Product Guide Two Stage Economizer

TWO STAGE ECONOMIZER PRODUCT GUIDE

Section BB-1 Rev. 07-10

Product Guide Two Stage Economizer

CONTENTS

OVERVIEW .................................................................................................................................................................................. 3
FEATURES AND BENEFITS ....................................................................................................................................................... 3
Reduces Fuel Use and Cost: ................................................................................................................................................... 3
Load Changes:......................................................................................................................................................................... 3
Emissions................................................................................................................................................................................. 3
ASME Construction: ................................................................................................................................................................. 3
High Efficiency Heat Exchanger: .............................................................................................................................................. 3
Self-Draining Design: ............................................................................................................................................................... 3
Low Pressure Drop: ................................................................................................................................................................. 4
Gas Tight Combustion Stack ................................................................................................................................................... 4
Condensing Economizer Control Options ................................................................................................................................ 4
Application ............................................................................................................................................................................... 4
1st Stage ............................................................................................................................................................................. 4
2nd Stage ............................................................................................................................................................................ 5
GUIDE .......................................................................................................................................................................................... 6
Tab 1: Application Data ............................................................................................................................................................ 6
Number of Boilers fed by DA ............................................................................................................................................... 6
Boiler Model Selection ......................................................................................................................................................... 6
Fuel Series .......................................................................................................................................................................... 6
Flue Gas Temperatures....................................................................................................................................................... 6
Feedwater Temperature ...................................................................................................................................................... 6
2nd Stage Inlet Water Type ................................................................................................................................................. 6
2nd Stage Inlet Water .......................................................................................................................................................... 6
2nd Stage Inlet Water Temperature .................................................................................................................................... 7
Exhaust Flow Direction ........................................................................................................................................................ 7
Tab 2: Economizer Selection ................................................................................................................................................... 7
Boiler Data Display .............................................................................................................................................................. 7
Model Selection ................................................................................................................................................................... 7
Economizer Model Displays ................................................................................................................................................ 8
Tab 3: Economizer Options...................................................................................................................................................... 8
Relief Valves ....................................................................................................................................................................... 8
Economizer Design Pressure .............................................................................................................................................. 9
Boiler Vent Mating Flanges and Gaskets ............................................................................................................................ 9

Section BB-2 Rev. 07-10

Product Guide Two Stage Economizer

Modulating MakeUp Valve................................................................................................................................................... 9

3-Way Condensate ByPass Valve V3 (Three Way Diverting Valve). ................................................................................... 9
Flow Balancing Valves ...................................................................................................................................................... 10
Transmitters ...................................................................................................................................................................... 10
Controls ............................................................................................................................................................................. 10
Vent Extension .................................................................................................................................................................. 11
Outdoor Coat – Paint ......................................................................................................................................................... 11
Economizer Supports ........................................................................................................................................................ 11
ASME Stamp / CRN .......................................................................................................................................................... 11
International Orders ........................................................................................................................................................... 12
Other offerings ................................................................................................................................................................... 12
TWO STAGE (C2X) BOILER EXHAUST ECONOMIZER SPECIFICATIONS ............................................................................ 13
1.0 GENERAL DESIGN .................................................................................................................................................. 13
2.0 CONSTRUCTION ..................................................................................................................................................... 13
3.0 OPTIONAL EQUIPMENT ......................................................................................................................................... 14

Section BB-3 Rev. 07-10

Product Guide Two Stage Economizer

OVERVIEW

Cleaver-Brooks, the innovator in packaged boiler designs, introduces the C2X line of
condensing economizers with the unique ability to maintain peak efficiency while firing different
fuels and while liquid flow rates through the system vary from 0-100%. These SYSTEMS are
unmatched in the industry and can deliver up to 95% fuel to steam efficiency.
The lower section of the economizer recovers energy by preheating the boiler feed water. The
upper section preheats virtually any cool liquid stream (makeup water, wash water, hot water
preheating, etc.) and the control system maximizes condensing when firing natural gas, then
automatically switches to a near condensing mode when firing #2 oil (if applicable).

FEATURES AND BENEFITS

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.
• Typical payback is less than one year

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.
• Reduce your fuel cost by up to 15% over a conventional steam boiler
• Reduce Greenhouse gas emissions by up to 15%

Section BB-4 Rev. 07-10

 Product Guide Two Stage Economizer

Model 4WI Steam Boiler Ratings 100 to 800 HP

Boiler H.P. 100 125 150 200 250 300 350 400 500 600 700 800
RATINGS- SEA LEVEL TO 700 FT.
Rated Capacity
3450 4313 5175 6900 8625 10350 12075 13800 17250 20700 24150 27600
(lbs-stam/hr at 212 ºF)
BTU Output (1000 Btu/hr) 3348 4184 5021 6695 8369 10043 11716 13390 16738 20085 23433 26780

FUEL CONSUMPTION AT RATED CAPACITY BASED ON NORMAL EFFICIENCY

Light Oil ghp (140000 Btu/gal) 29.2 36.4 43.7 58.3 72.9 87.5 102.1 116.6 145.8 175 204.1 233.3

Gas CFH (1000 Btu) 4082 5103 6123 8165 10206 12247 14288 16329 20412 24494 28576 32659

Natarul Gas (m3/hr) 115.5 144.33 173.2 230.93 339.88 346.675 404.41 462.14 577.6 693.1 808.81 924.278
ECONOMIZER (efficiency 15% 212 ºF- 230 ºF)

Light Oil ghp (140000 Btu/gal) 24.82 30.94 37.145 49.555 61.965 74.375 86.785 99.11 123.93 148.8 173.49 198.305

Gas CFH (1000 Btu) 3470 4337.6 5204.6 6940.3 8675.1 10410 12145 13880 17350 20820 24290 27760.15

Natarul Gas (m3/hr) 98.14 122.68 147.22 196.29 288.9 294.674 343.75 392.82 490.96 589.1 687.49 785.6363
Blower Motor hp (60ppm)
2 5 5 7.5 10 15 15 20 15 25 30 50
(See note A)
Blower Motor hp (30ppm)
3 7.5 7.5 15 15 20 20 25 30 40 50 75
(See note A)
Oil pump motor no. 2 oil 0.5 0.5 0.5 0.5 0.5 0.75 0.75 0.75 0.75 0.75 1 1
Air compressor motor hp
3 3 3 3 5 5 5 5 7.5 7.5 7.5 7.5
(No. 2 oil firing only)
BOILER DATA

Heating Surface sq-ft (Fireside) 500 625 750 1000 1250 1500 1750 2000 2500 3000 3500 See Note B

NOTE
A. Blower motor size for boiler operating pressure 125psig and less, contact your local cleaver brooks authorized representative for higher
B. 800 hp boilers are available 3500 or 4000 sq-ft of heating surface.

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.

Section BB-5 Rev. 07-10

Product Guide Two Stage Economizer

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

Condensing Economizer Control Options

• Hawk ICS Advanced
• 10" color HMI
• CEC200
• 5.7" color HMI
• 8 DI, 4 AI, 6 RO
• CEC100
• 2" LCD
• 8 DI, 4 AI, 6 RO

Application
1st Stage

• Preheat Boiler Feedwater

• Running Feedwater directly through the economizer (direct feedwater heating) –
continuous run pump and modulating feedwater control is required.
• On/Off Feedwater Control
• Convert to modulating control OR
• Supply Circulating Pump and Tank System must be proposed
• Circulating pump and tank systems are only available up to 150 lb boiler design
pressure.
• Storage Tank Selection
• Based on MBH of Economizer Recovery
• General rule of thumb is to pick 20-30 GPM for the circulating pump flowrate.
• Minimum water flow rate through the economizer should be the maximum
evaporation rate of the boiler.
• Add liquid temperature control assembly
• ByPass Damper Open reduces the heat recovery by up to 50%
• May need additional means of removing the excess heat within the system.

Section BB-6 Rev. 07-10

Product Guide Two Stage Economizer

• Make-Up Water / Process Water Heating

• Must have Minimum of 50% makeup to ensure a sufficient heat sink
• Even with this guideline, flow may still be interrupted, which can cause steaming in the
economizer.
• Add a tank and pump upstream of the feedwater tank.
• Then flow is not interrupted.
• Recommend SS Headers (All SS Liquid Side)
• Untreated Condensate – Carbonic Acid
• MU Water – O2 Corrosion
• If water is less than 150°F, may recommend a C1X – Single Stage Condensing
Economizer
• Hot Water Return
• Supply Circulating Pump to draw water from, and return it to, the system hot water
return.
• Use approximately 2-3 gpm per economizer tube as the minimum water flow rate.
• Note:
• Saturated Steam Temp versus Feedwater Temperature
• High Fire use lowest flow possible to keep a Temperature difference of 15 or
20°F below the sat. temp of the boiler
• Supply Temperature + Boiler Delta T (LPS/HW) = Flue Gas Temp

2nd Stage

• Any Cool Liquid Stream (50 - 120 F)

• Make-Up Water
• Utilize the valve package and controls to feed water through the second stage
and into the DA
• Process Water
• Circulating pump or storage tank may be needed.
• Have to ensure continuous flow through the second stage when the boiler is in
operation
• Wash Water
• Circulating pump or storage tank may be needed.
• Have to ensure continuous flow through the second stage when the boiler is in
operation
• Hot Water Preheating
• Supply Circulating Pump to draw water from, and return it to, the system hot water
return.
• Use approximately 2-3 gpm per economizer tube as the minimum water flow rate.

Section BB-7 Rev. 07-10

Product Guide Two Stage Economizer

GUIDE
Tab 1: Application Data Number
of Boilers fed by DA

• The number of boilers selected determines the options for controls

• 1 Boiler is selected an existing Hawk, new Hawk, or CEC controller can be utilized
• Greater than 1 boiler requires a separate CEC-20x controller to monitor the
economizer
Boiler Model Selection

• Select the correct Cleaver Brooks boiler model.

• For non Cleaver Brooks models select “Other”
Fuel Series

• Natural Gas Only:

• Condense Temperature ~140°F
• Natural Gas and/or #2 Oil:
• Natural Gas Condense Temp ~140°F
• #2 oil Condense Temperature: ~180°F
• Note: Economizer CANNOT be using the Condensing Mode when firing #2 Oil
Flue Gas Temperatures

• Predicted Values are Calculated

• Can override the Defaulted Value
Feedwater Temperature

• Minimum Temperature: 200°F

• Maximum Temperature: 230°F
2nd Stage Inlet Water Type

• Options
• Make Up, Percentage
• Process, gpm
2nd Stage Inlet Water

• Make Up, Percentage

• Minimum: 50
• Maximum: 200
• Process, gpm
• Minimum: 50% of Feedwater Flow Rate (gpm)
• Maximum: 200% of Feedwater Flow Rate (gpm)

Section BB-8 Rev. 07-10

Product Guide Two Stage Economizer

2nd Stage Inlet Water Temperature

• Minimum: 50°F
• Maximum: 110°F
Exhaust Flow Direction

• Options:
• Vertical
• Horizontal
• Default: Vertical

Tab 2: Economizer Selection

Boiler Data Display

• Display field in the upper left corner

• Shows the Boiler Information formed from Tab 1 Selections
Model Selection

• C2X Economizer model is selected based on Horsepower

• 100-2200 HP high pressure
• C2X Features
• All upper coil components are 316 stainless steel
• All gas side surfaces are 316 stainless steel to eliminate corrosion
• Tube core assemblies are individually removable and made from 316 stainless steel
tube with Aluminum fins (Al-Fuse)
• Tube to header connections are externally located compression fitting, no welding
is required for tube replacements
• 316 stainless steel exhaust gas bypass, interior shell, condensate drain, and
transition connections
• 2" of factory insulation, inlet/outlet gaskets, ASME relief valves, and drain are included
• Hinged, full face access door for inspecting
• ASME Stamp-SEC.VIII:DIV.I(“UM”)
• Removable tubes with unions and Swagelok fittings
• Tube replacement without welding or cutting
• Hinged access door
• UM stamp standard
• Removable panels allow for complete cleaning
• Built-stainless steel condensate pan and drain
• Built in by-pass damper
• Allow manual stack temperature control and heat adjustment
• Standard design pressure of 300 psig – higher pressures are also available
• 12 gauge 316 stainless steel exterior

Section BB-9 Rev. 07-10

Product Guide Two Stage Economizer

• Internal bypass for W.C. back pressure control

• The upper coil, lower coil, modulating valves, control system and other system
components are sized as a system to deliver the maximum possible cost savings.

Boiler Economizer Length Width Height Liquid Surface Dry Wt. Wet Wt.
2 (lbs.) (lbs.)
HP Model (in.) (in.) (in.) Conn. Area (ft )
100 C2X-K3466AL 52 43 43.92 2" 635 1105 1166
125 C2X-K36a6AL 52 43 59 2" 1079 1545 1647
150 C2X-K37C6AL 52 43 67.6 2" 1335 1805 1931
200 C2X-K3Ac6AL 52 43 76.3 2" 1590 2045 2195
300 C2X-M38B6AL 70 58 65.5 2" 1907 2401 2575
400 C2X-M3Ac6AL 70 58 76.3 2" 2383 2861 3078
500 C2X-R3Ac6AL 80 66 76.3 2.5" 2780 3255 3501
600 C2X-R3BE6AL 80 66 87 2.5" 3337 3785 4080
700 C2X-S3BE6AL 88 73 87 2.5" 3813 3995 4336
800 C2X-S3Cf6AL 88 73 97.8 2.5" 4450 4601 4998
900 C2X-T3Df6AL 98 82 102.14 2.5" 5291 5455 5952
1000 C2X-T3DH6AL 98 82 108.6 2.5" 5720 5865 6402
1100 C2X-T3Ei6AL 98 82 119.4 2.5" 6435 6555 7159
1200 C2X-U3DH6AL 106 90 108.6 2.5" 6355 6415 6999
1300 C2X-U3EI6AL 106 90 119.4 2.5" 7150 7175 7831
1400 C2X-U3FK6AL 106 90 130.17 2.5" 7945 7935 8664
1500 C2X-U3Gl6AL 106 90 141 2.5" 8740 8695 9534
1800 C2X-U3HN6AL 106 90 151.7 2.5" 9535 9455 10370
2200 C2X-U3JQ6AL 106 90 173.3 2.5" 11123 10975 12041

Economizer Model Displays

• Displays all of the information once an Economizer model is selected

• Economizer Weights and Dimensions
• Natural Gas Estimated Performance

Tab 3: Economizer Options

Relief Valves

• Recommend
• (1) 1st Stage
• ¾" NPT ASME Relief Valve: 300psig
• Default: 150 Desig Pressure
• ¾" NPT ASME Relief Valve: 400psig
• Default: 200ST, 250ST
• (1) 2nd Stage
• ¾" NPT ASME Relief Valve: 300psig
• Default

Section BB- Rev. 07-10

10
Product Guide Two Stage Economizer

Economizer Design Pressure

• If ¾" NPT ASME Relief Valve: 300psig Selected

• 1st Stage: 300psig / 2nd Stage: 300psig
• If ¾" NPT ASME Relief Valve: 400psig Selected
• 1st Stage: 400psig / 2nd Stage: 300psig

Boiler Vent Mating Flanges and Gaskets

• C2X Models Option

Flange Size (CB Mating Flange

Mating Flange) Gasket
12" I.D. 12" I.D.
16" I.D. 16" I.D.
18" I.D. 18" I.D.
20" I.D. 20" I.D.
24" I.D. 24" I.D.
32" I.D. 32" I.D.
36" I.D. 36" I.D.
42" I.D. 42" I.D.

Modulating MakeUp Valve

• Modulating Make-Up ByPass, 1/2" NPT, N.C. Valve

• Recommended in Make-Up Flow applications
• Valve diverts Make-Up Water into the second stage to help prevent steaming
• Not Required for Process Flow Applications

3-Way Condensate ByPass Valve V3 (Three Way Diverting Valve)

• Recommended in Make-Up Flow Applications

• Diverts Condensate to the Second Stage when Steaming is sensed
• Size Based on Specified Pressure Drop and Boiler Flow Rate
• Pressure Drop
• Minimum: 5psi
• Maximum: 20psi
• Optional Sizes
• 1" NPT (Cv = 10)
• 1-1/4" NPT (Cv = 16)
• 1-1/2" NPT (Cv = 25)
• 2" NPT (Cv = 40)
• 2-1/2" NPT (Cv = 63)

Section BB- Rev. 07-10

11
Product Guide Two Stage Economizer

Flow Balancing Valves

• Recommended in Make-Up Flow and Multiple Boiler/Economizer Applications

• Require (1) Valve per Economizer
• Ensures consistent flow to the Second Stage of Multiple Economizers
• Size Based on Specified Pressure Drop and Boiler Flow Rate
• Pressure Drop
• Minimum: 5psi
• Maximum: 20psi
• Optional Sizes
• 1/2" NPT (Cv = 26)
• 3/4" NPT (Cv = 55)
• 1" NPT (Cv = 110)
• 1-1/4" NPT (Cv = 180)
• 1-1/2" NPT (Cv = 270)
• 2" NPT (Cv = 500)

Transmitters

• Water Temperature Transmitter 0-1000F

• Recommend: (4) Four
• Gas Temperature Transmitter 0-1000F
• Recommend: (2) Two

Controls

• CEC-10x (x–Specifies the Number of Boilers)

• Utilized for (1) Economizer or Retrofit Applications

• LCD Text Display

• CEC-20x (x–Specifies the Number of Boilers)

• Utilized for 1 – 4 Economizer Application

• LCD 6" Touch Color Display
• Hawk
• Utilized for (1) Economizer Application
• Existing or New Hawk can be Utilized

Section BB-10 Rev. 07-10

Product Guide Two Stage Economizer

Vent Extension

• Only Required for CBLE, 4WI, and CBR boilers.

• 2000lb. 12" Vent Stub Extension
• Available for 70HP to 800 HP
• Additional support is needed to completely secure an Economizer

12" 2000lb. Vent Extension

(Equivalent Horsepower)
70 HP to 100 HP
125 HP to 225 HP
250 HP to 350 HP
400 HP to 800 HP
Outdoor Coat – Paint

• Required for outdoor insulations

Economizer Supports

• Option available within the Firetube Program (Tab: Pressure Vessel)

ASME Stamp / CRN

• ASME National Board “UM”

• Standard
• ASME National Board Stamp – Sec. VIII; Div. I (‘U’)
• Optional
• Required (Water Volume is larger at the specified Design Pressure)
•
3
1-1/2 ft @ 600psi (Design Pressure)
•
3
3 ft @ 350psi (Design Pressure)
• 5 ft# @ 250psi (Design Pressure
• ASME National Board Stamp – Sec. I (‘S’)
• Optional
• CRN (Must Specify CRN Province)
• Optional

Section BB-11 Rev. 07-10

Product Guide Two Stage Economizer

International Orders

• Ship to Thomasville
• Export Packaging

Other offerings

• CRE or CCE
• Single Stage (Non-Condensing) Economizer
• Boiler Feedwater, Hot Water Return, Make-Up Water
• C1X
• Single Stage Condensing Economizer
• Process or Make-Up Water
• Hot Water of Low Pressure Steam Application

Section BB-12 Rev. 07-10

Product Guide Two Stage Economizer

TWO STAGE (C2X) BOILER EXHAUST ECONOMIZER SPECIFICATIONS

1.0 GENERAL DESIGN
1.1 Furnish and install an exhaust gas economizer in the exhaust duct of the boiler in
accordance with the following specifications as designed and manufactured by Cain Industries, Inc.
1.2 The economizer shall be a light weight design for easier installation, rectangular, and
manufactured and tested in accordance with the requirements of Section VIII, Division I of the
ASME Boiler and Pressure Vessel Code.
1.3 The economizer shall have two liquid circuits. The circuit closest to the entering exhaust
gas shall be used to preheat boiler feedwater. The circuit closest to the exiting exhaust gas shall
be used to heat boiler make-up water or process water.
1.4 The economizer shall be designed to include as standard, an internal, high temperature
heat resistant design Flue Gas By-pass Diverter to provide for: emergency by-pass, requiring no
additional duct work for controlling either:
A. Stack Corrosion B. Turn Down Performance C. Excessive flue gas back
pressure due to fouling
1.5 The Economizer shall have a hinged, full face, gas tight, inspection door,
providing access to the heating surface for inspection and/or cleaning.
1.6 The Economizer must be completely drainable when mounted in the vertical position
or horizontal position.
1.7 Header manifolds for low liquid flow pressure drop shall be provided. The liquid header
manifolds shall also contain 3/4" NPT connections for venting, draining, and/or safety relief
valves as required.
1.8 Compression fitted Al-Fuse fin tubes shall be connected to header manifolds for ease of
tube replacement requiring no welding.

2.0 CONSTRUCTION
2.1 Feedwater section: Design Pressure: 300 psig @650°F.; Test Pressure: 450 psig;
Max. Flue Gas Inlet Temperature: 750°F.
2.2 Make-up water section: Design Pressure: 150 psig @550°F.; Test Pressure: 225 psig;
Max. Flue Gas Inlet Temperature: 750°F.
2.3 Fins: pitch 6 Fins/In. Max.; Material: Aluminum; Thickness: .020"; Height: .50"; Alfuse
metallurgically bonded to the tube.
2.4 Tube: outside diameter: 1.0"; Wall Thickness: .065"; Material: TP316 Stainless steel
ERW
2.5 The Feedwater header manifolds are constructed of carbon steel. The make-
up/process water header manifolds are constructed of 304 stainless steel. All of the make-
up/process water liquid side surfaces are stainless steel.
2.6 2" thks. 1000°F thermofiber factory installed, high temperature insulation shall cover
the shell less the header assemblies and stack adapters.
2.7 Exterior surfaces shall be 12ga. 304 stainless steel and shall be primed and painted
with a high temperature metallic paint rated for 1000°F. The inner shell shall be 304 stainless
steel.
2.8 (2) Stainless steel economizer to stack adapters are included.

Section BB-13 Rev. 07-10

Product Guide Two Stage Economizer

3.0 OPTIONAL EQUIPMENT

4.1 (2) 50-500°F, bimetal, 3" adjustable dial, water temperature thermometers with wells.
4.2 (2) 50-300°F, bimetal, 3" adjustable dial, water temperature thermometers with wells.
4.3 (2) 150-750°F Bi-metallic flue gas temperature thermometers, 3" dial.
4.4 (1) 300 psig safety relief valve.

4.5 (1) 150 psig safety relief valve.

Section BB-14 Rev. 07-10