner pumps and valves, and contribute to deposits on boiler heating surfaces.
ITEM
GROSS HEATING
VALUES
No. 2 Oil 140,000 Btu/gal.
No 5 Oil 148,000 Btu/gal.
No. 6 Oil 150,000 Btu/gal.
1 Therm 100,000 Btu
1 kW 3,413 Btu
Table I4-11. Typical Units for Fuels
I4-16
06-08
PROPERTY
ASTM TEST
METHOD
B
FUEL OIL GRADE
No. 1 No. 2
No. 4
(Light)
No. 4
No 5
(Light)
No. 5
(Heavy)
No. 6
Flash Point C min D 93 38 38 38 55 55 55 60
Water and sediment,% vol max D 1796 0.05 0.05 (0.50)
C
(0.50)
C
(1.00)
C
(1.00)
C
(2.00)
C
Distillation temperature C D 85
10% vol recovered, max 215
90% vol recovered, min 282
max 288 338
Kinematic viscosity at 40 C mm
2
/s D 445
Minimum viscosity 1.3 1.9 1.9 >5.5
Maximum viscosity 2.1 3.4 5.5 24.0
D

Kinematic viscosity at 100 C mm
2
/s
Minimum viscosity 5.0 9.0 15.0
Maximum viscosity 8.9
D
14.9
D
50.0
D
Ramsbottom carbon residue on 10%
distillation residue% mass, max D 524 0.15 0.35
Ash,% mass, max D 482 0.05 0.15 0.10 0.15
Sulfur,% mass, max
E
D 129 0.50 0.50
Copper, strip corrosion rating, max,
3h at 50 C D 130 No. 3 No. 3
Density at 15 C, kg/m
3
D 1298
Minimum density
>876
F

Maximum density 850 876
Pour Point C, ma
G
D 97 -18 -6 -6 -6
H
A
It is the intent of these classifications that failure to meet any requirement of a given grade does not automatically place an oil in
the next lower grade unless in fact it meets all requirements of the lower grade. However, to meet special operating conditions
modification of individual limiting requirements may be agreed upon among purchaser, seller, and manufacturer.
B
The test methods indicated are the approved referee methods.
C
The amount of water by distillation by Test Method D 95 plus the sediment by extraction by Test Method D 473 shall not exceed
the value shown in the table. For Grade No.6 fuel oil, the amount of sediment by extraction shall not exceed 0.50 mass%, and a
deduction in quantity shall be made for all water and sediment in excess of 1.0 mass%.
D
Where low sulfur fuel oil is required, fuel oil falling in the viscosity range of a lower numbered grade down to and including No. 4
can be supplied by agreement between the purchaser and supplier. The viscosity range of the initial shipment shall be identified
and advance notice shall be required when changing from one viscosity range and another. This notice shall be in sufficient time
to permit the user to make the necessary adjustments.
E
Other sulfur limits may apply in selected areas in the United States and in other countries.
F
This limit assures a minimum heating value and also prevents misrepresentation and misapplication of this product as Grade
No. 2.
G
Lower or higher pour points can be specified whenever required by conditions of storage or use. When a pour point less than
-18 C is specified, the minimum viscosity at 40 C for grade No. 2 shall be 1.7 MM.
2
/S. and the minimum 90% recovered temper-
ature shall be waived.
H
Where low sulfur fuel oil is required, Grade No. 6 fuel oil will be classified as Low Pour (+15 C max) or High Pour (no max).
Low Pour fuel oil should be used unless tanks and lines are heated.
Table I4-12. Detailed Requirements for Fuel Oils - Properties of Fuel Oil
I4-17
06-08
Distillation - The distillation test shows the volatility of a fuel and the ease with
which it can be vaporized. The test is of greater significance for oils that are to be
burned in vaporizing type burners than for the atomizing type. For example, the
maximum 10% and 90% distilled temperatures are specified for grade No. 1 fuel.
The limiting10% value assures easy starting in vaporizing type burner and the 90%
limit excludes heavier fractions that would be difficult to vaporize.
The limits specified for grade No. 2 heating oil define a product that is acceptable
for burners of the atomizing type in household heating installations. Distillation
limits are not specified for fuel oils of grades No. 4, 5, and 6.
Viscosity Limits for Grades Nos1214 1 and 2 - The viscosity of an oil is a measure
of its resistance to flow. In fuel oil it is highly significant since it indicates both the
relative ease with which the oil will flow or can be pumped and the case of
atomization.
Viscosity limits for No. 1 and No. 2 grades are specified to help maintain uniform
fuel flow in appliances with gravity flow, and to provide satisfactory atomization and
constant flow rate through the small nozzles of household burners. For the heavier
grades of industrial and bunker fuel oils, viscosity is of major importance, so that
adequate preheating facilities can be provided to permit them to be pumped to the
burner and to provide good atomization. However, it is equally important that the
maximum viscosity under the existing conditions be such that the oil can be
pumped satisfactorily from the storage tank to the preheater.
Density - Density alone is of little significance as an indication of the burning
characteristics of fuel oil. However, when used in conjunction with other properties,
GRADE OF FUEL OIL
FLASH
POINT F
MIN
POUR
POINT
F MAX
WATER &
SEDIMENT
% MAX
CARBON
RESIDUE
ON 10%
RESIDUUM
% MAX
ASH%
MAX
DISTILLATION
TEMPERATURES, F
10%
POINT
MAX
90%
POINT
MAX
END
POINT
MAX
1. Distillate oil intended for
vaporizing pot-type burners
and other burners requiring
this grade.
100
or
legal
0 trace 0.15 420 625
2. A distillate oil for general
purpose domestic heating for
use in burners not requiring
No. 1.
100
or
legal
20 0.10 0.35 - 675
4. An oil for burner installations
not equipped with preheating
facilities.
130
or
legal
20 0.50 0.10
5.A residual type oil for burner
installations equipped with pre-
heating facilities.
130
or
legal
1.00 0.10
6.An oil for use in burners
equipped with preheaters per-
mitting a high viscosity fuel,
130
or
legal
2.00
Table I4-13. Detailed Requirements for Fuel Oil Grade of Fuel Oil
I4-18
06-08
it is of value in mass-volume relationships and in calculating the specific energy
(heating value) of an oil.
Corrosion - The corrosion test serves to indicate the presence or absence of
materials that could corrode copper, brass, and bronze components of the fuel
system. This property is specified only for Nos. 1 and 2 distillate fuel oils.
Limited sulfur content of fuel oil can be required to meet federal, state, or local
legislation or regulations.
Nitrogen - Nitrogen oxide emission regulations have been imposed on certain
combustion facilities as a function of fuel nitrogen content. For purposes of these
regulations, distillate fuels, low nitrogen residual fuels, and high nitrogen residual
fuels have been defined by their nitrogen content. Installations are required to meet
different emission standards according to the classification of the fuel being used.
When regulations require such a distinction to be made, fuel nitrogen specifications
can be needed in the contractual agreement between the purchaser and the
supplier.
I4-19
06-08
F
i
g
u
r
e

I
4
-
6
.

F
u
e
l

O
i
l

V
i
s
c
o
s
i
t
y

a
n
d

T
e
m
p
e
r
a
t
u
r
e

C
u
r
v
e
s
I4-20
06-08
Water The relevant properties of water are shown in Table I4-14.
Table I4-14. Thermal Properties of Water
I4-21
06-08
ABS. PRESSURE SPECIFIC VOLUME (ft.
3
/lb) ENTHALPY (Btu/lb) ENTROPY (Btu/lb,F)
TEMP
F PSIA IN. HG
SAT.
LIQUID EVAP.
SAT.
VAPOR
SAT.
LIQUID EVAP.
SAT.
VAPOR
SAT.
LIQUID EVAP.
SAT.
VAPOR
t p p v
f
v
fg
v
g
h
f
h
fg
h
g
s
f
s
fg
s
g
32 0.08854 0.1803 0.01602 3306 3306 0.00 1075.8 1075.8 0.0000 2.1877 2.1877
33 0.09223 0.1878 0.01602 3180 3180 1.01 1075.2 1076.2 0.0020 2.1821 2.1841
34 0.09603 0.1955 0.01602 3061 3061 2.02 1074.7 1076.7 0.0041 2.1764 2.1805
35 0.09995 0.2035 0.01602 2947 2947 3.02 1074.1 1077.1 0.0061 2.1709 2.1770
36 0.10401 0.2118 0.01602 2837 2837 4.03 1073.6 1077.6 0.0081 2.1654 2.1735
37 0.10821 0.2203 0.01602 2732 2732 5.04 1073.0 1078.0 0.0102 2.1598 2.1700
38 0.11256 0.2292 0.01602 2632 2632 6.04 1072.4 1078.4 0.0122 2.1544 2.1666
39 0.11705 0.2383 0.01602 2536 2536 7.04 1071.9 1078.9 0.0142 2.1489 2.1631
40 0.12170 0.2478 0.01602 2444 2444 8.05 1071.3 1079.3 0.0162 2.1435 2.1597
41 0.12652 0.2576 0.01602 2356 2356 9.05 1070.7 1079.7 0.0182 2.1381 2.1563
42 0.13150 0.2677 0.01602 2271 2271 10.05 1070.1 1080.2 0.0202 2.1327 2.1529
43 0.13665 0.2782 0.01602 2190 2190 11.06 1069.5 1080.6 0.0222 2.1274 2.1496
44 0.14199 0.2891 0.01602 2112 2112 12.06 1068.9 1081.0 0.0242 2.1220 2.1462
45 0.14752 0.3004 0.01602 2036.4 2036.4 13.06 1068.4 1081.5 0.0262 2.1167 2.1429
46 0.15323 0.3120 0.01602 1964.3 1964.3 14.06 1067.8 1081.9 0.0282 2.1113 2.1395
47 0.15914 0.3240 0.01603 1895.1 1895.1 15.07 1067.3 1082.4 0.0302 2.1060 2.1362
48 0.16525 0.3364 0.01603 1828.6 1828.6 16.07 1066.7 1082.8 0.0321 2.1008 2.1329
49 0.17157 0.3493 0.01603 1764.7 1764.7 17.07 1066.1 1083.2 0.0341 2.0956 2.1297
50 0.17811 0.3626 0.01603 1703.2 1703.2 18.07 1065.6 1083.7 0.0361 2.0903 2.1264
51 0.18486 0.3764 0.01603 1644.2 1644.2 19.07 1065.0 1084.1 0.0380 2.0852 2.1232
52 0.19182 0.3906 0.01603 1587.6 1587.6 20.07 1064.4 1084.5 0.0400 2.0799 2.1199
53 0.19900 0.4052 0.01603 1533.3 1533.3 21.07 1063.9 1085.0 0.0420 2.0747 2.1167
54 0.20642 0.4203 0.01603 1481.0 1481.0 22.07 1063.3 1085.4 0.0439 2.0697 2.1136
55 0.2141 0.4359 0.01603 1430.7 1430.7 23.07 1062.7 1085.8 0.0459 2.0645 2.1104
56 0.2220 0.4520 0.01603 1382.4 1382.4 24.06 1062.2 1086.3 0.0478 2.0594 2.1072
57 0.2302 0.4686 0.01603 1335.9 1335.9 25.06 1061.6 1086.7 0.0497 2.0544 2.1041
58 0.2386 0.4858 0.01604 1291.1 1291.1 26.06 1061.0 1087.1 0.0517 2.0493 2.1010
59 0.2473 0.5035 0.01604 1248.1 1248.1 27.06 1060.5 1087.6 0.0536 2.0443 2.0979
60 0.2563 0.5218 0.01604 1206.6 1206.7 28.06 1059.9 1088.0 0.0555 2.0393 2.0948
61 0.2655 0.5407 0.01604 1166.8 1166.8 29.06 1059.3 1088.4 0.0574 2.0343 2.0917
62 0.2751 0.5601 0.01604 1128.4 1128.4 30.05 1058.8 1088.9 0.0593 2.0293 2.0886
63 0.2850 0.5802 0.01604 1091.4 1091.4 31.05 1058.2 1089.3 0.0613 2.0243 2.0856
64 0.2951 0.6009 0.01605 1055.7 1055.7 32.05 1057.6 1089.7 0.0632 2.0194 2.0826
65 0.3056 0.6222 0.01605 1021.4 1021.4 33.05 1057.1 1090.2 0.0651 2.0145 2.0796
66 0.3164 0.6442 0.01605 988.4 988.4 34.05 1056.5 1090.6 0.0670 2.0096 2.0766
67 0.3276 0.6669 0.01605 956.6 956.6 35.05 1056.0 1091.0 0.0689 2.0047 2.0736
68 0.3390 0.6903 0.01605 925.9 925.9 36.04 1055.5 1091.5 0.0708 1.9998 2.0706
69 0.3509 0.7144 0.01605 896.3 896.3 37.04 1054.9 1091.9 0.0726 1.9950 2.0676
70 0.3631 0.7392 0.01606 867.8 867.9 38.04 1054.3 1092.3 0.0745 1.9902 2.0647
71 0.3756 0.7648 0.01606 840.4 840.4 39.04 1053.8 1092.8 0.0764 1.9854 2.0618
72 0.3886 0.7912 0.01606 813.9 813.9 40.04 1053.2 1093.2 0.0783 1.9805 2.0588
73 0.4019 0.8183 0.01606 788.3 788.4 41.03 1052.6 1093.6 0.0802 1.9757 2.0559
74 0.4156 0.8462 0.01606 763.7 763.8 42.03 1052.1 1094.1 0.0820 1.9710 2.0530
75 0.4298 0.8750 0.01607 740.0 740.0 43.03 1051.5 1094.5 0.0839 1.9663 2.0502
Steam
Table I4-15. Saturated Steam Properties, Temperature Table (Sheet 1 of 7)
Steam properties are shown in Table I4-15 and Table I4-16.
I4-22
06-08
76 0.4443 0.9046 0.01607 717.1 717.1 44.03 1050.9 1094.9 0.0858 1.9615 2.0473
77 0.4593 0.9352 0.01607 694.9 694.9 45.02 1050.4 1095.4 0.0876 1.9569 2.0445
78 0.4747 0.9666 0.01607 673.6 673.6 46.02 1049.8 1095.8 0.0895 1.9521 2.0416
79 0.4906 0.9989 0.01608 653.0 653.0 47.02 1049.2 1096.2 0.0913 1.9475 2.0388
80 0.5069 1.0321 0.01608 633.1 633.1 48.02 1048.6 1096.6 0.0932 1.9428 2.0360
81 0.5237 1.0664 0.01608 613.9 613.9 49.02 1048.1 1097.1 0.0950 1.9382 2.0332
82 0.5410 1.1016 0.01608 595.3 595.3 50.01 1047.5 1097.5 0.0969 1.9335 2.0304
83 0.5588 1.1378 0.01609 577.4 577.4 51.01 1046.9 1097.9 0.0987 1.9290 2.0277
84 0.5771 1.1750 0.01609 560.1 560.2 52.01 1046.4 1098.4 0.1005 1.9244 2.0249
85 0.5959 1.2133 0.01609 543.4 543.5 53.00 1045.8 1098.8 0.1024 1.9198 2.0222
86 0.6152 1.2527 0.01609 527.3 527.3 54.00 1045.2 1099.2 0.1042 1.9153 2.0195
87 0.6351 1.2931 0.01610 511.7 511.7 55.00 1044.7 1099.7 0.1060 1.9108 2.0168
88 0.6556 1.3347 0.01610 496.6 496.7 56.00 1044.1 1100.1 0.1079 1.9062 2.0141
89 0.6766 1.3775 0.01610 482.1 482.1 56.99 1043.5 1100.5 0.1097 1.9017 2.0114
90 0.6982 1.4215 0.01610 468.0 468.0 57.99 1042.9 1100.9 0.1115 1.8972 2.0087
91 0.7204 1.4667 0.01611 454.4 454.4 58.99 1042.4 1101.4 0.1133 1.8927 2.0060
92 0.7432 1.5131 0.01611 441.2 441.3 59.99 1041.8 1101.8 0.1151 1.8883 2.0034
93 0.7666 1.5608 0.01611 428.5 428.5 60.98 1041.2 1102.2 0.1169 1.8838 2.0007
94 0.7906 1.6097 0.01612 416.2 416.2 61.98 1040.7 1102.6 0.1187 1.8794 1.9981
95 0.8153 1.6600 0.01612 404.3 404.3 62.98 1040.1 1103.1 0.1205 1.8750 1.9955
96 0.8407 1.7117 0.01612 392.8 392.8 63.98 1039.5 1103.5 0.1223 1.8706 1.9929
97 0.8668 1.7647 0.01612 381.7 381.7 64.97 1038.9 1103.9 0.1241 1.8662 1.9903
98 0.8935 1.8192 0.01613 370.9 370.9 65.97 1038.4 1104.4 0.1259 1.8618 1.9877
99 0.9210 1.8751 0.01613 360.4 360.5 66.97 1037.8 1104.8 0.1277 1.8575 1.9852
100 0.9492 1.9325 0.01613 350.3 350.4 67.97 1037.2 1105.2 0.1295 1.8531 1.9826
101 0.9781 1.9915 0.01614 340.6 340.6 68.96 1036.6 1105.6 0.1313 1.8488 1.9801
102 1.0078 2.0519 0.01614 331.1 331.1 69.96 1036.1 1106.1 0.1330 1.8445 1.9775
103 1.0382 2.1138 0.01614 321.9 321.9 70.96 1035.5 1106.5 0.1348 1.8402 1.9750
104 1.0695 2.1775 0.01615 313.1 313.1 71.96 1034.9 1106.9 0.1366 1.8359 1.9725
105 1.1016 2.2429 0.01615 304.5 304.5 72.95 1034.3 1107.3 0.1383 1.8317 1.9700
106 1.1345 2.3099 0.01615 296.1 296.2 73.95 1033.8 1107.8 0.1401 1.8274 1.9675
107 1.1683 2.3786 0.01616 288.1 288.1 74.95 1033.3 1108.2 0.1419 1.8232 1.9651
108 1.2029 2.4491 0.01616 280.3 280.3 75.95 1032.7 1108.6 0.1436 1.8190 1.9626
109 1.2384 2.5214 0.01616 272.7 272.7 76.94 1032.1 1109.0 0.1454 1.8147 1.9601
110 1.2748 2.5955 0.01617 265.3 265.4 77.94 1031.6 1109.5 0.1471 1.8106 1.9577
111 1.3121 2.6715 0.01617 258.2 258.3 78.94 1031.0 1109.9 0.1489 1.8064 1.9553
112 1.3504 2.7494 0.01617 251.3 251.4 79.94 1030.4 1110.3 0.1506 1.8023 1.9529
113 1.3896 2.8293 0.01618 244.6 244.7 80.94 1029.8 1110.7 0.1524 1.7981 1.9505
114 1.4298 2.9111 0.01618 238.2 238.2 81.93 1029.2 1111.1 0.1541 1.7940 1.9481
115 1.4709 2.9948 0.01618 231.9 231.9 82.93 1028.7 1111.6 0.1559 1.7898 1.9457
116 1.5130 3.0806 0.01619 225.8 225.8 83.93 1028.1 1112.0 0.1576 1.7857 1.9433
117 1.5563 3.1687 0.01619 219.9 219.9 84.93 1027.5 1112.4 0.1593 1.7816 1.9409
118 1.6006 3.2589 0.01620 214.2 214.2 85.92 1026.9 1112.8 0.1610 1.7776 1.9386
119 1.6459 3.3512 0.01620 208.6 208.7 86.92 1026.3 1113.2 0.1628 1.7735 1.9363
120 1.6924 3.4458 0.01620 203.25 203.27 87.92 1025.8 1113.7 0.1645 1.7694 1.9339
121 1.7400 3.5427 0.01621 198.02 198.03 88.92 1025.2 1114.1 0.1662 1.7654 1.9316
122 1.7888 3.6420 0.01621 192.93 192.95 89.92 1024.6 1114.5 0.1679 1.7614 1.9293
123 1.8387 3.7436 0.01622 188.01 188.02 90.91 1024.0 1114.9 0.1696 1.7574 1.9270
124 1.8897 3.8475 0.01622 183.23 183.25 91.91 1023.4 1115.3 0.1714 1.7533 1.9247
125 1.9420 3.9539 0.01622 178.59 178.61 92.91 1022.9 1115.8 0.1731 1.7493 1.9224
3
TEMP
F PSIA IN. HG
SAT.
LIQUID EVAP.
SAT.
VAPOR
SAT.
LIQUID EVAP.
SAT.
VAPOR
SAT.
LIQUID EVAP.
SAT.
VAPOR
t p p v
f
v
fg
v
g
h
f
h
fg
h
g
s
f
s
fg
s
g
I4-23
06-08
126 1.9955 4.0629 0.01623 174.09 174.10 93.91 1022.3 1116.2 0.1748 1.7454 1.9202
127 2.0503 4.1745 0.01623 169.71 169.72 94.91 1021.7 1116.6 0.1765 1.7414 1.9179
128 2.1064 4.2887 0.01624 165.46 165.47 95.91 1021.1 1117.0 0.1782 1.7374 1.9156
129 2.1638 4.4055 0.01624 161.33 161.35 96.90 1020.5 1117.4 0.1799 1.7335 1.9134
130 2.2225 4.5251 0.01625 157.32 157.34 97.90 1020.0 1117.9 0.1816 1.7296 1.9112
131 2.2826 4.6474 0.01625 153.43 153.44 98.90 1019.4 1118.3 0.1833 1.7257 1.9090
132 2.3440 4.7725 0.01626 149.65 149.66 99.90 1018.8 1118.7 0.1849 1.7218 1.9067
133 2.4069 4.9005 0.01626 145.97 145.99 100.90 1018.2 1119.1 0.1866 1.7179 1.9045
134 2.4712 5.0314 0.01626 142.40 142.42 101.90 1017.6 1119.5 0.1883 1.7141 1.9023
135 2.5370 5.1653 0.01627 138.93 138.95 102.90 1017.0 1119.9 0.1900 1.7102 1.9002
136 2.6042 5.3022 0.01627 135.56 135.58 103.90 1016.4 1120.3 0.1917 1.7063 1.8980
137 2.6729 5.4421 0.01628 132.29 132.30 104.89 1015.9 1120.8 0.1934 1.7024 1.8958
138 2.7432 5.5852 0.01628 129.10 129.12 105.89 1015.3 1121.2 0.1950 1.6987 1.8937
139 2.8151 5.7316 0.01629 126.00 126.02 106.89 1014.7 1121.6 0.1967 1.6948 1.8915
140 2.8886 5.8812 0.01629 122.99 123.01 107.89 1014.1 1122.0 0.1984 1.6910 1.8894
141 2.9637 6.0341 0.01630 120.06 120.08 108.89 1013.5 1122.4 0.2000 1.6873 1.8873
142 3.0404 6.1903 0.01630 117.22 117.23 109.89 1012.9 1122.8 0.2016 1.6835 1.8851
143 3.1188 6.3500 0.01631 114.45 114.46 110.89 1012.3 1123.2 0.2033 1.6797 1.8830
144 3.1990 6.5132 0.01631 111.75 111.77 111.89 1011.7 1123.6 0.2049 1.6760 1.8809
145 3.281 6.680 0.01632 109.13 109.15 112.89 1011.2 1124.1 0.2066 1.6722 1.8788
146 3.365 6.850 0.01632 106.58 106.60 113.89 1010.6 1124.5 0.2083 1.6685 1.8768
147 3.450 7.024 0.01633 104.10 104.12 114.89 1010.0 1124.9 0.2099 1.6648 1.8747
148 3.537 7.202 0.01633 101.69 101.71 115.89 1009.4 1125.3 0.2116 1.6610 1.8726
149 3.627 7.384 0.01634 99.34 99.36 116.89 1008.8 1125.7 0.2133 1.6573 1.8706
150 3.718 7.569 0.01634 97.06 97.07 117.89 1008.2 1126.1 0.2149 1.6537 1.8685
151 3.811 7.759 0.01635 94.83 94.85 118.89 1007.6 1126.5 0.2165 1.6500 1.8665
152 3.906 7.952 0.01635 92.67 92.68 119.89 1007.0 1126.9 0.2182 1.6463 1.8645
153 4.003 8.150 0.01636 90.56 90.57 120.89 1006.4 1127.3 0.2198 1.6427 1.8624
154 4.102 8.351 0.01636 88.51 88.52 121.89 1005.8 1127.7 0.2214 1.6390 1.8604
155 4.203 8.557 0.01637 86.51 86.52 122.89 1005.2 1128.1 0.2230 1.6354 1.8584
156 4.306 8.767 0.01637 84.56 84.58 123.89 1004.7 1128.6 0.2246 1.6318 1.8564
157 4.411 8.981 0.01638 82.67 82.69 124.89 1004.1 1129.0 0.2263 1.6282 1.8545
158 4.519 9.200 0.01638 80.82 80.84 125.89 1003.5 1129.4 0.2279 1.6246 1.8525
159 4.629 9.424 0.01639 79.03 79.04 126.89 1002.9 1129.8 0.2295 1.6210 1.8505
160 4.741 9.652 0.01639 77.27 77.29 127.89 1002.3 1130.2 0.2311 1.6174 1.8485
161 4.855 9.885 0.01640 75.57 75.58 128.89 1001.7 1130.6 0.2327 1.6138 1.8466
162 4.971 10.122 0.01640 73.91 73.92 129.89 1001.1 1131.0 0.2343 1.6103 1.8446
163 5.090 10.364 0.01641 72.29 72.30 130.89 1000.5 1131.4 0.2360 1.6067 1.8427
164 5.212 10.611 0.01641 70.71 70.73 131.89 999.9 1131.8 0.2376 1.6032 1.8408
165 5.335 10.863 0.01642 69.17 69.19 132.89 999.3 1132.2 0.2392 1.5997 1.8388
166 5.461 11.120 0.01643 67.67 67.69 133.89 998.7 1132.6 0.2408 1.5961 1.8369
167 5.590 11.382 0.01643 66.21 66.23 134.89 998.1 1133.0 0.2424 1.5926 1.8350
168 5.721 11.649 0.01644 64.79 64.80 135.90 997.5 1133.4 0.2440 1.5891 1.8331
169 5.855 11.921 0.01644 63.40 63.41 136.90 996.9 1133.8 0.2455 1.5857 1.8312
170 5.992 12.199 0.01645 62.04 62.06 137.90 996.3 1134.2 0.2472 1.5822 1.8293
171 6.131 12.483 0.01645 60.72 60.74 138.90 995.7 1134.6 0.2488 1.5787 1.8275
172 6.273 12.772 0.01646 59.43 59.45 139.90 995.1 1135.0 0.2503 1.5753 1.8256
173 6.417 13.066 0.01647 58.18 58.20 140.90 994.5 1135.4 0.2519 1.5718 1.8237
174 6.565 13.366 0.01647 56.96 56.97 141.90 993.9 1135.8 0.2535 1.5684 1.8219
175 6.715 13.671 0.01648 55.76 55.78 142.91 993.3 1136.2 0.2551 1.5649 1.8200
3
TEMP
F PSIA IN. HG
SAT.
LIQUID EVAP.
SAT.
VAPOR
SAT.
LIQUID EVAP.
SAT.
VAPOR
SAT.
LIQUID EVAP.
SAT.
VAPOR
t p p v
f
v
fg
v
g
h
f
h
fg
h
g
s
f
s
fg
s
g
I4-24
06-08
176 6.868 13.983 0.01648 54.60 54.61 143.91 992.7 1136.6 0.2567 1.5615 1.8182
177 7.024 14.301 0.01649 53.46 53.48 144.91 992.1 1137.0 0.2583 1.5581 1.8164
178 7.183 14.625 0.01650 52.35 52.37 145.91 991.5 1137.4 0.2599 1.5547 1.8146
179 7.345 14.955 0.01650 51.27 51.29 146.92 990.8 1137.7 0.2614 1.5513 1.8127
180 7.510 15.291 0.01651 50.21 50.23 147.92 990.2 1138.1 0.2630 1.5480 1.8109
181 7.678 15.633 0.01651 49.18 49.20 148.92 989.6 1138.5 0.2645 1.5446 1.8091
182 7.850 15.982 0.01652 48.18 48.19 149.92 989.0 1138.9 0.2661 1.5412 1.8073
183 8.024 16.337 0.01653 47.19 47.21 150.93 988.4 1139.3 0.2676 1.5379 1.8055
184 8.202 16.699 0.01653 46.24 46.25 151.93 987.8 1139.7 0.2692 1.5346 1.8038
185 8.383 17.068 0.01654 45.29 45.31 152.93 987.2 1140.1 0.2708 1.5312 1.8020
186 8.567 17.443 0.01654 44.39 44.40 153.94 986.6 1140.5 0.2723 1.5279 1.8002
187 8.755 17.825 0.01655 43.50 43.51 154.94 986.0 1140.9 0.2739 1.5246 1.7985
188 8.946 18.214 0.01656 42.62 42.64 155.94 985.4 1141.3 0.2754 1.5213 1.7967
189 9.141 18.611 0.01656 41.77 41.79 156.95 984.8 1141.7 0.2770 1.5180 1.7950
190 9.339 19.014 0.01657 40.94 40.96 157.95 984.1 1142.0 0.2785 1.5147 1.7932
191 9.541 19.425 0.01658 40.13 40.15 158.95 983.4 1142.4 0.2801 1.5114 1.7915
192 9.746 19.843 0.01658 39.34 39.36 159.96 982.8 1142.8 0.2816 1.5082 1.7898
193 9.955 20.269 0.01659 38.57 38.58 160.96 982.2 1143.2 0.2831 1.5049 1.7880
194 10.168 20.703 0.01659 37.81 37.83 161.97 981.6 1143.6 0.2846 1.5017 1.7863
195 10.385 21.144 0.01660 37.07 37.09 162.97 981.0 1144.0 0.2862 1.4984 1.7846
196 10.605 21.593 0.01661 36.35 36.37 163.97 980.4 1144.4 0.2877 1.4952 1.7829
197 10.830 22.050 0.01661 35.64 35.66 164.98 979.7 1144.7 0.2892 1.4920 1.7812
198 11.058 22.515 0.01662 34.95 34.97 165.98 979.1 1145.1 0.2907 1.4888 1.7795
199 11.290 22.987 0.01663 34.28 34.30 166.99 978.5 1145.5 0.2923 1.4856 1.7779
200 11.526 23.467 0.01663 33.62 33.64 167.99 977.9 1145.9 0.2938 1.4824 1.7762
202 12.011 24.455 0.01665 32.35 32.37 170.00 976.6 1146.6 0.2969 1.4760 1.7729
204 12.512 25.475 0.01666 31.14 31.15 172.02 975.4 1147.4 0.2999 1.4697 1.7696
206 13.031 26.531 0.01667 29.97 29.99 174.03 974.2 1148.2 0.3029 1.4634 1.7663
208 13.568 27.625 0.01669 28.86 28.88 176.04 972.9 1148.9 0.3059 1.4571 1.7630
210 14.123 28.755 0.01670 27.80 27.82 178.05 971.6 1149.7 0.3090 1.4508 1.7598
212 14.696 29.922 0.01672 26.78 26.80 180.07 970.3 1150.4 0.3120 1.4446 1.7566
214 15.289 31.129 0.01673 25.81 25.83 182.08 969.0 1151.1 0.3149 1.4385 1.7534
216 15.901 32.375 0.01674 24.88 24.90 184.10 967.8 1151.9 0.3179 1.4323 1.7502
218 16.533 33.662 0.01676 23.99 24.01 186.11 966.5 1152.6 0.3209 1.4262 1.7471
220 17.186 34.992 0.01677 23.13 23.15 188.13 965.2 1153.4 0.3239 1.4201 1.7440
222 17.861 36.365 0.01679 22.31 22.33 190.15 963.9 1154.1 0.3268 1.4141 1.7409
224 18.557 37.782 0.01680 21.53 21.55 192.17 962.6 1154.8 0.3298 1.4080 1.7378
226 19.275 39.244 0.01682 20.78 20.79 194.18 961.3 1155.5 0.3328 1.4020 1.7348
228 20.016 40.753 0.01683 20.06 20.07 196.20 960.1 1156.3 0.3357 1.3961 1.7318
230 20.780 42.308 0.01684 19.365 19.382 198.23 958.8 1157.0 0.3387 1.3901 1.7288
232 21.567 43.911 0.01686 18.703 18.720 200.25 957.4 1157.7 0.3416 1.3842 1.7258
234 22.379 45.564 0.01688 18.067 18.084 202.27 956.1 1158.4 0.3444 1.3784 1.7228
236 23.217 47.269 0.01689 17.456 17.473 204.29 954.8 1159.1 0.3473 1.3725 1.7199
238 24.080 49.027 0.01691 16.869 16.886 206.32 953.5 1159.8 0.3502 1.3667 1.7169
240 24.969 50.837 0.01692 16.306 16.323 208.34 952.2 1160.5 0.3531 1.3609 1.7140
242 25.884 52.701 0.01694 15.765 15.782 210.37 950.8 1161.2 0.3560 1.3551 1.7111
244 26.827 54.620 0.01696 15.245 15.262 212.39 949.5 1161.9 0.3589 1.3494 1.7083
246 27.798 56.597 0.01697 14.745 14.762 214.42 948.2 1162.6 0.3618 1.3436 1.7054
248 28.797 58.631 0.01699 14.265 14.282 216.45 946.8 1163.3 0.3647 1.3379 1.7026
250 29.825 60.725 0.01700 13.804 13.821 218.48 945.5 1164.0 0.3675 1.3323 1.6998
3
TEMP
F PSIA IN. HG
SAT.
LIQUID EVAP.
SAT.
VAPOR
SAT.
LIQUID EVAP.
SAT.
VAPOR
SAT.
LIQUID EVAP.
SAT.
VAPOR
t p p v
f
v
fg
v
g
h
f
h
fg
h
g
s
f
s
fg
s
g
I4-25
06-08
252 30.884 62.880 0.01702 13.360 13.377 220.51 944.2 1164.7 0.3704 1.3266 1.6970
254 31.973 65.098 0.01704 12.933 12.950 222.54 942.8 1165.3 0.3732 1.3210 1.6942
256 33.093 67.378 0.01705 12.522 12.539 224.58 941.4 1166.0 0.3761 1.3154 1.6915
258 34.245 69.723 0.01707 12.127 12.144 226.61 940.1 1166.7 0.3789 1.3099 1.6888
260 35.429 72.134 0.01709 11.746 11.763 228.64 938.7 1167.3 0.3817 1.3043 1.6860
262 36.646 74.612 0.01710 11.379 11.396 230.68 937.3 1168.0 0.3845 1.2988 1.6833
264 37.897 77.159 0.01712 11.026 11.043 232.72 936.0 1168.7 0.3874 1.2933 1.6807
266 39.182 79.775 0.01714 10.687 10.704 234.76 934.5 1169.3 0.3902 1.2878 1.6780
268 40.502 82.463 0.01715 10.359 10.376 236.80 933.2 1170.0 0.3930 1.2824 1.6753
270 41.858 85.225 0.01717 10.044 10.061 238.84 931.8 1170.6 0.3958 1.2769 1.6727
272 43.252 88.062 0.01719 9.739 9.756 240.88 930.3 1171.2 0.3986 1.2715 1.6701
274 44.682 90.974 0.01721 9.446 9.463 242.92 929.0 1171.9 0.4014 1.2661 1.6675
276 46.150 93.963 0.01722 9.163 9.181 244.96 927.5 1172.5 0.4041 1.2608 1.6649
278 47.657 97.031 0.01724 8.891 8.908 247.01 926.1 1173.1 0.4069 1.2554 1.6623
280 49.203 100.18 0.01726 8.628 8.645 249.06 924.7 1173.8 0.4096 1.2501 1.6597
282 50.790 103.41 0.01728 8.374 8.391 251.10 923.3 1174.4 0.4124 1.2448 1.6572
284 52.418 106.72 0.01730 8.129 8.146 253.15 921.8 1175.0 0.4152 1.2395 1.6547
286 54.088 110.12 0.01732 7.892 7.910 255.20 920.4 1175.6 0.4179 1.2343 1.6522
288 55.800 113.61 0.01733 7.664 7.682 257.26 918.9 1176.2 0.4207 1.2290 1.6497
290 57.556 117.19 0.01735 7.444 7.461 259.31 917.5 1176.8 0.4234 1.2238 1.6472
292 59.356 120.85 0.01737 7.231 7.248 261.36 916.0 1177.4 0.4261 1.2186 1.6447
294 61.201 124.61 0.01739 7.025 7.043 263.42 914.6 1178.0 0.4288 1.2134 1.6422
296 63.091 128.46 0.01741 6.827 6.844 265.48 913.1 1178.6 0.4315 1.2083 1.6398
298 65.028 132.40 0.01743 6.635 6.652 267.53 911.6 1179.1 0.4343 1.2031 1.6374
300 67.013 136.44 0.01745 6.449 6.466 269.59 910.1 1179.7 0.4369 1.1980 1.6350
302 69.046 140.58 0.01747 6.269 6.287 271.66 908.6 1180.3 0.4397 1.1929 1.6326
304 71.127 144.82 0.01749 6.096 6.114 273.72 907.2 1180.9 0.4424 1.1878 1.6302
306 73.259 149.16 0.01751 5.928 5.946 275.78 905.6 1181.4 0.4450 1.1828 1.6278
308 75.442 153.60 0.01753 5.766 5.783 277.85 904.1 1182.0 0.4477 1.1777 1.6254
310 77.68 _ 0.01755 5.609 5.626 279.92 902.6 1182.5 0.4504 1.1727 1.6231
312 79.96 _ 0.01757 5.457 5.474 281.99 901.0 1183.1 0.4530 1.1677 1.6207
314 82.30 _ 0.01759 5.310 5.327 284.06 899.5 1183.6 0.4557 1.1627 1.6184
316 84.70 _ 0.01761 5.167 5.185 286.13 898.0 1184.1 0.4584 1.1577 1.6161
318 87.15 _ 0.01763 5.030 5.047 288.20 896.5 1184.7 0.4611 1.1527 1.6138
320 89.66 _ 0.01765 4.896 4.914 290.28 894.9 1185.2 0.4637 1.1478 1.6115
322 92.22 _ 0.01768 4.767 4.785 292.36 893.3 1185.7 0.4664 1.1428 1.6092
324 94.84 _ 0.01770 4.642 4.660 294.43 891.8 1186.2 0.4690 1.1379 1.6069
326 97.52 _ 0.01772 4.521 4.538 296.52 890.2 1186.7 0.4717 1.1330 1.6047
328 100.26 _ 0.01774 4.403 4.421 298.60 888.6 1187.2 0.4743 1.1281 1.6024
330 103.06 _ 0.01776 4.289 4.307 300.68 887.0 1187.7 0.4769 1.1233 1.6002
332 105.92 _ 0.01778 4.179 4.197 302.77 885.4 1188.2 0.4795 1.1184 1.5979
334 108.85 _ 0.01781 4.072 4.090 304.86 883.8 1188.7 0.4821 1.1136 1.5957
336 111.84 _ 0.01783 3.968 3.986 306.95 882.2 1189.2 0.4847 1.1088 1.5935
338 114.89 _ 0.01785 3.868 3.886 309.04 880.6 1189.6 0.4873 1.1040 1.5913
340 118.01 _ 0.01787 3.770 3.788 311.13 879.0 1190.1 0.4900 1.0992 1.5891
342 121.20 _ 0.01790 3.675 3.693 313.23 877.4 1190.6 0.4926 1.0944 1.5870
344 124.45 _ 0.01792 3.584 3.602 315.33 875.7 1191.0 0.4952 1.0896 1.5848
346 127.77 _ 0.01794 3.495 3.513 317.43 874.1 1191.5 0.4978 1.0848 1.5826
348 131.17 _ 0.01797 3.408 3.426 319.53 872.4 1191.9 0.5004 1.0801 1.5805
350 134.63 _ 0.01799 3.324 3.342 321.63 870.7 1192.3 0.5029 1.0754 1.5783
3
TEMP
F PSIA IN. HG
SAT.
LIQUID EVAP.
SAT.
VAPOR
SAT.
LIQUID EVAP.
SAT.
VAPOR
SAT.
LIQUID EVAP.
SAT.
VAPOR
t p p v
f
v
fg
v
g
h
f
h
fg
h
g
s
f
s
fg
s
g
I4-26
06-08
352 138.16 _ 0.01801 3.243 3.261 323.74 869.1 1192.8 0.5055 1.0707 1.5762
354 141.77 _ 0.01804 3.164 3.182 325.85 867.3 1193.2 0.5081 1.0660 1.5741
356 145.45 _ 0.01806 3.087 3.105 327.96 865.6 1193.6 0.5106 1.0613 1.5719
358 149.21 _ 0.01808 3.012 3.030 330.07 863.9 1194.0 0.5132 1.0566 1.5698
360 153.04 _ 0.01811 2.939 2.957 332.18 862.2 1194.4 0.5158 1.0519 1.5677
362 156.95 _ 0.01813 2.869 2.887 334.30 860.5 1194.8 0.5183 1.0473 1.5656
364 160.93 _ 0.01816 2.801 2.819 336.42 858.8 1195.2 0.5209 1.0426 1.5635
366 165.00 _ 0.01818 2.734 2.752 338.54 857.1 1195.6 0.5235 1.0380 1.5615
368 169.15 _ 0.01821 2.669 2.687 340.66 855.3 1196.0 0.5260 1.0334 1.5594
370 173.37 _ 0.01823 2.606 2.625 342.79 853.5 1196.3 0.5286 1.0287 1.5573
372 177.68 _ 0.01826 2.545 2.564 344.91 851.8 1196.7 0.5311 1.0241 1.5553
374 182.07 _ 0.01829 2.486 2.504 347.04 850.0 1197.0 0.5336 1.0196 1.5532
376 186.55 _ 0.01831 2.428 2.446 349.18 848.2 1197.4 0.5362 1.0150 1.5512
378 191.12 _ 0.01834 2.372 2.390 351.31 846.4 1197.7 0.5388 1.0104 1.5492
380 195.77 _ 0.01836 2.317 2.335 353.45 844.6 1198.1 0.5413 1.0059 1.5471
382 200.50 _ 0.01839 2.264 2.282 355.59 842.8 1198.4 0.5438 1.0013 1.5451
384 205.33 _ 0.01842 2.212 2.231 357.73 841.0 1198.7 0.5463 0.9968 1.5431
386 210.25 _ 0.01844 2.162 2.180 359.88 839.1 1199.0 0.5488 0.9923 1.5411
388 215.26 _ 0.01847 2.113 2.131 362.02 837.3 1199.3 0.5514 0.9877 1.5391
390 220.37 _ 0.01850 2.0651 2.0836 364.17 835.4 1199.6 0.5539 0.9832 1.5371
392 225.56 _ 0.01853 2.0187 2.0372 366.33 833.6 1199.9 0.5564 0.9787 1.5351
394 230.85 _ 0.01855 1.9734 1.9920 368.48 831.7 1200.2 0.5589 0.9742 1.5331
396 236.24 _ 0.01858 1.9293 1.9479 370.64 829.9 1200.5 0.5614 0.9698 1.5311
398 241.73 _ 0.01861 1.8864 1.9050 372.80 827.9 1200.7 0.5639 0.9653 1.5292
400 247.31 _ 0.01864 1.8447 1.8633 374.97 826.0 1201.0 0.5664 0.9608 1.5272
405 261.71 _ 0.01871 1.7448 1.7635 380.39 821.2 1201.6 0.5726 0.9497 1.5223
410 276.75 _ 0.01878 1.6512 1.6700 385.83 816.3 1202.1 0.5788 0.9386 1.5174
415 292.45 _ 0.01886 1.5635 1.5823 391.29 811.3 1202.6 0.5850 0.9276 1.5126
420 308.83 _ 0.01894 1.4811 1.5000 396.77 806.3 1203.1 0.5912 0.9166 1.5078
425 325.92 _ 0.01902 1.4036 1.4226 402.27 801.2 1203.5 0.5974 0.9056 1.5030
430 343.72 _ 0.01910 1.3308 1.3499 407.79 796.0 1203.8 0.6035 0.8947 1.4982
435 362.27 _ 0.01918 1.2623 1.2815 413.34 790.8 1204.1 0.6097 0.8838 1.4935
440 381.59 _ 0.01926 1.1979 1.2171 418.90 785.4 1204.3 0.6158 0.8730 1.4887
445 401.68 _ 0.01935 1.1371 1.1565 424.49 780.0 1204.5 0.6219 0.8622 1.4840
450 422.6 _ 0.0194 1.0799 1.0993 430.1 774.5 1204.6 0.6280 0.8513 1.4793
455 444.3 _ 0.0195 1.0258 1.0453 435.7 768.9 1204.6 0.6341 0.8406 1.4746
460 466.9 _ 0.0196 0.9748 0.9944 441.4 763.2 1204.6 0.6402 0.8298 1.4700
465 490.3 _ 0.0197 0.9266 0.9463 447.1 757.4 1204.5 0.6463 0.8190 1.4653
470 514.7 _ 0.0198 0.8811 0.9009 452.8 751.5 1204.3 0.6523 0.8083 1.4606
475 539.9 _ 0.0199 0.8380 0.8579 458.6 745.4 1204.0 0.6584 0.7976 1.4560
480 566.1 _ 0.0200 0.7972 0.8172 464.4 739.4 1203.7 0.6645 0.7868 1.4513
485 593.3 _ 0.0201 0.7586 0.7787 470.2 733.1 1203.3 0.6705 0.7761 1.4466
490 621.4 _ 0.0202 0.7221 0.7423 476.0 726.8 1202.8 0.6766 0.7653 1.4419
495 650.6 _ 0.0203 0.6874 0.7077 481.9 720.4 1202.3 0.6826 0.7546 1.4372
500 680.8 _ 0.0204 0.6545 0.6749 487.8 713.9 1201.7 0.6887 0.7438 1.4325
505 712.0 _ 0.0205 0.6233 0.6438 493.8 707.1 1200.9 0.6948 0.7331 1.4278
510 744.3 _ 0.0207 0.5935 0.6142 499.8 700.3 1200.1 0.7008 0.7223 1.4231
515 777.8 _ 0.0208 0.5653 0.5861 505.8 693.4 1199.2 0.7069 0.7115 1.4184
520 812.4 _ 0.0209 0.5385 0.5594 511.9 686.4 1198.2 0.7130 0.7006 1.4136
525 848.1 _ 0.0210 0.5130 0.5340 518.0 679.1 1197.1 0.7191 0.6897 1.4088
3
TEMP
F PSIA IN. HG
SAT.
LIQUID EVAP.
SAT.
VAPOR
SAT.
LIQUID EVAP.
SAT.
VAPOR
SAT.
LIQUID EVAP.
SAT.
VAPOR
t p p v
f
v
fg
v
g
h
f
h
fg
h
g
s
f
s
fg
s
g
I4-27
06-08
530 885.0 _ 0.0212 0.4886 0.5098 524.1 671.8 1195.9 0.7252 0.6788 1.4040
535 923.2 _ 0.0213 0.4655 0.4868 530.3 664.3 1194.6 0.7313 0.6679 1.3991
540 962.5 _ 0.0215 0.4434 0.4649 536.6 656.6 1193.2 0.7374 0.6568 1.3942
545 1003.2 _ 0.0216 0.4224 0.4440 542.9 648.8 1191.7 0.7435 0.6458 1.3893
550 1045.2 _ 0.0218 0.4022 0.4240 549.3 640.8 1190.0 0.7497 0.6346 1.3843
555 1088.5 _ 0.0219 0.3831 0.4050 555.7 632.6 1188.3 0.7559 0.6234 1.3793
560 1133.1 _ 0.0221 0.3647 0.3868 562.2 624.2 1186.4 0.7621 0.6121 1.3742
565 1179.1 _ 0.0222 0.3472 0.3694 568.8 615.5 1184.3 0.7683 0.6007 1.3690
570 1226.5 _ 0.0224 0.3304 0.3528 575.4 606.7 1182.1 0.7746 0.5893 1.3638
575 1275.4 _ 0.0226 0.3143 0.3369 582.1 597.7 1179.8 0.7809 0.5777 1.3585
580 1325.8 _ 0.0228 0.2989 0.3217 588.9 588.4 1177.3 0.7872 0.5659 1.3532
585 1377.7 _ 0.0230 0.2841 0.3071 595.8 578.8 1174.6 0.7936 0.5541 1.3477
590 1431.2 _ 0.0232 0.2700 0.2931 602.8 569.0 1171.8 0.8001 0.5421 1.3422
595 1486.2 _ 0.0234 0.2563 0.2797 609.8 558.9 1168.7 0.8066 0.5299 1.3365
600 1542.9 _ 0.0236 0.2432 0.2668 617.0 548.5 1165.5 0.8131 0.5176 1.3307
605 1601.2 _ 0.0239 0.2306 0.2545 624.3 537.7 1162.0 0.8197 0.5051 1.3248
610 1661.2 _ 0.0241 0.2185 0.2426 631.6 526.7 1158.4 0.8264 0.4924 1.3188
615 1723.0 _ 0.0244 0.2068 0.2312 639.1 515.3 1154.4 0.8331 0.4795 1.3126
620 1786.6 _ 0.0247 0.1955 0.2201 646.7 503.6 1150.3 0.8398 0.4664 1.3062
625 1852.0 _ 0.0250 0.1845 0.2095 654.4 491.4 1145.8 0.8467 0.4530 1.2997
630 1919.3 _ 0.0253 0.1740 0.1992 662.3 478.8 1141.1 0.8536 0.4394 1.2930
635 1988.5 _ 0.0256 0.1637 0.1893 670.4 465.6 1136.0 0.8607 0.4254 1.2861
640 2059.7 _ 0.0260 0.1538 0.1798 678.6 452.0 1130.5 0.8679 0.4110 1.2789
645 2132.9 _ 0.0264 0.1441 0.1705 687.0 437.7 1124.7 0.8752 0.3962 1.2715
650 2208.2 _ 0.0268 0.1348 0.1616 695.7 422.8 1118.5 0.8828 0.3809 1.2637
655 2285.7 _ 0.0273 0.1256 0.1528 704.8 406.9 1111.7 0.8906 0.3651 1.2557
660 2365.4 _ 0.0278 0.1165 0.1442 714.2 390.2 1104.4 0.8987 0.3485 1.2472
665 2447.4 _ 0.0283 0.1076 0.1359 724.1 372.4 1096.4 0.9071 0.3311 1.2382
670 2531.8 _ 0.0290 0.0987 0.1277 734.4 353.2 1087.7 0.9159 0.3127 1.2285
675 2618.7 _ 0.0297 0.0899 0.1196 745.4 332.6 1078.0 0.9251 0.2931 1.2183
680 2708.1 _ 0.0305 0.0810 0.1115 757.3 309.9 1067.2 0.9351 0.2719 1.2071
685 2800.2 _ 0.0315 0.0719 0.1034 770.1 284.7 1054.8 0.9459 0.2487 1.1946
690 2895.1 _ 0.0328 0.0625 0.0953 784.4 256.0 1040.4 0.9578 0.2227 1.1805
695 2992.9 _ 0.0344 0.0520 0.0864 801.2 220.7 1021.9 0.9719 0.1911 1.1630
700 3093.7 _ 0.0369 0.0392 0.0761 823.3 172.1 995.4 0.9905 0.1484 1.1389
702 3134.9 _ 0.0385 0.0325 0.0710 835.4 145.2 980.6 1.0006 0.1249 1.1256
704 3176.7 _ 0.0410 0.0234 0.0645 852.7 106.0 958.7 1.0152 0.0911 1.1063
705 3197.7 _ 0.0438 0.0152 0.0589 869.2 69.1 938.4 1.0293 0.0593 1.0886
705.4 3206.2 _ 0.0503 0 0.0503 902.7 0 902.7 1.0580 0 1.0580
3
TEMP
F PSIA IN. HG
SAT.
LIQUID EVAP.
SAT.
VAPOR
SAT.
LIQUID EVAP.
SAT.
VAPOR
SAT.
LIQUID EVAP.
SAT.
VAPOR
t p p v
f
v
fg
v
g
h
f
h
fg
h
g
s
f
s
fg
s
g
I4-28
06-08
ABS.
PRESS
TEMP
SPECIFIC
VOLUME (ft.
3
/lb)
ENTHALPY (Btu/lb) ENTROPY (Btu/lb,F) INTERNAL ENERGY (Btu/lb)
PSIA F
SAT.
LIQUID
SAT.
VAPOR
SAT.
LIQUID EVAP.
SAT.
VAPOR
SAT.
LIQUID EVAP.
SAT.
VAPOR
SAT.
LIQUID EVAP.
SAT.
VAPOR
p t v
f
v
g
h
f
h
fg
h
g
s
f
s
fg
s
g
u
f
u
fg
u
g
14.696 212.00 0.01672 26.80 180.07 970.3 1150.4 0.3120 1.4446 1.7566 180.02 897.5 1077.5
15 213.03 0.01672 26.29 181.11 969.7 1150.8 0.3135 1.4415 1.7549 181.06 896.7 1077.8
16 216.32 0.01674 24.75 184.42 967.6 1152.0 0.3184 1.4313 1.7497 184.37 894.3 1078.7
17 219.44 0.01677 23.39 187.56 965.5 1153.1 0.3231 1.4218 1.7449 187.51 892.0 1079.5
18 222.41 0.01679 22.17 190.56 963.6 1154.2 0.3275 1.4128 1.7403 190.50 889.9 1080.4
19 225.24 0.01681 21.08 193.42 961.9 1155.3 0.3317 1.4043 1.7360 193.36 887.8 1081.2
20 227.96 0.01683 20.089 196.16 960.1 1156.3 0.3356 1.3962 1.7319 196.10 885.8 1081.9
21 230.57 0.01685 19.192 198.79 958.4 1157.2 0.3395 1.3885 1.7280 198.73 883.9 1082.6
22 233.07 0.01687 18.375 201.33 956.8 1158.1 0.3431 1.3811 1.7242 201.26 882.0 1083.3
23 235.49 0.01689 17.627 203.78 955.2 1159.0 0.3466 1.3740 1.7206 203.71 880.2 1083.9
24 237.82 0.01691 16.938 206.14 953.7 1159.8 0.3500 1.3672 1.7172 206.07 878.5 1084.6
25 240.07 0.01692 16.303 208.42 952.1 1160.6 0.3533 1.3606 1.7139 208.34 876.8 1085.1
26 242.25 0.01694 15.715 210.62 950.7 1161.3 0.3564 1.3544 1.7108 210.54 875.2 1085.7
27 244.36 0.01696 15.170 212.75 949.3 1162.0 0.3594 1.3484 1.7078 212.67 873.6 1086.3
28 246.41 0.01698 14.663 214.83 947.9 1162.7 0.3623 1.3425 1.7048 214.74 872.1 1086.8
29 248.40 0.01699 14.189 216.86 946.5 1163.4 0.3652 1.3368 1.7020 216.77 870.5 1087.3
30 250.33 0.01701 13.746 218.82 945.3 1164.1 0.3680 1.3313 1.6993 218.73 869.1 1087.8
31 252.22 0.01702 13.330 220.73 944.0 1164.7 0.3707 1.3260 1.6967 220.63 867.7 1088.3
32 254.05 0.01704 12.940 222.59 942.8 1165.4 0.3733 1.3209 1.6941 222.49 866.3 1088.7
33 255.84 0.01705 12.572 224.41 941.6 1166.0 0.3758 1.3159 1.6917 224.31 864.9 1089.2
34 257.58 0.01707 12.226 226.18 940.3 1166.5 0.3783 1.3110 1.6893 226.07 863.5 1089.6
35 259.28 0.01708 11.898 227.91 939.2 1167.1 0.3807 1.3063 1.6870 227.80 862.3 1090.1
36 260.95 0.01709 11.588 229.60 938.0 1167.6 0.3831 1.3017 1.6848 229.49 861.0 1090.5
37 262.57 0.01711 11.294 231.26 936.9 1168.2 0.3854 1.2972 1.6826 231.14 859.8 1090.9
38 264.16 0.01712 11.015 232.89 935.8 1168.7 0.3876 1.2929 1.6805 232.77 858.5 1091.3
39 265.72 0.01714 10.750 234.48 934.7 1169.2 0.3898 1.2886 1.6784 234.36 857.2 1091.6
40 267.25 0.01715 10.498 236.03 933.7 1169.7 0.3919 1.2844 1.6763 235.90 856.1 1092.0
41 268.74 0.01716 10.258 237.55 932.6 1170.2 0.3940 1.2803 1.6743 237.42 855.0 1092.4
42 270.21 0.01717 10.029 239.04 931.6 1170.7 0.3960 1.2764 1.6724 238.91 853.8 1092.7
43 271.64 0.01719 9.810 240.51 930.6 1171.1 0.3980 1.2726 1.6706 240.37 852.7 1093.1
44 273.05 0.01720 9.601 241.95 929.6 1171.6 0.4000 1.2687 1.6687 241.81 851.6 1093.4
45 274.44 0.01721 9.401 243.36 928.6 1172.0 0.4019 1.2650 1.6669 243.22 850.5 1093.7
46 275.80 0.01722 9.209 244.75 927.7 1172.4 0.4038 1.2613 1.6652 244.60 849.5 1094.1
47 277.13 0.01723 9.025 246.12 926.7 1172.9 0.4057 1.2577 1.6634 245.97 848.4 1094.4
48 278.45 0.01725 8.848 247.47 925.8 1173.3 0.4075 1.2542 1.6617 247.32 847.4 1094.7
49 279.74 0.01726 8.678 248.79 924.9 1173.7 0.4093 1.2508 1.6601 248.63 846.4 1095.0
50 281.01 0.01727 8.515 250.09 924.0 1174.1 0.4110 1.2474 1.6585 249.93 845.4 1095.3
48 278.45 0.01725 8.848 247.47 925.8 1173.3 0.4075 1.2542 1.6617 247.32 847.4 1094.7
49 279.74 0.01726 8.678 248.79 924.9 1173.7 0.4093 1.2508 1.6601 248.63 846.4 1095.0
50 281.01 0.01727 8.515 250.09 924.0 1174.1 0.4110 1.2474 1.6585 249.93 845.4 1095.3
51 282.26 0.01728 8.359 251.37 923.0 1174.4 0.4127 1.2442 1.6569 251.21 844.3 1095.5
52 283.49 0.01729 8.208 252.63 922.2 1174.8 0.4144 1.2409 1.6553 252.46 843.3 1095.8
53 284.70 0.01730 8.062 253.87 921.3 1175.2 0.4161 1.2377 1.6538 253.70 842.4 1096.1
54 285.90 0.01731 7.922 255.09 920.5 1175.6 0.4177 1.2346 1.6523 254.92 841.5 1096.4
55 287.07 0.01732 7.787 256.30 919.6 1175.9 0.4193 1.2316 1.6509 256.12 840.6 1096.7
56 288.23 0.01733 7.656 257.50 918.8 1176.3 0.4209 1.2285 1.6494 257.32 839.7 1097.0
57 289.37 0.01734 7.529 258.67 917.9 1176.6 0.4225 1.2255 1.6480 258.49 838.7 1097.2
58 290.50 0.01736 7.407 259.82 917.1 1176.9 0.4240 1.2226 1.6466 259.63 837.8 1097.4
59 291.61 0.01737 7.289 260.96 916.3 1177.3 0.4255 1.2197 1.6452 260.77 836.9 1097.7
60 292.71 0.01738 7.175 262.09 915.5 1177.6 0.4270 1.2168 1.6438 261.90 836.0 1097.9
61 293.79 0.01739 7.064 263.20 914.7 1177.9 0.4285 1.2140 1.6425 263.00 835.2 1098.2
Table I4-16. Saturated Steam Properties, Pressure Table (Sheet 1 of 5)
I4-29
06-08
62 294.85 0.01740 6.957 264.30 913.9 1178.2 0.4300 1.2112 1.6412 264.10 834.3 1098.4
63 295.90 0.01741 6.853 265.38 913.1 1178.5 0.4314 1.2085 1.6399 265.18 833.4 1098.6
64 296.94 0.01742 6.752 266.45 912.3 1178.8 0.4328 1.2059 1.6387 266.24 832.6 1098.8
65 297.97 0.01743 6.655 267.50 911.6 1179.1 0.4342 1.2032 1.6374 267.29 831.8 1099.1
66 298.99 0.01744 6.560 268.55 910.8 1179.4 0.4356 1.2006 1.6362 268.34 831.0 1099.3
67 299.99 0.01745 6.468 269.58 910.1 1179.7 0.4369 1.1981 1.6350 269.36 830.2 1099.5
68 300.98 0.01746 6.378 270.60 909.4 1180.0 0.4383 1.1955 1.6338 270.38 829.4 1099.8
69 301.96 0.01747 6.291 271.61 908.7 1180.3 0.4396 1.1930 1.6326 271.39 828.6 1100.0
70 302.92 0.01748 6.206 272.61 907.9 1180.6 0.4409 1.1906 1.6315 272.38 827.8 1100.2
71 303.88 0.01749 6.124 273.60 907.2 1180.8 0.4422 1.1881 1.6303 273.37 827.0 1100.4
72 304.83 0.01750 6.044 274.57 906.5 1181.1 0.4435 1.1857 1.6292 274.34 826.3 1100.6
73 305.76 0.01751 5.966 275.54 905.8 1181.3 0.4447 1.1834 1.6281 275.30 825.5 1100.8
74 306.68 0.01752 5.890 276.49 905.1 1181.6 0.4460 1.1810 1.6270 276.25 824.7 1101.0
75 307.60 0.01753 5.816 277.43 904.5 1181.9 0.4472 1.1787 1.6259 277.19 824.0 1101.2
76 308.50 0.01754 5.743 278.37 903.7 1182.1 0.4484 1.1764 1.6248 278.12 823.3 1101.4
77 309.40 0.01754 5.673 279.30 903.1 1182.4 0.4496 1.1742 1.6238 279.05 822.5 1101.6
78 310.29 0.01755 5.604 280.21 902.4 1182.6 0.4508 1.1720 1.6228 279.96 821.7 1101.7
79 311.16 0.01756 5.537 281.12 901.7 1182.8 0.4520 1.1698 1.6217 280.86 821.0 1101.9
80 312.03 0.01757 5.472 282.02 901.1 1183.1 0.4531 1.1676 1.6207 281.76 820.3 1102.1
81 312.89 0.01758 5.408 282.91 900.4 1183.3 0.4543 1.1654 1.6197 282.65 819.6 1102.2
82 313.74 0.01759 5.346 283.79 899.7 1183.5 0.4554 1.1633 1.6187 283.52 818.9 1102.4
83 314.59 0.01760 5.285 284.66 899.1 1183.8 0.4565 1.1612 1.6177 284.39 818.2 1102.6
84 315.42 0.01761 5.226 285.53 898.5 1184.0 0.4576 1.1592 1.6168 285.26 817.5 1102.8
85 316.25 0.01761 5.168 286.39 897.8 1184.2 0.4587 1.1571 1.6158 286.11 816.8 1102.9
86 317.07 0.01762 5.111 287.24 897.2 1184.4 0.4598 1.1551 1.6149 286.96 816.1 1103.1
87 317.88 0.01763 5.055 288.08 896.5 1184.6 0.4609 1.1530 1.6139 287.80 815.4 1103.2
88 318.68 0.01764 5.001 288.91 895.9 1184.8 0.4620 1.1510 1.6130 288.63 814.8 1103.4
89 319.48 0.01765 4.948 289.74 895.3 1185.1 0.4630 1.1491 1.6121 289.45 814.1 1103.6
90 320.27 0.01766 4.896 290.56 894.7 1185.3 0.4641 1.1471 1.6112 290.27 813.4 1103.7
91 321.06 0.01767 4.845 291.38 894.1 1185.5 0.4651 1.1452 1.6103 291.08 812.8 1103.9
92 321.83 0.01768 4.796 292.18 893.5 1185.7 0.4661 1.1433 1.6094 291.88 812.2 1104.1
93 322.60 0.01768 4.747 292.98 892.9 1185.9 0.4672 1.1413 1.6085 292.68 811.5 1104.2
94 323.36 0.01769 4.699 293.78 892.3 1186.1 0.4682 1.1394 1.6076 293.47 810.9 1104.4
95 324.12 0.01770 4.652 294.56 891.7 1186.2 0.4692 1.1376 1.6068 294.25 810.2 1104.5
96 324.87 0.01771 4.606 295.34 891.1 1186.4 0.4702 1.1358 1.6060 295.03 809.6 1104.6
97 325.61 0.01772 4.561 296.12 890.5 1186.6 0.4711 1.1340 1.6051 295.80 808.9 1104.7
98 326.35 0.01772 4.517 296.89 889.9 1186.8 0.4721 1.1322 1.6043 296.57 808.3 1104.9
99 327.08 0.01773 4.474 297.65 889.4 1187.0 0.4731 1.1304 1.6035 297.33 807.7 1105.0
100 327.81 0.01774 4.432 298.40 888.8 1187.2 0.4740 1.1286 1.6026 298.08 807.1 1105.2
101 328.53 0.01775 4.391 299.15 888.2 1187.4 0.4750 1.1268 1.6018 298.82 806.5 1105.3
102 329.25 0.01775 4.350 299.90 887.6 1187.5 0.4759 1.1251 1.6010 299.57 805.9 1105.4
103 329.96 0.01776 4.310 300.64 887.1 1187.7 0.4768 1.1234 1.6002 300.30 805.3 1105.6
104 330.66 0.01777 4.271 301.37 886.5 1187.9 0.4778 1.1216 1.5994 301.03 804.7 1105.7
105 331.36 0.01778 4.232 302.10 886.0 1188.1 0.4787 1.1199 1.5986 301.75 804.1 1105.9
106 332.05 0.01778 4.194 302.82 885.4 1188.2 0.4796 1.1182 1.5978 302.47 803.5 1106.0
107 332.74 0.01779 4.157 303.54 884.9 1188.4 0.4805 1.1166 1.5971 303.19 802.9 1106.1
108 333.42 0.01780 4.120 304.26 884.3 1188.6 0.4814 1.1149 1.5963 303.90 802.4 1106.3
109 334.10 0.01781 4.084 304.97 883.7 1188.7 0.4823 1.1133 1.5956 304.61 801.8 1106.4
110 334.77 0.01782 4.049 305.66 883.2 1188.9 0.4832 1.1117 1.5948 305.30 801.2 1106.5
111 335.44 0.01782 4.015 306.37 882.6 1189.0 0.4840 1.1101 1.5941 306.00 800.6 1106.6
112 336.11 0.01783 3.981 307.06 882.1 1189.2 0.4849 1.1085 1.5934 306.69 800.0 1106.7
ABS.
PRESS
TEMP
SPECIFIC
VOLUME (ft.
3
/lb)
PSIA F
SAT.
LIQUID
SAT.
VAPOR
SAT.
LIQUID EVAP.
SAT.
VAPOR
SAT.
LIQUID EVAP.
SAT.
VAPOR
SAT.
LIQUID EVAP.
SAT.
VAPOR
p t v
f
v
g
h
f
h
fg
h
g
s
f
s
fg
s
g
u
f
u
fg
u
g
I4-30
06-08
113 336.77 0.01784 3.947 307.75 881.6 1189.4 0.4858 1.1069 1.5927 307.38 799.4 1106.8
114 337.42 0.01784 3.914 308.43 881.1 1189.5 0.4866 1.1053 1.5919 308.05 798.9 1106.9
115 338.07 0.01785 3.882 309.11 880.6 1189.7 0.4875 1.1037 1.5912 308.73 798.4 1107.1
116 338.72 0.01786 3.850 309.79 880.0 1189.8 0.4883 1.1022 1.5905 309.41 797.8 1107.2
117 339.36 0.01787 3.819 310.46 879.5 1190.0 0.4891 1.1007 1.5898 310.07 797.2 1107.3
118 339.99 0.01787 3.788 311.12 879.0 1190.1 0.4900 1.0992 1.5891 310.73 796.7 1107.4
119 340.62 0.01788 3.758 311.78 878.4 1190.2 0.4908 1.0977 1.5885 311.39 796.1 1107.5
120 341.25 0.01789 3.728 312.44 877.9 1190.4 0.4916 1.0962 1.5878 312.05 795.6 1107.6
121 341.88 0.01790 3.699 313.10 877.4 1190.5 0.4924 1.0947 1.5871 312.70 795.0 1107.7
122 342.50 0.01791 3.670 313.75 876.9 1190.7 0.4932 1.0933 1.5865 313.35 794.5 1107.8
123 343.11 0.01791 3.642 314.40 876.4 1190.8 0.4940 1.0918 1.5858 313.99 793.9 1107.9
124 343.72 0.01792 3.614 315.04 875.9 1190.9 0.4948 1.0903 1.5851 314.63 793.4 1108.0
125 344.33 0.01792 3.587 315.68 875.4 1191.1 0.4956 1.0888 1.5844 315.26 792.8 1108.1
126 344.94 0.01793 3.560 316.31 874.9 1191.2 0.4964 1.0874 1.5838 315.89 792.3 1108.2
127 345.54 0.01794 3.533 316.94 874.4 1191.3 0.4972 1.0859 1.5832 316.52 791.8 1108.3
128 346.13 0.01794 3.507 317.57 873.9 1191.5 0.4980 1.0845 1.5825 317.15 791.3 1108.4
129 346.73 0.01795 3.481 318.19 873.4 1191.6 0.4987 1.0832 1.5819 317.77 790.7 1108.5
130 347.32 0.01796 3.455 318.81 872.9 1191.7 0.4995 1.0817 1.5812 318.38 790.2 1108.6
131 347.90 0.01797 3.430 319.43 872.5 1191.9 0.5002 1.0804 1.5806 318.99 789.7 1108.7
132 348.48 0.01797 3.405 320.04 872.0 1192.0 0.5010 1.0790 1.5800 319.60 789.2 1108.8
133 349.06 0.01798 3.381 320.65 871.5 1192.1 0.5018 1.0776 1.5793 320.21 788.7 1108.9
134 349.64 0.01799 3.357 321.25 871.0 1192.2 0.5025 1.0762 1.5787 320.80 788.2 1109.0
135 350.21 0.01800 3.333 321.85 870.6 1192.4 0.5032 1.0749 1.5781 321.40 787.7 1109.1
136 350.78 0.01800 3.310 322.45 870.1 1192.5 0.5040 1.0735 1.5775 322.0 787.2 1109.2
137 351.35 0.01801 3.287 323.05 869.6 1192.6 0.5047 1.0722 1.5769 322.59 786.7 1109.3
138 351.91 0.01801 3.264 323.64 869.1 1192.7 0.5054 1.0709 1.5763 323.18 786.2 1109.4
139 352.47 0.01802 3.242 324.23 868.7 1192.9 0.5061 1.0696 1.5757 323.77 785.7 1109.5
140 353.02 0.01802 3.220 324.82 868.2 1193.0 0.5069 1.0682 1.5751 324.35 785.2 1109.6
141 353.57 0.01803 3.198 325.40 867.7 1193.1 0.5076 1.0669 1.5745 324.93 784.8 1109.7
142 354.12 0.01804 3.177 325.98 867.2 1193.2 0.5083 1.0657 1.5740 325.51 784.3 1109.8
143 354.67 0.01804 3.155 326.56 866.7 1193.3 0.5090 1.0644 1.5734 326.08 783.8 1109.8
144 355.21 0.01805 3.134 327.13 866.3 1193.4 0.5097 1.0631 1.5728 326.65 783.3 1109.9
145 355.76 0.01806 3.114 327.70 865.8 1193.5 0.5104 1.0618 1.5722 327.22 782.8 1110.0
146 356.29 0.01806 3.094 328.27 865.3 1193.6 0.5111 1.0605 1.5716 327.78 782.3 1110.1
147 356.83 0.01807 3.074 328.83 864.9 1193.8 0.5118 1.0592 1.5710 328.34 781.9 1110.2
148 357.36 0.01808 3.054 329.39 864.5 1193.9 0.5124 1.0580 1.5705 328.90 781.4 1110.3
149 357.89 0.01808 3.034 329.95 864.0 1194.0 0.5131 1.0568 1.5699 329.45 780.9 1110.4
150 358.42 0.01809 3.015 330.51 863.6 1194.1 0.5138 1.0556 1.5694 330.01 780.5 1110.5
152 359.46 0.01810 2.977 331.61 862.7 1194.3 0.5151 1.0532 1.5683 331.10 779.5 1110.6
154 360.49 0.01812 2.940 332.70 861.8 1194.5 0.5165 1.0507 1.5672 332.18 778.5 1110.7
156 361.52 0.01813 2.904 333.79 860.9 1194.7 0.5178 1.0483 1.5661 333.26 777.6 1110.9
158 362.53 0.01814 2.869 334.86 860.0 1194.9 0.5191 1.0459 1.5650 334.23 776.8 1111.0
160 363.53 0.01815 2.834 335.93 859.2 1195.1 0.5204 1.0436 1.5640 335.39 775.8 1111.2
162 364.53 0.01817 2.801 336.98 858.3 1195.3 0.5216 1.0414 1.5630 336.44 775.0 1111.4
164 365.51 0.01818 2.768 338.02 857.5 1195.5 0.5229 1.0391 1.5620 337.47 774.1 1111.5
166 366.48 0.01819 2.736 339.05 856.6 1195.7 0.5241 1.0369 1.5610 338.49 773.2 1111.7
168 367.45 0.01820 2.705 340.07 855.7 1195.8 0.5254 1.0346 1.5600 339.51 772.3 1111.8
170 368.41 0.01822 2.675 341.09 854.9 1196.0 0.5266 1.0324 1.5590 340.52 771.4 1111.9
172 369.35 0.01823 2.645 342.10 854.1 1196.2 0.5278 1.0302 1.5580 341.52 770.5 1112.0
174 370.29 0.01824 2.616 343.10 853.3 1196.4 0.5290 1.0280 1.5570 342.51 769.7 1112.2
176 371.22 0.01825 2.587 344.09 852.4 1196.5 0.5302 1.0259 1.5561 343.50 768.8 1112.3
178 372.14 0.01826 2.559 345.06 851.6 1196.7 0.5313 1.0238 1.5551 344.46 767.9 1112.4
ABS.
PRESS
TEMP
SPECIFIC
VOLUME (ft.
3
/lb)
PSIA F
SAT.
LIQUID
SAT.
VAPOR
SAT.
LIQUID EVAP.
SAT.
VAPOR
SAT.
LIQUID EVAP.
SAT.
VAPOR
SAT.
LIQUID EVAP.
SAT.
VAPOR
p t v
f
v
g
h
f
h
fg
h
g
s
f
s
fg
s
g
u
f
u
fg
u
g
I4-31
06-08
180 373.06 0.01827 2.532 346.03 850.8 1196.9 0.5325 1.0217 1.5542 345.42 767.1 1112.5
182 373.96 0.01829 2.505 347.00 850.0 1197.0 0.5336 1.0196 1.5532 346.38 766.2 1112.6
184 374.86 0.01830 2.479 347.96 849.2 1197.2 0.5348 1.0175 1.5523 347.34 765.4 1112.8
186 375.75 0.01831 2.454 348.92 848.4 1197.3 0.5359 1.0155 1.5514 348.29 764.6 1112.9
188 376.64 0.01832 2.429 349.86 847.6 1197.5 0.5370 1.0136 1.5506 349.22 763.8 1113.0
190 377.51 0.01833 2.404 350.79 846.8 1197.6 0.5381 1.0116 1.5497 350.15 763.0 1113.1
192 378.38 0.01834 2.380 351.72 846.1 1197.8 0.5392 1.0096 1.5488 351.07 762.1 1113.2
194 379.24 0.01835 2.356 352.64 845.3 1197.9 0.5403 1.0076 1.5479 351.98 761.3 1113.3
196 380.10 0.01836 2.333 353.55 844.5 1198.1 0.5414 1.0056 1.5470 352.89 760.6 1113.5
198 380.95 0.01838 2.310 354.46 843.7 1198.2 0.5425 1.0037 1.5462 353.79 759.8 1113.6
200 381.79 0.01839 2.288 355.36 843.0 1198.4 0.5435 1.0018 1.5453 354.68 759.0 1113.7
205 383.86 0.01842 2.234 357.58 841.1 1198.7 0.5461 0.9971 1.5432 356.88 757.1 1114.0
210 385.90 0.01844 2.183 359.77 839.2 1199.0 0.5487 0.9925 1.5412 359.05 755.2 1114.2
215 387.89 0.01847 2.134 361.91 837.4 1199.3 0.5512 0.9880 1.5392 361.18 753.2 1114.4
220 389.86 0.01850 2.087 364.02 835.6 1199.6 0.5537 0.9835 1.5372 363.27 751.3 1114.6
225 391.79 0.01852 2.0422 366.09 833.8 1199.9 0.5561 0.9792 1.5353 365.32 749.5 1114.8
230 393.68 0.01854 1.9992 368.13 832.0 1200.1 0.5585 0.9750 1.5334 367.34 747.7 1115.0
235 395.54 0.01857 1.9579 370.14 830.3 1200.4 0.5608 0.9708 1.5316 369.33 745.9 1115.3
240 397.37 0.01860 1.9183 372.12 828.5 1200.6 0.5631 0.9667 1.5298 371.29 744.1 1115.4
245 399.18 0.01863 1.8803 374.08 826.8 1200.9 0.5653 0.9627 1.5280 373.23 742.4 1115.6
250 400.95 0.01865 1.8438 376.00 825.1 1201.1 0.5675 0.9588 1.5263 375.14 740.7 1115.8
255 402.70 0.01868 1.8086 377.89 823.4 1201.3 0.5697 0.9549 1.5246 377.01 739.0 1116.0
260 404.42 0.01870 1.7748 379.76 821.8 1201.5 0.5719 0.9510 1.5229 378.86 737.3 1116.1
265 406.11 0.01873 1.7422 381.60 820.1 1201.7 0.5740 0.9472 1.5212 380.68 735.6 1116.3
270 407.78 0.01875 1.7107 383.42 818.5 1201.9 0.5760 0.9436 1.5196 382.48 733.9 1116.4
275 409.43 0.01878 1.6804 385.21 816.9 1202.1 0.5781 0.9399 1.5180 384.26 732.3 1116.6
280 411.05 0.01880 1.6511 386.98 815.3 1202.3 0.5801 0.9363 1.5164 386.01 730.7 1116.7
285 412.65 0.01883 1.6228 388.73 813.7 1202.4 0.5821 0.9327 1.5149 387.74 729.1 1116.8
290 414.23 0.01885 1.5954 390.46 812.1 1202.6 0.5841 0.9292 1.5133 389.45 727.5 1116.9
295 415.79 0.01887 1.5689 392.16 810.5 1202.7 0.5860 0.9258 1.5118 391.13 725.9 1117.0
300 417.33 0.01890 1.5433 393.84 809.0 1202.8 0.5879 0.9225 1.5104 392.79 724.3 1117.1
310 420.35 0.01894 1.4944 397.15 806.0 1203.1 0.5916 0.9159 1.5075 396.06 721.3 1117.4
320 423.29 0.01899 1.4485 400.39 803.0 1203.4 0.5952 0.9094 1.5046 399.26 718.3 1117.6
330 426.16 0.01904 1.4053 403.56 800.0 1203.6 0.5988 0.9031 1.5019 402.40 715.4 1117.8
340 428.97 0.01908 1.3645 406.66 797.1 1203.7 0.6022 0.8970 1.4992 405.46 712.4 1117.9
350 431.72 0.01913 1.3260 409.69 794.2 1203.9 0.6056 0.8910 1.4966 408.45 709.6 1118.0
360 434.40 0.01917 1.2895 412.67 791.4 1204.1 0.6090 0.8851 1.4941 411.39 706.8 1118.2
370 437.03 0.01921 1.2550 415.59 788.6 1204.2 0.6122 0.8794 1.4916 414.27 704.0 1118.3
380 439.60 0.01925 1.2222 418.45 785.8 1204.3 0.6153 0.8738 1.4891 417.10 701.3 1118.4
390 442.12 0.01930 1.1910 421.27 783.1 1204.4 0.6184 0.8683 1.4867 419.88 698.6 1118.5
400 444.59 0.0193 1.1613 424.0 780.5 1204.5 0.6214 0.8630 1.4844 422.6 695.9 1118.5
410 447.01 0.0194 1.1330 426.8 777.7 1204.5 0.6243 0.8578 1.4821 425.3 693.3 1118.6
420 449.39 0.0194 1.1061 429.4 775.2 1204.6 0.6272 0.8527 1.4799 427.9 690.8 1118.7
430 451.73 0.0194 1.0803 432.1 772.5 1204.6 0.6301 0.8476 1.4777 430.5 688.2 1118.7
440 454.02 0.0195 1.0556 434.6 770.0 1204.6 0.6329 0.8426 1.4755 433.0 685.7 1118.7
450 456.28 0.0195 1.0320 437.2 767.4 1204.6 0.6356 0.8378 1.4734 435.5 683.2 1118.7
460 458.50 0.0196 1.0094 439.7 764.9 1204.6 0.6383 0.8330 1.4713 438.0 680.7 1118.7
470 460.68 0.0196 0.9878 442.2 762.4 1204.6 0.6410 0.8283 1.4693 440.5 678.2 1118.7
480 462.82 0.0197 0.9670 444.6 759.9 1204.5 0.6436 0.8237 1.4673 442.9 675.7 1118.6
490 464.93 0.0197 0.9470 447.0 757.5 1204.5 0.6462 0.8191 1.4653 445.2 673.4 1118.6
ABS.
PRESS
TEMP
SPECIFIC
VOLUME (ft.
3
/lb)
PSIA F
SAT.
LIQUID
SAT.
VAPOR
SAT.
LIQUID EVAP.
SAT.
VAPOR
SAT.
LIQUID EVAP.
SAT.
VAPOR
SAT.
LIQUID EVAP.
SAT.
VAPOR
p t v
f
v
g
h
f
h
fg
h
g
s
f
s
fg
s
g
u
f
u
fg
u
g
I4-32
06-08
ABS.
PRESS
TEMP
SPECIFIC
VOLUME (ft.
3
/in
2
)
ENTHALPY (Btu/lb) ENTROPY (Btu/lb,F)
INTERNAL
ENERGY (Btu/lb)
PSIA F
SAT.
LIQUID EVAP.
SAT.
VA-
POR
SAT.
LIQUID EVAP.
SAT.
VA-
POR
SAT.
LIQUID EVAP.
SAT.
VA-
POR
SAT.
LIQUID
SAT.
VA-
POR
p t v
f
v
fg
v
g
h
f
h
fg
h
g
s
f
s
fg
s
g
u
f
u
g
500 467.01 0.0197 0.9081 0.9278 449.4 755.0 1204.4 0.6487 0.8147 1.4634 447.6 1118.6
520 471.07 0.0198 0.8717 0.8915 454.1 750.1 1204.2 0.6536 0.8060 1.4596 452.2 1118.4
540 475.01 0.0199 0.8379 0.8578 458.6 745.4 1204.0 0.6584 0.7976 1.4560 456.6 1118.3
560 478.85 0.0200 0.8065 0.8265 463.0 740.8 1203.8 0.6631 0.7893 1.4524 460.9 1118.2
580 482.58 0.0201 0.7772 0.7973 467.4 736.1 1203.5 0.6676 0.7813 1.4489 465.2 1118.0
600 486.21 0.0201 0.7497 0.7698 471.6 731.6 1203.2 0.6720 0.7734 1.4454 469.4 1117.7
620 489.75 0.0202 0.7238 0.7440 475.7 727.2 1202.9 0.6763 0.7658 1.4421 473.4 1117.5
640 493.21 0.0203 0.6995 0.7198 479.8 722.7 1202.5 0.6805 0.7584 1.4389 477.4 1117.3
660 496.58 0.0204 0.6767 0.6971 483.8 718.3 1202.1 0.6846 0.7512 1.4358 481.3 1117.0
680 499.88 0.0204 0.6553 0.6757 487.7 714.0 1201.7 0.6886 0.7441 1.4327 485.1 1116.7
700 503.10 0.0205 0.6349 0.6554 491.5 709.7 1201.2 0.6925 0.7371 1.4296 488.8 1116.3
720 506.25 0.0206 0.6156 0.6362 495.3 705.4 1200.7 0.6963 0.7303 1.4266 492.5 1116.0
740 509.34 0.0207 0.5973 0.6180 499.0 701.2 1200.2 0.7001 0.7237 1.4237 496.2 1115.6
760 512.36 0.0207 0.5800 0.6007 502.6 697.1 1199.7 0.7037 0.7172 1.4209 499.7 1115.2
780 515.33 0.0208 0.5635 0.5843 506.2 692.9 1199.1 0.7073 0.7108 1.4181 503.2 1114.8
800 518.23 0.0209 0.5478 0.5687 509.7 688.9 1198.6 0.7108 0.7045 1.4153 506.6 1114.4
820 521.08 0.0209 0.5329 0.5538 513.2 684.8 1198.0 0.7143 0.6983 1.4126 510.0 1114.0
840 523.88 0.0210 0.5186 0.5396 516.6 680.8 1197.4 0.7177 0.6922 1.4099 513.3 1113.6
860 526.63 0.0211 0.5049 0.5260 520.0 676.8 1196.8 0.7210 0.6862 1.4072 516.6 1113.1
880 529.33 0.0212 0.4918 0.5130 523.3 672.8 1196.1 0.7243 0.6803 1.4046 519.9 1112.6
900 531.98 0.0212 0.4794 0.5006 526.6 668.8 1195.4 0.7275 0.6744 1.4020 523.1 1112.1
UNIT CONVERSIONS
Note that pressures are typically given in gauge pressure. This is the difference
between the absolute pressure in the boiler and the absolute pressure of the
surroundings. A gauge reads pressure differences (in most cases, the difference
between the pressure of the substance and that of the atmosphere). Therefore,
gauge pressure may be positive or negative (vacuum). Gauge pressures, in U.S.
(English Engineering) units, are referred to as psig (pounds per square inch gauge,
although the g is frequently omitted).
An absolute pressure is the pressure above zero pressure, which can only be
positive. Most thermodynamic tables are based on absolute pressure. In U.S. units,
absolute pressure is referred to as psia (pounds per square inch absolute).
Absolute pressure is calculated by adding the absolute pressure of the surroundings
(atmospheric pressure) to the gauge pressure. In general, for U.S. units (psig) to
convert gauge pressure to absolute pressure, add 14.696. Conversely, to convert
absolute pressure to gauge pressure, subtract 14.696.
The following information is included for your convenience.
Temperature Conversion
Conversions Factors 2
pH Values
Salinity Indicating Readings Conversion Table
Useful Physical Constants
Conversions Table
Approximate Common Equivalents
Conversions Accurate to Parts per Million
I4-33
06-08
I4-34
06-08
Table I4-17. Temperature Conversion
I4-35
06-08
Table I4-18. Conversion Factors (Sheet 1 of 9)
I4-36
06-08
Table I4-18. Conversions Factors (Sheet 2 of 9)
I4-37
06-08
I4-38
06-08
I4-39
06-08
I4-40
06-08
I4-41
06-08
I4-42
06-08
.Table I4-18. Conversions Factors (Sheet 7 of 9)
I4-43
06-08
I4-44
06-08
Table I4-21. Useful Physical Constants
Table I4-20. Salinity Indicating Readings
Conversion Tables
Table I4-19. pH Values
I4-45
06-08
Table I4-22. Conversions Table
I4-46
06-08
Table I4-23. Approximate Common
Equivalents
Table I4-24. Conversions Accurate to Parts per
Million
I4-47
06-08
STANDARD ASSOCIATIONS
American Gas Association (AGA)
1515 Wilson Blvd.
Arlington, VA 22209
703-524-2000
American National Standards Institute (ANSI)
11 West 42nd Street
New York, NY 10036
212-642-4900
ANSI acts as the national coordinating institution through which interested
organizations voluntarily cooperate in establishing, recognizing, and improving
standards.
American Society of Heating Refrigerating and Air Conditioning Engineers
(ASHRAE)
1791 Tullie Circle, NE
Atlanta, GA 30329
American Society of Mechanical Engineers (ASME)
345 East 47th Street
New York, NY 10017
212-705-8500
The ASME develops test codes for boilers and pressure vessels and for power
applications, and serves as a sponsor for ANSI in developing safety codes and
standards.
American Society for Nondestructive Testing
3200 Riverside Drive
Columbus, Ohio 43221
American Society for Testing and Materials (ASTM)
1916 Race Street
Philadelphia, PA 19103-1187
ASTM is the largest voluntary standards development system in the world
publishing standards for materials, products, systems and services.
Canadian Standards Association (CSA)
178 Rexdale Blvd.
Etobicoke, Ontario, Canada M9W 1R3
416-747-4044
CSA, a nonprofit nongovernmental body, which promotes nationwide standards for
product design, construction and performance for Canada. CSA is a recognized
testing agency.
Canadian Gas Association (CGA)
55 Scarsdale Road
Don Mils, Ontario M3B 2R3
416-447-6465
CGA, a nonprofit association of manufacturers of gas utilities, provides certification
service based on standards established by CSA.
I4-48
06-08
Factory Mutual System (FM)
1151 Boston-Providence Turnpike
Norwood, MA 02062
617-762-4300
FM is an association of 4 mutual insurance companies dedicated to minimizing loss
of insured property. Through its research arm, the Factory Mutual Research
Corporation, it investigates means of preventing and minimizing fire and other
losses. FM laboratories provide product testing and approval.
85 Woodland Street
Hartford, CT 06105
203-520-7412
IRI is composed of stock insurance companies providing indemnity for damage
caused by such perils as fire, explosion, and windstorm. To assist their
policyholders, IRI provides an advisory engineering service. Part of this service is
the development of recommendations which serve as standards for IRI itself and its
policyholders.
Kemper Insurance Company
1 Kemper Drive
Long Grove, IL 60049
708-320-2000
The HPR (Highly Protective Risk) Department of Kemper has developed a set of
recommendation for gas and oil fired boiler furnaces. These recommendations are
used to determine the underwriting acceptability of proposals and completed
installations.
National Board of Boiler and Pressure Vessel Inspectors
1055 Crupper Avenue
Columbus, OH 43229-1183
614-888-8320
The National Board is an organization comprised of Chief Inspectors of states and
cities of the US and provinces of Canada organized for the purpose of promoting
greater safety in the construction, installation, inspection and repair of boilers and
pressure vessels.
National Electric Code (NEC)
1 Batterymarch Park
Quincy, MA 02269-9101
The National Electric Code is a standard established for safe wiring procedures in
the interest of personal safety and fire protection. The code is adopted and
copyrighted by the NFPA (see National Fire Protection Association).
National Fire Protection Association (NFPA)
1 Batterymarch Park
Quincy, MA 02269-9101
NFPA develops and promotes standards for the purpose of advancing the science
and improving the methods of fire protection and prevention.
I4-49
06-08
Underwriters Laboratories (UL and cUL)
333 Pfingsten Road
Northbrook, IL 60062
UL is a nonprofit organization which operates laboratories for testing for public
safety. They provide listings, classification, recognition and certificate. UL is a
recognized testing agency for the U.S. and Canada.
Underwriters Laboratories of Canada (ULC)
7 Crouse Road
Scarborough, Ontario M1R 3A9
ULC is an agency sponsored by the Canadian Underwriters Association that tests
and certifies products and materials against ULC established standards. It has no
relationship to UL of the U.S.
United States Department of Energy (DOE)
100 Independence Avenue, SW
Washington, DC 20585
United States Environmental Protection Agency (EPA)
Office of Air Quality
Planning & Standards
Research Triangle Park, NC 27711
I4-50
06-08
Notes:
I5-1
8-06
Section I5
Alternative fuels systems sales and technical guide
Section 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-2
Section 2: Digester and landfill gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-2
2.1 Definition and sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-2
2.2 Characteristics of digester gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-2
2.3. Digester/landfill gas system evaluation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-3
2.4. Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-4
2.5. Control Schemes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-6
Section 3: Flammable Liquids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I5-8
3.1 Definition and sources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-8
3.2. Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-8
3.3. Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-9
3.3.4 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-11
Section 4 Waste Oil Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I5-12
4.1. Definition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-12
4.2 Fuel Specification Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-12
4.3 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-13
4.4 Base System Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-14
4.5 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-15
Section 5 Fuels requiring special engineering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-15
Section 6 Unacceptable fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I5-15
Alternative Fuel Systems Section I
I5-2
8-06
SECTION 1: INTRODUCTION
Cleaver-Brooks defines alternative fuel(s) as that which is other than standard
commercially available fuel; used with a burner/boiler combination. Standard,
commercially available fuels, include: natural gas, light and heavy oils. Hence, all
other fuels including but not limited to digester gas, landfill gas, solvents, waste
oils, hydrogen, town gas, or biogas are considered nonstandard, waste or,
alternative.
Over the years, Cleaver-Brooks has offered alternative fuel systems and gained
considerable experience in this field including custom designs, engineered around
specific, onsite requirements.
We have found too, the majority of the waste fuels available for boiler applications
can be grouped into three (3) categories: flammable liquids, digester (landfill) gas,
and waste oil. We have; therefore, standardized product offerings for these three
common alternative fuels. In addition, Cleaver-Brooks offers products for other
waste fuels, but these require up front engineering evaluation before design
begins
The purpose of this guide is to provide the reader with a working knowledge of the
characteristics of the most common alternative fuels (digester/landfill, flammable
liquids and waste oils), the features of our system(s), and the type of information
required for these projects.
You do not have to be an expert to be successful in promoting alternative fuels
systems. You do; however, have to know the basics concerning these fuels, features
of our system(s), ask the right questions, and assemble a complete information
package for each inquiry.
With the fuel prices almost tripling in the last 10 years, there is tremendous
opportunity in pursuing the alternative fuel business.
SECTION 2:DIGESTER AND LANDFILL GASES
2.1 Definition and sources
Digester gas typically refers to gas produced by the fermentation of organic matter
such as manure, wastewater sludge, municipal solid waste, or any other
biodegradable feedstock, under anaerobic (oxygen present) conditions. Digester
gas is also called biogas, swamp gas, landfill gas, sewer gas, landfill gas,
depending on where it is produced. Each variant has different levels of methane
and carbon dioxide with other minor gases. However; in general, the heating value
and composition of these gases is essentially known and; therefore, they can be
used as a fuel in Cleaver-Brooks boilers.
2.2 Characteristics of digester gas
Characteristics of digester gas vary depending on a source. Typical chemical
breakdown variations and properties are presented in the following tables.

Section I Alternative Fuel Systems
I5-3
8-06
Table I5-1. Typical analysis of the digester gas
Table I5-2. Digester and natural gas comparison
2.3. Digester/landfill gas system evaluation.
2.3.1.1 Digester gas has only about half the heating value of natural gas, is heavier
than natural gas, and is typically supplied at a lower pressure than natural gas.
These facts create the need for a system that can handle high flow rates of gas with
minimum pressure drop.
2.3.1.2 The higher flow rates also have a major impact on burner design and
performance. A special burner should be used to provide adequate gas velocities for
good mixing but without excessive pressure drop.
2.3.1.3 Digester gas usually contains some hydrogen sulfide (H2S), and is
saturated with water. These characteristics create a corrosive environment for the
gas piping, valving, exhaust breeching and stack should condensation occur. We;
therefore, require (contact) components be resilient to these conditions, using
materials such as stainless steel; providing better corrosion resistance when
compared to carbon steel.
2.3.1.4 Digester gas systems are usually hot water or low pressure steam systems
because they are often used for heating at the site location. These boilers produce
low flue gas exit temperatures adding to the corrosive issues in the boiler system.
2.3.1.5 The digester gas supply is not always reliable and can be frequently
interrupted. Therefore, the boiler system must be capable of responding to
interruptions or inadequate supply of digester gas while continuing to meet the
plants heat demand.
2.3.1.6 Often natural gas is used as a primary backup when digester gas supply
interruptions occur. Normally, this is accomplished by the use of a dual canister gas
burner housing with a control system that can automatically change over to the
backup fuel.
Component Chemical Formula % Vol
Methane CH4 50-65
Carbon Dioxide CO2 35-50
Hydrogen Sulfide H2S Trace 2
Water Vapor H2O 3-6
Other Gases CO, N2, O2 1-10
Characteristic Units Digester Gas Natural gas
Heating Value Btu/Scf 500-600 950-1100
Specific gravity (Air =
1.0) N/A 0.85 0.95 0.6 0.64
Hydrogen Sulfide % Vol Trace - 2 None
Water Vapor % Vol 3 6 (Sturated) None
Temperature (F 75-120 Ambient
Supply Pressure IWC 6-15
27.7 277 (1 10
PSIG)
I5-4
8-06
Figure I5-1. Dual Canister Burner
2.4. Components.
Sulfur in any gas can be combined with hydrogen in the combustion process
resulting in (corrosive) hydrogen sulfide. During cold startups, and if the
combustion gas is cooled below its dew point, condensation occurs and the
hydrogen sulfide condenses with the water vapor. This product is extremely
damaging to carbon steel as well as some gasket materials. Therefore, it is
imperative the correct materials are selected to ensure long life of the equipment.
2.4.1. Gas Train. Separate gas trains are supplied for natural gas and digester gas.
Corrosion resistive components are used for valves and switches on the digester gas
train. In addition, all digester gas trains are supplied with two automatic safety
shut off valves regardless of insurance requirements This, to ensure that the
corrosive gas does not leak into the boiler when not in use. These automatic shut
off valves have electric or pneumatic spring-return actuators.
2.4.2. Gas Pressure Regulator Since digester gas is usually supplied at relatively
low pressure (6-15 W.C.), the gas pressure regulator must be capable of operation
at high gas flow rates with minimum pressure drop. Since most regulator suppliers
sizing data is based on natural gas, a correction factor is used to properly size the
regulator.
2.4.3. Dual gas burner. For integral head firetube boilers firing digester gas with a
I5-5
8-06
backup gas, Cleaver-Brooks uses our patented dual canister housing burner (see
figure 1). The design of this burner system allows separate combustion control for
two gases with different fuel characteristics.
The dual canister burner components are sized such that the digester gas system
components are designed based on the digester gas fuel composition. The backup
fuel system is separately designed based on the backup fuel composition.
Hence, different materials may be used for each fuel to ensure long component life,
maximum burner efficiencies, and safety.
Figure I5-2. Dual Gas Train Schematic
* Optional components
Table 1:
Natural Gas
Tag #
Digester Gas
Tag #
Function
TAG # Tag # Function
PCV-010 PCV-020 Gas Pressure Regulator
HV-010A HV-020A Manual Shut Off Valve
PSL-010 PSL-020A Low Gas Pressure Switch
FV-010A FV-020A Automatic Shut Off Valve
FV-010B FV-020B Vent valve
FV-010C FV-020C Automatic Shut Off Valve
PSH-010 PSH-020 High Gas Pressure Switch
HV-010B HV-020B Manual Shut Off Valve
CV-010 CV-020 Firing Rate Modulating Valve
NA PSL-020B Automatic Fuel Changeover Switch *
NA T-020 Flame Arrester with Check Valve*
I5-6
8-06
2.5. Control Schemes.
Over the years Cleaver-Brooks used many different control schemes when digester
gas was fired in a boiler. Most of these schemes were customized to the specific
customer needs. Control scheme selection can be based on a number of factors
including digester gas pressure, boiler size, number of boilers in a plant, and
availability of digester gas. The most common control schemes are described
below.
2.5.1. Automatic fuel changeover. The purpose of this control scheme is to
automatically switch a boiler fuel from digester gas to a back up fuel whenever
digester gas supply becomes insufficient to meet the control settings. This option
requires an automatic fuel changeover pressure switch, which is typically installed
prior to the digester gas pressure regulator. When the boiler demand exceeds
availability of the digester gas fuel, digester gas pressure drops tripping the
changeover pressure switch and the controls will modulate to the minimum firing
position. Once minimum burner position is proven, the burner shuts down and then
re-starts, firing the back up fuel. When digester gas pressure is restored, the
aforementioned sequence is reversed, and the burner re-starts, firing digester gas.
2.5.2. Preferential firing. The purpose of this control scheme is to fire all the
available digester gas available. In order for this control scheme to work, another
boiler is required to maintain adequate steam pressure (water temperature) when
the digester gas supply cannot meet heat/process load demand.

Figure I5-3. Preferential Firing Control Scheme
Pressure/Temperature controller PTC-030 receives boiler outlet temperature signal
I5-7
8-06
from temperature transmitter TT-040 and digester gas pressure signal from pressure
transmitter PT-020. Output to the firing rate control valve CV-020 is based on these
two signals. When digester gas pressure is above set point, firing rate is based on
the heat demand, i.e. boiler outlet water temperature. When digester gas pressure
drops below set point, firing rate signal is reduced to maintain digester gas pressure.
Hence the control scheme ensures that all available digester gas can be burned.
Automatic fuel changeover and low fire hold is incorporated into the control
algorithm of PTC-030.
2.5.3. Simultaneous Firing. This control scheme is used when there is a
requirement to burn all available digester gas, maintain steam pressure (water
temperature), and provide automatic fuel changeover without burner shutdown.
Figure I5-4. Simultaneous Firing
Temperature indicating controller TIC-040 receives boiler outlet temperature signal
from temperature transmitter TT-040. Control signal from TIC-040 is sent to
digester gas firing rate controller FC-020 and natural gas firing rate controller FC-
010. Firing rate controllers provide control signal to digester and natural gas firing
rate control valves CV-020 and CV-010.
Parallel positioning or full metered combustion control is incorporated in the
simultaneous firing control scheme. This control scheme can become quite complex
and requires PLC based control hardware.
I5-8
8-06
SECTION 3: FLAMMABLE LIQUIDS.
3.1 Definition and sources.
Flammable liquids are defined as having temperatures between 70 F and 140 F at
which they give off vapor in such a concentration that combined with air, a
flammable mixture is formed. Hence, they can be extremely hazardous since
inadequate ventilation can allow flash back from a source of ignition to the liquid.
These liquids can also be classified as halogenated or non-halogenated. Halogens
are elements like chlorine that will form corrosive compounds as products of
combustion, hence halogenated liquids are more difficult to handle and they require
that the burner and fuel train utilize materials that are corrosive resistant. Because
of the corrosive nature of halogenated liquids, most manufacturing companies try to
use non-halogenated flammable liquids. These are produced as a byproduct from
the manufacturing of printed circuit boards, pharmaceuticals, plastics, tobacco,
machined parts or textiles.
Flammable liquids include solvents, paint thinners, xylene, methanol, methyl ethyl
keytone, benzene, acetone, toluene, isopropanol, and mineral spirits.
Benefits of burning flammable liquids in lieu of other fuels include:
Fuel costs of the plant can be substantially reduced
Liability associated with off site disposal is reduced
Expansive waste hauling costs and paperwork are reduced or eliminated
Future uncertainty of off site disposal alternatives is reduced
3.2. Characteristics
Flammable liquids cover a wide range of types and therefore their compositions
vary greatly. However, they do share some characteristics such as:
Heating Value As sampled (Typically 50,000 100,000
Btu/Gal
Flash PointL Less then 140(F
Viscosity 30 100 SSU
Water 30% maximum
Chlorine/Halogens 0.4% maximum
Ash 1% maximum
Solids 1% maximum
Metals 50 ppm maximum
I5-9
8-06
)
3.3. Evaluation
3.3.1. Design concerns Using waste liquids as an alternate boiler fuel poses some
major design concerns that if not addressed properly, can lead to safety problems
and boiler equipment failures. To understand these design concerns, the
characteristics of the waste fuel must be analyzed.
Typical characteristics that have an effect on combustion include:
Low lubricity can result in premature wear to pumps, seals, and valves
Low viscosity may require heating to properly flow through the fuel system
High or variable water content can cause combustion issues
Variable heating value can cause combustion issues
Contamination with dirt or solids can lead to plugging of components
Incompatibility with brass, buna or carbon steel due to corrosive nature of
the fuel
Typical problems resulting from firing flammable liquids without proper equipment
and controls include:
Flame stability problems
Fuel valve failure
Supply pump failure
Burner gun vapor lock
Variations in excess air level
Corrosion and sooting of the boiler
Poor control and adjustment of air/fuel ratios
Loss of steam supply without standard fuel backup
High potential for boiler occurances
The benefits of energy recovery are quickly lost if the system is not properly
designed to handle the specified flammable liquid. Therefore, it is critical that the
fuel characteristics are known; typically accomplished by analyzing a fuel sample.
3.3.2. Critical factors Many factors must be considered before a system can be
designed to burn flammable liquid fuels. In addition, decisions on project feasibility,
system options, and percent input ratio must be known. The following factors are
typically considered:
Halogens - Flammable liquids with high amounts of chlorine or other halogens
can cause corrosive damage to the boiler and accessory equipment and, may
require off gas pollution control equipment. Flammable liquids containing more
than 0.4% halogens can sometimes be handled at a reduced input ratio.
Therefore, for most applications, materials with halogens in excess of 0.4% are
not feasible as an alternate boiler fuel
Metals and Solids - Burning materials with high amounts of metals can pose air
pollution problems which can be a limiting factor for the project, and may
require a special permit. Handling materials with high amounts of solids
requires filtration and ash removal equipment to avoid plugging and/or erosion
I5-10
8-06
of components. This additional equipment increases the capital expense of the
project and adds to the maintenance requirements of the system. Accurate
information on metals, solids, and ash content will allow for the most
economical package to be quoted while ensuring longevity of the equipment.
Waste Fuel Variations - The base simultaneous fired system will allow for some
variations in heating value and other waste fuel contents. When large variations
are expected, additional controls to monitor composition of waste fuel can be
provided. These controls can include oxygen trim systems for boiler excess air
monitoring and control, heating value biasing systems to regulate the fuel flow
input if variations occur, and flow meters with annunciation and recorders.
These systems provide additional safety and reliability when an unreliable fuel
source is being fired. However, these control systems can be expensive. The
best way to reduce the cost and complexity of the system is to control the
consistency of the fuel stream.
Percent Input Ratio - The percent input ratio is the percent of heat that the
waste fuel contributes to total input of the boiler. Maximum waste fuel inputs
for the base system are 50% when fired with natural gas and 40% when fired
with oil. For each inquiry, the percent input of the waste fuel must be
determined. The lower the percent input, the less effect variations in the waste
fuel will have on combustion and excess air levels. The higher the percent
input, the greater amount of waste can be handled with the system. Therefore,
the quantity of waste being produced and the average firing rate and run time of
the boiler must be known to determine the optimum percent input of the waste
fuel.
Cost and Liability The liability associated with designing combustion and fuel
handling equipment to handle an unreliable fuel source is extremely high.
Therefore, when insufficient information is provided, the system must be
designed conservatively, and costs increase. Therefore, it is critical that
accurate and complete information is provided to ensure that the system is
designed safely and cost effectively.
3.3.3 Base System Features The base system is designed to handle consistent
liquid wastes within the listed fuel specification parameters. This base system
incorporates several features that provide safety and reliability including:
3.3.3.1 Simultaneous Firing The alternate fuel is fired simultaneously with natural
gas or oil to enhance stability and ensure complete combustion (see figure 4).
Natural gas is preferred as the supplemental fuel, due to greater flame stability and
burner configuration. When oil is used as the supplemental fuel, a dual burner gun
arrangement is supplied which ensures that the two fuels are not combined until
they enter the combustion chamber.
Simultaneous firing provides the following advantages:
Enhanced Flame Stability
Stable Combustion Temperature
Reduced Excess Air Variations
Safer Operation
I5-11
8-06
3.3.3.2 Separate Metering Control The practice of mixing alternative liquid fuels
with oil and utilizing a standard oil system for metering can be dangerous and is not
recommended.
Therefore, our base system is designed with a completely separate metering system,
fuel shut-off assembly, and pumping station for the waste fuel.
This feature provides separate control and adjustment of the waste fuel supply to
the burner. Steam production is maintained even if this fuel system is not
operational.
By isolating the waste fuel system from the standard fuel system, additional
monitoring and control options; compensating for waste fuel variations, can be
easily incorporated.
3.3.3.3 Materials of Construction The system utilizes special stainless steel pump
internals, fuel shut off valves, fuel metering valves, pressure switches and piping.
These special materials of construction provide extended life of the equipment and
enhance the safety of the system.
3.3.3.4 Pumps Pumping of these liquids at high pressure without pulsation
requires a positive displacement pump with close tolerances.
Special pump designs and materials of construction are provided, taking into
account the low lubricity of the liquid.
Even with the special designs, pump life can be a problem for these applications. If
the customer has had success with a specific pump for the waste material, we can
provide a similar pump or provide the system requirements to the customer so they
can supply the pump.
Regardless of who is responsible for providing the pump equipment, funds for spare
pumps should be identified as a required operating expense.
3.3.3.5 Reverse Purge The system utilizes a reverse purge system to prevent vapor
lock in the burner gun, rough light-off, and tip fouling.
The purge system pulls the flammable liquid out of the gun and back to the waste
fuel source at every boiler shutdown.
3.3.3.6. Control Panel The system is provided with PLC based control panel to
control, monitor and annunciate all waste fuel functions. The panel includes
Human Machine Interface (HMI) for easy identification of any system problem.
Retrofit systems are provided with revised wiring diagrams to show the waste fuel
system connection points.
3.3.4 Options The system may be provided with any of the following options
depending on the project requirements.
Automatic Change Over To The Standard Fuel Firing
Oxygen Trim System
Filtration Modules to remove contaminants and solids from the waste fuel
All Stainless Steel Wetted Parts
Flow Meters and Flow Totalization
I5-12
8-06
SECTION 4 WASTE OIL FUELS.
4.1. Definition.
Waste oils are heavy oils used for lubrication or hydraulic applications; discarded or
recycled due to contamination or loss of lubricity. Examples include machine oil,
fish oil, and transmission fluid.
Benefits of using waste oil to supplement a plants energy requirements include:
The fuel costs of the plant can be substantially reduced.
Liability associated with off-site disposal is reduced.
Expensive waste hauling costs and paperwork are reduced or eliminated.
Future uncertainty of recycling or off-site disposal alternatives is reduced.
4.2 Fuel Specification Parameters
The base system for waste oils is designed to handle waste streams that do not
exceed the following:
Heating Value As sampled (Typical 100,000 150,000 Btu/Gal)
Flash Point 140( F or higher
Specific Gravity As sampled (Typical 0.9 1.1)
Viscosity Under 150 SSU @ 260( F
Water 5% Maximum
Total Halogens 1,000 ppm maximum
Ash 1% maximum
Solids 1% maximum
4.3 Evaluation
For each inquiry, the waste fuel specification and site conditions are evaluated.
Decisions on project feasibility, base system options, and percent input ratio are
based on the following critical factors.
Waste Fuel Variations
Key evaluation factors include the ability of the waste oil combustion system to
compensate for moderate variations in heating value, viscosity, and contaminant
level.
By utilizing simultaneous firing, batch blending, viscosity control, and additional
combustion controls, the Cleaver-Brooks system will allow for predictable variations
in the waste oil.
However, compensating for drastic variations in the waste fuel requires more
complex and expensive control packages.
Anything that can be done by the customer to maintain waste fuel consistency will
reduce the cost and complexity of the system.
I5-13
8-06
Contaminants - Waste oil will typically contain dirt and solids. Failure to remove
these contaminants can result in fouling of the fuel metering equipment and sooting
of the boiler.
Water is also a common contaminant found in waste oil. Although small quantities
of water mixed in an emulsion can help combustion, high quantities of water can
cause flame stability problems.
Viscosity - Maintaining adequate viscosity levels for proper atomization is a critical
factor when burning any oil. Waste oil usually has a higher viscosity/temperature
curve than conventional oils.
The common solution to this problem is to increase the setpoint on the oil heat
exchanger to reduce the viscosity to an acceptable level.
Metals and Halogens - The EPA has national standards regulating the quantities of
metals, halogens, and PCBs that can be present in waste oil used for energy
recovery.
Local standards pertaining to emissions of metals and acids also should be
investigated during the feasibility stage of each project.
Cleaver-Brooks will provide information on calculated emission levels based on the
waste fuel analysis.
However, the ultimate responsibility for permitting the project and control of the oil
content lies with the customer.
Boiler Size and Loads - Waste oil systems are only available on Cleaver-Brooks
boilers that utilize air or steam atomization (50 HP and above)
Consideration must also be given to the load demand on the boiler.
Frequent cycling of the boiler while firing waste oil can result in low oil and
combustion temperatures. This condition will usually result in sooting and fouling of
the boiler.
Therefore, as with any alternate fuel application, information on the boiler loading
and total boiler room steam demand is required with each inquiry.
Percent Input Ratio - The percent input ratio is the percent heat that the waste fuel
contributes to total input of the boiler compared to the percent heat of the
supplemental (standard) fuel.
Maximum waste fuel inputs for simultaneous fired systems are 50% when fired with
natural gas and 40% when fired with oil.
For each inquiry, the percent input of the waste fuel must be determined. The
lower the percent input, the less effect variations in the waste fuel will have on
combustion and excess air levels. Therefore, the quantity of waste being produced
and the average firing rate and run time of the boiler must be known to determine
the optimum percent input of the waste oil.
Cost and Liability - The liability and cost associated with designing combustion and
fuel handling equipment to handle an alternate fuel is relatively high. Therefore,
when insufficient information is provided, we must assume worst case conditions
and quote accordingly, and the price will escalate. Even with an accurate definition
of the project conditions, these systems are expensive. Without good information it
is very difficult to provide a reasonable and competitive price and package.
I5-14
8-06
4.4 Base System Features.
The base system alternate fuel system designed to handle waste oil fuels within the
listed fuel specification parameters, incorporates several features that provide safety
and reliability.
4.4.1 Simultaneous Firing with simultaneous firing, the alternate fuel is fired
simultaneously with natural gas or oil. Natural gas is preferred as the supplemental
fuel due to greater flame stability and reduced burner modification. When oil is
used as the supplemental fuel, a dual burner gun arrangement is supplied. The two
fuels are not combined until they enter the combustion chamber.
Simultaneous firing provides the following advantages:
- Enhanced Flame Stability
- Stable Combustion Temperature
- Reduced Excess Air Variations
- Safer Operation
Some waste oils (e.g. fish oil, recycled clean oil) can be burned by itself without
modifications to the standard fuel oil delivery system. However without the benefits
of simultaneous firing the risks associated with firing the waste oil are increased.
Therefore, formal documentation from the customer outlining his responsibility to
maintain a consistent waste fuel stream is required before a straight fired system
can be proposed.
4.4.2 Separate Metering Control In most cases the practice of mixing these types of
wastes with oil and utilizing a standard oil system for metering can be dangerous
and is not recommended.
Therefore, our system is designed with a completely separate metering system, fuel
shutoff assembly, and pumping station for the waste fuel.
This feature provides separate control and adjustment of the waste fuel to the
burner. Steam production is maintained even if the waste fuel system is not
operational.
By isolating the waste fuel system from the standard fuel system, additional
monitoring and control options to compensate for waste fuel variations can be easily
incorporated.
4.4.3. Viscosity Control One of the key features to the waste oil combustion system
is accurate viscosity control.
Standard heavy oil systems include an oil heat exchanger to preheat the oil to a set
point temperature. At these temperatures, the viscosity of the oil is reduced to an
adequate level for proper atomization.
The Cleaver-Brooks waste oil system automatically adjusts the oil temperature
when the oil viscosity changes. The system also monitors and controls oil
temperature throughout the metering system all the way to the burner gun tip.
I5-15
8-06
The burner gun is specifically designed to minimize heat losses and tip fouling.
With this automatic viscosity control system, many waste oils with high or variable
viscosity can now be successfully burned in Cleaver-Brooks boilers.
4.4.4. Filtration Module If required, system includes a filtration module to remove
solids, dirt from the waste oil.
Depending on the storage tank arrangement, a secondary recirculation pump in
conjunction with the filtration module may be required.
4.45 Control Panel The system is provided with a PLC based control panel to
control, monitor and annunciate all waste fuel functions. The panel includes
Human Machine Interface (HMI) for easy identification of any system problem.
Retrofit systems are provided with revised wiring diagrams to show the waste fuel
system connection points.
4.5 Options
The system may be provided with any of the following options depending on the
project requirements:
Automatic Change Over To The Standard Fuel Firing
Oxygen Trim System
Filtration Modules to remove contaminants and solids from the waste fuel
All Stainless Steel Wetted Parts
Flow Meters and Flow Totalization
SECTION 5. FUELS REQUIRING SPECIAL ENGINEERING.
The following is the list of fuels, which will require special engineering.
Hydrogen
Refinery gases
Contaminated air
Coke oven gas
SECTION 6 UNACCEPTABLE FUELS.
The following fuels will be unacceptable to be used in Cleaver-Brooks boilers.
Solid fuels
Acids
Radioactive material
Caustics
I5-16
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Notes
J-1
06-08
A
ABSOLUTE PRESSURE - Pressure above zero pressure; the sum of
the gauge and atmospheric pressures.
ACCUMULATOR - (STEAM) A pressure vessel containing water and/or
steam, which is used to store the heat of steam for use at a late
period and at some lower pressure.
ACID CLEANING - The process of cleaning the interior surfaces of
steam generating units by filling the unit with dilute acid accompa-
nied by an inhibitor to prevent corrosion, and subsequently draining,
washing and neutralizing the acid by a further wash of alkaline water.
ACIDITY - Represents the amount of free carbon dioxide, mineral
acids and salts (especially sulphates of iron and aluminum) which
hydrolyze to give hydrogen ions in water and is reported as milliequiv-
alents per liter of acid, or ppm acidity as calcium carbonate, or pH
the measure of hydrogen ions concentration.
ADIABATIC FLAME TEMPERATURE - The theoretical temperature
that would be attained by the products of combustion provided the
entire chemical energy of the fuel, the sensible heat content of the
fuel and combustion above the datum temperature were transferred
to the products of combustion. This assumes: No heat loss to sur-
roundings and no dissociation.
AIR - The mixture of oxygen, nitrogen, and other gases, which with
varying amounts of water vapor, forms the atmosphere of the earth.
AIR ATOMIZING OIL BURNER - A burner for firing oil in which the oil
is atomized by compressed air, which is forced into and through one
or more streams of oil which results in the breaking of the oil into a
fine spray.
AIR DEFICIENCY - Insufficient air, in an air-fuel mixture, to supply the
oxygen required for complete oxidation of the fuel.
AIR-FREE - The descriptive characteristic of a substance from which
air has been removed.
AIR-FUEL RATIO - The ratio of the weight, or volume, of air to fuel.
AIR INFILTRATION - The leakage of air into a setting or duct.
AIR, SATURATED - Air which contains the maximum amount of water
vapor that it can hold at its temperature and pressure.
AIR VENT - A valved opening in the top of the highest drum of a
boiler or pressure vessel for venting air.
ALARM - A suitable horn, bell, light or other device which when oper-
ated will give notice of malfunction or off normal condition.
ALKALINITY - Represents the amount of carbonates, bicarbonates,
hydroxides and silicates or phosphates in the water and is reported as
grains per gallon, or ppm as calcium carbonate.
ALLOWABLE WORKING PRESSURE - See design pressure.
AMBIENT AIR - The air that surrounds the equipment. The standard
ambient air for performance calculations is air at 80 F, 60% relative
humidity, and a barometric pressure of 29.921 in. Hg, giving a spe-
cific humidity of 0.013 lb of water vapor per lb of dry air.
AMBIENT TEMPERATURE - The temperature of the air surrounding
the equipment.
ANALYSIS - Quantitative determination of the constituent parts.
ANALYSIS, ULTIMATE - Chemical analysis of solid, liquid or gaseous
fuels. In the case of coal or coke, determination of carbon, hydrogen,
sulfur, nitrogen, oxygen, and ash.
AQUASTAT - Water limit temperature control, a safety device often
used on boilers.
ARRESTER - A device to impede the flow of large dust particles or
sparks from a stack, usually screening at the top.
AS-FIRED FUEL - Fuel in the condition as fed to the fuel burning
equipment.
ASH - The incombustible inorganic matter in the fuel.
ASH-FREE BASIS - The method of reporting fuel analysis, whereby
ash is deducted and other constituents are recalculated to total
100%.
ASH PIT - A pit or hopper located below a furnace where refuse is
accumulated and from which refuse is removed at intervals.
ASME - The American Society of Mechanical Engineers.
ASPIRATING BURNER - A burner in which the fuel in a gaseous or
finely divided form is burned in suspension, the air for combustion
being supplied by bringing into contact with the fuel, air drawn
through one or more openings by the lower static pressure created by
the velocity of the fuel stream.
AS-RECEIVED FUEL - Fuel in the condition as received at the plant.
ATMOSPHERIC AIR - Air under the prevailing atmospheric conditions.
ATMOSPHERIC PRESSURE - The barometric reading of pressure
exerted by the atmosphere. At sea level 14.7 lb per sq in. or 29.92
in. of mercury.
ATOMIZER - A device by means of which a liquid is reduced to a very
fine spray.
AVAILABLE DRAFT - The draft which may be utilized to cause the
flow of air for combustion or the flow of products of combustion.
AVAILABILITY FACTOR - The fraction of time during which the unit is
in operable condition.
AXIAL FAN - Consists of a propeller or disc type of wheel within a cyl-
inder that discharges air parallel to the axis of the wheel.
Section J
GLOSSARY
J-2
Glossary
06-08
B
BAFFLE - A plate or wall for deflecting gases or liquids.
BAFFLE TILE - A tile for deflecting gases.
BAFFLE-TYPE COLLECTOR - A device in gas paths utilizing baffles so
arranged as to deflect dust particles out of the gas stream.
BAG FILTER - A device containing one or more cloth bags for recover-
ing particles from the dust laden gas or air which is blown through it.
BAG-TYPE COLLECTOR - A filter in which the cloth filtering medium
is made in the form of cylindrical bags.
BAROMETRIC PRESSURE - Atmospheric pressure as determined by
a barometer usually expressed in inches of mercury.
BASE LOAD - Base load is the term applied to that portion of a sta-
tion or boiler load that is practically constant for long periods.
BEADED TUBE END - The rounded exposed end of a rolled tube
when the tube metal is formed over against the sheet in which the
tube is rolled.
BLIND NIPPLE - A nipple, or a short piece of pipe or tube, closed at
one end.
BLOWDOWN - Boiler water that is removed from the boiler in order to
maintain the desired concentration levels of suspended and dissolved
solids in the boiler and removal of sludge.
BLOWDOWNSAFETY VALVE - The difference between the pressure
at which a safety valve opens and at which it closes.
BLOWDOWN VALVE - A valve generally used to continuously regulate
concentration of solids in the boiler, not a drain valve. (Often called
continuous blowdown.)
BLOW-OFF VALVE - A specially designed, manually operated, valve
that connects to the boiler for the purpose of reducing the concentra-
tion of solids in the boiler or for draining purposes. (Often called bot-
tom blowdown.)
BLOWER - A fan used to force air under pressure.
BOILER - A closed vessel in which water is heated, steam is gener-
ated, steam is superheated, or any combination thereof, under pres-
sure or vacuum by the application of heat from combustible fuels,
electricity or nuclear energy.
BOILER EFFICIENCY - The term boiler efficiency is often substi-
tuted for combustion or thermal efficiency. True boiler efficiency is the
measure of fuel-to-steam efficiency.
BOILER HORSEPOWER - The evaporation of 34-1/2 lbs of water per
hour from a temperature of 212 F into dry saturated steam at the
same temperature. Equivalent to 33,475 Btu/hr.
BOILER RATING - The heating capacity of a boiler expressed in boiler
horsepower, Btu/hour, or pounds of steam/hour.
BOILER SHELL- The outer cylindrical portion of a pressure vessel.
BOILER WATER - A term construed to mean a representative sample
of the circulating boiler water, after the generated steam has been
separated and before the incoming feed water or added chemical
becomes mixed with it so that its composition is affected.
BOILING - The conversion of a liquid into vapor with the formation of
bubbles.
BOILING OUT - The boiling of highly alkaline water in boiler pressure
parts for the removal of oils, greases, etc.
BOOSTER FAN - A device for increasing the pressure or flow of a gas.
BREECHING - A duct that transports the products of combustion
between parts of a steam generating unit or to the stack.
BRIDGEWALL - A wall in a furnace over which the products of com-
bustion pass.
BRITISH THERMAL UNIT (Btu) - The mean British Thermal Unit is 1/
180 of the heat required to raise the temperature of 1 lb of water from
32 F to 212 F at a constant atmospheric pressure. A Btu is essen-
tially 252 calories.
BUCKSTAY - A structural member placed against a furnace or boiler
wall to restrain the motion of the wall.
BUNKER C OIL - Residual fuel oil of high viscosity commonly used in
marine and stationary steam power plants. (No. 6 fuel oil)
BURNER - A device for the introduction of fuel and air into a furnace
at the desired velocities, turbulence and concentration.
BURNER WINDBOX - A plenum chamber around a burner that main-
tains an air pressure sufficient for proper distribution and discharge of
secondary air.
BURNER WINDBOX PRESSURE - The air pressure maintained in the
windbox or plenum chamber measured above atmospheric pressure.
BY-PASS - A passage for a fluid, permitting a portion of the fluid to
flow around its normal pass flow channel.
C
C - Carbon element, the principal combustible constituent of all fuels.
CaCO
3
- Calcium Carbonate.
CALORIE - The mean calorie is 1/100 of the heat required to raise the
temperature of 1 gram of water from Zero C to 100 C at a constant
atmospheric pressure. It is about equal to the quantity of heat
required to raise one gram of water 1 C. Another definition is: A calo-
rie is 3600/860 joules.
CALORIMETER - Apparatus for determining the calorific value of a
fuel.
CAPACITY FACTOR - The ratio of the average load carried to the max-
imum design capacity.
CARBON - Element. The principal combustible constituent of all fuels.
CARRYOVER - The chemical solids and liquid entrained with the
steam from a boiler.
CASING - A covering of sheets of metal or other material such as fire
resistant composition board used to enclose all or a portion of a steam
generating unit.
CENTRAL STATION - A power plant or steam heating plant that gener-
ates power or steam.
CENTRIFUGAL FAN - Consists of a fan rotor or wheel within a housing
that discharges air at a right angle to the axis of the wheel.
CHEMICAL ANALYSIS - Determination of the principal chemical con-
stituents.
CHEMICAL FEED PIPE - A pipe inside a boiler drum through which
chemicals for treating the boiler water are introduced.
CHIMNEY - A brick, metal or concrete stack.
CIRCULATION - The movement of water and steam within a steam
generating unit.
J-3
06-08
CIRCULATION RATIO - The ratio of water entering a circuit to the
steam generated by that passes that circuit in a unit of time.
CIRCULATOR - A pipe or tube to pass steam or water between upper
boiler drums usually located where the heat absorption is low. Also
used to apply to tubes connecting headers of horizontal water tube
boilers with drums.
CLEANOUT DOOR - A door placed so that accumulated refuse may
be removed room a boiler setting.
CO - Carbon monoxide.
CO
2
- Carbon dioxide.
COLLECTOR - A device used for removing gas borne solids from flue
gas.
COLLOID - A finely divided organic substance which tends to inhibit
the formation of dense scale and results in the deposition of sludge, or
causes it to remain in suspension, so that it may be blown from the
boiler.
COMBUSTIBLE LOSS - The loss representing the unliberated thermal
energy occasioned by failure to oxidize completely some of the com-
bustible matter in the fuel.
COMBUSTIBLES - The heat producing constituents of a fuel.
COMBUSTION - The rapid chemical combination of oxygen with the
combustible elements of a fuel resulting in the release of heat.
COMBUSTION AIR - Air used in the combustion process. Air contains
oxygen which is required to combust fuel.
COMBUSTION CHAMBER - See Furnace.
COMBUSTION EFFICIENCY - The effectiveness of the burner to com-
pletely burn the fuel. A well designed burner will operate with as little
as 10 to 20% excess air, while converting all combustibles in the fuel
to useful energy.
COMPLETE COMBUSTION - The complete oxidation of all the com-
bustible constituents of a fuel.
CONCENTRATION - (1) The weight of solids contained in a unit
weight of boiler or feed water. (2) The number of times that the dis-
solved solids have increased from the original amount in the feedwa-
ter to that in the boiler water due to evaporation in generating steam.
CONDENSATE Condensed water resulting from the removal of latent
heat from steam.
CONDUCTION - The transmission of heat through and by means of
matter unaccompanied by any obvious motion of the matter.
CONDUCTIVITY - (1) A material property relating heat flux (heat
transferred per unit area per unit time) to a temperature difference. In
American units, it is typically defined as the amount of heat (Btu)
transmitted in one hour through one square foot of material 1 inch
thick, with a temperature difference of 1F between the two surfaces
of the material.
(2) The property of a water sample to transmit electric current under
a set of standard conditions. Usually expressed as microhms conduc-
tance.
CONTINUOUS BLOWDOWN - The uninterrupted removal of concen-
trated boiler water from a boiler to control total solids concentration in
the remaining water.
CONTROL - Any manual or automatic device for the regulation of a
machine to keep it at normal operation. If automatic, the device is
motivated by variations in temperature, pressure, water level, time,
light, or other influences.
CONTROL VALVE - A valve used to control the flow of air, gas, water,
steam or other substance.
CONVECTION - The transmission of heat by the circulation of a liquid
or gas. It may be natural, with the circulation caused by buoyancy
affects due to temperature differences, or forced with circulation
caused by a mechanical device such as a fan or pump.
CORROSION - The wasting away of metal due to chemical action. In
a boiler, usually caused by the presence of O
2
, CO
2
, or an acid.
CROWN SHEET - In a firebox boiler, the plate forming the top of the
furnace.
CRUDE OIL - Unrefined petroleum.
CSD-1 - Abbreviation for the ASME standard for Controls and Safety
Devices.
D
DAMPER - A device for introducing a variable pressure drop in a sys-
tem used for regulating the volumetric flow of a gas, such as air.
DAVIT - The structure on large firetube boilers from which the front
and rear doors are suspended when opened.
DEAERATION - Removal of air and gases from boiler feed water prior
to its introduction to a boiler.
DEGASIFICATION - Removal of gases from samples of steam taken
for purity test. Removal of CO
2
from water as in the ion exchange
method of softening.
DELAYED COMBUSTION - A continuation of combustion beyond the
furnace. (See also Secondary Combustion.)
DESIGN LOAD - The load for which a steam generating unit is
designed, considered the maximum load to be carried.
DESIGN PRESSURE - The pressure used in the design of a boiler for
the purpose of calculating the minimum permissible thickness or
physical characteristics of the different parts of the boiler.
DESIGN STEAM TEMPERATURE - The temperature of steam for
which a boiler is designed.
DEW POINT - The temperature at which condensation starts.
DISENGAGING SURFACE - The surface of the boiler water from
which steam is released.
DISSOCIATION - The process by which a chemical compound breaks
down into simpler constituents, as do CO
2
and H
2
O at high tempera-
ture.
DISSOLVED SOLID - Those solids in water which are in solution.
DISTILLATE FUELS - Liquid fuels distilled usually from crude petro-
leum.
DISTILLATION - Vaporization of a substance with subsequent recov-
ery of the vapor by condensation. Often used in less precise sense to
refer to vaporization of volatile constituents of a fuel without subse-
quent condensation.
J-4
Glossary
06-08
DISTILLED WATER - Water produced by vaporization and condensa-
tion with a resulting higher purity.
DOWNCOMER - A tube or pipe in a boiler or waterwall circulating
system through which fluid flows downward.
DOWNTIME - Amount of time a piece of equipment is not opera-
tional.
DRAFT - The difference between atmospheric pressure and some
lower pressure existing in the furnace stack or gas passages of a
steam generating unit.
DRAFT DIFFERENTIAL - The difference in static pressure between
two points in a system.
DRAFT GAUGE -A device for measuring draft, usually in inches of
water.
DRAIN - A valved connection at the lowest point for the removal of all
water from the pressure parts.
DRUM - A cylindrical shell closed at both ends designed to withstand
internal pressure.
DRY AIR - Air with which no water vapor is mixed. This term is used
comparatively, since in nature there is always some water vapor
included in air, and such water vapor, being a gas, is dry.
DRYBACK BOILER - Firetube boiler with a refractory lined back door.
Door opens to allow maintenance and/or inspection.
DRY GAS - Gas containing no water vapor.
DRY-GAS LOSS - The loss representing the difference between the
heat content of the dry exhaust gases and their heat content at the
temperature of ambient air.
DRY STEAM - Steam containing no moisture. Commercially dry
steam containing not more than one half of one percent moisture.
DUCT - A passage for air or gas flow.
E
ECONOMIZER - Utilizes waste heat by transferring heat from flue
gases to warm incoming feedwater.
EDR - Equivalent direct radiation is the rate of heat transfer from a
radiator or convector. It is equivalent to the square feet of surface area
necessary to transfer heat at the same rate at which it is produced by
a generator. A single boiler horsepower equals 140 ft
2
EDR.
EFFICIENCY - The ratio of output to input. See also Combustion,
Fuel-to-Steam and Thermal Efficiency.
EJECTOR - A device which utilizes the kinetic energy in a jet of water
or other fluid to remove a fluid or fluent material from tanks or hop-
pers.
ELECTRIC BOILER - A boiler in which electric energy is used as the
source of heat.
ELECTROSTATIC PRECIPITATOR - A device for collecting dust, mist
or fume from a gas stream, by placing an electrical charge on the par-
ticle and removing that particle onto a collecting electrode.
ENTRAINMENT - The conveying of particles of water or solids from
the boiler water by the steam.
EQUALIZER - Connections between parts of a boiler to equalize pres-
sures.
EQUIVALENT EVAPORATION - Evaporation expressed in pounds of
water evaporated from a temperature of 212 F to dry saturated steam
at 212 F.
EVAPORATION - The change of state from a liquid to a vapor.
EVAPORATION RATE - The number of pounds of water that is evapo-
rated in a unit of time.
EXCESS AIR - Air supplied for combustion in excess of that theoreti-
cally required for complete oxidation.
EXPANSION JOINT - The joint to permit movement due to expansion
without undue stress.
EXPLOSION DOOR - A door in a furnace or boiler setting that is
designed to be opened by a pre-determined gas pressure.
EXTERNAL TREATMENT - Treatment of boiler feed water prior to its
introduction into the boiler.
F
FAN - A machine consisting of a rotor and housing for moving air or
gases at relatively low pressure differentials.
FAN PERFORMANCE - A measure of fan operation in terms of vol-
ume, total pressures, static pressures, speed, power input, mechani-
cal and static efficiency, at a stated air density.
FAN PERFORMANCE CURVES - The graphical presentation of total
pressure, static pressure, power input, mechanical and static effi-
ciency as ordinates and the range of volumes as abscissa, all at con-
stant speed and air density.
FEED PUMP - A pump that supplies water to a boiler.
FEEDWATER - Water introduced into a boiler during operation. It
includes make-up and return condensate.
FEEDWATER TREATMENT - The treatment of boiler feed water by the
addition of chemicals to prevent the formation of scale or to eliminate
other objectionable characteristics.
FGR - Flue Gas Recirculation or the recirculation of flue gas with com-
bustion air to reduce NOx emissions.
FILTER - Porous material through which fluids or fluid - and solid mix-
tures are passed to separate matter held in suspension.
FIN - A fin is an extended surface, a solid, experiencing energy trans-
fer by conduction within its boundaries, as well as energy transfer with
its surroundings by convection and/or radiation, used to enhance heat
transfer by increasing surface area.
FIN TUBE - A tube with one or more fins.
FIRED PRESSURE VESSEL - A vessel containing a fluid under pres-
sure exposed to heat from the combustion of fuel.
FIRETUBE - A type of boiler design in which combustion gases flow
inside the tubes and water flows outside the tubes.
FIRING RATE CONTROL - A pressure temperature or flow controller
which controls the firing rate of a burner according to the deviation
from pressure or temperature set point. The system may be arranged
to operate the burner on-off, high-low or in proportion to load demand.
FIXED CARBON - The carbonaceous residue less the ash remaining in
the test container after the volatile matter has been driven off in mak-
ing the proximate analysis of a solid fuel.
J-5
06-08
FLAME - A luminous body of burning gas or vapor.
FLAME DETECTOR - A device which indicates if a fuel (liquid, gas-
eous, or pulverized) is burning, or if ignition has been lost. The indica-
tion may be transmitted to a signal or to a control system.
FLAME PROPAGATION RATE - Speed of travel of ignition through a
combustible mixture.
FLAME SAFEGUARD - A control that sequences the burner through
several stages of operation to provide proper air purge, ignition, nor-
mal operation, and shutdown for safe operation.
FLAMMABILITY - Susceptibility to combustion.
FLASHING - The process of producing steam by discharging water
into a region of pressure lower than the saturation pressure that corre-
sponds to the water temperature
FLASH POINT - The lowest temperature at which, under specified
conditions, fuel oil gives off enough vapor to flash into a momentary
flame when ignited.
FLUE - A passage for products of combustion.
FLUE GAS - The gaseous product of combustion in the flue to the
stack.
FOAMING - The continuous formation of bubbles which have suffi-
ciently high surface tension to remain as bubbles beyond the disen-
gaging surface.
FORCED CIRCULATION - The circulation of water in a boiler by
mechanical means external to the boiler.
FORCED-DRAFT FAN - A fan supplying air under pressure to the fuel
burning equipment.
FOULING - The accumulation of refuse in gas passages or on heat
absorbing surfaces which results in undesirable restriction to the flow
of gas or heat.
FM - Factory Mutual.
FREE ASH - Ash which is not included in the fixed ash.
FUEL - A substance containing combustible used for generating heat.
FUEL-AIR MIXTURE - Mixture of fuel and air.
FUEL-AIR RATIO - The ratio of the weight, or volume, of fuel to air.
FUEL OIL - A liquid fuel derived from petroleum or coal.
FUEL-TO-STEAM EFFICIENCY - The ratio of heat added to boiler
feedwater to produce the output steam to the amount of energy input-
ted with fuel.
FURNACE - An enclosed space provided for the combustion of fuel.
FURNACE PRESSURE - Pressure occurring inside the combustion
chamber; positive if greater than atmospheric, negative if less than
atmospheric, and neutral if equal to atmospheric.
FURNACE VOLUME - The cubic contents of the furnace or combus-
tion chamber.
FUSIBLE PLUG - A hollowed threaded plug having the hollowed por-
tion filled with a low melting point material.
G
GAS ANALYSIS - The determination of the constituents of a gaseous
mixture.
GAS BURNER - A burner that uses gas or fuel.
GAS PRESSURE REGULATOR - A spring loaded, dead weighted or
pressure balanced device which will maintain the gas pressure to the
burner supply line.
GAUGE COCK - A valve attached to a water column or drum for
checking water level.
GAUGE GLASS - The transparent part of a water gauge assembly con-
nected directly or through a water column to the boiler, below and
above the water line, to indicate the water level in a boiler.
GAUGE PRESSURE - The pressure above atmospheric pressure.
GRADE - Oil classification according to quality, generally based on
ASTM specifications.
GRAINS PER CU-FT - The term for expressing dust loading in weight
per unit of gas volume (7000 grains equals one pound).
GRAINS (WATER) - A unit of measure commonly used in water analy-
sis for the measurement of impurities in water (17.1 grains = 1 part
per million - ppm).
GRAVITY - Weight index of fuels: liquid, petroleum products
expressed either as specific, Baume or A.P.I. (American Petroleum
Institute) gravity; weight index of gaseous fuels as specific gravity
related to air under specified conditions; or weight index of solid fuels
as specific gravity related to water under specified conditions.
H
HANDHOLE - An access opening in a pressure part usually not
exceeding 6"in its longest dimension.
HANDHOLE COVER - A handhole closure.
HARDNESS - A measure of the amount of calcium and magnesium
salts in water. Usually expressed as grains per gallon or ppm as
CaCO
3
.
HARD WATER - Water which contains calcium or magnesium in an
amount which require an excessive amount of soap to form a lather.
HEAT AVAILABLE - The thermal energy above a fixed datum that is
capable of being absorbed for useful work.
HEAT BALANCE - An accounting of the distribution of the heat input,
output and losses.
HEAT EXCHANGER - A vessel in which heat is transferred from one
medium to another.
HEAT RELEASE RATE - Rate that describes the heat available per
square foot of heat-absorbing surface in the furnace or per cubic foot
of volume.
HEATING SURFACE - Those surfaces which are exposed to products
of combustion on one side and water on the other. This surface is
measured on the side receiving the heat.
HEATING VALUE - The quantity of heat released by a fuel through
complete combustion. It is commonly expressed in Btu per lb, per gal-
lon, or cu-ft.
HIGH GAS PRESSURE CONTROL - A control to stop the burner if the
gas pressure is too high.
HIGH OIL TEMPERATURE CONTROL - A control to stop the burner if
the oil temperature is too high.
HYDROCARBON - A chemical compound of hydrogen and carbon.
J-6
Glossary
06-08
HYDROSTATIC TEST - A strength and tightness test of a closed pres-
sure vessel by water pressure.
I
IGNITION - The initiation of combustion.
IGNITION TEMPERATURE - Lowest temperature of a fuel at which
combustion becomes self-sustaining.
ILLUMINANTS - Light oil or coal compounds that readily burn with a
luminous flame, such as ethylene, propylene and benzene.
INCOMPLETE COMBUSTION - The partial oxidation of the combusti-
ble constituents of a fuel.
INDUCED DRAFT FAN- A fan exhausting hot gases from the heat
absorbing equipment.
INERT GASEOUS CONSTITUENTS - Incombustible gases such as
nitrogen which may be present in a fuel.
INHIBITOR - A substance which selectively retards a chemical action.
An example in boiler work is the use of an inhibitor, when using acid
to remove scale, to prevent the acid from attacking the boiler metal.
INJECTOR - A device utilizing a steam jet to entrain and deliver feed
water into a boiler.
INSULATION - A material of low thermal conductivity used to reduce
heat losses.
INTEGRAL BLOWER - A blower built as an integral part of a device to
supply air thereto.
INTEGRAL-BLOWER BURNER - A burner of which the blower is an
integral part.
INTERLOCK - A device to prove the physical state of a required condi-
tion, and to furnish that proof to the primary safety control circuit.
INTERMITTENT BLOWDOWN - the blowing down of boiler water at
intervals.
INTERNAL TREATMENT - The treatment of boiler water by introduc-
ing chemicals directly into the boiler.
ION - A charged atom or radical which may be positive or negative.
IRI - Industrial Risk Insurers.
L
LAGGING - A light gauge steel covering used over a boiler, usually
combined with insulation, to provide a low temperature outer surface.
LEAKAGE - The uncontrolled quantity of fluid which enters or leaves
through the enclosure of air or gas passages.
LIBERATION - See Heat Release.
LIMIT CONTROL - A switching device that completes or breaks an
electrical circuit at predetermined pressures or temperatures. Also
known as an interlock. See interlock.
LINING - The material used on the furnace side of a furnace wall. It is
usually of high grade refractory tile or brick or plastic refractory mate-
rial.
LOAD - The rate of output required; also the weight carried.
LOAD FACTOR - The ratio of the average load in a given period to the
maximum load carried during that period.
LOW GAS PRESSURE CONTROL - A control to stop the burner if gas
pressure is too low.
LOW OIL TEMPERATURE CONTROL - (Cold Oil Switch) A control to
prevent burner operation if the temperature of the oil is too low.
LOW WATER CUTOFF - Safety device that shuts off the boiler/burner
in the event of low water, preventing pressure vessel failure.
LUG - Any projection, like an ear, used for supporting or grasping.
M
MAKE-UP - The water added to boiler feed to compensate for that lost
through exhaust, blowdown, leakage, etc.
MANHOLE - The opening in a pressure vessel of sufficient size to per-
mit a man to enter.
MANIFOLD - A pipe or header for collection of a fluid from, or the dis-
tribution of a fluid to a number of pipes or tubes.
MANUAL GAS SHUTOFF VALVE - A manually operated valve in a gas
line for the purpose of completely turning on or shutting off the gas
supply.
MANUFACTURED GAS - Fuel gas manufactured from coal, oil, etc.,
as differentiated from natural gas.
MAXIMUM ALLOWABLE WORKING PRESSURE - The maximum
gauge pressure permissible in a completed boiler. The MAWP of the
completed boiler shall be less than or equal to the lowest design pres-
sure determined for any of its parts. This pressure is based upon either
proof tests or calculations for every pressure part of the boiler using
nominal thickness exclusive of allowances for corrosion and thickness
required for loadings other than pressure. It is the basis for the pres-
sure setting of the pressure relieving devices protecting the boiler.
MAXIMUM CONTINUOUS LOAD - The maximum load which can be
maintained for a specified period.
MAXIMUM INSTANTANEOUS DEMAND - The sudden load demand
on a boiler beyond which an unbalanced condition may be established
in the boiler's internal flow pattern and/or surface release conditions.
MECHANICAL ATOMIZING OIL BURNER - A burner which uses the
pressure of the oil for atomization.
MECHANICAL DRAFT - The negative pressure created by mechanical
means.
MICRON - One millionth of a meter, or 0.000039 in. or 1/25400 in.
The diameter of dust particles is often expressed in microns.
MINIATURE BOILER - Fire pressure vessels which do not exceed the
following limits:
16 in. inside diameter of shell; 42 in., overall length to outside of
heads at center; 20 sq ft water heating surface; or 100 psi maximum
allowable working pressure.
MMBtu - Millions of Btus (British Thermal Units).
MOISTURE - Water in the liquid or vapor phase.
MOISTURE IN STEAM - Particles of water carried in steam, expressed
as the percentage by weight.
J-7
06-08
MOISTURE LOSS - The boiler flue gas loss representing the difference
in the heat content of the moisture in the exit gases and that at the
temperature of the ambient air.
MULTIFUEL BURNER - A burner by means of which more than one
fuel can be burned.
MULTIPORT BURNER - A burner having a number of nozzles from
which fuel and air are discharged.
N
NATURAL CIRCULATION - The circulation of water in a boiler caused
by differences in density.
NATURAL GAS - Gaseous fuel occurring in nature.
NET POSITIVE SUCTION HEAT (NPSH) - The liquid pressure that
exists at the suction end of a pump. If the NPSH is insufficient, the
pump can cavitate.
NOx - Abbreviation for all of the family of oxides of nitrogen.
NOZZLE - a short flanged or welded neck connection on a drum or
shell for the outlet or inlet of fluids; also a projecting spout through
which a fluid flows.
O
OIL BURNER - A burner for firing oil.
OIL HEATING AND PUMPING SET - A group of apparatus consisting
of a heater for raising the temperature of the oil to produce the
desired viscosity, and a pump for delivering the oil at the desired pres-
sure.
OPERATING CONTROL - A control to start and stop the burner - must
be in addition to the high limit control.
OPERATING PRESSURE - The pressure at which a boiler is operated.
ORGANIC MATTER - Compounds containing carbon often derived
from living organisms.
ORIFICE - (1) The opening from the whirling chamber of a mechani-
cal atomizer or the mixing chamber of a steam atomizer through
which the liquid fuel is discharged. (2) A calibrated opening in a
plate, inserted in a gas stream for measure velocity of flow.
ORSAT - a gas-analysis apparatus in which certain gaseous constitu-
ents are measured by absorption in separate chemical solution.
OVERPRESSURE - Minimum operating pressure of a hot water boiler
sufficient to prevent the water from steaming.
OXIDATION - chemical combination with oxygen.
OXIDIZING ATMOSPHERE - An atmosphere which tends to promote
the oxidation of immersed materials.
OXYGEN ATTACK - Corrosion or pitting in a boiler caused by oxygen.
P
PACKAGED BOILER - A boiler supplied with all of its components -
burner, controls and auxiliary equipment, designed as a single engi-
neered package, and ready for on-site installation.
PACKAGED STEAM GENERATOR - See Packaged Boiler.
PARTICLE SIZE - A measure of dust size, expressed in microns or per
cent passing through a standard mesh screen.
PASS - A confined passageway, containing heating surface, through
which a fluid flows in essentially one direction.
PERFECT COMBUSTION - The complete oxidation of all the combus-
tible constituents of a fuel, utilizing all the oxygen supplied.
PETROLEUM - Naturally occurring mineral oil consisting predomi-
nately of hydrocarbons.
pH - The hydrogen ion concentration of a water to denote Acidity or
Alkalinity. A pH of 7 is neutral. A pH above 7 denotes alkalinity while
one below 7 denotes acidity. This pH number is the negative exponent
of 10 representing hydrogen ion concentration in grams per liter. For
instance a pH of 7 represent 10
-7
grams per liter.
PILOT - (See also Ignitor. ) A flame which is utilized to ignite the fuel
at the main burner or burners.
PITOT TUBE - An instrument which will register total pressure and
static pressure in a gas stream, used to determine its velocity.
PITTING - A concentrated attack by oxygen or other corrosive chemi-
cals in a boiler, producing a localized depression in the metal surface.
PORT - An opening through which fluid passes.
POST PURGE - A method of scavenging the furnace and boiler passes
to remove all combustible gases after flame failure controls have
sensed pilot and main burner shutdown and safety shut-off valves are
closed.
ppm - Abbreviation for parts per million. Used in chemical determina-
tions as one part per million parts by weight.
PRECIPITATE - To separate materials from a solution by the formation
of insoluble matter by chemical reaction. The material which is
removed.
PRECIPITATION - The removal of solid or liquid particles from a fluid.
PREHEATED AIR - Air at a temperature exceeding that of the ambient
air.
PRESSURE - Force per unit of area.
PRESSURE DROP - The difference in pressure between two points in
a system, caused by resistance to flow.
PRESSURE VESSEL - A closed vessel or container designed to confine
a fluid at a pressure above atmospheric.
PRIMARY AIR - Air introduced with the fuel at the burner.
PRIMING - The discharge of steam containing excessive quantities of
water in suspension from a boiler, due to violent ebullition.
PROCESS STEAM - Steam used for industrial purposes other than for
producing power.
PRODUCTS OF COMBUSTION - The gases, vapors, and solids result-
ing form the combustion of fuel.
PULSATION - Rapid fluctuations in pressure.
PURGE - To introduce air into the furnace and the boiler flue passages
in such volume and manner as to completely replace the air or gas-air
mixture contained therein.
J-8
Glossary
06-08
R
RADIATION LOSS - A comprehensive term used in a boiler-unit heat
balance to account for the conduction, radiation, and convection heat
losses from the boiler to the ambient air.
RATED CAPACITY - The manufacturers stated capacity rating for
mechanical equipment; for instance, the maximum continuous
capacity in pounds of steam per hour for which a boiler is designed.
RATE OF BLOWDOWN - A rate normally expressed as a percentage of
the water fed.
RATING - See Load.
RAW WATER - Water supplied to the plant before any treatment.
REACTION - A chemical transformation or change brought about by
the interaction of two substances.
REASSOCIATION - The recombination of the products of dissociation.
RECIRCULATION - The reintroduction of part of the flowing fluid to
repeat the cycle of circulation.
REDUCING ATMOSPHERE - An atmosphere which tends to 1) pro-
mote the removal of oxygen from a chemical compound; 2) promote
the reduction of immersed materials.
REDUCTION - Removal of oxygen from a chemical compound.
REFRACTORY - Brickwork or castable used in boilers to protect metal
surfaces and for boiler baffles.
RELATIVE HUMIDITY - The ratio of the mass of water vapor present
in a unit volume of gas to the maximum possible mass of water vapor
in unit volume of the same gas at the same temperature and pres-
sure.
RELIEF VALVE (Safety Relief Valve) - An automatic pressure relieving
device actuated by the pressure upstream of the valve and character-
ized by opening pop action with further increase in lift with an
increase in pressure over popping pressure.
RESIDUAL FUELS - Products remaining from crude petroleum by
removal of some of the water and an appreciable percentage of the
more volatile hydrocarbons.
RESIN - A bead-like material used in chemical exchange for softeners
and dealkalizers.
RESISTANCE - Impediment to gas flow, such as pressure drop or
draft loss through a dust collector. Usually measured in inches water
column ( wc).
RETURN FLOW OIL BURNER - A mechanical atomizing oil burner in
which part of the oil supplied to the atomizer is withdrawn and
returned to storage or to the oil line supplying the atomizer.
RINGELMANN CHART - A series of four rectangular grids of black
lines of varying widths printed on a white background, and used as a
criterion of blackness for determining smoke density in stack gas
streams.
ROTARY OIL BURNER - A burner in which atomization is accom-
plished by feeding oil to the inside of a rapidly rotating cup.
S
SADDLE - A casting, fabricated chair, or member used for the pur-
pose of support.
SAFE WORKING PRESSURE - See Design Pressure.
SAFETY VALVE - A spring loaded valve that automatically opens when
pressure attains the valve setting. Used to prevent excessive pressure
from building up in a boiler.
SAFETY SHUT-OFF VALVE - A manually opened, electrically latched,
electrically operated safety shut-off valve designed to automatically
shut off fuel when de-energized.
SAMPLING - The removal of a portion of a material for examination or
analysis.
SATURATED AIR - Air which contains the maximum amount of water
vapor that it can hold at its temperature and pressure.
SATURATED STEAM - Steam at the temperature and pressure at
which evaporation occurs.
SATURATED TEMPERATURE - The temperature at which evaporation
occurs at a particular pressure.
SATURATED WATER - Water at its boiling point.
SCALE - A hard coating or layer of materials on surfaces of boiler pres-
sure parts.
SECONDARY AIR - Air for combustion supplied to the furnace to sup-
plement the primary air.
SECONDARY TREATMENT - Treatment of boiler feed water or internal
treatment of boiler-water after primary treatment.
SEDIMENT - (1) Matter in water which can be removed from suspen-
sion by gravity or mechanical means. (2) A non-combustible solid
matter which settles out at bottom of a liquid; a small percentage is
present in residual fuel oils.
SEGREGATION - The tendency of refuse of varying compositions to
deposit selectively in difference parts of the unit.
SELF-SUPPORTING STEEL STACK - A steel stack of sufficient
strength to require no lateral support.
SERVICE WATER - General purpose water which may or may not have
been treated for a special purpose.
SHELL - The cylindrical portion of a pressure vessel.
SLUDGE - A soft water-formed sedimentary deposit which normally
can be removed by blowing down.
SLUG - A large dose of chemical treatment applied internally to a
steam boiler intermittently. Also used sometimes instead of priming
to denote a discharge of water out through a boiler steam outlet in rel-
atively large intermittent amounts.
SMOKE - Small gas borne particles of carbon or soot, less than 1
micron in size, resulting from incomplete combustion of carbonaceous
materials and of sufficient number to be observable.
SOFTENING - The act of reducing scale forming calcium and magne-
sium impurities from water.
SOFT WATER - Water which contains little or no calcium or magne-
sium salts, or water from which scale forming impurities have been
removed or reduced.
SOLUTION - A liquid, such as boiler water, containing dissolved sub-
stances.
SOOT - Unburned particles of carbon derived from hydrocarbons.
SOOT BLOWER - A mechanical device for discharging steam or air to
clean heat absorbing surfaces.
J-9
06-08
SPALLING - The breaking off of the surface of refractory material as a
result of internal stresses.
SPECIFIC HEAT - The quantity of heat, expressed in Btu, required to
raise the temperature of 1 lb of a substance 1
o
F.
SPECIFIC HUMIDITY - The weight of water vapor in a gas water-
vapor mixture per unit weight of dry gas.
SPRAY ANGLE - The angle included between the sides of the cone
formed by liquid fuel discharged from mechanical, rotary atomizers
and by some forms of steam or air atomizers.
SPRAY NOZZLE - A nozzle from which a liquid fuel is discharged in
the form of a spray.
STACK - A vertical conduit, which due to the difference in density
between internal and external gases, creates a draft at its base.
STACK DRAFT - The magnitude of the draft measured at the inlet to
the stack.
STACK EFFECT - That portion of a pressure differential resulting from
difference in elevation of the points of measurement.
STACK EFFLUENT - Gas and solid products discharged from stacks.
STAGNATION - The condition of being free from movement or lacking
circulation.
STANDARD AIR - Dry air weighing 0.075 lb per cu ft at sea level
(29.92"Barometric Pressure) and 70
o
F.
STANDARD FLUE GAS - Gas weighing 0.078 lb per cu ft at sea level
(29.92"Barometric Pressure) and 70
o
F.
STATIC PRESSURE - The measure of potential energy of a fluid.
STEAM - The vapor phase of water, unmixed with other gases.
STEAM ATOMIZING OIL BURNER - A burner for firing oil which is
atomized by steam. It may be of the inside or outside mixing type.
STEAM BINDING - A restriction in circulation due to a steam pocket
or a rapid steam formation.
STEAM GAUGE - A gauge for indicating the pressure of steam.
STEAM GENERATING UNIT - A unit to which water, fuel, and air are
supplied and in which steam is generated. It consists of a boiler fur-
nace, and fuel burning equipment, and may include as component
parts water walls, superheater, reheater, economizer, air heater, or
any combination thereof.
STEAM PURITY- The degree of contamination. Contamination is
expressed in ppm.
STEAM QUALITY - The percent by weight of vapor in a steam and
water mixture.
STEAM SEPARATOR - A device for removing the entrained water from
steam.
STRAINER - A device, such as a filter, to retain solid particles allow-
ing a liquid to pass.
STRATIFICATION - Non-homogeneity existing transversely in a gas
stream.
STUD - A projecting pin serving as a support or means of attachment.
SUPERHEATED STEAM - Steam with its temperature raised above
that of saturation. The temperature in excess of its saturation temper-
ature is referred to as superheat.
SURFACE BLOWOFF - Removal of water, foam, etc. from the surface
at the water level in a boiler. The equipment for such removal.
SURGE - The sudden displacement or movement of water in a closed
vessel or drum.
SUSPENDED SOLIDS - Undissolved solids in boiler water.
SWINGING LOAD - A load that changes at relatively short intervals.
T
TERTIARY AIR - Air for combustion supplied to the furnace to supple-
ment the primary and secondary air.
THEORETICAL AIR - The quantity of air required for perfect combus-
tion.
THEORETICAL DRAFT - The draft which would be available at the
base of a stack if there were no friction or acceleration losses in the
stack.
THEORETICAL FLAME TEMPERATURE - See Adiabatic Flame Tem-
perature.
THERM - A unit of heat applied especially to gas. One therm =
100,000 Btu.
THERMAL EFFICIENCY - The efficiency of a boiler, based on the ratio
of heat absorbed to total heat input. This does not include heat loss
from the boiler shell.
THERMAL SHOCK - A cycle of temperature swings that result in fail-
ure of metal due to expansion and contraction.
THERMOCOUPLE - A temperature measuring instrument.
TILE - A preformed refractory, usually applied to shapes other than
standard brick.
TOTAL AIR - The total quantity of air supplied to the fuel and products
of combustion. Percent total air is the ratio of total air to theoretical
air, expressed as percent.
TOTAL PRESSURE - The sum of the static and velocity pressures.
TOTAL SOLIDS CONCENTRATION - The weight of dissolved and sus-
pended impurities in a unit weight of boiler water, usually expressed
in ppm.
TRAP - A receptacle for the collection of undesirable material.
TREATED WATER - Water which has been chemically treated to make
it suitable for boiler feed.
TRIM - Ancillary boiler components, like water level controls, pressure
controls, and temperature controls.
TUBE - A hollow cylinder for conveying fluids.
TUBE HOLE - A hole in a drum, heater, or tube sheet to accommodate
a tube.
TURBULENT BURNER - A burner in which fuel and air are mixed and
discharged into the furnace in such a manner as to produce turbulent
flow from the burner.
TURNDOWN RATIO - Ratio of maximum to minimum fuel or steam
input or boiler output.
U
ULTIMATE ANALYSIS - See Analysis Ultimate.
UL LISTED - Product certification that indicates the product meets
J-10
Glossary
06-08
safety standards determined by Underwriters Laboratories. (ULC and
cUL indicate Canadian requirements.)
UNACCOUNTED-FOR LOSS - That portion of a boiler heat balance
which represents the difference between 100 per cent and the sum of
the heat absorbed by the unit and all the classified losses expressed
as per cent.
UNBURNED COMBUSTIBLE - The combustible portion of the fuel
which is not completely oxidized.
UNFIRED PRESSURE VESSEL - A vessel designed to withstand inter-
nal pressure, neither subjected to heat from products of combustion
nor an integral part of a fired pressure vessel system.
USE FACTOR - The ratio of hours in operation to the total hours in
that period.
V
VA - Volt amperes.
VAPOR - The gaseous product of evaporation.
VAPORIZATION - The change from liquid or solid phase to the vapor
phase.
VELOCITY PRESSURE - The measure of the kinetic energy of a fluid.
VENT - An opening in a vessel or other enclosed space for the
removal of gas or vapor.
VERTICAL FIRING - An arrangement of a burner such that air and
fuel are discharged into the furnace in practically a vertical direction.
VISCOSITY - Measure of the internal friction of a fluid or its resistance
to flow.
VOLATILE MATTER Those products given off by a material as gas or
vapor, determined by definite prescribed methods.
VOLUME OF AIR - The number of cu ft of air per min expressed at fan
outlet conditions.
W
WASTE HEAT - Sensible heat in non-combustible gases discharged to
the environment.
WATER - A liquid composed of two parts of hydrogen and sixteen
parts oxygen by weight.
WATER COLUMN - A vertical tubular member connected at its top
and bottom to the steam and water space respectively of a boiler, to
which the water gauge, water level controls, and fuel cutoff may be
connected.
WATER GAUGE - The gauge glass and its fittings for attachment.
WATER HAMMER - A sudden increase in pressure of water due to an
instantaneous conversion of momentum to pressure.
WATER LEVEL - The elevation of the surface of the water in a boiler.
WATER SOFTENER - Removes hardness (CaCO
3
) from water through
an ion exchange of sodium with calcium and magnesium.
WATER TUBE - A tube in a boiler having the water and steam on the
inside and heat applied to the outside.
WATER VAPOR - A synonym for steam, usually used to denote steam
of low absolute pressure.
WEEP - A term usually applied to a minute leak in a boiler joint which
forms droplets (or tears) of water very slowly.
WETBACK BOILER - Firetube boiler design wherein the back portion
of the boiler has a water jacket.
WET-BULB TEMPERATURE - The lowest temperature which a water
wetted body will attain when exposed to an air current. This is the
temperature of adiabatic saturation, and can be used to measure
humidity.
WETNESS - A term used to designate the percentage of water in
steam. Also used to describe the presence of a water film on heating
surface interiors.
WET STEAM - Steam containing moisture.
WINDBOX - A chamber below the grate or surrounding a burner,
through which air under pressure is supplied for combustion of the
fuel.
WINDBOX PRESSURE - The static pressure in the windbox of a
burner or stoker.

Boiler Book - Cleaver Brooks

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Boiler Book - Cleaver Brooks

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TABLE OF CONTENTS

Firetube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A

EXTERNALLY POWERED PRESSURE SENSOR (0-15 PSI OR 0-150 PSI). 1

6-16 0.5 0.5 1.0

total load =2160 hrs 650 kBtu/hr. +1440 2500 kBtu/hr.

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