Boiler Book 2005 PDF

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

B1 Model FLX Boilers
B2 Model 4 Boilers
B3 Model 5 Boilers
B4 Electric Boilers
B5 - TrueFire Boilers
B6 - ClearFire Boilers
Industrial Watertube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
Stacks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
Economizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G
Feedwater Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section H
H1 Spraymaster Deaerators (Single Tank)
H2 Spraymaster Deaerators (Duo Tank)
H3 Boilermate Deaerators
H4 Surge Tanks
H5 Boiler Feed Systems
H6 Chemical Feed Systems and Metering Pumps
H7 Filters
H8 Softeners
H9 Dealkalizers
H10 Blowdown Separators
H11 Blowdown Heat Recovery Systems
H12 Flash Tank Heat Exchangers
H13 Sample Coolers
System Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section I

I1 Boiler Selection Considerations
I2 Hot Water Systems
I3 Steam Systems
I4 General Engineering Data
Glossary/Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section J
A1_TEXT.fm Page 1 Tuesday, December 10, 2002 2:35 PM
Section A1
GENERAL
Model CB Boilers A2
Model CB-LE Boilers A3
Model CBW Boilers A4
Model CBH Boiler (discontinued) A5
Model CB Ohio Special Boilers A6
Model CBE Boilers A7
Model CEW Boilers A8
Model CEW-LN Boilers A9
Model CEW Ohio Special Boilers A10
Model CBL Boilers A11
Model ICB Boilers A12
Model ICB-LN Boilers A13
A1-1
12-02
General Firetube Boilers
FEATURES AND BENEFITS Heavy duty motor with direct drive, maintenance free, case-
less fan.
The following Cleaver-Brooks firetube boiler models (CB,
CB-LE, CBW, CB Ohio Special) include the following fea- Integral forced draft fan eliminates the need for:
tures and benefits. Large diameter breeching.
High chimneys.
Packaged Design with Integral Front Head:
Induced draft fans.
Integral front head provides proper burner/boiler
compatibility for maximum efficiency and ease of Barometric dampers.
maintenance.
Sequencing draft controls.
Packaged boiler is factory assembled, wired, and tested for
guaranteed performance and reliability. Thick Fiberglass Insulation:
Packaged design allows for easy connection of utilities, 2" insulation covered with sturdy sheet metal lagging
minimum start-up requirements, and lower long-term provides maximum efficiency and durable construction.
maintenance requirements.
All units finished with hard enamel paint coating.
Built and tested to ASME standards.
Customer Service and Support:
Single Point Positioning Combustion Control Package:
Boiler start-up, final adjustment, and operator training
Accurate, repeatable combustion control for responsiveness provided with all firetube boilers.
to load swings.
Emergency service response 24 hours a day, 7 days a week,
Single point linkage assembly for air and fuel simplifies from the industrys most advanced worldwide computerized
adjustments and reduces start-up and maintenance costs. parts/service distribution network.
Unique variable contour.cam assembly allows accurate Largest network of factory trained technicians provide:
adjustment and enhances safe operation of the boiler.
System trouble shooting.
Computerized burner control provides accurate sequencing
and continuous monitoring for optimum safety, efficiency, Operator training.
and reliability. Customized factory-backed planned maintenance
programs.
Low Stack Temperatures:
Emergency boiler rental.
Guaranteed efficiency verified by low stack temperatures.
Total after-sale support.
Reduced fuel and operating costs.
Low Excess Air:

Operates at 3% O2 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.
Provides reliable, high quality (98.5% dry) source of steam.
Quiet Operation:
Integral front head with vibration free combustion air fan
provides quiet operation.
Ideal for sound critical applications, like hospitals and
schools.
A1-2
12-02
Firetube Boilers General
PRODUCT OFFERING The Model CB Ohio Special Boiler (standard offering) design
is based on operator requirements of the state of Ohio, under
Cleaver-Brooks firetube boilers are available in low pressure the rules and regulations for unattended units.
steam, high pressure steam, and hot water designs. Burners are
available to fire natural gas, light oil, heavy oil, or a combina- 100 hp through 225 hp.
tion of oil and gas. Optional alternate fuel (propane, mixed Four-pass dryback design (100 hp).
gas, digester gas, etc.) burners are also available.
Two-pass dryback design (125-225 hp).
The firetube product offering is available in the following
models. 150, 200 and 250 psig high pressure steam.
The Model CB Boiler (standard offering) is the premium fire- 15 psig low pressure steam.
tube product offering providing maximum boiler efficiency, Natural gas or light oil firing.
the widest range of size and pressures, and premium control
packages. The Model CBE Boiler (standard offering) provides high qual-
ity steam or hot water, utilizing a baseline boiler/burner design.
Four-pass dryback design.
Three-pass dryback design.
15 hp through 800 hp.
60-350 hp.
150-350 psig high pressure steam.
15 psig low pressure steam.
30 or 125 psig hot water.
30 and 125 psig hot water.
Natural gas, light oil, or heavy oil firing.
Natural gas or light oil.
The Model CB (LE) Boiler is the premium firetube product
offering with a low emission package. The Model CEW Boiler (standard offering) provides high
quality steam or hot water, utilizing a baseline boiler/burner
Four-pass dryback design. design.
125-800 hp. Three-pass wetback design.
20-60 ppm packages (natural gas). 125-800 hp.
15 psig low pressure steam. 15 psig low pressure steam.
150-300 psig high pressure steam. 150-250 psig high pressure steam.
30 and 125 psig hot water. 30 and 125 psig hot water.
Natural gas or light oil. Natural gas or light oil.
The Model CBW Boiler (standard offering) provides the The Model CEW-LN Boiler is the baseline firetube product
advantages of the Cleaver-Brooks integral front head in a offering with a low emission package.
three-pass wetback design.
Three-pass wetback design.
125-800 hp.
100 hp through 800 hp.
30 ppm package (natural gas).
30 or 125 psig hot water.
Natural gas or light oil.
A1-3
12-02
The Model CEW Ohio Special Boiler (standard offering) MODEL NUMBER, FUEL SERIES
baseline design is based on operator requirements of the state
of Ohio, under the rules and regulations of unattended units.
NUMBER, HORSEPOWER, AND
DESIGN PRESSURE
The model designation for Cleaver-Brooks firetube boilers
100-225 hp. includes the following:
15 psig low pressure steam. Light Oil: Series 100
150-200 psig high pressure steam. Natural Gas: Series 700
Natural gas or light oil. Heavy Oil: Series 600
The Model CBL Boiler (standard offering) line provides high Light Oil and Natural Gas: Series 200
quality steam utilizing a boiler/burner package.
Heavy Oil and Natural Gas: Series 400
Three or four-pass wetback design.
For example, a model CB700-350-150ST would represent a
800-1500 hp. model CB boiler, natural gas fired, 350 hp, 150 psig steam
150-250 psig high pressure steam. design pressure.
Natural gas, light oil, or heavy oil firing. All Cleaver-Brooks firetube boilers are built in accordance
with ASME Codes and, with the exception of the Ohio Special
The Model ICB Boiler is a baseline firetube product, designed Boilers and CBL Boilers, UL/ULC standards.
to provide high quality steam or hot water. Its revolutionary
design incorporates the key features and benefits of both the Insurance requirements (e.g., Industrial Risk Insurance IRI,
wetback and dry back firetube boilers. Factory Mutual FM, etc.) or special local code requirements
may dictate additional controls or equipment to be included.
Three or four-pass Intercooled design. Please contact your local Cleaver-Brooks authorized represen-
100 800 hp. tative for assistance in completing your specification or for
additional information and optional equipment.
Refer to Table A1-1 for information on the standard product
150 300 psig high pressure steam. offering for each firetube boiler model.
Natural gas or light oil firing.
The Model ICB-LN Boiler is a baseline firetube product,
designed to provide high quality steam or hot water with a low
emission package. Its revolutionary design incorporates the
key features and benefits of both the wetback and dry back
firetube boilers.
Three or four-pass Intercooled design.
100 800 hp.
30 ppm package (natural gas).
150 300 psig high pressure steam.
A1-4
12-02
Table A1-1. Quick Comparison of Standard Features for Cleaver-Brooks FIretube Boilers
CEW OHIO
CB CBLE CBW CB OHIO SPECIAL CBE CEW CEW-LN SPECIAL CBL ICB ICB-LN
15-800 HP 125-800 HP 100-800 HP 100-225 HP 60-350 HP 125-800 HP 125-800 HP 100-225 HP 800-1500 HP 100-800 HP 100-800 HP
MODEL (SECTION A2) (SECTION A3) (SECTION A4) (SECTION A6) (SECTION A7) (SECTION A8) (SECTION A9) (SECTION A10) (SECTION A11) (SECTION A12) (SECTION A13)
Rated Capacity 15-800 hp 125-800 hp 100-800 hp 100-225 hp 60-350 hp 125-800 hp 125-800 hp 100-225 hp 800-1500 hp 100-800 hp 100-800 hp
Design Steam Steam Steam Steam Only Steam Steam Steam Steam Steam Steam Steam
PressureA 15-300 psig 15-300 psig 15-250 psig 15-250 psig 15-300 psig 15-250 psig 15-250 psig 15-250 psig 150-250 psig 15-300 psig 15-300 psig
Hot Water Hot Water Hot Water Hot Water Hot Water Hot Water Hot Water Hot Water
30 & 125 psig 30 & 125 psig 30 & 125 psig 30 & 125 psig 30 & 125 psig 30 & 125 psig 30 & 125 psig 30 & 125 psig
Boiler Type 4-Pass Dry Back 4-Pass Dry Back 3-Pass Wet Back Passes VaryC 3-Pass Dry Back 3-Pass Wet Back 3-Pass Wet Back 3 Pass Wet Back 3 or 4-Pass Wet 4-Pass Intercooled 4-Pass Intercooled
Back 3-Pass Option 3-Pass Option
Shell Size 36" 15-40 hp 60" 125-200 hp 60" 100-200 hp 48" 100 hp 48" 60-100 hp 60" 125-200 hp 60" 125-200 hp 60" 100-225 hp 114" or 126"E 55" 100-125 hp 55" 100-125 hp
48" 50-100 hp 78" 250-350 hp 78" 250-400 hp 60"125-225 hp 60" 125-200 hp 78" 250-400 hp 78" 250-400 hp 60" 150-200 hp 60" 150-200 hp
60" 125-200 hp 96" 400-800 hp 96" 500-800 hp 78" 250-350 hp 96" 500-800 hp 96" 500-800 hp 72" 250-300 hp 72" 250-300 hp
78" 250-350 hp 78" 350-400 hp 78" 350-400 hp
96" 400-800 hp 92" 500-600 hp 92" 500-600 hp
106" 700-800 hp 106" 700-800 hp
Fuel 15-800 hp No. 2 Oil, No. 2 Oil, 100-225 hp No. 2 Oil, No. 2 Oil, No. 2 Oil, No. 2 Oil, 800-1300 hp No. 2 Oil, No. 2 Oil,
No. 2 Oil, Gas, Gas, Gas, No. 2 Oil, Gas, Gas, Gas, Gas, No. 2 Oil, Gas, Natural Gas Natural Gas
Combination Combination Combination Gas, Combination Combination Combination Combination Combination Combination Oil/ Combination Oil/
Oil/Gas Oil/Gas Oil/Gas Combination Oil/Gas Oil/Gas Oil/Gas Oil/Gas Oil/Gas Gas Gas
Oil/Gas
50-800 hp No. 6 OilB, 100 hp 800-1500 hp
No. 6 OilB, Gas, No. 6 Oil, Gas
Gas, Combination Gas, 800-1000 hp
Combination Oil/Gas Combination No. 6 Oil, Gas,
Oil/Gas Oil/Gas Combination
12-02
Oil/Gas
Firing Method 15-20 hp Full Modulation Full Modulation Full Modulation Full Modulation Full Modulation Full Modulation Full Modulation Full Modulation Full Modulation Full Modulation
On-off
30-40 hp
Low-High-Low-Off
50-800 hp
Full Modulation
Air Damper Type Single Blade Rotary Rotary Rotary Multi-Blade Multi-Blade Rotary Multi-Blade Rotary & Louvers Multiblade Rotary
15-40 hp 125-350 hp, 100-250 hp
Rotary 50-800 hp Rotary 400-800 hp Rotary 300-800 hpF
Paint Color Blue Blue Blue Blue Blue Blue Blue Blue Blue Blue Blue
Approvals UL & ULC UL & ULC UL & ULC N/A UL & cUL UL & cUL Boiler/ UL & cUL N/A 800-1000 hp UL & UL & cUL UL & cUL
Boiler/Burner Boiler/Burner Boiler/Burner Boiler/Burner Burner Boiler/Burner CSA Boiler/Burner Boiler/Burner
(Burner Only)
Steam Trim-Low McD&M 157 McD&M 157 McD&M 157 McD&M 157 McD&M 157 McD&M 157 McD&M 157 McD&M 157 McD&M 193-7 McD&M 157, McD&M 157,
Water Control McD&M 193 McD&M 193
Steam Trim Aux Warrick 3C-2 Warrick 3C-2 Warrick 3C-2 Warrick 3C-2 Warrick 3C-2 Warrick 3C-2 Warrick 3C-2 Warrick 3C-2 Warrick 3C-2 Warrick 3C-2 Warrick 3C-2
Low Water Control
Water Trim-Low McD&M McD&M McD&M N/A McD&M McD&M McD&M N/A N/A McD&M McD&M
Water Control PS 750-MT-120 PS 750-MT-120 PS 750-MT-120 PS 750-MT-120 PS 750-MT-120 PS 750-MT-120 PS 750-MT-120 PS 750-MT-120
A Consult your local Cleaver-Brooks authorized representative for higher design pressures.
B Consult your local Cleaver-Brooks authorized representative for No. 4 & No. 5 oil applications.
C Ohio Special-Model CB 100 hp 4-pass dryback, 125-225 hp 2-pass dryback.
E Shell varies by square foot of pressure vessel and boiler horsepower.
F ICB Three-Pass Boiler utilizes multiblade 100-350 and Rotary 400-800.
Table A1-1. Quick Comparison of Standard Features for Cleaver-Brooks FIretube Boilers (Continued)
CEW OHIO
Controls Hi Limit (MR), Hi Limit (MR), Hi Limit (MR), Hi Limit (MR), Hi Limit (MR), Hi Limit (MR), Hi Limit (MR), Hi Limit (MR), Hi Limit (MR), Hi Limit (MR), Hi Limit (MR),
Steam & Hot Oper. Limit, Oper. Limit, Oper. Limit, Oper. Limit, Oper.Limit, Oper. Limit, Oper. Limit, Oper. Limit, Oper. Limit, Oper. Limit, Oper. Limit,
Water Controls Firing Rate Firing Rate Firing Rate Firing Rate Firing Rate Firing Rate Firing Rate Firing Rate Firing Rate Firing Rate Firing Rate
30-800 hp
Surface Blowoff HPS-Std HPS-Std HPS-Std HPS-Std HPS-Std HPS-Std HPS-Std HPS-Std HPS-Std HPS-Std HPS-Std
Conn. & Dip LPS-Conn. Only LPS-Conn. Only LPS-Conn. Only LPS-Conn. Only LPS-Conn. Only LPS-Conn. Only LPS-Conn. Only LPS-Conn. Only LPS-Conn. Only LPS-Conn. Only
Tube on top C/L
Air Vent HW-Std. HW-Std. HW-Std. N/A HW-Std. HW-Std. HW-Std. N/A N/A HW-Std HW-Std
Connection
Stack Yes Yes Yes Yes No No No No Yes No No
Thermometer
Drain Valve-HW & No No No No No No No No N/A No No
15 psig-Steam
Front Door Hinge 15-200 hp Hinge 125-200 hp Hinge 100-200 hp Hinge Davit Davit Davit Davit Davit Davit Davit
Davit/Hinge Davit /Hinge Davit/Hinge
250-800 hp 250-800 hp 250-800 hp
Rear Door Hinge 15-100 hp Davit Davit Hinge 100 hp Davit Davit Davit Davit Davit Davit Davit
Davit 125-800 hp Davit 125-225 hp
Insulation 2 inch 2 inch 2 inch 2 inch 2 inch 2 Inch 2 Inch 2 Inch 2 Inch 2 inch 2 inch
Standard 3 Phase 3 Phase 3 Phase 3 Phase 60-80 hp- 3 Phase 3 Phase 3 Phase 3 Phase 3 Phase 3 Phase
Voltage 1 Phase
Requirements 100-350 hp-
12-02
3 Phase
Fuse Protection Control Circuit & Control Circuit & Control Circuit & Control Circuit & Control Circuit & Control Circuit & Control Circuit & Control Circuit & Control Circuit & Control Circuit & Control Circuit &
All 3 Phase Loads All 3 Phase Loads All 3 Phase Loads All 3 Phase Loads All 3 Phase Loads All 3 Phase Loads All 3 Phase Loads All 3 Phase Loads All 3 Phase Loads All 3 Phase Loads All 3 Phase Loads
Except Remote Except Remote Except Remote Except Remote Except Remote Except Remote Except Remote Except Remote Except Remote Except Remote Except Remote
Oil Pump Oil Pump Oil Pump Oil Pump Oil Pump Oil Pump Oil Pump Oil Pump Oil Pump Oil Pump Oil Pump
Control Circuit Yes Yes Yes Yes Yes-3 Phase Only Yes Yes Yes Yes Yes Yes
Transformer
Flame Safeguard Cleaver-Brooks Cleaver-Brooks Cleaver-Brooks Cleaver-Brooks Cleaver-Brooks Cleaver-Brooks Cleaver-Brooks Cleaver-Brooks Cleaver-Brooks Cleaver-Brooks Cleaver-Brooks
Control CB780 CB780 CB780 CB780 CB110 CB110 CB110 CB110 CB110 CB110 CB110
Scanner Type Infrared Infrared Infrared Infrared Ultraviolet Ultraviolet Ultraviolet Ultraviolet Ultraviolet Ultraviolet Ultraviolet
(Gas & No. 2 Oil)
Infrared (No. 6 Oil)
Control Panel Front Head with Front Head with Front Head with Front Head with Burner without Burner without Burner without Burner without Burner without On Burner Remote-Right Side
Location Key Lock Key Lock Key Lock Key Lock Key Lock Key Lock Key Lock Key Lock Key Lock without Key Lock without
Key Lock
Indicating Lights 50-800 hp LD, FV, LW, FF LD, FV, LW, FF LD, FV, LW, FF LD, FV, LW, FF LD, FV, LW, FF LD, FV, LW, FF LD, FV, LW, FF LD, FV, LW, FF LD, FV, LW, FF LD, FV, LW, FF
LD, FV, LW, FF
Type of Pilot Interrupted Gas Interrupted Gas Interrupted Gas Interrupted Gas Interrupted Gas Interrupted Gas Interrupted Gas Interrupted Gas Interrupted Gas Interrupted Gas Interrupted Gas
Pilot-Gas, Pilot-Gas & All Pilot-Gas, Pilot-Gas, No. 6 Oil Pilot-Gas & All Pilot-Gas, No. 2 Oil Pilot-Gas, No. 2 Oil Pilot-Gas, No. 2 Oil Pilot-Gas, No. 2 Oil, Pilot-Gas, No. 2 Oil Pilot-Gas, No. 2 Oil
No. 6 Oil & All Combination No. 6 Oil & All & All Combination & All Combination & & No. 6 Oil All Combination All Combination
Combination Combination Combination All Combination All Combination &
15-800 hp All Combination
Direct Spark Spark Ignited Oil Spark Ignited Oil Spark Ignited Oil No. 2 Oil
Ignition-No. 2 Oil Pilot No. 2 Oil Pilot No. 2 Oil Pilot No. 2 Oil Direct Spark
15-40 hp Ignition
Spark Ignited Oil 60-100 hp
Pilot-No. 2 Oil Gas Pilot
50-800 hp 125-350 hp
Table A1-1. Quick Comparison of Standard Features for Cleaver-Brooks FIretube Boilers (Continued)
CEW OHIO
Gas Burner Type High Radiant High Radiant High Radiant High Radiant High Radiant High Radiant High Radiant High Radiant High Radiant High Radiant High Radiant
Multi-Port- Multi-Port- Multi-Port- Multi-Port 100 hp Multi-Port Multi-Port Multi-Port Multi-Port Multi-Port Multi-Port Multi-Port
All Except All Except All Except Annular 125-225 hp
125-200 hp- 125-200 hp- 125-200 hp-
Annular Entry Annular Entry Annular Entry
Main Gas Valve Motorized Motorized Motorized Motorized Solenoid, Motorized Solenoid, Motorized Solenoid, Motorized Solenoid, Motorized Motorized Solenoid, Motorized Solenoid, Motorized
Main Gas Butterfly Valve Butterfly Valve Butterfly Valve Butterfly Valve Butterfly Valve Butterfly Valve Butterfly Valve Butterfly Valve Butterfly Valve Butterfly Valve Butterfly Valve
Control System
Gas Pressure Required, Not Required, Not Required, Not Required, Not Included Included Included Included Included Included Included
Regulator Included Included Included Included
Gas Pilot Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
Regulator
High & Low Gas No-15-50 hp Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
Pressure Yes-60-800 hp
Switches
Oil Burner Type Air Atomizing Air Atomizing Air Atomizing Air Atomizing Pressure Atomizing Pressure Atomizing Air Atomizing Air Atomizing Air Atomizing Pressure Air Atomizing
60-200 hp 125-200 hp Air Compressor Atomizing
Air Atomizing Air Atomizing 125-300 hp- 100-150 hp
250-350 hp 250-800 hp Mounted Air Atomizing
Air Compressor- Air Compressor - 350-800 hp- 200-800 hp
Shipped Loose Shipped loose Shipped Loose
Main Oil Valves Solenoid Solenoid Solenoid Solenoid Solenoid Solenoid Solenoid Solenoid Motorized Solenoid Solenoid
Oil Control Metering Valve Metering Valve Metering Valve Metering Valve Metering System Metering System Metering System Metering System Metering System Metering System Metering System
12-02
System
Oil Pump Included Included Included Included Included Included Included Included Included Included Included
Location of Oil No. 2 Oil 15-40 hp No. 2 Oil No. 2 Oil No. 2 Oil No. 2 Oil 60-200 hp No. 2 Oil No. 2 Oil No. 2 Oil No. 2 Oil No. 2 Oil No. 2 Oil
Pump on Front Head; 125-800 hp 100-800 hp Remote 100-225 hp Burner Mounted 125-200 hp 125-800 hp 100-225 hp Remote 100-150 hp 100-800 hp
50-800 hp Remote Remote Remote No. 2 Oil Burner Mounted Remote Remote Burner Mounted Remote
250-350 hp No. 2 Oil No. 2 Oil
No. 6 Oil No. 6 Oil No. 6 Oil Remote 250-800 hp No. 6 Oil Mounted 200-800 hp
50-800 hp, Remote 100-800 hp Remote 100-225 hp Remote on Oil Pump/Oil Remote
Remote Heater Skid
NOx Control No-Use CBLE Induced FGRD No-Use CEW-LN N/A N/A No-Use CEW-LN Induced FGR N/A Optional-Induced No-Use ICB-LN Induced FGR
(LE Option) 30 ppm(Natural FGR 30 ppm 30 ppm
125-800 hp Gas) (Natural Gas) up to (Natural Gas)
20-60 ppm 1300 hp.
(Natural Gas)
Maximum Stack 15-40 hp + or-0.25" W.C. + or-0.50" W.C. + or-0.25" W.C. + or-0.25" W.C. + or-0.25" W.C. + or-0.25" W.C. + or-0.25" W.C. + or-0.50" W.C. + or-0.25" W.C. + or-0.25" W.C.
Pressure + or-0.25" W.C.
Variation 50-800 hp + or-0.25" W.C.
+ or-0.50" W.C. With FGR
Start-Up Included Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
D Altitude, size, and fuel series limitations may apply.

Notes
A1-8
12-02
Section A2
MODEL CB BOILERS
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-3
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-4
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-21
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-21
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-21
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-24
Blowdown Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-24
Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-27
Gas-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-30
Gas Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-31
Oil-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-36
No. 6 Oil Piping, Storage Tank Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-36
Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-44
Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-44
Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-44
Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-44
SAMPLE SPECIFICATION (MODEL CB BOILER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-47
ILLUSTRATIONS
Figure A2-1. Model CB Steam Boiler Dimensions and Weights (15 and 150 psig Design Pressure -
15 to 100 hp) Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-10
125 to 800 hp) Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-12
Figure A2-3. Model CB Hot Water Boiler Dimensions (30 psig and 125 psig Design Pressure -
15 to 100 hp) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-14
15 to 100 hp) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-16
Figure A2-5. Space Required to Open Rear Head on Model CB Boilers Equipped with Davits . . . . . . . . . . . . . . . . . . . A2-18
Figure A2-6. Lifting Lug Location, Model CB Boilers - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-18
Figure A2-7. Model CB Boiler Mounting Piers 20
Figure A2-8. Predicted Stack Temperature Increase for Pressure Greater Than 125 psig . . . . . . . . . . . . . . . . . . . . . . . . A2-23
Figure A2-9. Standard Gas Train Connection Size and Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-34
A2-1
07-02
Model CB Boilers Firetube Boilers
Figure A2-10. Typical Gas Piping Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-35
Figure A2-11. Model CB Gas Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-36
Figure A2-12. No. 2 Oil Connection Size, Location and Recommended Line Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-37
Figure A2-13. No. 6 Oil Connection Size, Location and Recommended Line Sizes, Model CB Boiler . . . . . . . . . . . . . . A2-37
Figure A2-14. No. 2 Oil Piping, Single Boiler Installation, Remote Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-38
Figure A2-15. No.2 Oil Piping, Single Boiler Installation Oil Pump Integral with Boiler . . . . . . . . . . . . . . . . . . . . . . . . A2-38
Figure A2-16. No. 2 Oil Piping, Multiple Boiler Installation, Remote Oil Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-39
Figure A2-17. No. 2 Oil Piping, Multiple Boiler Installation, Oil Pump Integral with Boiler . . . . . . . . . . . . . . . . . . . . . A2-39
Figure A2-18. No. 2 Oil Piping, Multiple Boiler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-40
Figure A2-21. No. 6 Oil Piping, Multiple Boiler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-41
Figure A2-22. No. 2 Oil Transfer Tank Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-42
Figure A2-23. Typical Fuel Storage Tank Arrangement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-42
Figure A2-24. Typical Cross Section of Bundled Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-43
Figure A2-25. Schematic of Standard Alstrom Hot Water Safety-Type Preheating System . . . . . . . . . . . . . . . . . . . . . . . A2-43
Figure A2-26. Boiler Room Length (Typical Layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-45
Figure A2-27. Boiler Room Width (Typical Layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-45
Figure A2-28. Breeching Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-46
TABLES
Table A2-1. Model CB Steam Boiler Ratings (15 - 100 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-5
Table A2-2. Model CB Steam Boiler Ratings (125 - 800 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-5
Table A2-3. Model CB Hot Water Boiler Ratings (15 - 100 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-6
Table A2-4. Model CB Hot Water Boiler Ratings (125 - 800 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-6
Table A2-5. Steam Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-7
Table A2-6. Hot Water Boiler Relief Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-8
Table A2-7. Predicted Fuel-to-Steam Efficiencies (%), Model CB Boilers - 10 psig, Natural Gas . . . . . . . . . . . . . . . . . A2-22
Table A2-8. Predicted Fuel-to-Steam Efficiencies (%), Model CB Boilers - 125 psig, Natural Gas . . . . . . . . . . . . . . . . A2-22
Table A2-9. Predicted Fuel-to-Steam Efficiencies (%), Model CB Boilers - 10 psig, No. 6 Oil . . . . . . . . . . . . . . . . . . . A2-22
Table A2-10. Predicted Fuel-to-Steam Efficiencies (%), Model CB Boilers - 125 psig, No 6 Oil . . . . . . . . . . . . . . . . . . A2-22
Table A2-11. Predicted Fuel-to-Steam Efficiencies (%), Model CB Boilers - 10 psig, No. 2 Oil . . . . . . . . . . . . . . . . . . A2-23
Table A2-12. Predicted Fuel-to-Steam Efficiencies (%), Model CB Boilers - 125 psig, No. 2 Oil . . . . . . . . . . . . . . . . . A2-23
Table A2-13. Model CB Boiler Emission Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-24
Table A2-14. Heating Surface, Model CB Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-24
Table A2-15. Steam Volume and Disengaging Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-25
Table A2-16. Water Circulation Rate and Temperature Drop for Hot Water Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-25
Table A2-17. Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity) . . . . . . . . . . . . . . . A2-26
Table A2-18. Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-26
Table A2-19. Model CB Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-27
Table A2-20. Sound Pressure Level Summary (50 - 800 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-27
Table A2-21. Model CB Boiler Sound Pressure Level Details (40 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-27
Table A2-22. Model CB Boiler Sound Pressure Level Details (50 - 125 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-28
Table A2-23. Model CB Boiler Sound Pressure Level Details (125 - 200 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-29
Table A2-26. Minimum Required Gas Pressure at Entrance to Standard and FM Gas Trains
(Downstream of Gas Pressure Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-31
Table A2-27. Minimum Gas Pressure at Entrance to Gas Trains Equipped with Industrial Risk Insurers
(IRI) Requirements (Downstream of Gas Pressure Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-31
Table A2-28. Under and Oversized Standard and FM Gas Trains, Model CB Boilers (50 - 800 hp) . . . . . . . . . . . . . . . . A2-32
Table A2-29. Under and Oversized IRI Gas Trains, Model CB Boilers (50 - 800 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-33
Table A2-30. Minimum Required Gas Pressure Altitude Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-33
Table A2-31. Maximum Gas Consumption (CFH) for Natural Gas and Propane Vapor & Gas Pilot Data. . . . . . . . . . . . A2-34
A2-2
07-02
Firetube Boilers Model CB Boilers
FEATURES AND BENEFITS Air atomizing oil burner available for proper oil atomization,
maximum combustion efficiency, and low maintenance
In addition to the features provided on all Cleaver-Brooks requirements.
Firetube Boilers, the following features apply specifically to
Model CB Firetube Boilers. The CB four-pass dryback boiler Air atomizing compressor provided with the boiler package
is the premium firetube boiler design available. for clean oil burning and ease of maintenance.
Combination gas/oil burners provide quick fuel changeover
Four-Pass Dryback Design: without re-adjustment of the burner.
Four-pass design provides high flue gas velocities and low Fuel oil controller eliminates the need for over 40
stack temperature for guaranteed maximum efficiency. connections, combining gauges, valves, and regulators into a
Dryback design provides full access to boiler tubes, tube single casting.
sheet, and furnace for ease of maintenance. Retractable oil nozzle provides easy access and cleaning and
Dryback design includes single rear tube sheet construction, eliminates coking of oil and nozzle tip when firing gas.
providing reduced tube sheet stresses.
Low NOx Capability Available:
Five Square Feet of Heating Surface per Boiler hp: 20 ppm NOx guarantee available on Model CB (LE) Boilers.
Maximum heat transfer with minimum thermal stresses
provide guaranteed efficiency and long boiler life. PRODUCT OFFERING
Highest guaranteed fuel-to-steam efficiencies. Model CB Firetube Boilers are available in low pressure
steam, high pressure steam, and hot water designs. Burners are
Low Furnace Location available to fire natural gas, light oil, heavy oil, or a combina-
tion of oil and gas. Optional alternate fuel burners are also
Furnace located well below water level with generous
available.
clearance from bottom of boiler, allowing proper circulation.
Model CB Boilers include:
Low furnace provides additional safety margin between
furnace and water level. Four-pass dryback design.
Reduces water carryover, producing drier steam. 15 hp through 800 hp.
150 psig - 350 psig high pressure steam.
Hinged or Davited Front and Rear Doors:
Provides full access to front and rear tube sheet and furnace.
30 psig or 125 psig hot water.
Reduces maintenance costs.
High Turndown Burner: The Model CBBoiler is the premium firetube product offering
4:1 turndown (gas and oil) is standard on boilers up to 250 providing maximum boiler efficiency, the widest range of size
hp. and pressures, and premium control packages.
Guaranteed 10:1 turndown (gas fired) 8:1 (No. 2 oil fired) Available options: For option details, contact your Cleaver-
standard on 250 hp through 800 hp. Brooks authorized representative. Options include the
following:
Advanced burner design provides maximum combustion
efficiencies and high turndown. Boiler Options
Reduced boiler cycling and maintenance. Auxiliary low water cut-off (standard on steam boilers).
Boiler stays on line during low load conditions for optimum Drain valves.
efficiency and performance. Additional screwed or flanged tappings.
Gas, No. 2 Oil, No. 6 Oil, and Combination Gas and Oil Special design pressures.
Burners Available: Surge load baffles.
High radiant multi-port gas burner designed for high gas Seismic design.
velocities and complete fuel/air mixing, providing
maximum combustion efficiencies.
A2-3
07-02
Internal hot water coils. Special pilot.

Blowdown valves. Alternate fuel firing (propane, digester gas, etc.).
Non-return valves. Special oil pumps.
Feedwater valves and regulators.
DIMENSIONS AND RATINGS
Special doors, davited, hinged, left swing.
Dimensions and ratings for the Model CB boilers are shown in
Special base rails. the following tables and illustrations:
Surface blowdown systems. Table A2-1. Model CB Steam Boiler Ratings (15 thru 100 hp)
Combustion relief door. Table A2-2. Model CB Steam Boiler Ratings (125 thru 800
Weather-proofing. hp)
Blend pump. Table A2-3. Model CB Hot Water Boiler Ratings (15 thru 100
hp)
Burner/Control Options
Table A2-4. Model CB Hot Water Boiler Ratings (125 thru
Special modulation controls. 800 hp)
Low NOx equipment. Table A2-5. Safety Valve Openings
Optional flame safeguard controller. Table A2-6. Relief Valve Openings
Lead/lag system. Figure A2-1. Model CB Steam Boiler Dimensions (15 and
High altitude design, up to 12,000 ft. 150 lb design pressure) (15 thru 100 hp)
Special insurance and code requirements (e.g., IRI, FM, Figure A2-2. Model CB Steam Boiler Dimensions (15 and
ASME CSD-1). 150 lb design pressure) (125 thru 800 hp)
Alarm bell/silence switch. Figure A2-3. Model CB Hot Water Boiler Dimensions (30 lb
design pressure) (15 thru 100 hp)
Special motor requirements (TEFC, high efficiency).
Figure A2-4. Model CB Hot Water Boiler Dimensions (20 lb
Remote contacts. design pressure) (125-800 hp)
Special purpose indicator lights. Figure A2-5. Space Required to Open Rear Head on Model
Main disconnect. CB Boilers Equipped with Davits
Elapsed time meter. Figure A2-6. Lifting Lug Locations, Model CB Boilers
Voltmeter/micro-ammeter. Figure A2-7. Model CB Boiler Mounting Piers
NEMA enclosures.
Low fire hold controls.
Remote emergency shut-off (115V).
Circuit breaker.
Day/night controls.
Special power requirements.
Fuel Options
Automatic fuel changeover.
Special gas pressure regulator.
Oversized/undersized gas trains.
Gas strainer.
Special fuel shut-off valves.
A2-4
07-02
Table A2-1. Model CB Steam Boiler Ratings (15 - 100 hp)

BOILER HP 15C 20C 30C 40C 50 60 70 80 100
RATINGS - SEA LEVEL TO 3000 FT
Rated Cap. (lbs steam/hr @212F) 518 690 1035 1380 1725 2070 2415 2760 3450
Btu Output (1000 Btu/hr) 502 670 1004 1339 1674 2009 2343 2678 3348
APPROXIMATE FUEL CONSUMPTION AT RATED CAPACITY

A 4.5 6.0 9.0 12.0 15.0 18.0 21.0 24.0 30.0
Light Oil (gph)
Heavy Oil (gph)B - - - - 14.0 16.5 19.5 22.5 28.0
Gas (cfh) 1000 Btu-Nat 625 835 1255 1675 2095 2510 2930 3350 4185
Gas (Therm/hr) 6.3 8.4 12.6 16.8 21.0 25.1 29.3 33.5 41.9
POWER REQUIREMENTS - SEA LEVEL TO 3000 FT, 60 HZ
Blower Motor hp (except gas) 1 1 1-1/2 2 2 2 2 2D 3
Gas Models (only) 1 1 1-1/2 2 2 2 2 2D 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
Air Compressor Motor hp Air Compressor Belt-Driven

2 2 2 2 2
(Oil firing Only) from Blower Motor
NOTES:
1. For altitudes above 3000 ft, contact your local Cleaver-Brooks authorized representative for verification of blower motor hp.
A. Based on 140,000 Btu/gal.
B. Based on 150,000 Btu/gal.
C. No. 6 Oil not available in 15-40 hp range.
D. 3 hp above 2000 ft.
Table A2-2. Model CB Steam Boiler Ratings (125 - 800 hp)
BOILER HP 125 150 200 250 300 350 400 500 600 700 750 800
RATINGS SEA LEVEL TO 3000 FT J
Rated Cap. (lbs steam/hr @ 212F) 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
Light Oil (gph)A 37.5 45.0 60.0 74.5 89.5 104.5 119.5 149.5 179.5 209.0 224.2 239.3
Heavy Oil (gph)B 35.0 42.0 56.0 69.5 83.5 97.5 111.5 139.5 167.5 195.5 209.2 223.4
Gas (cfh)
MBTU-nat 5230 6280 8370 10460 12555 14650 16750 20925 25100 29300 31385 33480
Gas
(Therm/hr) 52.3 62.8 83.7 104.6 125.5 146.5 167.5 209.3 251.0 293.0 313.8 334.8
Blower Motor hp (except gas) 5 7-1/2 15 7-1/2 10C 15D 10C 15E 20F 30G 40L 50H
Gas Models (only) 5 5 10 7-1/2 7-1/2I 15 10C 15E 20F 30G 40L 50H
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
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 3/4
Oil Heater kW No. 6 Oil 5 5 5 7-1/2 7-1/2 7-1/2 7-1/2 7-1/2 K 7-1/2K 7-1/2K 7-1/2K 7-1/2K
Air Compressor Motor hp Air Compressor Belt-Driven 7-1/2 7-1/2 7-1/2 7-1/2 7-1/2 7-1/2
(Oil firing Only) From Blower Motor
NOTES:
1. For altitudes above 3000 ft, contact your local Cleaver-Brooks autho- F. 30 hp above 2500 ft.
rized representative for verification of blower motor hp. G. 40 hp above 2000 ft.
A. Based on 140,000 Btu/gal. H. 60 hp above 3000 ft.
B. Based on 150,000 Btu/gal. I. 10 hp above 2500 ft.
C.15 hp above 2500 ft. J. Sea level to 2,500 ft for 300 and 350 Hp sizes.
D. 20 hp above 2500 ft. K. 10 kW on low pressure.
E. 20 hp above 2000 ft. L. 50 hp above 2500 ft.
A2-5
07-02
Table A2-3. Model CB Hot Water Boiler Ratings (15 - 100 hp)
BOILER HP 15c 20c 30c 40c 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 625 835 1255 1675 2095 2510 2930 3350 4185 4185 5230
Gas (Therm/hr) 6.3 8.4 12.6 16.8 21.0 25.1 29.3 33.5 41.9 41.9 52.3
Blower Motor hp (except gas) 1 1 1-1/2 2 2 2 2 2D 3 3 3
Gas Models (only) 1 1 1-1/2 2 2 2 2 2D 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
Air Compressor Motor hp Air Compressor Belt-Driven 2 2 2 2 2 2 2

(Oil firing Only) from Blower Motor
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 A2-4. Model CB Hot Water Boiler Ratings (125 - 800 hp)
BOILER HP 150 175A 200 250 300 350 400 500 600 700 750 800
J
Rated Cap. Btu Output

5021 5858 6695 8369 10043 11716 13390 16738 20085 23432 25106 26779
(1000 Btu/hr)
APPROXIMATE FUEL CONSUMPTON AT RATED CAPCITY
Light Oil (gph)A 45.0 52.5 60.0 74.5 89.5 104.5 119.5 149.5 179.5 209.0 224.2 239.3
Heavy Oil (gph)B 42.0 49.0 56.0 69.5 83.5 97.5 111.5 139.5 167.5 195.5 209.3 223.4
Gas (cfh)
MBtu-Natural Gas 6280 7320 8370 10460 12555 14650 16750 20925 25100 29300 31385 33480
(Therm/hr) 62.8 73.2 83.7 104.6 125.5 146.5 167.5 209.3 251.0 293.0 313.8 334.8
Blower Motor hp
(except gas) 7-1/2 7-1/2 15 7-1/2 10C 15D 10C 15E 20F 30G 40K 50H
Gas Models (only) 5 5 10 7-1/2 7-1/2I 15 10C 15E 20F 30G 40K 50H
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 3/4
Oil Heater kW No. 6 Oil 5 5 5 7-1/2 7-1/2 7-1/2 10 10 10 10 10 10
Air Compressor Motor hp (Oil 7-1/2 7-1/2 7-1/2 7-1/2 7-1/2 7-1/2
firing Only)
NOTES:
1. For altitudes above 3000 ft, contact your local Cleaver-Brooks au-
thorized representative for verification of blower motor hp. F. 30 hp above 2500 ft.
A. Based on 140,000 Btu/gal. G. 40 hp above 2000 ft.
B. Based on 150,000 Btu/gal. H. 60 hp above 3000 ft.
C. 15 hp above 2500 ft. I. 10 hp above 2500 ft.
D. 20 hp above 2500 ft. J. Sea level to 2,500 ft for 300 and 350 hp sizes.
E. 20 hp above 2000 ft. K. 50 hp above 2500 ft.
A2-6
07-02
Table A2-5. Steam Boiler Safety Valve Openings

VALVE
15 PSIG STEAM 100 PSIG STEAM 125 PSIG STEAM 150 PSIG STEAM 200 PSIG STEAM 250 PSIG STEAM
SETTING
NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET
BOILER VALVES SIZE VALVES SIZE VALVES SIZE VALVES SIZE VALVES SIZE VALVES SIZE
HP REQ'D (IN.) REQ'D (IN.) REQ'D (IN.) REQ'D (IN.) REQ'D (IN.) REQ'D (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 1-1/4 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
(1) 1-1/2 (1) 1-1/2 (1) 1-1/4

125 1 3 2 1-1/2 2 2 2 2 1
(1) 1-1/4 (1) 1-1/4 (1) 1
(1) 2 (1) 1-1/2 (1) 1

150 1 3 2 2 1-1/2 2 2 1-1/4 2
(1) 1-1/2 (1) 1-1/4 (1) 1-1/4
(1) 1-1/2
200 2 2-1/2 2 2 2 (2) 1-1/2 2 2) 1-1/2 2 2 (2) 1-1/4
(1) 1-1/4
(1) 2-1/2 (1) 2-1/2 (1) 2 (1) 1-1/2

250 2 2 2 2 2 2 1-1/2 2
(1) 3 (1) 2 (1) 1-1/2 (1) 1-1/4
(1) 2-1/2 (1) 2

300 2 3 2 2-1/2 2 2 2 2 2 1-1/2
(1) 2 (1) 1-1/2
(1) 2 (1) 2-1/2 (1) 2-1/2 (1) 1-1/2

350 3 3 2 2-1/2 2 2 2 2
(2) 3 (2) 2 (1) 2 (1)2
(2) 3 (1) 2 (1) 2-1/2 (1) 2

400 3 3 2 2-1/2 2 2 2 2
(1) 2-1/2 (2) 2-1/2 (1) 2 (1) 1-1/2
(2) 2-1/2 (1) 2-1/2

500 3 3 3 2-1/2 3 2 2-1/2 2 2 2
(1) 2 (1) 2
(1) 2-1/2 (3) 2-1/2 2-1/2 (1) 2

600 4 4 3 2-1/2 3 2 2-1/2 2
(3) 3 (1) 2 (1) 2 (1) 2-1/2
(3) 3 (3) 2-1/2 (3) 2-1/2 (2) 2-1/2

700 5 5 4 3 2 2-1/2 2 2-1/2
(2)2-1/2 (2) 2 (1) 2 (1) 2
(2) 2-1/2
(3) 3 (3) 2-1/2 (3) 2-1/2
750 5 5 4 3 (1) 2 2 2-1/2 2 2-1/2
(2)2-1/2 (2) 2 (1) 2
(3) 3 (3) 2-1/2 (3) 2-1/2 (2) 2-1/2

800 5 5 4 3 2 2-1/2 2 2-1/2
(2)2-1/2 (2) 2 (1) 2 (1)2
NOTE: Valve manufacturers are Kunkle, Consolidated or Conbraco, depending on availability.
A2-7
07-02
Table A2-6. Hot Water Boiler Relief Valve Openings

VALVE
30 PSIG HW 60 PSIG HW 100 PSIG HW 125 PSIG HW
SETTING
NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET

BOILER VALVES SIZE VALVES SIZE VALVES SIZE VALVES SIZE
HP REQ'D (IN.) REQ'D (IN.) REQ'D (IN.) REQ'D (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
125 1 2-1/2 1 2 1 2 1 1-1/4
125A 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
(1) 1
175A 2 1 2-1/2 1 2 1 2
(1) 2-1/2
(1) 2-1/2
200 2 1 2-1/2 1 2 1 2
(1) 1-1/4
(1) 2
250 2 1 2-1/2 1 2-1/2 1 2
(1) 2-1/2
(1) 1
300 2 2-1/2 2 1 2-1/2 1 2-1/2
(1) 2-1/2
(2) 2-1/2 (1) 2-1/2

350 3 2 1 2-1/2 1 2-1/2
(1) 1 (1) 2
(1) 2 (1) 2 (1) 1

400 3 2 2 1 2-1/2
(2) 2-1/2 (1) 2-1/2 (1) 2-1/2
(1) 1 (1) 2-1/2 (1) 1

500 4 2 (2) 2-1/2 2 2
(3) 2-1/2 (1) 1-1/4 (1) 2-1/2
(3) 2-1/2 (1) 1-1/4 (1) 2 (1) 2-1/2

600 4 3 2 2
(1) 2 (2) 2-1/2 (1) 2-1/2 (1) 1-1/4
(1) 1 (1) 2 (1) 2-1/2

700 5 3 2 (2) 2-1/2 2
(4) 2-1/2 (2) 2-1/2 (1) 2
(1) 1 (1) 2 (1) 2-1/2

750 5 3 2 (2) 2-1/2 2
(4) 2-1/2 (2) 2-1/2 (1) 2
(1) 1 (1) 2 (1) 2-1/2

800 5 3 2 (2) 2-1/2 2
(4) 2-1/2 (2) 2-1/2 (1) 2
NOTES:
1.Hot water relief valves are Kunkle #537.
2. BHP followed by A designates hot water boilers furnished in a smaller vessel size with additional tubes in the
upper portion of the vessel.
A2-8
07-02
NOTES
A2-9
07-02
NOTE: ALLOW 3 FEET

FOR DOOR SWING
PER NEC
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 F 36 36 45 57 46 46 65-1/2 65-1/2 75

Nozzle - 15 psig
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
15 to 100 hp) Sheet 1 of 2
A2-10
07-02
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 64-3/4 64-3/4 64-3/4 64-3/4 64-3/4
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 64-3/4
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 4 4 4 6A 6A 6A 6A 6A 8A
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
High Pressure (150 psig only)

Surface Blowoff, Top CL T 1 1 1 1 1 1 1 1 1
Steam Nozzle Y 1-1/2 1-1/2 2 2 3 3 3 3 4B
Blowdown, Front and Rear W 1 1 1 1 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4
VENT STACK
Diameter (flgd connection) BB 6 6 8 8 10 10 12 12 12
Front Ring Flange to Vent CL CC 4 4 5 5 6 6 7 7 7
MINIMUM CLEARANCES
C DD 44 44 44 44 55 55 55 55 55
Rear Door Swing
Front Door SwingC 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 BOILER 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
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.
A. ANSI 150 psig flange.
B. ANSI 300 psig flange.
C. 15 thru 100 hp standard hinged door.
A2-11
07-02
NOTE: ALLOW 3 FEET

FOR DOOR SWING
PER NEC
BOILER HP DIM 125 150 200 250 300 350 400 500 600 700 750 800
LENGTHS
Overall A 174-1/2 199-/12 232-1/2 197 227 257 210 244 284 317 319 319
Shell B 125 149 180 144 171 201 152 186 222 255 255 255
Base Frame C 124 148 179 143 170 200 151 185 221 254 254 254
Front Head Extension D 30 31 33 29 32 32 26 26 30 30 32 32
Rear Head Extension E 19-1/2 19-1/2 19-1/2 24 24 24 32 32 32 32 32 32
Front Ring Flange to Nozzle - F 62-1/2 74-1/2 90 72 85-1/2 100-1/2 76 93 111 127-1/2 127-1/2 127-1/2
15 psig
Front Ring Flange to Nozzle - F 55 66 78 59-1/2 73 88 62 79 97 127-1/2 127-1/2 127-1/2

150 psig
Ring Flange to Base G 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2
WIDTHS
Overall I 85 85 85 103 103 103 123 123 123 123 123 123
ID, Boiler J 60 60 60 78 78 78 96 96 96 96 96 96
Center to Water Column K 45 45 45 54 54 54 64 64 64 64 64 64
Center to Outside Hinge KK 35 35 35 51 51 51 62 62 62 62 62 62
Center to Lagging L 33 33 33 42 42 42 51 51 51 51 51 51
Center to Auxiliary LWCO LL 40 40 40 49 49 49 59 59 59 59 59 59
Base, Outside M 52-1/2 52-1/2 52-1/2 64-3/8 64-3/8 64-3/8 72 72 72 72 72 72
Base, Inside N 44-1/2 44-1/2 44-1/2 52-3/8 52-3/8 52-3/8 56 56 56 56 56 56
A2-12
07-02
BOILER HP DIM 125 150 200 250 300 350 400 500 600 700 750 800
HEIGHTS
Base to Steam Outlet (15 psig only) PL 77 77 77 96 96 96 116 116 116 116 116 116
Overall OO 88 88 88 106 106 106 126 126 126 126 126 126
Base to Vent Outlet O 85 85 85 106 106 106 126 126 126 126 126 126
Base to Steam Outlet (150 psig PH 77 77 77 96 96 96 116 116 116 116 116 116
only)
Davit (Front) DF - - - 104 104 104 125 125 125 125 125 125
Davit (Rear) DR 84-3/4 84-3/4 84-3/4 104 104 104 126 126 126 126 126 126
Height of Base Q 12 12 12 10 10 10 12 12 12 12 12 12
Base to Bottom of Boiler R 16 16 16 17 17 17 19 19 19 19 19 19
BOILER CONNECTIONS
Chemical Feed H 1 1 1 1 1 1 1 1 1 1 1 1
Feedwater, Right and Left S 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 2-1/2
Low Pressure (15 psig only)

Steam Nozzle (Note A) U 8 8 10 10 12 12 12 12 12 12 12 12
Drain, Front and Rear W 1-1/2 1-1/2 2 2 2 2 2 2 2 2 2 2
High Pressure (150 psig only) T 1 1 1 1 1 1 1 1 1 1 1 1

Surface Blowoff, Top CL
Steam Nozzle (Note B) Y 4 4 4 6 6 6 6 8 8 8 8 8
Blowdown, Front and Rear W 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2 2 2 2
VENT STACK
Diameter (flgd. connection) BB 16 16 16 20 20 20 24 24 24 24 24 24
Front Ring Flange to Vent CL CC 9 9 9 10-1/2 10-1/2 10-1/2 12-1/2 12-1/2 12-1/2 12-1/2 12-1/2 12-1/2
MINIMUM CLEARANCES
Rear Door Swing DD 32C 32C 32C 43C 43C 43C 53C 53C 53C 53C 53C 53C
Front Door Swing EE 67 67 67 89C 89C 89C 108C 108C 108C 108C 108C 108C
Tube Removal, Rear FF 115 139 170 131 157 187 135 169 205 238 238 238
Tube Removal, Front GG 103 127 158 116 142 172 116 151 187 220 220 220
Rear of Boiler RR 307 355 417 364 417 477 395 463 535 601 601 601
Front of Boiler RF 260 308 370 303 356 416 322 390 462 528 528 528
Thru Window or Doorway RD 224 248 279 275 302 332 313 347 383 416 416 416
WEIGHT IN LBS
Normal Water Capacity 5750 7250 8625 10670 13000 15465 15340 19300 23425 27790 27790 27790
Approx. Ship Wgt - 15 psig 12200 12900 15200 21800 24000 27300 33500 38400 44000 51400 51400 51400
NOTES:
1. Air compressor belt driven from blower motor on sizes 125 thru 350 hp.
2. Control Panel relocation on boilers 250 hp and up.
4. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension prints.
C. Davit equipped, standard, 125 - 800 hp (rear door).
D. Davit equipped, standard, 250- 800 hp (front door)
A2-13
07-02
LWCO
NOTE: ALLOW 3 FEET

FOR DOOR SWING
PER NEC
80/ 100/
BOILER HP DIM 15 20 30 40 50 60 70 100A 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
15 to 100 hp) - Sheet 1 of 2
A2-14
07-02
80/ 100/
BOILER HP DIM 15 20 30 40 50 60 70 100A 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 67 67 67 67 67
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 - ThreadedA 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 CL 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
Approx. Ship. Wgt. 30 psig 3000 3100 3650 4350 6800 7000 8000 8100 8800
Approx. Ship. Wgt. 125 psig 3300 3400 3880 4580 7100 7300 8350 8450 9150
NOTES:
1. Accompanying dimensions and ratings while sufficiently accurate for layout purposes, must be confirmed for construction
by certified dimension prints.
4. 15 - 100 hp, hinged door standard.
5. Add 370lbs to the 80 hp ship weight for 100A and 485 lbs to the 100 hp ship weight for the 125A.
A. Dip Tube included.
Figure A2-3. Model CB Hot Water Boiler Dimensions (30 psig Design Pressure -
15 to 100 hp) - Sheet 2 of 2
A2-15
07-02
LWCO
NOTE: ALLOW 3 FEET

FOR DOOR SWING
PER NEC
A
150/
BOILER HP DIM 125 200 250 300 350 400 500 600 700 750 800
175A
LENGTHS
Overall A 174-1/2 199-1/2 232-1/2 197 227 257 210 244 284 317 319 319
Shell B 125 149 180 144 171 201 152 186 222 255 255 255
Base Frame C 124 148 179 143 170 200 151 185 221 254 254 254
Front Head Extension D 30 31 33 29 32 32 26 26 30 30 32 32
Rear Head Extension E 19-1/2 19-1/2 19-1/2 24 24 24 32 32 32 32 32 32
Front Ring Flange to Return F 91 102 131 104-1/2 131-1/2 161-1/2 111-1/2 139 175 207 207 207
Front Ring Flange to Outlet G 114 136 167 131 158 188 146 170 206 239 239 239
Ring Flange to Base H 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2
WIDTHS
Overall I 75-1/2 75-1/2 75-1/2 93 93 93 113 113 113 113 113 113
ID, Boiler J 60 60 60 78 78 78 96 96 96 96 96 96
Center to Entrance Box K 42-1/2 42-1/2 42-1/2 51 51 51 62 62 62 62 62 62
Center to Outside Hinge KK 35 35 35 51 51 51 62 62 62 62 62 62
Base, Outside M 52-1/2 52-1/2 52-1/2 64-3/8 64-3/8 64-3/8 72 72 72 72 72 72
Base, Inside N 44-1/2 44-1/2 44-1/2 52-3/8 52-3/8 52-3/8 56 56 56 56 56 56
Figure A2-4. Model CB Hot Water Boiler Dimensions (30 psig Design Pressure - 125 - 800 hp) - Sheet 1 of 2
A2-16
07-02
150/
BOILER HP DIM 125 200 250 300 350 400 500 600 700 750 800
175A
HEIGHTS
Overall OO 88 88 88 106 106 106 126 126 126 126 126 126
Base to Vent Outlet O 85 85 85 106 106 106 126 126 126 126 126 126
Base to Return and Outlet P 77 77 77 96 96 96 116 116 116 116 116 116
Davit (Front) DF - - - 104 104 104 125 125 125 125 125 125
Davit (Rear) DR 84-3/4 84-3/4 84-3/4 104 104 104 126 126 126 126 126 126
Height of Base Q 12 12 12 10 10 10 12 12 12 12 12 12
Base to Bottom of Boiler R 16 16 16 17 17 17 19 19 19 19 19 19
BOILER CONNECTION
Waterfill Conn. Right & Left S 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 2-1/2
Water Return FlangeA T 6 6 6 8 8 8 10 10 12 12 12 12
Water Outlet Flange U 6 6 6 8 8 8 10 10 12 12 12 12
Air Vent V 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2 2 2 2
Drain, Front and Rear W 1-1/2 1-1/2 2 2 2 2 2 2 2 2 2 2
Auxiliary Connection X 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 1-1/4
VENT STACK
Diameter (flgd. connection) BB 16 16 16 20 20 20 24 24 24 24 24 24
Front Ring Flange to vent CL CC 9 9 9 10-1/2 10-1/2 10-1/2 12-1/2 12-1/2 12-1/2 12-1/2 12-1/2 12-1/2
MINIMUM CLEARANCES
Rear Door Swing DD 32B 32B 32B 43B 43B 43B 53B 53B 53B 53B 53B 53B
Front Door Swing EE 67 67 67 89B 89B 89B 108B 108B 108B 108B 108B 108B
Tube Removal, Rear FF 115 139 170 131 157 187 135 169 205 238 238 238
Tube, Removal, Front GG 103 127 158 116 142 172 117 151 187 220 220 220
Rear of Boiler RR 307 355 417 364 417 477 395 463 535 601 601 601
Front of Boiler RF 260 308 370 303 356 416 322 390 462 528 528 528
Thru Window or Doorway RD 224 248 279 275 302 332 313 347 383 416 416 416
WEIGHT IN LBS
Water Capacity Flooded 7670 9295 11130 13880 16840 20090 20630 25925 31510 36600 36600 36600
Approx. Ship. Wgt. 30 psig 12100 12800 15100 21700 23900 27200 33400 38300 43900 51300 51300 51300
Approx. Ship. Wgt. 125 psig 12500 13200 15500 22500 24700 28000 34400 39300 44900 52300 52300 52300
NOTES:
1. Accompanying dimensions and ratings while sufficiently accurate for layout purposes, must be confirmed for construction
by certified dimension prints.
2. Control panel relocated on boilers 250 hp and up.
5. Davited front doors are standard on 250 - 800 hp.
6. Add 480 lbs to the 150 hp ship weight for 175A.
A. Dip Tube included.
B. Davited rear doors are standard on 125 - 800 hp units.
Figure A2-4. Model CB Hot Water Boiler Dimensions (30 psig Design Pressure - 125 - 800 hp) - Sheet 2 of 2
A2-17
07-02
DIMENSION (INCHES)
BOILER HP
A B C D E
15 - 40, 50A 20 36 28 45 20 PLAN VIEW

50 - 100, 100A, 125A 27 48 38 60 26
125 - 200, 175A 33 55 45 68 32
250 - 350 42 69 58 86 43
400 - 800 51 88 71 109 53

NOTE:
1. Dimensions in inches.
2. 15 - 100 hp (100A & 125A)
boilers are standardly equipped with hinges. Davit available as an
option.
Figure A2-5. Space Required to Open Rear Head on Model CB Boilers Equipped with Davits
Figure A2-6. Lifting Lug Location, Model CB Boilers - Sheet 1 of 2
A2-18
07-02
BOILER ALL DIMENSIONS IN INCHES

VIEW
HP 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
125A Hot Water B 68 27 100 10 2-1/2
125 All B 80-1/4 29-3/4 70-1/2 10 2-1/2
150 All A 80-1/4 29-3/4 83-1/2 10 2-1/2
175A Hot Water B 80-1/4 29-3/4 83-1/2 10 2-1/2
200 All B 80-1/4 29-3/4 114-1/2 10 2-1/2
250 Steam B 99 36 72 10 3
Hot Water B 99 36 72 10 3
300 Steam B 99 36 99 10 3
Hot Water B 99 36 99 10 3
350 Steam B 99 36 129 10 3
Hot Water B 99 36 129 10 3
400 Steam B 119 34-1/2 83 10 3
Hot Water B 119 34-1/2 83 11 3
500 Steam B 119 34-1/2 117 11 3
Hot Water B 119 34-1/2 117 11 3
600 Steam B 119 34-1/2 153 11 3
Hot Water B 119 34-1/2 153 11 3
700 Steam B 119 34-1/2 186 11 3
Hot Water B 119 34-1/2 186 11 3
750 Steam B 119 34-1/2 186 11 3
Hot Water B 119 34-1/2 186 11 3
800 Steam B 119 34-1/2 186 11 3
Hot Water B 119 34-1/2 186 11 3
NOTE:
1. A, B and C Dimensions may vary by 1/2 inch.
2. BHP followed by A designates hot water boilers furnished in a smaller vessel size with additional tubes in upper portion of vessel.
Figure A2-6. Lifting Lug Location, Model CB Boilers - Sheet 2 of 2
A2-19
07-02
BOILER HP A B C D E F G X
15-20 6 8 59 17 33 3 22 9-3/4
25-30 6 8 77 17 33 3 22 9-3/4
40-50A 6 8 103 17 33 3 22 9-3/4
50-60 6 8 91 26 42 4 29-5/8 8-1/4
70-80, 100A 6 8 130 26 42 4 29-5/8 8-1/4
100, 125A 6 8 148 26 42 4 29-5/8 8-1/4
125 6 9 124 39-1/2 57-1/2 4 44-1/2 10-1/4
150, 175A 6 9 148 39-1/2 57-1/2 4 44-1/2 10-1/4
200 6 9 179 39-1/2 57-1/2 4 44-1/2 10-1/4
250 6 12 143 46 70 6 52-3/8 22-1/2
300 6 12 170 46 70 6 52-3/8 22-1/2
350 6 12 200 46 70 6 52-3/8 22-1/2
400 6 14 151 50 78 8 56 24-1/2
500 6 14 185 50 78 8 56 24-1/2
600 6 14 221 50 78 8 56 24-1/2
700-750-800 6 14 254 50 78 8 56 24-1/2
NOTE:
1. All numbers in table are in inches.
2. 6-inch high mounting piers recommended for use beneath the boiler base frame. The use of these piers provides increased inspection
accessibility to the piping beneath the boiler and added height for washing down the area beneath the boiler.
Figure A2-7. Model CB Boiler Mounting Piers
A2-20
07-02
PERFORMANCE DATA 4. Any efficiency verification testing will be based on the stack
loss method.
Efficiency When specifying the efficiencies in the tables, be sure to
include the specific guarantee conditions to maximize the
Tables A2-7, A2-8, A2-9, A2-10, A2-11, and A2-12 show pre- effectiveness of your efficiency specification. If you have any
dicted fuel-to-steam efficiencies (including radiation and con- questions regarding the efficiency specifications, please con-
vection losses) for Cleaver-Brooks Model CB Firetube boilers. tact your local Cleaver-Brooks authorized representative. For
For specific efficiencies on firetube boiler offerings not listed efficiencies and stack temperatures at operating pressures not
here, contact your local Cleaver-Brooks authorized representa- listed, follow these procedures:
tive.
When the operating steam pressure is between 10 psig and 125
Cleaver-Brooks offers an industry leading fuel-to-steam boiler psig, interpolate the values from the efficiency tables.
efficiency guarantee for Model CB Firetube Boilers. The guar-
antee is based on the fuel-to-steam efficiencies shown in the When the operating steam pressure is above 125 psig, esti-
efficiency tables and the following conditions. The efficiency mated efficiency can be calculated as follows:
percent number is only meaningful if the specific conditions of Example:
the efficiency calculations are clearly stated in the specifica-
tion (see Cleaver-Brooks publication CB-7768 for a detailed Boiler: 350 hp.
description of efficiency calculations). Fuel: natural gas.
The boiler manufacturer shall guarantee that, at the time of Operating steam pressure: 200 psig.
startup, the boiler will achieve fuel-to-steam efficiency (as
shown in the tables listed above) at 100% firing rate (add effi- Find the fuel-to-steam efficiency at 100% firing rate. From
ciency guarantees at 25%, 50%, and 75% of rating, if Table A2-8 for a 350 hp boiler operating at 100% firing rate
required). If the boiler(s) fail to achieve the corresponding and an operating steam pressure of 125 psig, the efficiency is
guaranteed efficiency as published, the boiler manufacturer 82.5%.
will rebate, to the ultimate boiler owner, five thousand dollars Using Figure A2-8, note that the stack temperature increases
($5,000) for every full efficiency point (1.0%) that the actual 36 F at the higher operating pressure. To estimate boiler effi-
efficiency is below the guaranteed level. The specified boiler ciency, use this rule of thumb: For every 40 F increase in stack
efficiency is based on the following conditions. temperature, efficiency decreases by 1%. Since the stack tem-
1. Fuel specification used to determine boiler efficiency: perature rise is 36 F, the decrease in the boiler efficiency at
200 psig operating pressure is calculated as follows: 36/40 =
Natural Gas .9%. Therefore, the boiler efficiency at 200 psig operating
Carbon, % (wt) = 69.98 pressure is 82.5 - .9 = 81.6%.
Hydrogen, % (wt) = 22.31
Sulfur, % (wt) = 0.0 Emissions
Heating value, Btu/lb = 21,830
The emission data included in this section consists of typical
No. 2 Oil uncontrolled emission levels for Cleaver-Brooks Model CB
Carbon, % (wt) = 85.8 Firetube Boilers.
Hydrogen, % (wt) = 12.7 Cleaver-Brooks Firetube boilers are available with the standard
Sulfur, % (wt) = 0.2 burner package for Model CB, or optional internal flue gas
Heating value, Btu/lb = 19,420 recirculation on Model CB (LE) (refer to Section A3).
No. 6 Oil The Cleaver-Brooks IFGR packages are integrated boiler/
Carbon, % (wt) = 86.6 burner/control packages designed specifically for Cleaver-
Hydrogen, % (wt) = 10.9 Brooks boilers. For detailed information on Cleaver-Brooks
Sulfur, % (wt) = 2.09 IFGR packages, refer to Model CB (LE) in Section A3.
2. Efficiencies are based on ambient air temperature of 80 F,
NOTICE
relative humidity of 30%, and 15% excess air in the exhaust
flue gas. The data in Table A2-13 represents typical emission
3. Efficiencies are based on manufacturers published radiation levels only. Guaranteed emission levels are available
and convection losses. (For Cleaver-Brooks radiation and con- from your local Cleaver-Brooks authorized represen-
vection losses, see Boiler Efficiency Facts Guide, publication tative.
number CB-7767).
A2-21
07-02
Table A2-7. Predicted Fuel-to-Steam Efficiencies (%), Table A2-9. Predicted Fuel-to-Steam Efficiencies (%),
Model CB Boilers - 10 psig, Natural Gas Model CB Boilers - 10 psig, No. 6 Oil
FIRING RATE (%) BOILER FIRING RATE (%)
BOILER
HP HP 25 50 75 100
25 50 75 100
50 83.0 83.2 82.9 82.4 50 86.8 87.0 86.6 86.1
60 82.9 83.1 82.7 82.3 60 86.7 86.9 86.5 86.0
70 84.5 84.7 84.3 83.9 70 88.4 88.6 88.2 87.7
80 84.6 84.8 84.5 84.0 80 88.5 88.7 88.3 87.8
100 84.4 85.0 84.8 84.4 100 88.2 88.5 88.3 88.0
125 83.3 83.6 83.4 83.2 125 87.2 87.4 87.2 87.0
150 84.4 84.6 84.5 84.3 150 88.4 88.5 88.3 88.1
200 85.0 85.3 85.1 84.9 200 88.9 89.2 88.9 88.7
250 85.0 84.7 84.0 83.3 250 88.8 88.5 87.8 87.1
300 85.3 85.3 84.6 83.9 300 89.1 89.2 88.4 87.7
350 85.3 85.7 85.2 84.5 350 89.1 89.5 89.0 88.4
400 84.5 84.7 84.6 84.4 400 88.4 88.5 88.4 88.1
500 85.5 85.7 85.5 85.2 500 89.4 89.5 89.3 89.2
600 85.7 86.0 85.8 85.6 600 89.5 89.9 89.7 88.4
700 85.7 86.2 86.0 85.7 700 89.6 90.0 89.8 89.6
750 85.8 86.1 85.9 85.6 750 89.7 90.0 89.8 89.5
800 85.8 86.1 85.9 85.6 800 89.7 90.0 89.8 89.5
Model CB Boilers - 125 psig, Natural Gas Model CB Boilers - 125 psig, No 6 Oil
BOILER FIRING RATE (%) FIRING RATE (%)
BOILER
HP 25 50 75 100 HP 25 50 75 100
50 80.2 80.5 80.4 80.1 50 83.9 84.2 84.0 83.8
60 80.1 80.4 80.3 80.1 60 83.8 84.1 83.9 83.8
70 81.7 82.0 81.9 81.7 70 85.5 85.8 85.6 85.4
80 81.8 82.1 82.0 81.8 80 85.6 85.9 85.7 85.6
100 81.5 82.4 82.3 82.2 100 84.6 85.8 85.9 85.8
125 80.4 80.9 81.0 81.0 125 84.1 84.6 84.7 84.8
150 81.5 82.0 82.0 82.1 150 85.3 85.8 85.8 85.8
200 82.2 82.7 82.7 82.7 200 86.0 86.5 86.4 86.5
250 82.0 82.0 81.6 81.3 250 85.8 85.7 85.3 85.0
300 82.6 82.7 82.2 81.9 300 86.3 86.4 86.0 85.6
350 82.6 83.2 82.8 82.5 350 86.4 87.0 86.6 86.2
400 81.8 82.2 82.4 82.2 400 85.5 85.9 86.0 85.9
500 82.8 83.2 83.3 83.1 500 86.5 86.9 87.0 86.9
600 82.9 83.5 83.6 83.5 600 86.7 87.3 87.4 87.2
700 83.0 83.6 83.6 83.6 700 86.8 87.3 87.4 87.4
750 83.1 83.6 83.7 83.5 750 86.9 87.4 87.5 87.3
800 83.1 83.6 83.7 83.5 800 86.9 87.4 87.5 87.3
A2-22
07-02
Model CB Boilers - 10 psig, No. 2 Oil Model CB Boilers - 125 psig, No. 2 Oil
BOILER FIRING RATE (%) BOILER FIRING RATE (%)

HP 25 50 75 100 HP 25 50 75 100
50 86.5 86.7 86.3 85.8 50 83.6 84.0 83.8 83.5
60 86.3 86.6 86.2 85.7 60 83.5 83.8 83.7 83.5
70 87.9 88.2 87.8 87.3 70 85.1 85.4 85.3 85.1
80 88.1 88.3 87.9 87.4 80 85.2 85.6 85.4 85.3
100 87.8 88.4 88.1 87.7 100 84.8 85.7 85.6 85.5
125 86.7 86.9 86.7 86.6 125 83.7 84.2 84.3 84.3
150 87.8 88.0 87.8 87.6 150 84.8 85.3 85.3 85.4
200 88.4 88.7 88.4 88.2 200 85.6 86.0 86.0 86.0
250 88.3 88.1 87.4 86.7 250 85.3 85.3 84.9 84.7
300 88.6 88.7 88.0 87.3 300 85.9 86.0 85.5 85.2
350 88.6 89.0 88.5 87.8 350 85.9 86.6 86.1 85.8
400 87.9 88.1 87.9 87.6 400 85.1 85.5 85.6 85.5
500 88.9 89.0 88.9 88.6 500 86.1 86.5 86.6 86.4
600 89.0 89.4 89.2 89.0 600 86.2 86.8 86.9 86.8
700 89.1 89.5 89.3 89.1 700 86.3 86.9 87.0 86.9
750 89.2 89.5 89.3 89.0 750 86.4 86.9 87.0 86.8
800 89.2 89.5 89.3 89.0 800 86.4 86.9 87.0 86.8
Figure A2-8. Predicted Stack Temperature Increase for Pressure Greater Than 125 psig
A2-23
07-02
Table A2-13. Model CB Boiler Emission Data

ESTIMATED LEVELS - UNCONTROLLED
POLLUTANT
NATURAL GAS NO. 2 OILB NO. 6 OILC
ppmA 200 90 95
CO
Lb/MMBtu 0.15 0.07 0.075
ppmA 100 185 502
NOx
Lb/MMBtu 0.12 0.25 0.67
ppmA 1 278 278
SOx
Lb/MMbtu 0.001 0.52 0.52
ppmA 40 50 70
HC/VOCs
Lb/MMBtu 0.016 0.025 0.035
ppmA - - -
PM
Lb/MMBtu 0.01 0.025 0.160
NOTES:
Refer to Section E for detailed emission information.
A. ppm levels corrected to 3% O2, dry basis.
B. Based on fuel constituent levels of:
Fuel-bound nitrogen content = 0.05% by weight
Sulfur content = 0.5% by weight
Ash content = 0.01% by weight
C. Based on fuel constituent levels of:
Conradson carbon residue = 16% by weight
Table A2-14. Heating Surface, Model CB Boilers

ENGINEERING DATA HEATING SURFACE (SQ-FT)
BOILER
The following engineering information is provided for Model HP FIRESIDE WATERSIDE
CB Firetube Boilers. Additional detail is available from your
15 75 85
local Cleaver-Brooks authorized representative. Refer to
20 100 109
Tables A2-14 through A2-18.
25 125 144
Blowdown Water Requirements 30 150 162
40 200 219
Some local codes require blowdown tanks to be constructed in
accordance with recommendations of the National Board of 50 250 266
Boiler and Pressure Vessel Inspectors. 60 300 323
The National Boards recommendations base the size of the 70 350 388
blowdown tank on the removal of at least 4 inches of water 80 400 441
from the boiler.
100 500 544
Table A2-19 lists the approximate quantity of water repre- 125 625 679
sented by 4 inches of water at normal operating level for
150 750 820
Cleaver-Brooks Model CB Boilers.
200 1000 1092
250 1250 1346
300 1500 1623
350 1750 1932
400 2000 2151
500 2500 2691
600 3000 3262
700 3500 3810
750 3500 3810
800 3500 3810
A2-24
07-02
Table A2-15. Steam Volume and Disengaging Area
STEAM VOLUME CU-FT STEAM RELIEVING AREA, SQ-IN
BOILER HP
A B
HIGH PRESSURE LOW PRESSURE HIGH PRESSUREA LOW PRESSUREB
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
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 75.8 102.5 10148 10960
500 95.0 128.5 12722 13740
600 115.4 156.1 15448 16685
700-750-800 134.0 181.3 17948 19385
NOTE: Based on normal water level.

A. Based on 150 psig design pressure.
B. Based on 15 psig design pressure.
Table A2-16. Water Circulation Rate and Temperature Drop for Hot Water Boiler
BOILER SYSTEM TEMPERATURE DROP - DEGREES F
BOILER OUTPUT
10 20 30 40 50 60 70 80 90 100
HP (1000)
BTU/HR 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
125 &125A 4185 836 418 279 209 168 140 120 105 93 84
150 5025 1005 503 335 251 201 168 144 126 112 100
175A 5858 1172 586 391 293 234 195 167 147 130 117
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
750 25106 5025 2510 1675 1255 955 840 720 625 555 500
800 26780 5360 2680 1785 1340 1075 895 765 670 595 535
NOTES: 1. Minimum recommended return water temperature is 150 F. Minimum recommended outlet temperature for Model CB Hot Water
Boilers is 170 F. Contact your local Cleaver-Brooks authorized representative for special hot water application information.
2. See Section H2 for over-pressure requirements.
A2-25
07-02
Table A2-17. Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity)
BOILER HP
OPERATING
PRESSURE 15 20 25 30 40 50 60 70 80 100 125 150 200 250 300 350 400 500 600 700 750 800
PSIG
15 4 4 4 4 6 6 6 6 6 8 8 8 10 10 12 12 12 12 12 12 12 12
30 2 2 2.5 2.5 3 4 4 4 4 6 6 6 8 8 8 10 10 10 12 12 12 12
40 2 2 2.5 2.5 3 3 4 4 4 6 6 6 6 8 8 8 10 10 10 12 12 12
50 1.5 2 2 2.5 2.5 3 3 4 4 4 6 6 6 6 8 8 8 8 10 10 12 12
75 1.5 2 2 2 2.5 3 3 3 4 4 4 4 6 6 6 8 8 8 8 10 10 10
100 1.5 1.5 2 2 2 3 3 3 3 4 4 4 6 6 6 6 6 8 8 8 8 10
125 1.5 1.5 2 2 2 3 3 3 3 4 4 4 4 6 6 6 6 8 8 8 8 8
150 1.5 1.5 2 2 2 2.5 2.5 2.5 2.5 2.5 3 3 4 4 6 6 6 6 6 8 8 8
200 1.5 1.5 2 2 2 2.5 2.5 2.5 2.5 2.5 2.5 3 4 4 4 4 6 6 6 6 6 6
250 1.5 1.5 2 2 2 2 2 2 2 2 2.5 2.5 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. 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 A2-18. Recommended Non-Return Valve Size
BOILER BOILER OPERATING PRESSURES (PSIG)

CAPACITY
HP (LBS/HR) 50 75 100 125 150 175 200 250
100 3450 3 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2
125 4313 4 3 3 3 3 2-1/2 2-1/2 2-1/2
150 5175 4 4 3 3 3 3 2-1/2 2-1/2
200 6900 4 4 4 3 3 3 3 3
250 8625 4 4 4 4 3 3 3 3
300 10350 6 4 4 4 4 4 4 3
350 12025 6 6 4 4 4 4 4 3
400 13800 6 6 4 4 4 4 4 4
500 17210 6 6 6 6 4 4 4 4
600 20700 8 8 6 6 6 4 4 4
700 24150 8 8 6 6 6 6 6 6
750 25875 8 8 6 6 6 6 6 6
800 27600 8 8 6 6 6 6 6 6
Note: Valve sizes (300 psig flanges) given in inches.
A2-26
07-02
Table A2-19. Model CB Blowdown Tank Sizing Information Sound Level

Table A2-20 summarizes predicted sound pressure levels for
BOILER HP WATER (GAL.)
Model CB Boilers. Tables A2-21 through A2-25 give detailed
15-20 26 octave band sound pressure levels for each boiler. These values
25-30 34 are based on standard motors. Optional motor types and alti-
tude conditions can increase sound levels.
40 47
50-60 55 Units
70-80 80 The units for the sound level tables are dBA (decibels, mea-
100 93
sured on the A-weighted scale) in reference to 0.0002
microbars (20 micro-Newtons per square meter). They are
125 97
standardly referenced in specifying and reporting sound pres-
150 118 sure levels on industrial equipment.
200 145 Test Method
250 146
The sound pressure levels in the above tables were obtained
300 176 from tests in accordance with the "ABMA Test Code for the
350 210 Measurement of Sound from Packages Boilers." In accordance
400 183
with this code, the sound pressure levels reported were mea-
sured on the boiler centerline 4-1/2 feet vertically above the
500 230
bottom of the base rails and 3 feet horizontally in front of the
600 280 end of the blower motor or front surface of the electrical cabi-
700-750 325 net.
800 325 Sound Level Meter
NOTE: Quantity of water removed from boiler by lowering normal wa- The sound level meter used complies with ANSI S1.4, Type 1
ter line 4".
(Precision). The readings are taken with the meter set for slow
response.
Table A2-20. Sound Pressure Level Summary (50 - 800 hp)
BOILER
50 60 70 80 100 125A 125 150 200 250 300 350 400 500 600 700 750 800
HP
HFO, dBA 79 79 79 79 81 82 83 83 83 88 88 89 83 83 83 85 87 88
LFO, dBA 78 78 78 78 79 79 81 82 81 86 86 85 80 82 82 82 83 84
HFG, dBA 77 77 78 78 78 79 81 80 82 84 86 86 82 82 82 85 86 87
LFG, dBA 72 73 74 75 75 75 78 77 78 81 82 83 80 81 81 82 83 84
NOTES: ABBREVIATIONS:
1. Boiler No. followed by an a designates hot water boilers furnished in a smaller vessel size with additional tubes HF = High Fire
in the upper portion of the vessel. LF = Low Fire
2. Sound Pressure levels measured on boilers operating in various locations and expressed in dBA are as follows: O = Oil
G = Gas
Table A2-21. Model CB Boiler Sound Pressure Level Details (40 hp)
FIRING SOUND OCTAVE BAND SOUND PRESSURE LEVELS IN dB RE .0002 MICROBAR
RATE LEVEL
FUEL dBA 31Hz 63Hz 125Hz 250Hz 500Hz 1kHz 2kHz 4kHz 8kHz 16kHz
A
40HP
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: LF = Low Fire A. The data shown above was taken on the 40 hp. Since the highest Sound Level is below 80
ABBREVIATIONS: O = Oil dBA, no additional 36" diameter Firetubes were tested. If Sound Level predictions are required
HF = High Fire G = Gas for the 15 thru 30 hp, use the values shown for the 40 hp.
A2-27
07-02
Table A2-22. Model CB Boiler Sound Pressure Level Details (50 - 125 hp)
RATE LEVEL
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
125A HP
LFG 75 69 70 76 78 73 71 65 63 59 50
LFO 79 68 73 78 78 75 74 76 63 59 54
HFG 79 70 70 77 79 75 75 69 63 59 50
HFO 82 70 71 78 80 79 78 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.
A2-28
07-02
RATE LEVEL
125 HP
LFG 78 76 70 78 80 80 73 65 58 56 51
LFO 81 80 75 82 82 81 77 74 67 63 60
HFG 81 79 73 87 78 80 76 71 64 57 51
HFO 83 78 78 89 79 82 81 77 64 70 58
150 & 175A HP
LFG 77 75 70 78 76 77 72 67 63 58 55
LFO 82 76 68 80 78 79 75 71 66 60 58
HFG 80 71 72 82 76 80 76 71 64 58 52
HFO 83 70 71 83 79 82 77 73 65 60 55
200 HP
LFG 78 74 74 78 79 79 72 65 58 54 50
LFO 81 76 74 79 77 81 75 71 62 60 55
HFG 82 77 76 82 79 81 78 72 62 55 50
HFO 83 76 76 81 78 82 79 73 66 59 53
NOTES:
1. ABBREVIATIONS:
HF = HighFire
LF = Low Fire
O = Oil
G = Gas
2. Boiler HP followed by an A designates hot water boilers furnished in a smaller vessel size with additional tubes in the upper portion of the vessel.

RATE LEVEL
250 HP
LFG 81 72 81 85 84 82 75 68 60 56 53
LFO 86 76 87 87 85 84 82 73 70 76 68
HFG 84 78 85 84 84 84 79 72 62 55 50
HFO 88 79 84 84 84 85 86 74 68 67 65
300 HP
LFG 82 75 74 80 83 83 78 71 65 58 53
LFO 86 80 77 80 84 82 81 75 75 77 72
HFG 86 77 78 84 87 85 82 77 67 60 53
HFO 88 82 80 84 85 85 83 79 72 67 69
350 HP
LFG 83 75 78 87 86 83 78 70 58 55
LFO 85 82 79 84 84 84 84 70 66 66
HFG 86 78 79 87 85 84 84 72 65 61
HFO 89 82 82 85 85 86 86 79 68 68
NOTE:
ABREVIATIONS:
HF = High Fire
LF = Low Fire
O = Oil
G = Gas
A2-29
07-02
RATE LEVEL
400 HP
LFG 80 70 79 85 87 78 70 66 61 55 50
LFO 80 74 83 86 87 78 71 67 63 58 50
HFG 82 73 84 87 89 80 74 70 64 57 50
HFO 83 75 85 87 89 80 75 71 73 58 52
500 HP
LFG 81 78 83 87 87 78 73 66 62 58 54
LFO 82 77 83 87 87 81 75 70 63 59 55
HFG 82 79 87 87 84 79 76 70 63 57 55
HFO 83 77 87 87 84 81 77 71 62 58 55
600 HP
LFG 81 78 83 87 87 79 73 66 62 58 54
LFO 82 77 83 87 87 81 75 70 63 59 55
HFG 82 79 87 87 84 79 76 70 63 57 55
HFO 83 77 87 87 84 81 77 71 62 58 55
700 HP
LFG 82 80 87 91 87 80 75 70 66 62 56
LFO 82 79 88 90 87 81 76 72 67 63 57
HFG 85 80 90 89 89 82 77 76 66 64 57
HFO 85 81 90 91 89 82 80 77 68 65 57
750 HP
LFG 83 82 89 93 87 81 76 71 67 63
LFO 83 80 90 92 87 82 77 73 68 64
HFG 86 81 91 90 89 83 79 89 68 66
HFO 87 82 91 92 89 83 81 80 70 68
800 HP
LFG 84 83 90 94 87 82 77 73 68 64
LFO 84 82 91 93 87 82 78 74 68 65
HFG 87 82 92 91 89 83 81 82 70 68
HFO 88 83 92 92 89 83 82 83 71 70
NOTE:
ABBREVIATIONS:
HF = High Fire
LF = Low Fire
O = Oil
G = Gas
Sound Pressure sound levels. (Since A-scale sound levels are dominated by
mid-frequency sounds, the A-scale sound levels between two
On large size boilers, the need for auxiliary equipment, and the
boilers can be in reasonable agreement even though the low
necessary interconnecting piping, make it impractical (and
and high frequencies of octave band measurement do not
sometimes impossible) to provide a boiler testing environment
closely correspond).
that is suitable for obtaining the data needed to develop Sound
Pressure Power levels.
Gas-Fired Burners
Typical Values
Sound pressure levels (dBA) for identical boilers will vary
between boiler rooms. In addition, variations will occur NOTICE
between different people using different sound meters on the
same boiler. And finally, no two boilers can be expected to A gas pressure regulator must be installed in the gas
give precisely the same sound levels. For these reasons, we can piping to each boiler. Gas pressure regulators for
only predict, but not guarantee, sound levels (dBA). Model CB Firetube Boilers are sized and selected on
a job-by-job basis. Therefore, gas pressure require-
Octave Band ments shown in Tables A2-26, A2-27, A2-28, A2-29,
When predicting sound pressures in octave bands (e.g., dB at and A2-30 list "regulated" gas pressure. Regulated
125 Hz), even greater variations between boilers, between gas pressure is the pressure downstream of the gas
sound meters, and between operators can be expected. These pressure regulator. Total gas pressure required for
larger variations in the low and high frequencies make octave the boiler equals regulated gas pressure plus the
band levels a less reliable method of reporting than A-scale pressure drop of the selected gas pressure regulator.
A2-30
07-02
Table A2-27. Minimum Gas Pressure at Entrance to Gas
Table A2-26. Minimum Required Gas Pressure at Entrance Trains Equipped with Industrial Risk Insurers (IRI)
to Standard and FM Gas Trains (Downstream of Gas Requirements (Downstream of Gas Pressure Regulator)
Pressure Regulator)
MODEL CB MODEL CB
NET REGD BOILER MIN PRESS
BOILER CONN SIZE HTBB MIN GAS
CONN SIZE PRESS. HTBB MIN GAS HP REQ'D
HP (IN) PRESS. REQD
(IN.) REQ'D PRESS. REQ'D (IN WC)
(IN. WC)
15 1-1/4 4.0 -
15 1-1/4 3.5 -
20 1-1/4 6.5 -
20 1-1/4 6.0 -
25 - - -
25 - - -
30 2 7.0 -
30 2 7.0 -
40 2 8.0 -
40 2 7.5 -
50A 2 7.5 -
50A 2 6.5 -
50 2 5.5 -
50 2 4.5 -
60 2 6.5 -
60 2 5.5 -
70 2 9.0 -
70 2 8.0 -
80 2 10.5 -
80 2 9.5 -
100A 2 11.0 -
100A 2 8.5 -
100 2 11.0 -
100 2 9.5 -
125A 2-1/2 11.5 -
125A 2-1/2 11.5 -
125 2-1/2 7.5 -
125 2-1/2 7.5 -
150 2-1/2 9.5 -
150 2-1/2 8.5 -
175A 2-1/2 12.5 -
175A 2-1/2 11.5 -
200 2-1/2 15.5 -
200 2-1/2 15.5 -
250 3 17.5 22.0
250 3 17.5 22.0
300 3 23.0 31.0
300 3 23.0 31.0
350 3 32.5 42.5
350 3 32.5 42.5
400 4 16.5 21.0
400 4 16.5 21.0
500 4 25.5 35.0
500 4 25.5 35.0
600 4 36.0 41.5
600 4 36.0 41.5
700 4 50.0 57.5
700 4 50.0 57.5
750 4 57.0 66.0
750 4 57.0 66.0
800 4 64.0 75.5
800 4 64.0 75.5
NOTES:
NOTES: 1.These gas pressure requirements effective on all boilers shipped after
1.These gas pressure requirements effective on all boiler shipped after July July 1,1992 for 15 - 350 hp and Sept. 1, 1993 for 400 - 800 hp.
1,1992 for 15 - 350 hp and Sept. 1, 1993 for 400 - 800 hp. 2. BHP followed by A designates hot water boiler furnished in a smaller
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.
vessel size with additional tubes in the upper portion of the vessel. 3. Pressures shown also apply to standard and FM gas trains for Canada.
3. For standard and FM gas pressure requirements for Canada, refer to A. Based on 1000 Btu/cu-ft natural gas and elevation up to 700 feet.
Table A2-27, IRI Trains. B. HTB is for high turndown (10:1) burners.
A. Based on 1000 Btu/cu-ft natural gas and elevations up to 700 feet.
B. HTB is for high turndown (10:1) burners.
Table A2-26 shows regulated gas pressure requirements for Capacity: The capacity can be determined by multiplying the
Model CB Boilers with standard or FM gas trains. maximum burning rate (CFH) by 1.15, see Table A2-31. This
15 percent over-capacity rating of the regulator provides for
Table A2-27 shows regulated gas pressure requirements for
proper regulation.
Model CB Boilers with IRI gas trains.
Spring Adjustment: The spring should be suitable for a range
Table A2-28 and A2-29 show regulated gas pressure with over
of adjustment from 50 percent under the desired regulated
and undersized gas trains.
pressure to 50 percent over.
Table A2-30 shows minimum required gas pressure altitude
Sharp Lock-Up: The regulator should include this feature to
conversion.
prevent the downstream pressure (between the regulator and
the boiler) from climbing when there is no gas flow.
Gas Pressure Regulator
Regulators in Parallel: This type of installation can be used
The following items should be considered when selecting a if the required gas volume is very large and if the pressure
regulator: drop must be kept to a minimum.
Pressure Rating: The regulator must have a pressure rating at Regulators in Series: This type of installation can be used if
least equivalent to that of the gas distribution system. the available gas pressure is over 5, 10, or 20 psig.
A2-31
07-02
Table A2-28. Under and Oversized Standard and FM Gas Trains, Model CB Boilers (50 - 800 hp)
50 60 70 80 100 100A 125A
PIPE PRESS PIPE PRESS PIPE PRESS PIPE PRESS PIPE PRESS PIPE PRESS PIPE PRESS
SIZE REQD SIZE REQD SIZE REQD SIZE REQD SIZE REQD SIZE REQD SIZE REQD
1-1/2 8.0 1-1/2 11.0 1-1/2 15.0 1-1/2 18.5 1-1/2 22.5 1-1/2 22.5 2 15.0
2 4.5 2 5.5 2 8.0 2 9.5 2 9.5 2 9.5 2-1/2 11.5
2-1/2 4.0 2-1/2 5.0 2-1/2 7.5 2-1/2 9.0 2-1/2 8.5 2-1/2 8.5 3 9.5
3 3.75 3 4.5 3 7.0 3 8.0 3 7.5 3 7.5
125 150 175A 200 250 300 350
2 11.0 2 14.5 2 20.0 2 26.0 2-1/2 29.5 2-1/2 44.5 2-1/2 62.0
2-1/2 7.5 2-1/2 8.5 2-1/2 11.5 2-1/2 15.5 3 22.0 3 31.0 3 42.5
3 5.5 3 6.5 3 9.5 3 12.5 4 15.5 4 22.5 4 31.0
4 4.5 4 5.0 4 7.0 4 9.0 4A 13.5 4A 20.0 4A 27.5
400 500 600 700 750 800
PIPE PRESS PIPE PRESS PIPE PRESS PIPE PRESS PIPE PRESS PIPE PRESS
SIZE REQD SIZE REQD SIZE REQD SIZE REQD SIZE REQD SIZE REQD
3 35.5 3 59.0 3 75.5 3 NA 3 NA 3 NA
4 21.0 4 35.0 4 41.5 4 57.5 4 66.0 4 75.5
4A 17.0 4A 27.5 4A 30.0 4A 42.0 4A 48.0 4A 55.1
NOTES:
1.Pipe size in inches, and pressure required in inches of WC.
2. Models followed by A designates hot water boilers furnished in a smaller vessel size with additional tubes in upper portion of vessel.
3. Pressure requirement is downstream of gas pressure regulator.
A. Low pressure drop Maxon valves (replaces 6" trains).
B. Standard gas train shown by shaded area.
C. Charts for 250 - 800 hp are for high turndown burners.
Depending on the regulator characteristics, one regulator Gas pressure regulator selction for high turndown (10:1)
would reduce the pressure to 2 to 3 psig, and a second burners is critical at minimum flow rates. Contact your local
regulator would reduce the pressure to the burner Cleaver-Brooks authorized representative for proper
requirements. selection.
Regulator Location: A straight run of gas line piping should Table A2-31 shows maximum gas consumption for natural gas
be used on both sides of the regulator to ensure proper and propane vapor.
regulator operation. This is particularly important when
pilot-operated regulators are used. The regulator can be Figure A2-9 shows standard gas train sizes and locations for
located close to the gas train connection, but 2 to 3 feet of Model CB Firetube Boilers.
straight run piping should be used on the upstream side of Figure A2-10 shows typical gas train piping layouts for multi-
the regulator. ple boiler applications.
When oxygen trim is used, the regulator selection must be Figure A2-11 shows gas train components.
consistent with details shown in Section D.
A2-32
07-02
Table A2-29. Under and Oversized IRI Gas Trains, Model CB Boilers (50 - 800 hp)
50 60 70 80 100 100A 125A
1-1/2 9.0 1-1/2 12.5 1-1/2 17.5 1-1/2 22.0 1-1/2 28.0 1-1/2 28.0 2 15.0
2 5.0 2 6.5 2 9.0 2 10.5 2 11.0 2 11.0 2-1/2 11.5
2-1/2 4.5 2-1/2 5.5 2-1/2 8.0 2-1/2 9.5 2-1/2 9.0 2-1/2 9.0 3 9.5
3 4.0 3 5.0 3 7.5 3 8.5 3 8.0 3 8.0
125 150 175A 200 250 300 350
2 11.0 2 14.5 2 20.0 2 26.0 2-1/2 29.5 2-1/2 44.5 2-1/2 62.0
2-1/2 7.5 2-1/2 9.5 2-1/2 12.5 2-1/2 15.5 3 22.0 3 31.0 3 42.5
3 5.5 3 6.5 3 9.5 3 12.5 4 15.5 4 22.5 4 31.0
4 4.5 4 5.0 4 7.0 4 9.0 4A 13.5 4A 20.0 4A 27.5
400 500 600 700 750 800
3 35.5 3 59.0 3 75.5 3 NA 3 NA 3 NA
4 21.0 4 35.0 4 41.5 4 57.5 4 66.0 4 75.5
4A 17.0 4A 27.5 4A 30.0 4A 42.0 4A 48.0 4A 55.5
NOTES:
1. Pipe size in inches, and pressure required in inches WC.
2. Models followed by A designate hot water boilers furnished in a smaller vessel size with additional tubes in upper portion
of vessel.
B. Standard gas train shown by shaded areas.
Table A2-30. Minimum Required Gas Pressure Altitude

Conversion
ALTITUDE CORRECTION ALTITUDE CORRECTION

(FT) FACTOR (FT) 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.
A2-33
07-02
Table A2-31. Maximum Gas Consumption (CFH) for Natural
Gas and Propane Vapor (1 of 2) Table A2-31. Gas Pilot Data (2 of 2)
TYPE OF GAS AND HEAT CONTENT Minimum Re-

BOILER
HP NATURAL GAS PROPANE GAS Connection quired Gas Maximum Per-
1000 (Btu/cu-ft) 2550 (Btu/cu-ft) BHP Size (inches) Pressure (Up missible Gas
NPT to 700 ) Pressure (psig)
15 625 245 Inches WC
20 835 330
25 1045 410 50-100 1/2 4 5
30 1255 490
40 1675 655 125-800 1/2 5 5
50A 2095 820
Manufac-
50 2095 820 Natural 1000 Propane 2500
BHP tured 500 Btu/ Btu/ Cu. Ft Btu/Cu Ft
60 2510 985 Cu. Ft
70 2930 1150
80 3350 1315 50-100 120 60 25
100A 4185 1640
100 4185 1640
125-200 200 100 40
125A 5230 2050
250-350 300 150 60
125 5230 2050
150 6280 2465 400-800 400 200 80
175A 7350 2880
200 8370 3280
250 10460 4105
300 12555 4925 Approximate Gas Usage:
350 14650 5745
400 16750 6570
1. Multiply the CFH rate by 0.007 to obtain the number of
500 20925 8205
cu.ft of gas used in 25 sec. (Length of (1) light off).
600 25100 9845 2. Multiply the number of cu. ft/light (item 1) by the esti-
700 29300 11480
mated number of lights/hour or per day to obtain the approx-
750 31385 12305
imate usage in cu.ft/hour or cu.ft/day.
800 33500 13140
NOTES:
BHP followed by A designates hot water boilers furnished in a smaller ves-
sel size with additional tubes in upper portion of vessel.
MODEL CB
BOILER CONNECTION LOCATION
HP SIZE DIMENSION
(IN.) (NPT) "A" (IN.)
15,20 1-1/4 61
25 - -
30 2 63
40,50A 2 63
50 2 44
60, 70, 80 2 51
100A, 100 2 61
125A 2-1/2 61
125 2-1/2 67-1/2
150, 200 2-1/2 67-1/2
250 3 70-1/2
300, 350 3 70-1/2
400, 500, 600, 700, 750, 4 109-1/2
800
NOTE: BHP followed by A designates hot water boiler fur-

nished in a smaller vessel size with additional tubes in upper
portion of vessel. Dimensions are for IRI gas trains.
Figure A2-9. Standard Gas Train Connection Size and Location
A2-34
07-02
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 instal-
lation. Actual requirements may vary depending on local codes or local gas company requirements which should be investigated prior
to preparation of specifications and prior to construction.
A. Utilities service valve.

B. Utilities service regulator.
C. Gas meter.
D. Piping from meter to boiler.
E. Gas pressure regulator at burner.
The size of the gas line from the meter to the gas pressure regulator at the boiler can be very important if gas pressures are marginal.
The gas line sizing is dependent on:
1. Gas pressure at outlet of gas meter (C)

2. Rate of gas flow required, CFH
3. Length of pipe run (D)
4. Pressure required at contractor connection point.
The local gas utility will advise the pressure that is available at the outlet of their meter.
Figure A2-10. Typical Gas Piping Layout
A2-35
07-02
INS UL FM IRI FM & IRI

ITEM DESCRIPTION
30- 60- 125- 300- 30- 125- 300- 125- 125- 300-
BOILER HP 15-20 15-20 15-20 30-100 15-20 30-100
50 100 250 800 100 250 800 800 250 800
1 Pilot Shut Off Cock x x x x x x x x x x x x x x x x

2 Pilot Shut Off Cock x x x x x x x
3 Shut Off Cock x x x x x x x x x x x x x x x x
4 Shut Off Cock x x x x x x x x x x x x x x x x
5 Pilot Pressure Regulator x x x x x x x x x x x x x x x x
6 Pilot Pressure Gauge x x x x x x x x x x x x x x x x
7 Gas Pilot Valve x x x x x x x x x x x x x x x x
8 High Gas Pressure Switch x x x x x x x x x x x x x x
9 Low Gas Pressure Switch x x x x x x x x x x x x x x
10 Main Gas Valve with POC x x x x x x x x x x x x
11 Main Gas Valve without POC x x x x x x x x x
12 Main Gas Valve with POC x x
13 Main Gas Valve without POC x x x x
14 Vent Valve x x x x x x x x x
15 Butterfly Valve x x x x x x x x x x x x
Figure A2-11. Model CB Gas Train Components

Oil-Fired Burners for the particular oil at this pumping temperature can be deter-
mined.
Fuel oil consumption information is shown on the boiler rating
sheets in the Dimensions and Rating Section. It is recommended to provide for tank and/or line heating on all
No. 6 oil installations to ensure against high viscosities at
Figure A2-12 shows the oil connection sizes and locations for decreased pumping temperatures. The following are two com-
Model CB Boilers firing No. 2 oil. mon methods:
Figure A2-13 shows the oil connection sizes and locations for 1. Provide a tank suction heater and bundling the steam or
Model CB Boilers firing No. 5 and No. 6 oil. water lines to the heater with the oil lines.
Figures A2-14 through A2-21 show typical oil systems and 2. Provide electric heating equipment on the oil lines and/or
layouts. in the storage tank.
Figure A2-22 shows the detail of an oil transfer tank (day tank)
typically utilized to provide a storage reservoir between the oil
system supply pump and the boiler oil pump. NOTICE
No. 6 Oil Piping, Storage Tank Heating The temperature in the oil suction line should not ex-
ceed 130 F as higher temperatures could cause va-
If the oil viscosity exceeds 4,000 SSU at the pumping temper- por binding of the oil pump and decreased oil flow.
ature, tank preheating is required.
See Figures A2-23 and A2-24 for an example of (No. 1 above)
Based on the climate conditions for the job location, the mini- tank heating method.
mum pumping temperature can be predicted, and the viscosity
See Figure A2-25 for examples of preheat-
A2-36
07-02
MODEL CB
RECOMMENDED OIL LINEA

SUPPLY SIZES
AND (STANDARD PIPE)
BOILER RE- (IN.)
HP TURN (IN.)
CONN STORAGE
SIZES TANK TO PUMP RETURN
(IN.) BOILER TO LINE TO
(NPT) OR PUMP BOILER TANK
CONNECT
15,20 3/4 8-1/4 3/4 NONE 3/4
25 - - - - -
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
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 34 1 1 1
700, 750, 800 1 34 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
equivalent feet of suction line.
B. This table is based on a single boiler installation.
Figure A2-12. No. 2 Oil Connection Size, Location and Recommended Line Sizes
GAS PILOT RECOMMENDED OIL LINE

SUPPLY RETURN CONNECTION SIZES
CONNECTION CONNECTION 4-5" WC PRESS. (STANDARD PIPE)
BOILER REQD (IN.)
HP
SIZE SIZE SIZE STORAGE RETURN
C PUMP TO
(IN.) A (IN.) (IN.) B (IN.) (IN.) TANK TO LINE TO
(IN.) BOILER
(NPT) (NPT) (NPT) PUMP TANK
50, 60, 70, 80, 100 1-1/4 27-3/4 3/4 19-3/4 1/2 28 2 1-1/4 1-1/4
125, 150 1-1/4 49-1/2 1-1/4 39 1/2 38 2-1/2 1-1/2 2
200 1-1/4 65-1/2 1-1/4 39 1/2 38 2-1/2 1-1/2 2
250, 300, 350 1-1/4 89-3/4 1-1/4 59-3/4 1/2 56 2-1/2 1-1/2 2
400, 500, 600,700, 750, 800 1-1/4 63 1-1/4 48 1/2 54 3 2 2
NOTES:
1. All dimensions in inches.
2.For suction lines with a maximum of 10 feet of lift and a total of 100 equivalent feet of suction line.
3. This table is based on a single boiler installation.
Figure A2-13. No. 6 Oil Connection Size, Location and Recommended Line Sizes, Model CB Boiler
A2-37
07-02
Figure A2-14. No. 2 Oil Piping, Single Boiler Installation,

Remote Oil Pump
Figure A2-15. No.2 Oil Piping, Single Boiler Installation Oil Pump
Integral with Boiler
A2-38
07-02
Figure A2-16. No. 2 Oil Piping, Multiple Boiler Installation,

Remote Oil Pumps
Figure A2-17. No. 2 Oil Piping, Multiple Boiler Installation, Oil

Pump Integral with Boiler
A2-39
07-02
STRAINER
VACUUM GAUGE GATE VALVE
CHECK
VALVE F.O.S.
GATE
VALVE
F.O.R.
STANDBY ADJUSTABLE
OIL PUMP PRESSURE
RELIEF VALVE
UNION (75 PSIG)
GATE VALVE RELIEF

VALVE PRESSURE
(100 PSIG) GAUGE
GATE VALVE
CHECK VALVE
USE LAYOUT FOR: MODEL CB . . . . . . . 50 THRU 800 HP
Relief valve on the boiler

must be set at 100 psig so
that adjustable pressure
relief valve in the loop
system is in control.
BOILER
BASE FRAME
BOILER
FRONT
F.O.S.
CONTACTOR
CONNECTIONS
Figure A2-18. No. 2 Oil Piping, Multiple Boiler Installation
F.O.R.
AT THIS POINT
Figure A2-19. No. 6 Oil Piping, Single Boiler Installation, Remote

Oil Pump
A2-40
07-02

Remote Oil Pumps
STRAINER
CHECK VACUUM GAUGE GATE VALVE
VALVE F.O.S.
GATE
VALVE F.O.R.
STANDBY ADJUSTABLE
OIL PUMP PRESSURE
RELIEF VALVE
TEMPERATURE (75 PSIG)
GAUGE
RELIEF PRESSURE
UNION GAUGE
VALVE
GATE VALVE (100 PSIG)
GATE
VALVES

OIL HEATER
BOILER
BASE FRAME
BOILER
FRONT F.O.S.
F.O.R.
CONTACTOR
Figure A2-21. No. 6 Oil Piping, Multiple Boiler Installation CONNECTIONS
AT THIS POINT
A2-41
07-02
Figure A2-22. No. 2 Oil Transfer Tank Detail
Figure A2-23. Typical Fuel Storage Tank Arrangement
A2-42
07-02
Note 1: The outer jacket of the four line bundle

should be protected by a waterproof covering to
protect the lines and insulation from moisture
damage. Tar paper and hot asphalt sealer have
been successfully used as a waterproof covering.
Note 2: When the bundle runs under driveways

or other traffic areas, a heavy duty outer jacket
of reinforced concrete, vitrified tile, or corrugated
steel is recommended.
Figure A2-24. Typical Cross Section of Bundled Lines
In order to properly preheat No. 6 oil, the minimum recommended boiler water temperature is 200 F. Some No. 6 oils must be preheated up
to 210 F, and higher boiler water temperatures are then desirable.
Although lower boiler water temperatures can be used, this condition means that the electric preheater will be doing more of the work. It is more
economical to use higher temperature boiler water for preheating than to use lower temperature water which increases the electric preheating
load.
To ensure the most trouble-free, dependable preheating system, a boiler water-to-water-to-oil preheating system is furnished as standard equip-
ment 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 ap-
plication.
The standard system does not have provisions for a hot water line to a storage tank heater.
Figure A2-25. Schematic of Standard Alstrom Hot Water Safety-Type Preheating System
A2-43
07-02
Boiler Room Information C. A vent fan in the boiler room is not recommended, as it
could create a slight vacuum under certain conditions
Figure A2-26 shows typical boiler room length requirements. and cause variations in the quantity of combustion air.
Figure A2-27 shows typical boiler room width requirements. This can result in unsatisfactory burner performance.
Figure A2-28 shows typical breeching arrangements. D. Under no condition should the total area of the air supply
openings be less than (1) square foot.
Stack Support Capabilities E. Size the openings by using the formula:
Cleaver-Brooks Firetube Boilers 15 hp through 100 hp can Area (sq-ft) = cfm/fpm
support up to 1,000 lbs without additional support. Firetube
boilers 125 hp through 800 hp can support up to 2,000 lbs 2. Amount of air required (cfm).
without additional support. A. Combustion Air = Rated bhp x 8 cfm/bhp.
Firetube sizes 250 hp through 800 hp can be reinforced to sup- B. Ventilation Air = Maximum bhp x 2 cfm/bhp
port 3,000 lbs.
C. Total recommended air, 10 cfm/bhp - up to 1000 feet
elevation. Add 3 percent more per 1000 feet of added
Stack/Breeching Size Criteria elevation.
The design of the stack and breeching must provide the 3. Acceptable air velocity in boiler room (fpm).
required draft at each boiler flue gas outlet. Proper draft is crit-
ical to burner performance. A. From floor to (7) foot height - 250 fpm.
Although constant pressure at the flue gas outlet of the Model B. Above (7) foot height - 500 fpm.
CB is not required, it is necessary to size the stack/breeching Example: Determine the area of the boiler room air supply
to limit flue gas pressure variation. For boiler sizes 50 800 openings for (1) 300 hp boiler at 800 feet altitude. The air
horsepower, the allowable pressure range is 0.5" W.C. to openings are to be 5 feet above floor level.
+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, Air required: 300 x 10 = 3000 cfm (from 2B above).
the allowable pressure range is 0.25" W.C. to +0.25" W.C. Air velocity: Up to 7 feet = 250 fpm (from 3 above).
For additional information, please review Section I4, General Area Required: Area = cfm = 3000/250 = 12 Sq-ft total.
Engineering Data (Stacks) and Section F, Stacks. Stack and
breeching sizes should always be provided by a reputable Area/Opening: 12/2 = 6 sq-ft/opening (2 required).
stack supplier who will design the stack and breeching system
based on the above criteria. Your local Cleaver-Brooks autho-
rized representative is capable of assisting in your evaluation NOTICE
of the stack/breeching design.
Consult local codes, which may supersede these re-
Boiler Room Combustion Air quirements.
When determining boiler room air requirements, the size of

the room, air flow, and velocity of air must be reviewed as fol-
lows:
1. Size (area) and location of air supply openings in boiler
room.
A. Two (2) permanent air supply openings in the outer
walls of the boiler room are recommended. Locate one
at each end of the boiler room, preferably below a height
of 7 feet. This allows air to sweep the length of the
boiler.
B. Air supply openings can be louvered for weather
protection, but they should not be covered with fine
mesh wire, as this type of covering has poor air flow
qualities and is subject to clogging by dust or dirt.
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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. Allow-
ance for door swing at the front provides sufficient aisle and working space at the front.
Figure A2-26. Boiler Room Length (Typical Layout)
BOILER HP 15-40 50-100 125-200 250-350 400-800
Dimension A 75" 81" 87" 96" 106"
Dimension B 103" 115" 127" 151" 183"
NOTES:
1. Recommended Minimum Distance Between Boiler and Wall. Dimension
"A" allows for a "clear" 42" aisle between the water column on the boil-
er and the wall. If space permits, this aisle should be widened.
2. Recommended Minimum Distance Between Boilers.
Dimension "B" between boilers allows for a "clear" aisle of:
42" - 15-200 hp
48" - 250-350 hp
60" - 400-800 hp
If space permits, this aisle should be widened.
Figure A2-27. Boiler Room Width (Typical Layout)
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MULTIPLE BOILERS WITH A COMMON STACK
NOTE: These stack breeching arrangements for mul-

tiple boilers are typical and not intended for your
specific design requirements. For additional infor-
mation, review Section F, Stacks.
Stack and breeching sizes should always be pro-

vided by a reputable stack supplier who will design
the stack and breeching system based on your spe-
cific criteria. Your local CLeaver-Brooks authorized
representative is capable of assisting in your evalua-
tion of stack and breeching design.
MULTIPLE BOILERS WITH INDIVIDUAL STACKS
Figure A2-28. Breeching Arrangement
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07-02
SAMPLE SPECIFICATION (MODEL CB BOILER)

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 specifica-
tions 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.
Model CB Steam Boiler (15-800 hp, Steam 15-350 psig)

1.0 Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-47
2.0 General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-47
3.0 Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-48
4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-49
5.0 Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-55
6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-56
7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-56
Model CB Hot Water Boiler (15-800 hp, 30 psig, 125 psig)

1.0 Boiler Characteristics (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-57
3.0 Hot Water Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-58
6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-65
7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-65
Model CB Steam Boiler (15-800 hp, Steam 15-350 psig)
1.0 Boiler Characteristics (Steam)

1.1 The Steam Boiler shall be Cleaver-Brooks Model CB, Fuel Series ______ (100, 200, 400, 600, 700), _____ hp designed for
_____ psig (15, 150, 200, or other psig steam). The maximum operating pressure shall be _____ psig.
1.2 The boiler shall have a maximum output of _____ Btu/hr, or _____ horsepower when fired with CS 12-48 _____ oil and/or nat-
ural gas, _____ Btu/cu-ft. Electrical power available will be _____ Volt _____ Phase _____ Cycle.
2.0 General Boiler Design

2.1 The boiler shall be a four pass horizontal firetube updraft boiler with five (5) square feet of heating surface per rated boiler
horsepower (except 750 or 800 hp). It shall be mounted on a heavy steel frame with integral forced draft burner and burner controls.
NOTICE
The complete package boiler shall be approved as a unit by Underwriters Laboratories and shall bear the UL/
ULC label, except in the case where 50 Hz has been selected.
2.1.1 The boiler shall be completely preassembled and 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.
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07-02
2.1.2 The boiler shall be built to comply with the following insurance and codes ____________________ (Factory Mutual, Indus-
trial Risk Insurance, ASME CSD-1).
2.2 Boiler Shell (Steam)
2.2.1 The boiler shell must be constructed in accordance with ASME Boiler Code and must receive authorized boiler inspection
prior to shipment. A copy of the inspection report shall be furnished to the purchaser.
2.2.2 Two lifting eyes shall be located on top of the boiler.
2.2.3 Front and rear doors on the boiler shall be hinged or davited. Doors are to be sealed with fiberglass tadpole gaskets and fas-
tened tightly using heavy capscrews that thread into replaceable brass nuts.
2.2.4 Rear refractory and insulation shall be contained in the formed door, which must swing open for inspection of brick work.
2.2.5 The boiler tubes shall not include turbulators, swirlers or other add-on appurtenances.
2.2.6 Front and rear tube sheets and all 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.
2.2.7 For boilers 125 horsepower and over, a manhole shall be provided.
2.2.8 The exhaust gas vent shall be located near the front of the boiler on the top center line and shall be capable of supporting:
15-100 hp. 1000 lbs and shall contain a stack thermometer
2.2.9 The boiler shell shall contain a chemical feed connection.
2.3 Observation ports for the inspection of flame conditions shall be provided at each end of the boiler.
2.4 The boiler insulation shall consist of a 2 inch blanket under a sectional preformed sheet metal lagging. This insulation must be
readily removable and capable of being reinstalled, if required.
2.5 The entire boiler base frame and other components shall be factory painted before shipment using a hard finish enamel coating.
3.0 Steam Boiler Trim

3.1 Water Column
A water column shall be located on the right hand side of the boiler complete with gauge glass set and water column blowdown
valves.
3.1.1 Feedwater Pump Control
The boiler feedwater pump control shall be included as an integral part of the water column to automatically actuate a motor driven
feed water pump maintaining the boiler water level within normal limits.
3.1.2 Low Water Cutoff
The low water cutoff shall be included as an integral part of the boiler feedwater control wired into the burner control circuit to pre-
vent burner operation if the boiler water level falls below a safe level.
3.2 Auxiliary Low Water Cutoff
Auxiliary low water cutoff manual reset shall be included, piped to the vessel, and wired to the burner control circuit. A manual
reset device shall be used on this control.
3.3 Steam Pressure Gauge
The steam pressure gauge shall be located at the front of the boiler and include cock and test connection.
3.4 Safety Valves
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07-02
Safety valves of a type and size to comply with ASME Code requirements shall be shipped loose.
3.5 Steam Pressure Controls
The steam pressure controls to regulate burner operation shall be mounted near the water column. Controls shall be a high limit
(manual reset), operating limit (auto reset), and firing rate control (30-800 hp).
4.0 Burner and Controls

4.1 Mode of Operation
Select one of the following:
A. 15 and 20 hp. Burner operation shall be on-off principle.
B. 30 and 40 hp. Burner operation shall be high-low-off principle. The burner shall always return to low fire position for igni-
tion.
C. 50 - 800 hp. Burner operation shall be full modulation principle. The burner shall always return to low fire position for igni-
tion.
4.2 Blower
4.2.1 Air for combustion shall be supplied by a forced draft blower mounted in the front boiler door, above the burner, to eliminate
vibration and reduce noise level.
4.2.2 Maximum sound level of the boiler/burner package shall not exceed _____ dbA (when measured in accordance with ABMA
Sound Test Standards).
4.2.3 The impeller shall be cast aluminum, radial blade, carefully balanced, and directly connected to the blower motor shaft.
4.3 Combustion Air Control
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 - 800 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 oper-
ation of the damper control motor.
4.4 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).
Fuel series 600 - No. 6 oil fired (4.4.4).
Fuel series 400 - No. oil or gas fired (4.4.5).
4.4.1 Fuel Series 700 - Gas Fired
4.4.1.1 Burner Type - The burner shall be integral with the front head of the boiler and of high radiant multi-port type for gas. The
burner shall be approved for operation on natural gas fuel.
4.4.1.2 Gas Pilot - The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the
pilot so that the primary gas valve cannot open until pilot flame has been established. The pilot train shall include two manual shut-
off valves, solenoid valve, pressure regulator and pressure gauge.
4.4.1.3 Gas Burner Piping - Gas burner piping on all units shall include primary gas shutoff valve, motor operated with proof of
closure switch and plugged leakage test connection. The main gas valve(s) shall be wired to close automatically in the event of
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07-02
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 fur-
nished at entrance to gas train. Select one of the following:
A. 15-50 hp. Burners equipped as shown above.
B. 60-100 hp. High and low gas pressure switches shall be provided.
C. 125-250 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an addi-
tional plugged leakage test connection shall be provided.
D. 300-800 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an addi-
tional plugged leakage test connection shall be provided. A vent valve shall be located between the safety shutoff valves.
4.4.1.4 Burner Turndown - Select one of the following:
A. 15 and 20 hp. Burner shall operate on the on/off principle.
B. 30 and 40 hp. Burner shall operate on the high-low-off principle with a turndown of 3:1 when firing natural gas.
C. 50-200 hp. Turndown range of burner shall be 4:1 when firing natural gas.
D. 250-800 hp. Turndown range of the burner shall be 10:1 when firing natural gas. (Consult with your local Cleaver-Brooks
authorized representative regarding high turndown capability based on available gas pressure.)
4.4.2 Fuel Series 100 - Light Oil Fired
4.4.2.1 Burner Type - The burner shall be integral with the front head of the boiler, and shall be a low pressure air atomizing type
approved for operation with CS12-48, Commercial No. 2 oil.
4.4.2.2 Oil Pilot - The oil pilot shall be air atomizing type with automatic electric ignition and include oil solenoid valve. An elec-
tronic detector shall monitor the pilot so that the primary oil valve cannot open until flame has been established.
4.4.2.3 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Select one of
the following:
A. 15 hp through 40 hp. The oil pump shall be integral with the burner and belt driven from the blower motor.
B. 50 hp through 800 hp. Separate motor driven pump set, shipped loose to be installed in a location favorable to the oil storage
tank, shall be provided.
4.4.2.4 Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, solenoid
shutoff valves, pressure gauges and fuel strainer, all integrally mounted on the unit. Select one of the following:
A. 50 hp through 800 hp. A fuel oil controller shall be provided to combine all of the fuel oil controls into a single casting
which is mounted on the front door of the unit. A single tip retractable nozzle shall be used for the low pressure air atomizing
burner.
B. 70 hp through 800 hp. A low oil pressure switch shall be included in the oil piping.
4.4.2.5 Low Pressure Air Atomizing - Select one of the following:
A. 15 hp through 40 hp. Belt driven air compressor, lubricating oil tank, oil level indicator, inlet air filter, air pressure gauge,
and low atomizing air pressure switch.
B. 50 hp through 100 hp. Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch.
C. 125 hp through 350 hp. Belt driven air compressor, lubricating air tank, oil level indicator, inlet air filter, air pressure gauge,
D. 400 hp through 800 hp. Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch.
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 200 hp. Turndown range shall be 4:1 when firing No. 2 oil.
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D. 250 hp through 800 hp. Turndown range shall be 8:1 when firing No. 2 oil.
4.4.3 Fuel Series 200 - Light Oil or Gas Fired
4.4.3.1 Burner Type - The burner, integral with the front head of the boiler, shall be a combination of the low pressure air atomizing
type for oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial
No. 2 Oil or natural gas.
4.4.3.2 Gas Pilot - The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the pilot
so that the primary fuel valve cannot open until flame has been established. The pilot train shall include two manual shut-off
valves, solenoid valve, pressure regulator and pressure gauge.
4.4.3.3 Oil Burner
4.4.3.3.1 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Select one
of the following:
B. 50 hp through 800 hp. Separate motor driven pump set, shipped loose, to be installed in a location favorable to the oil stor-
age tank, shall be provided.
4.4.3.3.2 Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, solenoid
burner.
4.4.3.3.3 Low pressure air atomizing. Select one of the following:
A. 15 hp through 40 hp. Belt driven air compressor, lubricating oil tank, oil level indicator, inlet air filter, air pressure gauge
C. 125 hp through 350 hp. Belt driven air compressor, lubricating air tank, oil level indicator, inlet air filter, air pressure gauge
4.4.3.4 Gas Burner
4.4.3.4.1 Gas Burner Piping - gas burner piping on all units shall include primary gas shutoff valve, motor operated with proof of
provided as a means for a tightness check of the primary shut off valve. An additional plug cock or butterfly valve shall be fur-
D. 300-800 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an addi-
4.4.3.5 Burner Turndown
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07-02
B. 30 and 40 hp. Burner shall operate on the high-low-off principle with a turndown of 3:1
C. 50-200 hp. Turndown range of the burner shall be 4:1.
D. 250-800 hp. Turndown range of the burner shall be 10:1 when 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.)
4.4.4 Fuel Series 600 - No. 6 Oil Fired
4.4.4.1 Burner Type - The burner shall be integral with the front head of the boiler and low pressure air atomizing type approved for
operation with CS12-48, Commercial No. 6 Oil.
pilot so that the primary oil valve cannot open until pilot flame has been established. The pilot train shall include two manual shut-
4.4.4.3 Oil Pump - An oil pump set with a capacity of approximately twice the maximum burning rate shall be included.
A separate motor driven pump set shall be included shipped loose for location favorable to the oil storage tank.
4.4.4.4 Oil Burner Piping - A fuel oil controller combining all of the fuel oil controls into a single casing shall be provided. Oil
pressure regulating devices, oil metering controls, solenoid shutoff valves, high and low oil temperature switches and necessary
pressure and temperature gauges shall be included in this packaged assembly mounted on the front door of the boiler. A fuel
strainer shall also be provided, mounted to the boiler. A single tip retractable nozzle shall be used for the low pressure air atomizing
burner. Flexible hoses shall be provided to allow easy removal of the nozzle for inspection when it is placed in the vice jaws located
on the front door of the boiler.
The metering valve shall permit circulation of hot oil to the burner at all times. The burner drawer oil piping and nozzle shall be
purged of oil on each shutdown.
For 70 through 800 hp, a low oil pressure switch shall be included in the oil piping.
A. 50 through 100 hp. Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch.
B. 125 through 350 hp. Belt driven air compressor, lubricating oil tank, oil level indicator, inlet air filter, air pressure gauge and
low atomizing air pressure switch.
C. 400 through 800 hp. Separate air compressor modules mounted on boiler base rail with low atomizing air pressure switch.
4.4.4.6 Oil Preheat
The oil shall be preheated by a steam heater and electric heater, each with thermostatic control. Both heaters shall be installed in a
single compact shell mounted, piped, and wired on the boiler. The thermostatic controls shall be set to cut-out the electric heater
when steam is available. Select one of the following:
A. 50 through 200 hp. Electric preheater size shall be 5 kW.
B. 250 through 800 hp. Electric preheater size shall be 7-1/2 kW.
NOTICE
15 psig only - 500 through 800 hp. Electric preheater size 10 kW.
4.4.5 Fuel Series 400 - No. 6 Oil or Gas Fired

4.4.5.1 Burner Type - The burner shall be integral with the front head of the boiler and shall be a combination of the low pressure
atomizing type for oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48
Commercial No. 6 oil or natural gas.
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A2-Text Page 53 Friday, December 13, 2002 12:38 PM
4.4.5.3 Oil Burner
4.4.5.3.1 Oil Pump - An oil pump set with a capacity of approximately twice the maximum burning rate shall be included.
4.4.5.3.2 Oil Burner Piping - A fuel oil controller combining all of the fuel oil controls into a single casing shall be provided. Oil
pressure regulating devices, oil metering controls, solenoid shutoff valves, high and low oil temperature switches, and the neces-
sary pressure and temperature gauges shall be included in this packaged assembly mounted on the front door of the boiler. A fuel
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.
4.4.5.6 Oil Preheat
NOTICE
15 psig only - 500 through 800 hp Electric preheater size 10 kw.
4.4.5.7 Gas Burner

4.4.5.7.1 Gas Burner Piping - Gas burner piping on all units shall include primary gas shutoff valve, motor operated with proof of
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. Select one of the following:
A. 50 hp. Burner equipped as shown above.
B. 60 through 100 hp. High and low gas pressure switches shall be provided.
C. 125 through 250 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an
additional plugged leakage test connection shall be provided.
D. 300 through 800 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an
additional leakage test connection shall be provided. A vent valve shall be located between the safety shutoff valves.
4.4.5.7.2 Burner Turndown - Turndown shall be 4:1.
4.5 Boiler Flame Safeguard Controller and Control Panel
4.5.1 CB780 Flame Safeguard
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07-02
4.5.1.1 Boilers with CB780 Control - Each boiler shall be factory equipped with flame safeguard controller providing technology
and functions equal to the Cleaver-Brooks Model CB780.
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 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 follow-
ing 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 linkages and pilot flame for minimum turndown tests.
4.5.1.2 Control Panel - The control panel shall be mounted on the front door of the boiler in a location convenient to the operator.
The hinged metal cabinet will have NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet key type lock.
The panel shall contain the boiler 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 and heavy oil fired boilers the panel will contain the fuel selector and/or oil heater selector switch.
The panel shall contain the following lights and switches:
4.5.1.3 Lights
White - load demanded.
White - fuel valve open.
Red - low water.
Red - flame failure.
4.5.1.4 Control Switches
Burner On-Off.
Manual-Automatic.
Manual Firing Rate Control.
4.5.1.5 Oil, heat and moisture resistant wire shall be used and identified with circuit numbers corresponding to the electrical wiring
diagram.
4.5.1.6 All electrical equipment and wiring shall be in conformance with Underwriters Laboratories requirements.
4.5.1.7 Boiler to be supplied with a control circuit transformer and fuse protection for the control circuit.
4.5.2 CB-HAWK Flame Safeguard
Each boiler shall be factory equipped with a Boiler Management Control System providing technology and functions equal to the
Cleaver-Brooks Model CB-HAWK.
The system shall consist of a computer based boiler controller and solid state sensors totally integrated to provide automatic burner
sequencing, flame supervision, and indications of system status, faults, and self-diagnostics.
The boiler controller shall consist of chassis, program module, keyboard display, and flame signal amplifier. It shall be the non-
recycle type and have a fixed operating sequence incapable of being manually altered. The sequence shall include standby, pre-
purge, pilot, main fuel ignition, and run, and post-purge periods.
The system shall incorporate full modulating control of fuel and combustion air as well as firing rate control based on system
demand.
The boiler controller shall have a non-volatile memory that retains history files and sequence status after interruptions.
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07-02
An 80 character, 2 line liquid crystal (LCD) display and keyboard shall be provided to adjust control settings and display 73 fault
messages, 12 diagnostic messages, 38 historical messages as well as system status messages and operating pressures and tempera-
tures. Boiler firing rate shall also be displayed in addition to the last 6 lockouts and boiler operating information when the lockout
occurred. Provisions for a security access code shall be provided.
Separate status indicators will show:
Ready: HAWK operational.
Demand: call for heat.
Main Valve: fuel valve open.
Low Water: low water condition.
Alarm: safety shutdowns.
The boiler controller shall incorporate a five function run/test switch.
The system shall be characterized for each individual model boiler. The system shall also incorporate a tailored pre-purge cycle
that minimizes pre-purge energy losses, while maintaining the maximum required air changes. It shall permit the user to select a
specific rate control program for precise load tracking that reduces on-off cycling due to load swings. The system shall also pro-
vide an integrated thermal stress protection program to prolong boiler life. An assured low fire cutoff feature shall also be pro-
vided.
The system shall monitor inputs from solid state sensor for gas pressure, oil pressure, and temperature. A single solid state sensor
shall be used for both on-off and proportioning control of the burner. The high/low limits and operating set points of all sensors
will be programmable from the keyboard display. The system shall be capable of detecting a jumpered or defective sensor. A
dynamic check of the gas pressure sensor shall be made prior to the main flame establishing period to ensure it is fully operational.
An optional 2 way communications module to allow for remote control of non-safety settings and monitoring of up to 6 boilers
shall also be available. Up to 3 pre-programmed telephone numbers shall be called in the event of a fault condition. Options such
as Lead/Lag, Boiler Efficiency, and Heating Boiler packages can be interfaced to this module without any change to the existing
system structure. The communications module shall be able to interface with an IBMTM PC or compatible system.
4.5.2.1 Control Panel: The control panel shall be mounted on the front door of the boiler in a location convenient to the operator.
The 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.
4.5.2.2 Oil, heat, and moisture resistant wire shall be used and identified with circuit numbers corresponding to the electrical wiring
diagram.
5.0 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 effi-
ciency guarantees at 25%, 50%, and 75% of rating, if required). If the boiler(s) fail to achieve the corresponding guaranteed effi-
ciency 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.
5.1 Fuel specification used to determine boiler efficiency:
5.1.1 Natural Gas
A2-55
07-02
Carbon, % (wt) = 69.98

Sulfur, % (wt) = 0.0
5.1.2 No. 2 Oil
Carbon, % (wt) = 85.8
5.1.3 No. 6 Oil
Carbon, % (wt) = 86.6
Sulfur, % (wt) = 2.09
5.2 Efficiencies are based on ambient air temperature of 80 F, relative humidity of 30%, and 15% excess air in the exhaust flue gas.
5.3 Efficiencies are based on manufacturers published radiation and convection losses. (For Cleaver-Brooks radiation and convec-
tion losses, see Boiler Efficiency Facts Guide, publication number CB-7767).
5.4 Any efficiency verification testing will be based on the stack loss method.
6.0 Warranty
6.1 All equipment is to be guaranteed against defects in materials and/or workmanship for a period of 12 months from date of
start-up or 18 months from date of shipment, whichever comes first.
7.0 Execution
7.1 Shop Tests
7.1.1 The packaged boiler must receive factory tests to check the construction, controls, and operation of the unit. All tests may be
witnessed by the purchaser, if desired.
7.2 Start-up Service
7.2.1 After boiler installation is completed, the manufacturer shall provide the services of a field representative for starting the unit
and training the operator at no additional costs.
7.2.1.1 A factory approved and authorized start-up report shall be submitted to the customer/user at the time of start-up.
A2-56
07-02
Model CB Hot Water Boiler (15-800 hp, 30 psig, 125 psig)
1.0 Boiler Characteristics (Hot Water)

1.1 The Hot Water Boiler shall be Cleaver-Brooks Model CB, Fuel Series ______ (100, 200, 400, 600, 700), _____ hp designed for
_____ psig (30, 125, or other psig hot water). The maximum water temperature will be _____ degree F, and the maximum system
temperature drop will be _____ degree F.
ural gas, _____ Btu/cu-ft. Electrical power available will be _____Volt _____ Phase _____ Cycle.

2.1 The boiler shall be a four pass horizontal firetube updraft boiler with five (5) square feet of heating surface per rated boiler
The complete package boiler shall be approved as a unit by Underwriters Laboratories and shall bear the UL/ULC label.
2.2 Boiler Shell (Hot Water)
2.2.2 The hot water return and outlet connections shall be located on the top center line of the boiler. The boiler shall be designated
to rapidly mix the return water with the boiler water. Forced internal circulation shall be used.
2.2.3 A dip tube shall be included as an integral part of the water outlet.
The shell must be furnished with adequate handholes to facilitate boiler inspection and cleaning.
2.5 The entire boiler based frame and other components shall be factory painted before shipment using a hard finish enamel coat-
ing.
A2-57
07-02
3.0 Hot Water Boiler Trim

3.1 Low Water Cutoff
A low water cutoff control (manual reset) shall be mounted on the top centerline of the boiler wired into the burner control circuit
to prevent burner operation if boiler water falls below a safe level.
3.2 Pressure and Temperature Gauges
Pressure and temperature gauges shall be mounted on the boiler with temperature sensing element located adjacent to the hot water
outlet.
3.3 Relief Valves
Water relief valves of a type and size to comply with ASME Code requirements shall be shipped loose.
3.4 Temperature Controls
Temperature controls to regulate burner operation shall be mounted on the unit with temperature sensing elements located adjacent
to the hot water outlet. Controls shall be high limit (manual reset), operating limit (auto reset), and firing rate control (30-800 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 igni-
tion.
C. 50 - 800 hp. Burner operation shall be full modulation principle. The burner shall always return to low fire position for igni-
tion.
4.2 Blower
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 - 800 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 oper-
ation of the damper control motor (remove this sentence when a CB-HAWK Flame Safeguard is used).
A2-58
07-02
Fuel series 600 - No. 6 oil fired (4.4.4).

Fuel series 400 - No. oil or gas fired (4.4.5).
125-250 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional
plugged leakage test connection shall be provided.
B. 30 and 40 hp. Burner shall operate on the high-low-off principle with a turndown of 3:1 when firing natural gas.
C. 50-200 hp. Turndown range of burner shall be 4:1 when firing natural gas.
D. 250-800 hp. Turndown range of the burner shall be 10:1 when firing natural gas. (Consult with your local Cleaver-Brooks
authorized representative regarding high turndown capability based on available gas pressure.)
the following:
B. 50 hp through 800 hp. Separate motor driven pump set, shipped loose to be installed in a location favorable to the oil storage
tank, shall be provided.
burner.
A2-59
07-02
A. 15 hp through 40 hp. Belt driven air compressor, lubricating oil tank, oil level indicator, inlet air filter, air pressure gauge,
C. 125 hp through 350 hp. Belt driven air compressor, lubricating air tank, oil level indicator, inlet air filter, air pressure gauge,
4.4.2.6 Burner Turndown - Turndown range of the burner shall be 4:1 when firing No. 2 oil. Select one of the following:
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 200 hp. Turndown range shall be 4:1 when firing No. 2 oil.
D. 250 hp through 800 hp. Turndown range shall be 8:1 when firing No. 2 oil.
No. 2 Oil or natural gas.
4.4.3.3 Oil Burner
of the following:
B. 50 hp through 800 hp. Separate motor driven pump set, shipped loose, to be installed in a location favorable to the oil stor-
age tank, shall be provided.
burner.
4.4.3.3.3 Low pressure air atomizing - Select one of the following:
A. 15 hp through 40 hp. Belt driven air compressor, lubricating oil tank, oil level indicator, inlet air filter, air pressure gauge
C. 125 hp through 350 hp. Belt driven air compressor, lubricating air tank, oil level indicator, inlet air filter, air pressure gauge
4.4.3.4 Gas Burner
A2-60
07-02
D. 300-800 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus and addi-
B. 30 and 40 hp. Burner shall operate on the high-low-off principle with a turndown of 3:1
C. 50-200 hp. Turndown range of the burner shall be 4:1.
D. 250-800 hp. Turndown range of the burner shall be 10:1 when firing natural gas and 8:1 on No. 2 oil. (Consult with your
local Cleaver-Brooks authorized representative regarding high turndown capability based on available gas pressure.)
purged of oil on each shutdown.
4.4.4.6 Oil Preheat
The oil shall be preheated by a safety type water-to-water-to-oil preheating system in conjunction with an electric preheater, each
with thermostatic control. Both heaters shall be mounted, piped, and wired on the boiler. Select one of the following:
C. 400 through 800 hp. Electric preheater size shall be 10 kW.
A2-61
07-02

pilot so that the 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.
4.4.5.3 Oil Burner
piping and nozzle shall be purged of oil at each shutdown.
4.4.5.6 Oil Preheat
The oil shall be preheated by a safety type water-to-water-to-oil preheating system in conjunction with an electric preheater, each
with thermostatic control. Both heaters shall be mounted, piped, and wired on the boiler. Select one of the following:
4.4.5.7 Gas Burner
provided as means for a tightness check of the primary shutoff valve. An additional plug cock or butterfly valve shall be furnished
A. 50 hp. Burner equipped as shown above.
B. 60 through 100 hp. High and low gas pressure switches shall be provided.
125 through 250 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an
A2-62
07-02
Controller shall be computerized solid state having sequence and flame-on lights and digital first out fault code indications of
cycles.
ing trip functions: pilot and main flame failure, high and low fire proving switch faults, running interlocks open, false flame signal
For combination gas-oil and heavy oil fired boilers the panel will contain the fuel selector and/or oil heater selector switch.
4.5.1.3 Lights
Red - low water.
Burner On-Off.
Manual-Automatic.
diagram.
demand.
A2-63
07-02
Separate status indicators will show:
vide an integrated thermal stress protection program to prolong boiler life. An assured low fire cutoff feature shall also be
provided.
will be programmable from the keyboard display. The system shall be capable of detecting a jumpered or defective sensor. A
An optional 2 way communications module with built-in modem to allow for remote control of non-safety settings and monitoring
of up to 6 boilers shall also be available. Up to 3 pre-programmed telephone numbers shall be called in the event of a fault condi-
tion. Options such as Lead/Lag, Boiler Efficiency, and Heating Boiler packages can be interfaced to this module without any
change to the existing system structure. The communications module shall be able to interface with an IBMTM PC or compatible
system.
and heavy oil fired boilers the panel will contain the fuel selector and/or oil heater selector switch.
diagram.

The boiler manufacturer shall guarantee that, at the time of startup, the boiler will achieve ________ fuel-to-steam efficiency at
A2-64
07-02

5.1.1 Natural Gas
Carbon, % (wt) = 69.98
5.1.2 No. 2 Oil
Carbon, % (wt) = 85.8
5.1.3 No. 6 Oil
Carbon, % (wt) = 86.6
Sulfur, % (wt) = 2.09
6.0 Warranty
6.1 All equipment is to be guaranteed against defects in materials and/or workmanship for a period of 12 months from date of start-
up or 18 months from date of shipment, whichever comes first.
7.0 Execution
7.1 Shop Tests
A2-65
07-02
NOTES
A2-66
07-02
Section A3
MODEL CB-LE BOILERS
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Available Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Specifying Boiler Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-23
Efficiency Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-23
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-23
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-26
Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-26
Gas-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-26
Oil-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-27
General Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-33
Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-33
SAMPLE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-38
ILLUSTRATIONS
Figure A3-1. Model CB-LE Steam Boiler Dimensions, 60 (15 - 150 psig Design Pressure) - Sheet 1 of 2 . . . . . . . . . . A3-8
Figure A3-4. Model CB-LE Hot Water Boiler Dimensions, 60 (30 and 125 psig Design Pressure) - Sheet 1 of 2 . . . . A3-14
Figure A3-7. Space Required to Open Rear Head on Model CB-LE Boilers Equipped with Davits . . . . . . . . . . . . . . . . A3-20
A3-1
02-02
Model CB-LE Boilers Firetube Boilers
Figure A3-8. Model CB-LE Boiler Mounting Piers (60 and 78) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-20
Figure A3-9. Model CB-LE Boiler Mounting Piers (96). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-21
Figure A3-10. Lifting Lug Location, Model CB-LE Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-22
Figure A3-11. Predicted Stack Temperature Increase for Pressure Greater Than 125 psig . . . . . . . . . . . . . . . . . . . . . . . A3-24
Figure A3-12. Standard Gas Train Connection Size and Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-28
Figure A3-14. Model CB-LE Gas Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-30
Figure A3-15. No. 2 Oil Connection Size, Location, and Recommended Line Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-30
Figure A3-17. No. 2 Oil Piping, Multiple Boiler Installation, Remote Oil Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-31
Figure A3-20. Typical Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-33
Figure A3-21. Boiler Room Length (Typical Layouts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-36
Figure A3-22. Boiler Room Width (Typical Layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-36
Figure A3-23. Breeching Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-37
TABLES
Table A3-1. Model CB-LE Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4
Table A3-2. Model CB-LE Hot Water Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4
Table A3-3. Model CB-LE Combustion Air Fan Motor Horsepower Requirements -
Operating Pressures 125 psig and Less, and All Hot Water Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
Table A3-4. Model CB-LE Combustion Air Fan Motor Horsepower Requirements -
Operating Pressures Greater Than 125 psig (Steam Boilers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
Table A3-5. Model CB-LE Boiler Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6
Table A3-6. Steam Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
Table A3-7. Hot Water Boiler Relief Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
Table A3-8. Predicted Fuel-to-Steam Efficiencies - Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-24
Table A3-9. Predicted Fuel-to-Steam Efficiencies - No. 2 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-25
Table A3-10. CB-LE Boilers - Natural Gas, Emission Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-25
Table A3-11. CB-LE Boilers - No. 2 Oil, Emission Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-25
Table A3-12. Model CB-LE Predicted Sound Levels30 ppm NOx Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-26
Table A3-13. Under and Oversized Standard, FM, and IRI Gas Trains, Model CB-LE Boilers . . . . . . . . . . . . . . . . . . . . A3-27
Table A3-14. Minimum Required Regulated Gas Pressure at the Entrance to Standard, FM, and IRI Gas Trains . . . . . . A3-27
Table A3-16. Maximum Gas Consumption (CFH) for Natural Gas and Propane Vapor . . . . . . . . . . . . . . . . . . . . . . . . . . A3-28
Table A3-17. Model CB-LE Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-34
Table A3-18. Heating Surface, Model CB-LE Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-34
Table A3-19. Steam Volume and Disengaging Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-35
Table A3-20. Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity) . . . . . . . . . . . . . . . . A3-35
Table A3-21. Recommended Non-Return Valve Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-35
Available as an option to the Model CB Firetube Dryback Boiler (125 - 800 hp), the Low Emission Option provides NOx control,
top performance, and reliable Cleaver-Brooks 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% O2):
NOx performance for 60 ppm (natural gas corrected to 3% O2) 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% O2) includes a larger combustion air fan/motor assembly
and a larger internal NOx reduction system.
Cleaver-Brooks' commitment to lowering emissions is based on more than 400 low NOx installations - all passing guaranteed
emission performance levels.
A3-2
02-02
Firetube Boilers Model CB-LE Boilers
FEATURES AND BENEFITS Full line of Model CB Firetube options.
The Cleaver-Brooks Model CB Boiler - the premium firetube Additional NOx reduction packages.
on the market today - includes the four-pass dryback design,
five square feet of heating surface per boiler horsepower, and DIMENSIONS AND RATINGS
maximum boiler efficiency. In addition to the features of the
Model CB Boiler, the Low Emission Option provides the fol- The Model CB-LE dimensions and ratings are provided in
lowing Tables A3-1 through A3-7, and in Figures A3-1 through A3-
10.
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 autho-
rized representative.
A3-3
02-02
Table A3-1. Model CB-LE Steam Boiler Ratings
BOILER HP 125 150 200 250 300 350 400 500 600 700 750 800
RATINGS SEA LEVEL TO 700 FT
Rated Steam Cap. (lbs/hr 4313 5175 6900 8625 10350 12075 13800 17250 20700 24150 25875 27600
from and @ 212 F)
Btu Output (1000 Btu/hr) 4184 5021 6695 8369 10043 11716 13390 16738 20085 23432 25106 26779
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 A3-3 and A3-4
Air Compressor Motor hp (Oil 3 3 3 3 3 3 7-1/2 7-1/2 7-1/2 7-1/2 7-1/2 7-1/2
firing Only)
NOTES:
Table A3-2. Model CB-LE Hot Water Boiler Ratings

BOILER HP 125 150 200 250 300 350 400 500 600 700 750 800
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 A3-3 and A3-4
Air Compressor Motor hp (Oil firing Only) 3 3 3 3 3 3 7-1/2 7-1/2 7-1/2 7-1/2 7-1/2 7-1/2
NOTES:
A3-4
02-02
Table A3-3. Model CB-LE Combustion Air Fan Motor

Horsepower Requirements - Operating Pressures 125 psig
and Less, and All Hot Water Boilers
MOTOR HP
BOILER HP
60 PPM 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 Table A3-4. Model CB-LE Combustion Air Fan Motor
350 15 25 40 40
Horsepower Requirements - Operating Pressures Greater Than
125 psig (Steam Boilers)
400 10 15 20 20
500 15 20 25 30
MOTOR HP
600 20 30 50 60 BOILER HP
700 30 50 75 75 60 PPM 30 PPM 25 PPM 20 PPM
750 50 60 75 NA 125 5 10 10 10
800 50 75 NA NA 150 10 10 10 15
NOTES: For elevations above 700 - contact your local Cleaver- 200 15 20 20 NA
Brooks authorized representative. 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 75B 75C
750 50 75 NA NA
800 60 75A NA NA
NOTES: For elevation above 700 - contact your local Cleaver-
Brooks authorized representative.
A. Downrate to 770 hp.
B. Downrate to 675 hp.
C. Downrate to 660 hp.
A3-5
02-02
Table A3-5. Model CB-LE Boiler Weights

HOT WATER STEAM
FUEL
BOILER HP SERIES 30 PSIG 125 PSIG 15 PSIG 150 PSIG 200 PSIG
100 11200 11600 11300 12000 12600
125 200 11400 11800 11500 12400 13000
700 11300 11700 11400 12300 12900
100 12300 12700 12400 13200 13900
150 200 12500 12900 12600 13500 14200
700 12300 12700 12400 13300 14000
100 14400 14800 14500 15500 16300
200 200 14500 14900 14600 15600 16400
700 14500 14900 14600 15600 16400
100 20700 21500 20800 22000 23800
250 200 21400 22200 21500 22800 24600
700 20900 21700 21000 22500 24300
100 23100 23900 23200 24800 26800
300 200 23500 24300 23600 25200 27200
700 23400 24200 23500 25000 27000
100 26200 27000 26300 27600 29100
350 200 26700 27500 26800 27800 29300
700 26400 27200 26500 27700 29200
100 33000 36970 33200 36270 39380
400 200 33300 37270 33500 36570 39680
700 33200 37170 33400 36470 39580
100 36600 40470 36810 39670 43480
500 200 36900 40780 37110 39970 43580
700 36800 40680 37010 39870 43280
100 41850 45905 42000 44725 49100
600 200 42150 46005 42300 45025 49400
700 42050 45915 42200 44925 49300
100 49450 53000 49300 51850 57015

700 200 49750 53300 49600 52150 57315
800
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.
A3-6
02-02
Table A3-6. Steam Boiler Safety Valve Openings

VALVE
SETTING
BOILER HP VALVES SIZE VALVES SIZE VALVES SIZE VALVES SIZE VALVES SIZE VALVES SIZE
REQ'D (IN.) REQ'D (IN.) REQ'D (IN.) REQ'D (IN.) REQ'D (IN.) REQ'D (IN.)
(1) 1-1/2 (1) 1-1/2 (1) 1-1/4
125 1 3 2 1-1/2 2 2 2 2 1
(1) 1-1/4 (1) 1-1/4 (1) 1
(1) 2 (1) 1-1/2 (1) 1
150 1 3 2 2 1-1/2 2 2 1-1/4 2
(1) 1-1/2 (1) 1-1/4 (1) 1-1/4
(1) 2 (1) 1-1/2
200 2 2-1/2 2 2 2 2 1-1/2 2 2 1-1/4
(1) 1-1/2 (1) 1-1/4
(1) 2-1/2 (1) 2-1/2 (1) 2 (1) 1-1/2
250 2 2 2 2 2 2 1-1/2 2
(1) 3 (1) 2 (1) 1-1/2 (1) 1-1/4
(1) 2-1/2 (1) 2
300 2 3 2 2-1/2 2 2 (2) 2 2 2 1-1/2
(1) 2 (1) 1-1/2
(1) 2 (1) 2-1/2 (1) 2-1/2 (1) 1-1/2
350 3 3 2 2-1/2 2 2 2 2
(2) 3 (2) 2 (1) 2 (1) 2
(2) 3 (1) 2 (1) 2-1/2 (1) 2
400 3 3 2 2-1/2 2 2 2 2
(1) 2-1/2 (2) 2-1/2 (1) 2 (1) 1-1/2
(2) 2-1/2 (1) 2-1/2
500 3 (3) 3 3 2-1/2 3 2 (2) 2-1/2 2 2 (2) 2
(1) 2 (1) 2
(3) 2-1/2 (2) 2-1/2 (1) 2
600 4 3 4 3 2-1/2 3 2 2-1/2 2
(1) 2 (1) 2 (1) 2-1/2
700, 750 & (3) 3 (3) 2-1/2 (3) 2-1/2 (2) 2-1/2
5 5 4 3 2 2-1/2 2 2-1/2
800 (2) 2-1/2 (2) 2 (1) 2 (1) 2
NOTES: Valve manufacturers are Kunkle, Consolidated or Conbraco, depending on availability.
Table A3-7. Hot Water Boiler Relief Valve Openings

VALVE
30 PSIG HW 60 PSIG HW 100 PSIG HW 125 PSIG HW
SETTING
BOILER HP VALVES SIZE VALVES SIZE VALVES SIZE VALVES SIZE
REQ'D (IN.) REQ'D (IN.) REQ'D (IN.) REQ'D (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
(1) 2-1/2
200 2 1 2-1/2 1 2 1 2
(1) 1-1/4
(1) 2
250 2 1 2-1/2 1 2-1/2 1 2
(1) 2-1/2
(1) 1
300 2 2-1/2 2 1 2-1/2 1 2-1/2
(1) 2-1/2
(2) 2-1/2 (1) 2-1/2
350 3 2 1 2-1/2 1 2-1/2
(1) 1 (1) 2
(1) 2 (1) 2 (1) 1
400 3 2 2 1 2-1/2
(2) 2-1/2 (2) 2-1/2 (1) 2-1/2
(1) 1 (1) 2-1/2 (1) 1
500 4 2 2-1/2 2 2
(3) 2-1/2 (1) 1-1/4 (1) 2-1/2
(3) 2-1/2 (1) 1-1 (1) 2 (1) 2-1/2
600 4 3 2 2
(1) 2 (2) 2-1/2 1) 2-1/2 (1) 1-1/4
700, 750 & (1) 1 (1) 2 (1) 2-1/2
5 3 2 2-1/2 2
800 (4) 2-1/2 (2) 2-1/2 (1) 2
NOTES: Hot water relief valves are Kunkle #537.
A3-7
02-02
BOILER HP DIM 125 150 200

LENGTHS
Overall (60 ppm System) A 171-1/2 196-1/2 228-1/2
Shell B 125 149 180
Base Frame C 124 148 179
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 56 70-1/2 90
Front Ring Flange to Nozzle -150 lb H 55 66 78
Ring Flange to Base F&G 1/2 1/2 1/2
Over Tubesheets V 113 137 168
Shell Extension P 12 12 12
Figure A3-1. Model CB-LE Steam Boiler Dimensions, 60 (15 - 150 psig Design Pressure) - Sheet 1 of 2
A3-8
02-02

WIDTHS
Overall I 85 85 85
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 77 77 77
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 U 8A 8A 10A
Drain, Front and Rear W 1-1/2 1-1/2 2
High Pressure (150 lb only) T 1 1 1
Steam Nozzle Y 4B 4B 4B
Blowdown, Front and Rear W 1-1/2 1-1/2 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.

A3-9
02-02

LENGTHS
Overall (60 ppm System) A 191-1/2 220 252
Shell B 144 171 201
Front Head Extension (60 ppm System) D 23-1/2 25 28
Rear Head Extension E 24 24 24
Front Ring Flange to Nozzle - 15 lb H 72 85-1/2 100-1/2
Front Ring Flange to Nozzle - 150 lb H 59-1/2 73 88
A3-10
02-02

WIDTHS
Overall I 103 103 103
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 52 52 52
HEIGHTS
Base to Steam Outlet X 96 96 96
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 10A 12A 12A
Drain, Front and Rear W 2 2 2
High Pressure (150 lb only) T 1 1 1
Steam Nozzle Y 6B 6B 6B
Blowdown, Front and Rear W 1-1/2 1-1/2 1-1/2
VENT STACK
MINIMUM CLEARANCES
Rear Door Swing DD 43 43 43
Tube Removal, Front GG 116 142 172
FROM:
WEIGHT IN LBS
Normal Water Capacity 10670 13000 15465

A3-11
02-02
BOILER HP DIM 400 500 600 700 750 800
LENGTHS
Overall (60 ppm System) A 206 228 262 299 300 300
Shell B 147 168 200 233 233 233
Base Frame C 112 133 165 198 198 198
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 23 23 23 23 23 23
Rear Ring Flange to Base G 12 12 12 12 12 12
Shell Flange to Nozzle 15 lb H 62 77 96 112 112 112
Shell Flange to Nozzle 150 lb H 60 78 96 112 112 112
Over Tubesheets V 130 151 183 216 216 216
Shell Extension P 17 17 17 17 17 17
A3-12
02-02
A3 Text Page 13 Monday, December 16, 2002 2:45 PM
BOILER HP DIM 400 500 600 700 750 800
WIDTHS
Overall I 123 123 123 123 123 123
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
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 56 56 56 56 56 56
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 116 116 116 116 116 116
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
Surface Blowoff, Top CL (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 12A 12A 12A 12A 12A 12A
High Pressure (150 psig Only) Y 6B 8B 8B 8B 8B 8B
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:
A3-13
02-02
LWCO
LENGTHS
Overall (60 ppm System) A 171-1/2 196-1/2 228-1/2
Shell B 125 149 180
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 Outlet HH 114 136 167
Front Ring Flange to Return H 89 102 131
Figure A3-4. Model CB-LE Hot Water Boiler Dimensions, 60 (30 and 125 psig Design Pressure) - Sheet 1 of 2
A3-14
02-02
A3 Text Page 15 Friday, December 13, 2002 12:54 PM
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 77 77 77
BOILER CONNECTION
Waterfill Conn. Right & Left S 1-1/2 1-1/2 2
Auxiliary Connection Z 1 1 1
Water Return Flange T 6A 6A 6A
Water Outlet Flange (2" Dip Tube Included) U 6A 6A 6A
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
FROM:
WEIGHT IN LBS
Water Capacity Flooded 7670 9295 11130
Approx. Ship. Wgt. 30 psig 11400 12500 14500


A3-15
02-02
LWCO

LENGTHS
Overall (60 ppm System) A 191-1/2 220 252
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
A3-16
02-02

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 96 96 96
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 8A 8A 8A
Water Outlet Flange (2" Dip Tube Included) U 8A 8 A

8A
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
NOTES: All connections are threaded unless indicted.

A3-17
02-02
LWCO
BOILER HP DIM 400 500 600 700 750 800
LENGTHS
Overall (60 ppm System) A 206 228 262 299 300 300
Shell B 147 168 200 233 233 233
Base Frame C 112 133 165 198 198 198
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 23 23 23 23 23 23
Rear Ring Flange to Base G 12 12 12 12 12 12
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
A3-18
02-02
BOILER HP DIM 400 500 600 700 750 800
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
Center to Lagging L 51 51 51 51 51 51
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 116 116 116 116 116 116
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 10A 10A 12A 12A 12A 12A
Water Outlet (2 Dip Tube Included) U 10A 10A 12A 12A 12A 12A
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
NOTES: All connections are threaded unless indicated:
A3-19
02-02
DIMENSIONS (INCHES)
BOILER HP
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 71 109 53
Figure A3-7. Space Required to Open Rear Head on Model CB-LE Boilers Equipped with Davits
125 6 9 124 39-1/2 57-1/2 4 44-1/2 9-3/4
150 6 9 148 39-1/2 57-1/2 4 44-1/2 9-3/4
200 6 9 179 39-1/2 57-1/2 4 44-1/2 9-3/4
250 6 12 143 46 70 6 52 22
300 6 12 170 46 70 6 52 22
350 6 12 200 46 70 6 52 22
NOTE:
Figure A3-8. Model CB-LE Boiler Mounting Piers (60 and 78)
A3-20
02-02
BOILER HP A B C D E F G
400 6 14 112 50 78 8 56
500 6 14 133 50 78 8 56
600 6 14 165 50 78 8 56
700-750-800 6 14 198 50 78 8 56
NOTE:
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 A3-9. Model CB-LE Boiler Mounting Piers (96)
A3-21
02-02
ALL DIMENSIONS IN INCHES

BOILER HP VIEW
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
Steam B 99 36 72 10 3
250
Hot Water B 99 36 81 10 3
Steam B 99 36 99 10 3
300
Hot Water B 99 36 108 10 3
Steam B 99 36 129 10 3
350
Hot Water B 99 36 138 10 3
Steam B 119 35-3/4 78 11 3
400
Hot Water B 119 35-3/4 78 11 3
Steam B 119 35-3/4 99 11 3
500
Hot Water B 119 35-3/4 99 11 3
Steam B 119 35-3/4 131 11 3
600
Hot Water B 119 35-3/4 131 11 3
700, 750 & Steam B 119 35-3/4 164 11 3

800 Hot Water B 119 35-3/4 164 11 3
NOTE: A, B and C dimensions may vary by 1/2 inch.
Figure A3-10. Lifting Lug Location, Model CB-LE Boilers
A3-22
02-02
PERFORMANCE DATA 2. Efficiencies are based on ambient air temperature of 80 F,

The Low Emission Option provides NOx reduction at current flue gas.
published and predicted fuel-to-steam efficiencies. Refer to
Tables A3-8 and A3-9. 3. Efficiencies are based on manufacturers published radiation
and convection losses. (For Cleaver-Brooks radiation and con-
vection losses, see Boiler Efficiency Facts Guide, publication
Specifying Boiler Efficiency
number CB-7767).
Cleaver-Brooks offers an industry leading fuel-to-steam boiler
4. Any efficiency verification testing will be based on the stack
efficiency guarantee for Model CB-LE Firetube Boilers. The
loss method.
guarantee is based on the fuel-to-steam efficiencies shown in
the efficiency tables and the following conditions. The effi- For efficiencies and stack temperatures at operating pressures
ciency percent number is only meaningful if the specific con- not listed, follow these procedures:
ditions of the efficiency calculations are clearly stated in the
When the operating steam pressure is between 10 psig and 125
specification (see Cleaver-Brooks publication CB-7768 for a
psig, interpolate the values from the efficiency tables.
detailed description of efficiency calculations).
When the operating steam pressure is above 125 psig, esti-
When specifying the efficiencies in the tables, be sure to
mated efficiency can be calculated as follows:
include the specific guarantee conditions to maximize the
effectiveness of your efficiency specification. If you have any Example:
questions regarding the efficiency specifications, please con-
Boiler: 350 hp.
tact your local Cleaver-Brooks authorized representative.
Fuel: natural gas.
Efficiency Specification Operating steam pressure: 200 psig.
The boiler manufacturer shall guarantee that, at the time of Find the fuel-to-steam efficiency at 100% firing rate. From
startup, the boiler will achieve fuel-to-steam efficiency (as Table A3-8 for a 350 hp boiler operating at 100% firing rate and
shown in Tables A3-8 and A3-9) at 100% firing rate (add effi- an operating steam pressure of 125 psig, the efficiency is
ciency guarantees at 25%, 50%, and 75% of rating, if 82.5%.
required). If the boiler(s) fail to achieve the corresponding
guaranteed efficiency as published, the boiler manufacturer Using Figure A3-11, note that the stack temperature increases
will rebate, to the ultimate boiler owner, five thousand dollars 36 F at the higher operating pressure. To estimate boiler effi-
($5,000) for every full efficiency point (1.0%) that the actual ciency, use this rule of thumb: For every 40 F increase in stack
efficiency is below the guaranteed level. temperature, efficiency decreases by 1%. Since the stack tem-
perature rise is 36 F, the decrease in the boiler efficiency at
The specified boiler efficiency is based on the following condi- 200 psig operating pressure is calculated as follows: 36/40 =
tions. .9%. Therefore, the boiler efficiency at 200 psig operating pres-
1. Fuel specification used to determine boiler efficiency: sure is 82.5 - .9 = 81.6%
Natural Gas
Emissions
Carbon, % (wt) = 69.98
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.
No. 2 Oil
Carbon, % (wt) = 85.8 NOTICE
The data in Tables A3-10 and A3-11 represent typical
emission levels only. Guaranteed emission levels are
available from your local Cleaver-Brooks authorized
No. 6 Oil representative.
Carbon, % (wt) = 86.6
Sulfur, % (wt) = 2.09
A3-23
02-02
Table A3-8. Predicted Fuel-to-Steam Efficiencies - Natural Gas

OPERATING PRESSURE = 10 psig OPERATING PRESSURE = 125 psig
BOILER
% OF LOAD % OF LOAD
HP
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
Figure A3-11. Predicted Stack Temperature Increase for Pressure Greater Than 125 psig
A3-24
02-02
Table A3-9. Predicted Fuel-to-Steam Efficiencies - No. 2 Oil
OPERATING PRESSURE = 10 psig OPERATING PRESSURE = 125 psig

BOILER
% OF LOAD % OF LOAD
HP
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 A3-10. CB-LE Boilers - Natural Gas, Emission Levels

ESTIMATED LEVEL
POLLUTANT
60 ppm 30 ppm 25 ppm 20 ppm
ppmA 200 50/150B 50/150B 200

CO
lb/MMBtu 0.15 0.04/0.11 0.04/0.11 0.15
ppmA 60 30 25 20
NOx
lb/MMBtu 0.07 0.035 0.03 0.024
ppmA 1 1 1 1
SOx
lb/MMBtu 0.001 0.001 0.001 0.001
ppmA 40 40 40 40
HC/VOC5
lb/MMBtu 0.016 0.016 0.016 0.016
ppmA - - - -
PM
lb/MMBtu 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 30 & 25 ppm system is 50 ppm (0.04 lb/MMBtu) when boiler is operating above 50% of rated capacity. CO emission is 150 ppm (0.11
lb/MMBtu) when boiler is operating below 50% of rated capacity.
Table A3-11. CB-LE Boilers - No. 2 Oil, Emission Levels

ESTIMATED LEVEL
POLLUTANT
60 ppm LE Option 30, 25, 20 ppm LE Option
ppmA 90 90
CO
lb/MMBtu 0.07 0.07
ppmA 185 140
NOx
lb/MMBtu 0.25 0.187
ppmA 278 278
SOx
lb/MMBtu 0.52 0.52
ppmA 50 60
HC/VOCs
lb/MMBtu 0.025 0.030
ppmA - -
PM
lb/MMBtu 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 = 0.05% by weight.
Sulfur content = 0.5% by weight.
Ash content = 0.01% by weight.
A3-25
02-02
ENGINEERING DATA Typical Values

Sound pressure levels (dbA) for the same boiler will vary
Sound Level between boiler rooms. Sound levels will vary with motor type,
NOx levels, and altitudes. In addition, variations will occur
Table A3-12 gives a summary of predicated sound pressure
between different people using different sound meters on the
levels for Model CB boilers with 30 ppm LE Options. Contact
same boiler. And finally, no two boilers can be expected to give
your local Cleaver-Brooks authorized representative for sound
precisely the same sound levels. For these reasons, we can only
levels or other LE Options.
predict, but not guarantee, sound levels (dbA).
Units
The units for the sound level tables are dbA (decibels, mea- Gas-Fired Burners
sured on the A-weighted scale) in reference to 0.0002
microbars (20 micro-Newtons per square meter). Their refer-
ence are standardly used in specifying and reporting sound NOTICE
pressure levels on industrial equipment.
A gas pressure regulator must be installed in the gas
Test Method piping to each boiler. Gas pressure regulators for
The sound pressure levels in the above tables were obtained Model CB Firetube Boilers are sized and selected on
from tests in accordance with the ABMA Test Code for the a job-by-job basis. Regulated gas pressure is the
Measurement of Sound from Packages Boilers. In accordance pressure downstream of the gas pressure regulator.
with this code the sound pressure levels reported were mea- Total gas pressure required for the boiler equals reg-
sured on the boiler centerline 4-1/2 feet vertically above the ulated gas pressure plus the pressure drop of the se-
bottom of the base rails and 3 feet horizontally in front of the lected gas pressure regulator.
end of the blower motor or front surface of the electrical cabi- Table A3-13 shows regulated gas pressure with over and
net. undersized gas trains.
Sound Level Meter Table A3-14 shows the required regulated gas pressure at the
The sound level meter used complies with ANSI S1.4, Type 1 entrance to the gas trains.
(Precision). The readings are taken with the meter set for slow Table A3-15 shows minimum required gas pressure altitude
response and corrected for background levels. conversion.
Sound Pressure The following items should be considered when selecting a
The large size boilers, the need for auxiliary equipment, and regulator:
the necessary interconnecting piping make it impractical (and Pressure Rating: The regulator must have a pressure rating at
sometimes impossible) to provide a boiler testing environment least equivalent to that of the gas distribution system.
which is suitable for taking the data needed to develop Sound
Pressure Power levels. Capacity: The capacity can be determined by multiplying the
maximum burning rate (CFH) by 1.15, see Table A3-16. This
15 percent over-capacity rating of the regulator provides for
Table A3-12. Model CB-LE Predicted Sound Levels proper regulation.
30 ppm NOx Systems Spring Adjustment: The spring should be suitable for a range
BOILER
HP
125 150 200 250 300 350 400 500 600 700 750 800 pressure to 50 percent over.
HFO, dbA 84 84 84 83 84 85 84 85 85 88 89 90 Sharp Lock-Up: The regulator should include this feature to
LFO, dbA 82 82 83 81 82 83 82 83 83 84 87 89 prevent the downstream pressure (between the regulator and
HFG, dbA 82 82 83 82 83 84 83 83 85 87 89 90 the boiler) from climbing when there is no gas flow.
LFG, dbA 81 81 82 81 82 83 81 81 82 84 86 88
Regulators in Parallel: This type of installation can be used if
NOTES
1. Sound pressure levels measured on boilers operat-
the required gas volume is very large and if the pressure drop
ing in various locations and expressed in dbA are as ABBREVIATIONS: must be kept to a minimum.
shown: HF = High Fire
2. Based on standard altitude fans and fan motors, 60 LF = Low Fire
Hz. O = Oil Regulators in Series: This type of installation can be used if
3. Contact your local Cleaver-Brooks authorized rep-
resentative for sound levels of 60, 25, or 20 ppm LE
G = Gas the available gas pressure is over 5, 10, or 20 psig.
Options. Depending on the regulator characteristics, one regulator
would reduce the pressure to 2 to 3 psig, and a second
A3-26
02-02
regulator would reduce the pressure to the burner Figure A3-13 shows typical gas train piping layouts for multi-
requirements. ple boiler applications.
Regulator Location: A straight run of gas line piping should Figure A3-14 shows standard gas train components.
be used on both sides of the regulator to ensure proper
regulator operation. This is particularly important when pilot Oil-Fired Burners
operated regulators are used. The regulator can be located
close to the gas train connection, but 2 to 3 feet of straight Fuel oil consumption information is shown on the boiler rating
run piping should be used on the upstream side of the sheets in the Dimensions and Rating Section.
regulator. Figure A3-15 shows the oil connection sizes and locations for
C-B O2 Trim Systems: If a C-B O2 Trim system will be Model CB Boilers firing No. 2 oil.
utilized, contact your local Cleaver-Brooks authorized Figures A3-16 through A3-18 show typical oil systems and
representative to be sure that a compatible regulator is layouts.
selected.
Figures A3-19 and A3-20 show the detail of an oil transfer
Table A3-16 shows maximum gas consumption for natural gas tank (day tank) typically utilized to provide a storage reservoir
and propane vapor. between the oil system supply pump and the boiler oil pump.
Figure A3-12 shows standard gas train sizes and locations for
Model CB Firetube Boilers.
Table A3-13. Under and Oversized Standard, FM, and IRI Gas Trains, Model CB-LE Boilers
125 150 200 250 300 350 400
PIPE PRESS PIPE PRESS PIPE PRESS PIPE PRESS PIPE PRESS PRESS PIPE PIPE PRESS
SIZE REQ SIZE REQ SIZE REQ SIZE REQ SIZE REQ REQ SIZE SIZE REQ
2 12.5 2 17.5 2 27.0 2-1/2 30.5 2-1/2 46.0 2-1/2 64.5 - -
2-1/2 9.0 2-1/2 11.5 2-1/2 16.5 3 23.0 3 32.5 3 45.0 3 36.5
3 7.0 3 9.5 3 13.5 4 15.5 4 24.0 4 33.5 4 22.0
4 6.0 4 8.0 4 10.0 4A 14.5 4A 21.5 4A 30.0 4A 18.0
500 600 700 750 800

Table A3-14. Minimum Required
Regulated Gas Pressure at the Entrance
PIPE PRESS PIPE PRESS PIPE PRESS PIPE PRESS PIPE PRESS to Standard, FM, and IRI Gas Trains
SIZE REQ SIZE REQ SIZE REQ SIZE REQ SIZE REQ
3 59.0 3 79.5 3 NA 3 NA 3 NA MODEL CB

BOILER
CONN SIZE HTBA MIN
4 35.0 4 45.5 4 62.0 4 71.5 4 83.0 HP GAS PRESS
(IN.)
REQ'D
4A 27.5 4A 34.5 4A 46.0 4A 53.5 4A 63.0 250 3 23.0
300 3 32.5
NOTES:
1.Pipe size in inches, and pressure required in inches of WC. 350 3 45.0
2. Standard gas train shown by shaded area. 400 4 22.0
A. Low pressure drop Maxon valves (replaces 6" trains). 500 4 35.0
600 4 45.5
700 4 62.0
750 4 71.5
800 4 83.0
NOTES:
1. Based on 1000 Btu/cu-ft natural gas and
elevations up to 700 feet.
A. HTB is for high turndown (10:1) burners.
A3-27
02-02
Table A3-15. Minimum Required Gas Pressure Altitude Table A3-16. Maximum Gas Consumption (CFH) for Natural
Conversion Gas and Propane Vapor
ALTITUDE CORRECTION ALTITUDE CORRECTION TYPE OF GAS AND HEAT CONTENT
(FT) FACTOR (FT) FACTOR BOILER
HP NATURAL GAS PROPANE GAS
1000 1.04 6000 1.25 1000 (Btu/cu-ft) 2550 (Btu/cu-ft)
2000 1.07 7000 1.30
125 5103 2000
3000 1.11 8000 1.35
150 6124 2402
4000 1.16 9000 1.40
200 8165 3202
5000 1.21 - -
250 10206 4002
To obtain minimum required gas pressure at altitudes
above 700 feet, multiply the pressure by the listed factors: 300 12247 4802
350 14280 5600
Oz/sq-in x 1.732 = Inches WC
Inches WC x 0.0361= psig. 400 16329 6404
Oz/sq-in x 0.0625 = psig.
Psig x 27.71 = Inches WC 500 20415 8006
Psig x 16.0 = Oz/sq-in.
600 24494 9605
700 28576 11206
750 30618 12007
800 32659 12807
MODEL CB
HP SIZE DIMENSION
(IN.) (NPT) A (IN.)
125 2-1/2 67-1/4
150, 200 2-1/2 67-1/2
250 3 70-1/2
300, 350 3 70-1/2
400, 500, 600, 4 109-1/2
700, 750, 800
Figure A3-12. Standard Gas Train Connection Size and Location
A3-28
02-02
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 specifi-
cations 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 sizing is dependent on:

A3-29
02-02

ITEM DESCRIPTION
125- 300- 125- 300- 125- 125- 300-
BOILER HP
250 800 250 800 800 250 800
1 Pilot Shut Off Cock x x x x x x x

2 Pilot Shut Off Cock x x x
3 Shut Off Cock x x x x x x x
4 Shut Off Cock x x x x x x x
5 Pilot Pressure Regulator x x x x x x x
6 Pilot Pressure Gauge x x x x x x x
7 Gas Pilot Valve x x x x x x x
8 High Gas Pressure Switch x x x x x x x
9 Low Gas Pressure Switch x x x x x x x
10 Main Gas Valve with POC x x x x x x x
11 Main Gas Valve without POC x x x x x
13 Vent Valve x x x x x
14 Butterfly Valve x x x x x x x
Figure A3-14. Model CB-LE Gas Train Components
MODEL CB
RECOMMENDED OIL LINEA

SUPPLY SIZES
AND (STANDARD PIPE)
BOILER RE- (IN. - IPS)
HP TURN A
CONN (IN.) STOR-
SIZES AGE PUMP RE-
(IN.) TANK TO TO TURN
(NPT) BOILER
OR PUMP BOILER LINE TO
TANK
CONNECT
125
150 3/4 12-1/2 1 1 1
200
250
300 3/4 34 1 1 1
350
400
500 3/4 11-3/4 1 1 1
600
700
750 1 11-3/4 1 1 1
800
NOTE: See No. 2 Oil Line Sizing Instruction for systems with other
conditions.
A. For suction line condition with a maximum of 10 Feet of lift and a
total of 100 feet of suction line.
Figure A3-15. No.2 Oil Connection Size, Location, and Recommended Line Sizes
A3-30
02-02

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

Installation, Remote Oil Pumps
A3-31
02-02
STRAINER
VACUUM GAUGE GATE VALVE
CHECK
VALVE F.O.S.
GATE
STANDBY VALVE F.O.R.
OIL PUMP
ADJUSTABLE
PRESSURE
RELIEF VALVE
UNION (75 PSIG)
PRESSURE
RELIEF GAUGE
VALVE
GATE VALVE (100 PSIG)
GATE
VALVE
CHECK
VALVE

BOILER
BOILER BASE FRAME
Figure A3-18. No. 2 Oil Piping, Multiple Boiler Installation FRONT
F.O.S.
CONTACTOR
CONNECTIONS F.O.R.
AT THIS POINT
A3-32
02-02
Figure A3-20. Typical Arrangement
General Boiler Information For additional information, please review Section I4, General
Table A3-17 shows blowdown tank sizing information. breeching sizes should always be provided by a reputable stack
Table A3-18 provides heating surface information. supplier who will design the stack and breeching system based
on the above criteria. Your local Cleaver-Brooks authorized
Table A3-19 provides steam volume and disengaging area representative is capable of assisting in your evaluation of the
information stack/breeching design.
Table A3-20 provides recommended steam nozzle sizes.
Table A3-21 provides recommended non-return valve sizes. Boiler Room Combustion Air
When determining boiler room air requirements, the size of the
Boiler Room Information room, air flow, and velocity of air must be reviewed as follows:
Figure A3-21 shows typical boiler room length requirements. 1. Size (area) and location of air supply openings in boiler
room.
Figure A3-22 shows typical boiler room width requirements.
A. Two (2) permanent air supply openings in the outer walls
Figure A3-23 shows typical breeching arrangements. of the boiler room are recommended. Locate (1) at each
end of the boiler room, preferably below a height of 7
Stack Support Capabilities feet. This allows air to sweep the length of the boiler.
All standard Cleaver-Brooks Firetube Boilers with an LE B. Air supply openings can be louvered for weather
option can support up to 2,000 lbs without additional support. protection, but they should not be covered with fine
LE Boilers 250 hp through 800 hp can be reinforced to support mesh wire, as this type of covering has poor air flow
3,000 lbs. qualities and is subject to clogging by dust or dirt.
C. A vent fan in the boiler room is not recommended, as it
Stack/Breeching Size Criteria could create a slight vacuum under certain conditions
and cause variations in the quantity of combustion air.
The design of the stack and breeching must provide the This can result in unsatisfactory burner performance.
ical to burner performance. D. Under no condition should the total area of the air supply
Although constant pressure at the flue gas outlet of the Model
CB-LE is not required, it is necessary to size the stack/breech- E. Size the openings by using the formula:
ing to limit flue gas pressure variation. The allowable pressure Area (sq-ft) = CFM/FPM
range is 0.25" W.C. to +0.25" W.C. 2. Amount of air required (cfm).
A3-33
02-02
A. Combustion Air = Rated bhp x 8 cfm/bhp. Table A3-18. Heating Surface, Model CB-LE Boilers
B. Ventilation Air = Maximum bhp x 2 cfm/bhp
C. Total recommended air = 10 cfm/bhp - up to 1000 feet BOILER HEATING SURFACE (SQ-FT)
HP
elevation. Add 3 percent more per 1000 feet of added FIRESIDE WATERSIDE
elevation. 125 625 679
150 750 820
3. Acceptable air velocity in Boiler Room (fpm).
200 1000 1092
A. From floor to (7) foot height - 250 fpm 250 1250 1346
B. Above (7) foot height - 500 fpm 300 1500 1623

350 1750 1932
Example: Determine the area of the boiler room air supply
400 2000 2151
openings for (1) 300 hp boiler at 800 feet altitude. The air
500 2500 2691
openings are to be 5 feet above floor level.
600 3000 3262
Air required: 300 x 10 = 3000 cfm (from 2B above). 700, 750, 800 3500 3810
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
quirements.
Table A3-17. Model CB-LE Blowdown Tank

Sizing Information
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".
A3-34
02-02
Table A3-19. Steam Volume and Disengaging Area
STEAM DISENGAGING AREA

STEAM VOLUME CU-FT SQ-IN
BOILER HP
HIGH PRESSUREA LOW PRESSUREB HIGH PRESSUREA LOW PRESSUREB
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

Table A3-20. Recommended Steam Nozzle Size

(To Maintain 4000 to 5000 fpm Nozzle Velocity)
Boiler HP
OPERATING
PRESSURE 125 150 200 250 300 350 400 500 600 700 750 800
PSIG
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 8 10 10 12 12 Table A3-21. Recommended Non-Return Valve Size

75 4 4 6 6 6 8 8 8 8 10 10 10 BOILER BOILER OPERATING PRESSURES (PSIG)
CAPACITY
100 4 4 6 6 6 6 6 8 8 8 8 10 HP (LBS/HR) 125 150 175 200 250
125 4 4 4 6 6 6 6 8 8 8 8 8 125 4313 3 3 2-1/2 2-1/2 2-1/2
150 3 3 4 4 6 6 6 6 6 8 8 8 150 5175 3 3 3 2-1/2 2-1/2
200 2.5 3 4 4 4 4 6 6 6 6 6 6 200 6900 3 3 3 3 3
250 2.5 2.5 3 4 4 4 4 6 6 6 6 6 250 8625 4 3 3 3 3
NOTES: 300 10350 4 4 4 4 3
2. Recommended steam nozzle sizes based on 4000 to 5000 fpm steam velocity. 350 12025 4 4 4 4 3
Spool pieces (300 lb flanges) are available in the following sizes (in inches):
3x2-1/2x30, 4x3x30, 6x4x36, 8x6x48, 10x8x48, and 12x8x48. 400 13800 4 4 4 4 4
500 17210 6 4 4 4 4
600 20700 6 6 4 4 4
700 24150 6 6 6 6 6
750 25875 6 6 6 6 6
800 27600 6 6 6 6 6
NOTE: Valve sizes (300 # Flanges) given in inches.
A3-35
02-02
DWG A
DWG B
DWG C
1. Shortest boiler room length (Dwg A) is obtained by allowing for possible future tube replacement (from front or rear of
boiler) through a window or doorway. Allowance is only made for minimum door swing at each end of the boiler. This
arrangement provides 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.
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 A3-21. 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.
Dimension B between boilers allows for a clear aisle of:
42" - 125 -200 hp
48" - 250-350 hp
60" - 400-800 hp
A3-36
02-02
NOTE: These stack breeching arrangements for multi-

ple 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.
A3-37
02-02
SAMPLE SPECIFICATION
The following sample specification is provided by Cleaver-Brook to assist you in meeting your customers specific needs and appli-
cations.
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% O2) 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)

1.0 Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-38
2.0 General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-38
3.0 Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-39
4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-40
5.0 Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-44
6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-44
7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-44
Model CB-LE Hot Water Boiler (125-800 hp, 30 psig, 125 psig)
1.0 Boiler Characteristics (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-45
3.0 Hot Water Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-46
4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-46
6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-50
7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-51
Model CB-LE Steam Boiler (125-800 hp, Steam 15-300 psig)

1.1 The Steam Boiler shall be Cleaver-Brooks Model CB, Fuel Series ______ (100, 200, 700), _____ hp designed for _____ psig
(15, 150, 200, or other psig steam). The maximum operating pressure shall be _____ psig.
ural gas, _____ Btu/cu-ft. Electrical power available will be _____ Volt _____ Phase _____ Cycle.

2.1 The boiler shall be a four pass horizontal firetube updraft boiler with five (5) square feet (except 750 or 800 hp) of heating sur-
face per rated boiler horsepower. It shall be mounted on a heavy steel frame with integral forced draft burner and burner controls.
NOTICE
A3-38
02-02
2.2.7 A manhole shall be provided.
2.2.8 The exhaust gas vent shall be located near the front of the boiler on the top center line and shall be capable of supporting 2000
lbs and shall contain a stack thermometer.
2.2.9 The boiler shell shall contain a chemical feed connection.
2.5 The entire boiler base frame and other components shall be factory painted before shipment using a hard finish enamel coating.
2.6 Emission Controls
2.6.1 Boiler shall be equipped with a low emission (LE) option for guaranteed NOx performance at ________ ppm, dry volume
basis and corrected to 3% O2 when firing natural gas.
2.6.2 The low emission option shall include an integral front head, burner, and boiler package, providing NOx reduction through an
internal 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.
2.6.3 Burner, boiler, and low NOx system shall be manufactured as a package by a single manufacturer. The Low Emission Option
to the CB Boiler shall included factory testing as a package, and shall bear the UL packaged label. The boiler nameplate shall
include the approved UL low NOx boiler model designation. No field assembly of the burner or low NOx equipment shall be
required.

3.1 Water Column
valves.
A3-39
02-02

3.4 Safety Valves
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.

Burner operation shall be full modulation principle. The burner shall always return to low fire position for ignition.
4.2 Blower
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 con-
trol motor (remove this sentence when CB-HAWK flame safeguard is used).
burner shall be approved for operation on natural gas fuel and equipped with an LE option.
A. 125-250 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an addi-
B. 300-800 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an addi-
A3-40
02-02
A. 125-200 hp. Turndown range of burner shall be 4:1 when firing natural gas.
B. 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.)
approved for operation with CS12-48, Commercial No. 2 oil and equipped with an LE option.
4.4.2.3 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Separate
motor driven pump set, shipped loose to be installed in a location favorable to the oil storage tank, shall be provided.
shutoff valves, pressure gauges and fuel strainer, all integrally mounted on the unit. A fuel oil controller shall be provided to com-
bine all of the fuel oil controls into a single casting which is mounted on the front door of the unit. A single tip retractable nozzle
shall be used for the low pressure air atomizing burner. A low oil pressure switch shall be included in the oil piping.
4.4.2.5 Low Pressure Air Atomizing
Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch.
4.4.2.6 Burner Turndown.
A. 125 hp through 200 hp. Turndown range shall be 4:1 when firing No. 2 oil.
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.)
No. 2 Oil or natural gas. The burner shall be equipped with an LE option.
4.4.3.3 Oil Burner
4.4.3.3.1 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Separate
motor driven pump set, shipped loose, to be installed in a location favorable to the oil storage tank, shall be provided.
4.4.3.3.3 Low pressure air atomizing - Separate air compressor module mounted on boiler base rail with low atomizing air pressure
switch.
4.4.3.4 Gas Burner
A3-41
02-02
B. 300-800 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus and addi-
A. 125-200 hp. Turndown range of the burner shall be 4:1.
B. 250-800 hp. Turndown range of the burner shall be 10:1 when 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.)
cycles.
The hinged metal cabinet shall have NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet key type lock.
For combination gas-oil fired boilers the panel shall contain the fuel selector switch.
4.5.1.3 Lights
Red - low water.
Burner On-Off.
Manual-Automatic.
diagram.
A3-42
02-02

demand.
Separate status indicators shall show:
Alarm: safety shutdowns
vided.
shall be programmable from the keyboard display. The system shall be capable of detecting a jumpered or defective sensor. A
system.
Panel shall have a removable sub-base for mounting the flame safeguard controller, plug-in type fuel modules and terminal blocks.
For combination gas-oil fired boilers the plug-in fuel module shall contain the fuel selector switch.
diagram.
A3-43
02-02

5.1 The boiler manufacturer shall guarantee that, at the time of startup, the boiler will achieve ________ fuel-to-steam efficiency at
Natural Gas
Carbon, % (wt) = 69.98
No. 2 Oil
Carbon, % (wt) = 85.8
No. 6 Oil
Carbon, % (wt) = 86.6
Sulfur, % (wt) = 2.09
6.0 Warranty
7.0 Execution
7.1 Shop Tests
A3-44
02-02
Model CB-LE Hot Water Boiler (125-800 hp, 30 psig, 125 psig)

1.1 The Hot Water Boiler shall be Cleaver-Brooks Model CB, Fuel Series ______ (100, 200, 700), _____ hp designed for _____
psig (30, 125 psig, or other hot water). The maximum water temperature shall be _____ degree F, and the maximum system tem-
perature drop shall be _____ degrees F.
ural gas, _____ Btu/cu-ft. Electrical power available shall be _____Volt _____ Phase _____ Cycle.

2.1 The boiler shall be a four pass horizontal firetube updraft boiler with five (5) square feet (except 750 or 800 hp) of heating sur-
face 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.
2.2.9 A manhole shall be provided.
2.2.10 The exhaust gas vent shall be located near the front of the boiler on the top center line and shall be capable of supporting
2000 lbs and shall contain a stack thermometer.
2.5 The entire boiler based frame and other components shall be factory painted before shipment using a hand finish enamel coat-
ing.
2.6.1 Boiler shall be equipped with a low emission (LE) option for guaranteed NOx performance at ________ ppm, dry volume
basis and corrected to 3% O2 when firing natural gas.
2.6.2 The low emission option shall include an integral front head, burner, and boiler package, providing NOx reduction through an
internal flue gas recirculation system using the combustion air fan, internal recirculation valve, and enhanced boiler design to
A3-45
02-02
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 lev-
els.
2.6.3 Burner, boiler, and low NOx system shall be manufactured as a package by a single manufacturer. The Low Emission Option
to the CB Boiler shall included factory testing as a package, and shall bear the UL packaged label. The boiler nameplate shall
include the approved UL low NOx boiler model designation. No field assembly of the burner or low NOx equipment shall be
required.

outlet.
3.3 Relief Valves
to the hot water outlet. Controls shall be high limit (manual reset), operating limit (auto reset), and firing rate control.

4.2 Blower
the fire according to load demand. Potentiometer type position controls shall be provided to regulate operation of the damper con-
trol motor (remove this sentence when CB-HAWK flame safeguard is used).
burner shall be approved for operation on natural gas fuel and equipped with an LE option.
A3-46
02-02
A. 125-200 hp. Turndown range of burner shall be 4:1 when firing natural gas.
B. 250-800 hp. Turndown range of the burner shall be 10:1 when firing 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.)
approved for operation with CS12-48, Commercial No. 2 oil and equipped with an LE option.
4.4.2.3 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Separate
4.4.2.5 Low Pressure Air Atomizing - Separate air compressor module mounted on boiler base rail with low atomizing air pressure
switch.
A. 125 hp through 200 hp. Turndown range shall be 4:1 when firing No. 2 oil.
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.)
No. 2 Oil or natural gas. The burner shall be equipped with an LE option.
4.4.3.3 Oil Burner
4.4.3.3.1 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Separate
A3-47
02-02
4.4.3.3.3 Low pressure air atomizing - Belt driven air compressor, lubricating oil tank, oil level indicator, inlet air filter, air pressure
gauge and low atomizing air pressure switch. Separate air compressor module mounted on boiler base rail with low atomizing air
pressure switch.
4.4.3.4 Gas Burner
B. 300-800 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus and addi-
A. 125-200 hp. Turndown range of the burner shall be 4:1.
B. 250-800 hp. Turndown range of the burner shall be 10:1 when 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.)
cycles.
4.5.1.3 Lights
A3-48
02-02
Red - low water.

Burner On-Off.
Manual-Automatic.
diagram.
demand.
vided.
A3-49
02-02
system.
fired boilers the panel shall contain the fuel selector switch.
diagram.

5.1 The boiler manufacturer shall guarantee that, at the time of startup, the boiler will achieve ________ fuel-to-steam efficiency at
Natural Gas
Carbon, % (wt) = 69.98
No. 2 Oil
Carbon, % (wt) = 85.8
No. 6 Oil
Carbon, % (wt) = 86.6
Sulfur, % (wt) = 2.09
6.0 Warranty
A3-50
02-02
7.0 Execution
7.1 Shop Tests
A3-51
02-02
NOTES
A3-52
02-02
Section A4
MODEL CBW BOILERS
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-3
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-14
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-14
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-15
Blowdown Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-15
Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-17
Burner Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-18
Gas - Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-18
Gas Pressure Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-18
Oil - Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-21
No. 6 Oil Piping, Storage Tank Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-21
Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-30
Stack and Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-30
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-33
Model CBW Steam Boiler (100-800 hp, Steam 15-250 psig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-33
Model CBW Hot Water Boiler (100-800 hp, 30 and 125 psig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-41
A4-1
10-02
Model CBW Boilers Firetube Boilers
ILLUSTRATIONS
Figure A4-1. Model CBW Steam Boiler Dimensions (100 thru 800 hp) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-8
Figure A4-2. Model CBW Hot Water Boiler Dimensions (100 thru 800 hp) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . A4-10
Figure A4-3. Model CBW Space Requirements to Open Rear Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-12
Figure A4-4. Model CBW Boiler Mounting Piers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-12
Figure A4-5. Lifting Lug Location, Model CBW Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-13
Figure A4-6. Model CBW Standard Gas Train Connection Size and Location, IRI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-21
Figure A4-7. Typical Gas Piping Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-22
Figure A4-8. Gas Train Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-23
Figure A4-9. No. 2 Oil Connection Size, Location and Recommended Line Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-24
Figure A4-10. No. 6 Oil Connection Size, Location and Recommended Line Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-24
Figure A4-11.No. 2 Oil Piping, Single Boiler Installation, Remote Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-25
Figure A4-14. No. 6 Oil Piping, Single Boiler Installation, Remote Oil Pumps 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-26
Figure A-15. No. 6 Oil Piping, Multiple Boiler Installation, Remote Oil Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-27
Figure A-16. No. 6 Oil Piping, Multiple Boiler Installation 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-27
Figure A-17. No. 2 Oil Transfer Tank Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-28
Figure A-18. Typical Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-28
Figure A-19. Typical Cross Section of Bundled Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-29
Figure A-20. Schematic of Standard Alstrom Hot Water Safety-Type Preheating System . . . . . . . . . . . . . . . . . . . . . . . . A4-29
Figure A-21. Boiler Room Length, Typical Layout (CBW Boilers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-31
Figure A-22. Boiler Room Width, Typical Layout (CBW Boilers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-31
Figure A-23. Breeching Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-32
TABLES
Table A4-1. Model CBW Steam Boiler Ratings (15 and 150 psig Design Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-5
Table A4-2. Model CBW Hot Water Boiler Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-5
Table A4-3.Model CBW Steam Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-6
Table A4-4. Model CBW Hot Water Boiler Relief Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-6
Table A4-5. Model CBW Boiler Emission Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-14
Table A4-6. Heating Surface, Model CBW Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-15
Table A4-7. Steam Volume and Disengaging Areas, Model CBW Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-15
Table A4-8. Water Circulation Rate and Temperature Drop for Hot Water Boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-16
Table A4-9. Recommended Steam Nozzle Size (to Maintain 4000 to 5000 fpm Nozzle Velocity) . . . . . . . . . . . . . . . . . A4-16
Table A4-10. Recommended Non-Return Valve Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-17
Table A4-11. Blowdown Tank Sizing Information, CBW Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-17
Table A4-12. Model CBW Boiler Sound Pressure Level Summary (100 - 800 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-18
Table A4-13. Model CBW Minimum Required Gas Pressure at Entrance to Standard and FM Gas Trains
(Downstream of Gas Pressure Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-19
Table A4-14. Model CBW Minimum Required Gas Pressure at Entrance to Gas Trains Equipped with
Industrial Risk (IRI) Requirements (Downstream of Gas Pressure Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-19
Table A4-15. Minimum Required Gas Pressure Altitude Conversion at 700 ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-19
Table A4-16. Under and Oversized Standard, FM, and IRI Gas Trains, Model CBW Boilers, 100 - 800 hp . . . . . . . . . . A4-20
Table A4-17. Model CBW Boiler Maximum Consumption (CFH) for Natural Gas and Propane Vapor . . . . . . . . . . . . . A4-20
The following section contains information on Cleaver- Brooks Model CBW Boilers.
A4-2
10-02
Firetube Boilers Model CBW Boilers
FEATURES AND BENEFITS Retractable oil nozzle provides easy access and cleaning and
eliminates coking of oil nozzle tip when ring gas.
The Model CBW 3-Pass Wetback boiler includes the integral
front head package on a wetback boiler vessel. In addition to
the features provided on all Cleaver-Brooks Firetube boilers, PRODUCT OFFERING
the following features apply to Model CBW Firetube Boilers. Model CBW boilers are available in low pressure steam, high
pressure steam, and hot water designs. Burners are available to
Three-Pass Wetback Design: re natural gas, light oil, heavy oil, or a combination of oil and
Three-pass wetback design provides good boiler efciency gas. Optional alternate fuel burners are also available.
with minimum refractory. Model CBW boilers include:
Five square feet of heating surface per boiler horsepower Three-pass wetback design.
(except 800 hp) provides guaranteed efciency performance
and long boiler life. 100 hp through 800 hp.
150 psig - 250 psig high pressure steam.
Hinged Front Door:
Provides full access to front tube sheet and furnace.
30 psig or 125 psig hot water.
Rear furnace access manhole provided.
Natural gas, light oil, or heavy oil ring.
High Turndown Burner: The Model CBW boiler provides the advantages of the
Cleaver-Brooks integral front head in a three-pass wetback
4:1 turndown (gas and oil) is standard on boilers up to 250
design.
hp.
Available options: For option details, contact your Cleaver-
Guaranteed 10:1 turndown (gas red) 8:1 (No. 2 oil red)
Brooks authorized representative. In summary, options include
standard on 250 hp through 800 hp.
the following:
Advanced burner design provides maximum combustion
Boiler Options
efciencies and high turndown.
Auxiliary low water cut-off (standard on steam boilers).
Reduced boiler cycling and maintenance.
Drain valves.
Boiler stays on line during low load conditions for optimum
efciency and performance. Additional screwed or anged tappings.
Special design pressures.
Gas, No. 2 Oil, and No. 6 Oil, and Combination Gas and Oil
Burners Available: Surge load bafes.
High radiant annular gas entry on 100-200 hp and high Seismic design.
radiant multi-port gas burner on 250-800 hp, designed for Internal hot water coils.
high gas velocities and complete fuel/air mixing, provides
maximum combustion efciencies. Blowdown valves.
Air atomizing oil burner available for proper oil atomization, Non-return valves.
maximum combustion efciency, and low maintenance Feedwater valves and regulators.
requirements.
Special doors, davited, hinged, left swing.
Air atomizing compressor provided with the boiler package
for clean oil burning and ease of maintenance. Special base rails.
Combination gas/oil burners provide quick fuel changeover Surface blowdown systems.
without re-adjustment of the burner. Combustion relief door.
Fuel oil controller eliminates the need for over 40 Weather-proong.
connections, combining gauges, valves, and regulators into
a single casting. Blend pump.
A4-3
10-02
Burner/Control Options Table A4-4. Model CBW Hot Water Boiler Relief Valve
Openings.
Special modulation controls.
Figure A4-1. Model CBW Steam Boiler Dimensions (100 -
Optional ame safeguard controller.
800 hp)
Lead/lag system.
FigureA4-2. Model CBW Hot Water Boiler Dimensions (100
High altitude design, up to 12,000 ft. - 800 hp)
Special insurance and code requirements (e.g., IRI, FM, Figure A4-3. Model CBW Boiler Space Requirements to
ASME CSD-1). Open Rear Door
Alarm bell/silence switch. Figure A4-4. Model CBW Boiler Mounting Piers
Special motor requirements (TEFC, high efciency). Figure A4-5. Lifting Lug Location, Model CBW Boilers
Remote contacts.
Special purpose indicator light.
Main disconnect.
Elapsed time meter.
Voltmeter/micro-ammeter.
NEMA enclosures.
Low re hold controls.
Circuit breaker.
Day/night controls.
Fuel Options
Gas strainer.
Special pilot.
Alternate fuel ring (digester gas, propane, etc.).
Special oil pumps.

Dimensions and ratings for the Model CBW boilers are shown
in the following tables and illustrations:
Table A4-1. Model CBW Steam Boiler Ratings (15 and 150
psig Design Pressure)
Table A4-2. Model CBW Hot Water Boiler Ratings
Table A4-3. Model CBW Steam Boiler Safety Valve
Openings.
A4-4
10-02
Table A4-1. Model CBW Steam Boiler Ratings (15 and 150 psig Design Pressure)
BOILER HP 100 125 150 200 250 300 350 400 500 600 700 750 800
BOILER OUTPUT
Rated Steam lb/hr (212F) 3450 4313 5175 6900 8625 10350 12075 13800 17250 20700 24150 25875 27600
Btu Output (1000 Btu/hr) 3348 4189 5021 6695 8369 10043 11716 13390 16738 20085 23432 25106 26780
Approximate Fuel Consumption
Light Oil gph (140000 Btu/gal) 30.0 37.5 45.0 60.0 74.5 89.5 104.5 119.5 149.5 179.5 209.0 224.0 239.0
Heavy Oil gph (150000 Btu/gal) 28.0 35.0 42.0 56.0 69.5 83.5 97.5 111.5 139.5 167.5 195.5 209.0 223.0
Nat. Gas cfh (1000 Btu/cu-ft) 4185 5230 6280 8370 10460 12555 14650 16750 20925 25100 29300 31385 33500
Nat. Gas Therms/hr 41.9 52.3 62.8 83.7 104.6 125.5 146.5 167.5 209.3 251.0 293.0 313.8 335.0
WEIGHT IN POUNDS
Normal Water Capacity 6385 6600 8050 11000 11394 13466 15861 17936 21353 25531 29835 29835 29835
Approx. Shipping Weight - 150 psig 12300 12950 14000 16850 21750 24300 26500 28750 38800 43950 50950 51200 51200
POWER REQUIREMENTS - ELECTRIC (60 HZ)c

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

Blower Motor hp Exc Gas Only 5 5 7-1/2 10 7-1/2 10 15 20 15 20 30 40 50
Blower Motor hp Gas Only 5 5 5 10 7-1/2 7-1/2 15 20 15 20 30 40 50
Oil Pump Motor hp No. 2 Oil 1/3 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4 1 1 1
Oil Pump Motor hp No. 6 Oil 1/3 1/2 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4 3/4 3/4
Oil Heater kW No. 6 Oil 5 5 5 5 7-1/2 7-1/2 7-1/2 10 10 10 10 10 10
Air Compressor Motor (hp) AIR COMPRESSOR BELT DRIVEN FROM BLOWER MOTOR 7-1/2 7-1/2 7-1/2 7-1/2 7-1/2
NOTES:
A. Standard voltage is 230/460/575/3/60 Hz. Control circuit is 115/1/60 Hz.
B. Larger motors may be required at higher altitudes.
A4-5
10-02
Table A4-3. Model CBW Steam Boiler Safety Valve Openings

VALVE SET- 15 PSIG STEAM 100 PSIG STEAM 125 PSIG STEAM 150 PSIG STEAM 200 PSIG STEAM 250 PSIG STEAM
TING
BOILER HP VALVES- SIZE VALVES- SIZE VALVES SIZE VALVES- SIZE VALVES- SIZE VALVES SIZE
100 1 2-1/2 1 2 1 2 1 1-1/2 1 1-1/2 1 1-1/4
125 1 3 2 1-1/2 2 (1) 1-1/2 2 (1) 1-1/2 2 (1) 1-1/4 2 1
(1) 1-1/4 (1) 1-1/4 (1) 1
150 1 3 2 (1) 2 2 1-1/2 2 (2) 1-1/4 2 1-1/4 2 (1) 1
(1) 1-1/2 (1) 1-1/4
200 2 2-1/2 2 2 2 (1) 2 2 1-1/2 2 (1) 1-1/2 2 1-1/4
(1) 1-1/2 (1) 1-1/4
250 2 (1) 2-1/2 2 (1) 2-1/2 2 2 2 (1) 2 2 1-1/2 2 (1) 1-1/2
(1) 3 (1) 2 (1) 1-1/2 (1) 1-1/4
300 2 3 2 2-1/2 2 (1) 2-1/2 2 (2) 2 2 (1) 2 2 1-1/2
(1) 2 (1) 1-1/2
350 3 (1) 2 3 (1) 2-1/2 2 2-1/2 2 (1) 2-1/2 2 2 2 (1) 1-1/2
(2) 3 (2) 2 (1) 2 (1)2
400 3 (2) 3 3 (1) 2 2 2-1/2 2 (1) 2-1/2 2 2 2 (1) 2
(1) 2-1/2 (2) 2-1/2 (1) 2 (1) 1-1/2
500 3 3 3 2-1/2 3 (2) 2-1/2 2 2-1/2 2 (1) 2-1/2 2 (2) 2
(1) 2 (1) 2
600 4 3 4 (3) 2-1/2 3 2-1/2 3 (2) 2-1/2 2 2-1/2 2 (1) 2
(1) 2 (1) 2 (1) 2-1/2
700, 750, 800 5 (3) 3 5 (3) 2-1/2 4 (3) 2-1/2 3 (2) 2-1/2 2 2-1/2 2 2-1/2
(2) 2-1/2 (2) 2 (1) 2 (1) 2
Table A4-4. Model CBW Hot Water Boiler Relief Valve Openings
VALVE 30 PSIG HW 60 PSIG HW 100 PSIG HW 125 PSIG HW 150 PSIG HW
SETTING
NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET
BOILER HP VALVES SIZE VALVES SIZE VALVES SIZE VALVES SIZE VALVES SIZE
REQ'D (IN.) REQ'D (IN.) REQ'D (IN.) REQ'D (IN.) REQ'D (IN.)
100 1 2-1/2 1 2 1 1-1/4 1 1-1/4 1 1-1/4
125 1 2-1/2 1 2 1 2 1 1-1/4 1 1-1/4
150 1 2-1/2 1 2-1/2 1 2 1 2 1 1- 1/4
200 2 (1) 2-1/2 1 2-1/2 1 2 1 2 1 2
(1) 1-1/4
250 2 (1) 2 1 2-1/2 1 2-1/2 1 2 1 2
(1) 2-1/2
300 2 (2) 2-1/2 2 (1) 3/4 1 2-1/2 1 2-1/2 1 2
(1) 2
350 3 (2) 2-1/2 2 2-1/2 1 (1) 2-1/2 1 2-1/2 1 2-1/2
(1) 1
400 3 (1) 2 2 (1) 2 2 (1) 1 1 2-1/2 1 2-1/2
(2) 2-1/2 (1) 2-1/2 (1) 2-1/2
500 4 (1) 1 2 2-1/2 2 (1) 2-1/2 2 (1) 1 1 2-1/2
(3) 2-1/2 (1) 1-1/4 (1) 2-1/2
600 4 (3) 2-1/2 3 (1) 1-1/4 2 (1) 2 2 (1) 1-1/4 2 (1) 1
(1) 2 (2) 2-1/2 (1) 2-1/2 (1) 2-1/2 (1) 2-1/2
700, 750, 800 5 (1) 1 3 (1) 2 2 2-1/2 2 (1) 2-1/2 2 (1) 1-1/4
(4) 2-1/2 (2) 2-1/2 (1) 2 (1) 2-1/2
NOTE: Hot water relief valves are Kunkle #137.
A4-6
10-02
NOTES
A4-7
10-02
NOTE: ALLOW 3 FEET

FOR DOOR SWING
PER NEC
BOILER HP DIM 100 125 150 200 250 300 350 400 500 600 700 750 800
LENGTH
Overall A 192 192 216 266 201 228 253 281 250 289 324 326 326
Shell B 158 158 181 229 168 192 217 242 220 255 290 290 290
Base Frame C 147 147 170 218 157 181 206 231 206 240 276 276 276
Front Head Extension D 30 30 31 33 29 32 32 35 26 30 30 32 32
Flange To Nozzle (15 psig) E 56 56 72 108 70 90 108 118 101 111 127-1/2 127-1/2 127-1/2
Flange to Nozzle (150 psig) F 56 56 72 108 70 90 108 118 101 111 127-1/2 127-1/2 127-1/2
WIDTHS
Overall I 85 85 85 85 103 103 103 103 123 123 123 123 123
I.D. Boiler J 60 60 60 60 78 78 78 78 96 96 96 96 96
Center to Water Column K 45 45 45 45 54 54 54 54 64 64 64 64 64
Center to Outside Hinge KK 35 35 35 35 51 51 51 51 62 62 62 62 62
Center to Lagging L 33 33 33 33 42 42 42 42 51 51 51 51 51
Centering to Auxiliary LWCO LL 40 40 40 40 49 49 49 49 59 59 59 59 59
Base-Outside M 51-1/2 51-1/2 51-1/2 51-1/2 64 64 64 64 72 72 72 72 72
Base-Inside N 43-1/2 43-1/2 43-1/2 43-1/2 52 52 52 52 56 56 56 56 56
Figure A4-1. Model CBW Steam Boiler Dimensions (100 thru 800 hp) - Sheet 1 of 2
A4-8
12-02
10-02
BOILER HP DIM 100 125 150 200 250 300 350 400 500 600 700 750 800
HEIGHTS
Overall OO 88 88 88 88 106 106 106 106 126 126 126 126 126
Base to Vent Outlet O 85 85 85 85 106 106 106 106 126 126 126 126 126
Base to Steam Outlet P 82-3/8 82-3/8 82-3/8 82-3/8 101-1/2 101-1/2 101-1/2 101-1/2 122 122 122 122 122
Davit - Front DF - - - - 105 105 105 105 126 126 126 126 126
Base Frame Q 12 12 12 12 10 10 10 10 12 12 12 12 12
Base to Bottom Boiler R 16 16 16 16 17 17 17 17 19 19 19 19 19
BOILER CONNECTION
Chemical Feed H 1 1 1 1 1 1 1 1 1 1 1 1 1
Feedwater - Right and 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 2-1/2
Left
Auxiliary Connection Z 1 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 1-1/4
Steam Nozzle (15 psig)A Y 8 8 8 10 10 12 12 12 12 12 12 12 12
Steam Nozzle (150 psig)B Y 4 4 4 4 6 6 6 6 8 8 8 8 8
Drain - Front & Rear W 1-1/2 1-1/2 1-1/2 2 2 2 2 2 2 2 2 2 2

(15 psig)
Blowdown - Front & Rear 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 2
(150 psig)
Surface Blow (150 lb only) T 1 1 1 1 1 1 1 1 1 1 1 1 1
Vent Stack Diameter BB 16 16 16 16 20 20 20 20 24 24 24 24 24

(Flanged)
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 12-5/8
MINIMUM CLEARANCE
Rear Door Swing DD 36 36 36 36 46 46 46 46 54 54 54 54 54
Front Head Swing EE 67 67 67 67 89 89 89 89 108 108 108 108 108
Tube Removal - Front Only GG 124 124 147 195 128 152 177 202 171 206 242 242 242
Minimum Room Length for: RF 318 318 364 460 342 390 440 490 445 515 586 586 586
Front Tube Removal
Minimum Room Length for: RD 261 261 284 332 303 327 352 377 382 417 452 452 452
Tube Removal Thru Door
NOTES:
3. Base rail mounted air compressor module on sizes 500 thru 800 hp.
A. Flanged 150 psig ANSI.
B. Flanged 300 psig ANSI.
Figure A4-1. Model CBW Steam Boiler Dimensions (100 thru 800 hp) - Sheet 2 of 2
A4-9
10-02
12-02
LWCO
NOTE: ALLOW 3 FEET

FOR DOOR SWING
PER NEC
BOILER HP DIM 100 125 150 200 250 300 350 400 500 600 700 750 800
LENGTHS
Overall A 192 192 216 266 201 228 253 281 250 289 324 326 326
Shell B 158 158 181 229 168 192 217 242 220 255 290 290 290
Base Frame C 147 147 170 218 157 181 206 231 206 240 276 276 276
Front Head Ext. D 30 30 31 33 29 32 32 35 26 30 30 32 32
Flange to Return E 100 100 123 171 108 132 157 178 134 169 204 204 204
Flange to Outlet F 125 125 148 196 134 158 183 210 170 205 240 240 240
WIDTHS
Overall I 75-1/2 75-1/2 75-1/2 75-1/2 93 93 93 93 113 113 113 113 113
I.D. Boiler J 60 60 60 60 78 78 78 78 96 96 96 96 96
Center to Entrance Box K 42-1/2 42-1/2 42-1/2 42-1/2 51 51 51 51 62 62 62 62 62
Center to Outside Hinge KK 35 35 35 35 51 51 51 51 62 62 62 62 62
Center to Lagging L 33 33 33 33 42 42 42 42 51 51 51 51 51
Base-Outside M 51-1/2 51-1/2 51-1/2 51-1/2 64 64 64 64 72 72 72 72 72
Base-Inside N 43-1/2 43-1/2 43-1/2 43-1/2 52 52 52 52 56 56 56 56 56
Figure A4-2. Model CBW Hot Water Boiler Dimensions (100 thru 800 hp) - Sheet 1 of 2
A4-10
12-02
10-02
BOILER HP DIM 100 125 150 200 250 300 350 400 500 600 700 750 800
HEIGHTS
Overall OO 88 88 88 88 106 106 106 106 126 126 126 126 126
Base to Vent Outlet O 85 85 85 85 106 106 106 106 126 126 126 126 126
Base to Return/Outlet P 82-1/2 82-1/2 82-1/2 82-1/2 101-1/2 101-1/2 101-1/2 101-1/2 123-1/2 123-1/2 123-1/2 123-1/2 123-1/2
Davit - Front DF - - - - 105 105 105 105 126 126 126 126 126
Base Frame Q 12 12 12 12 10 10 10 10 12 12 12 12 12
Base to Bottom Boiler R 16 16 16 16 17 17 17 17 19 19 19 19 19
BOILER CONNECTIONS
Waterfill - Right & Left 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 2-1/2
Auxiliary Connection Z 1 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 1-1/4
Water Return U 4 6 6 6 8 8 8 10 10 12 12 12 12
Water OutletA Y 4 6 6 6 8 8 8 10 10 12 12 12 12
Drain - Front & Rear W 1-1/2 1-1/2 1-/12 2 2 2 2 2 2 2 2 2 2
Air Vent T 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2 2 2 2
Vent Stack Dia BB 16 16 16 16 20 20 20 20 24 24 24 24 24

(Flanged)
Flange to Center Vent CC 9 9 9 9 10-1/2 10-1/2 10-1/2 10-1/2 12-5/8 12-5/8 12-5/8 12-5/8 12-5/8
MINIMUM CLEARANCE
Rear Door Swing DD 36 36 36 36 46 46 46 46 54 54 54 54 54
Front Head Swing EE 67 67 67 67 89 89 89 89 108 108 108 108 108
Tube Removal - Front GG 124 124 147 195 128 152 177 202 171 206 242 242 242
Only
Min. Room Length for: RF 318 318 364 460 342 390 440 490 445 515 586 586 586
Front Tube Removal
Min. Room Length for: RD 261 261 284 332 303 327 352 377 382 417 452 452 452
Tube Removal thru
Door
NOTES:
1. Air compressor belt driven from blower motor on sizes 100thru 400 hp. All compressor module on sizes 500 thru 800 hp.
A. 2 dip tube in outlet.
Figure A4-2. Model CBW Hot Water Boiler Dimensions (100 thru 800 hp) - Sheet 2 of 2
A4-11
10-02
12-02
DIMENSIONS (INCHES)
BOILER HP
A B C D E
100-200 33 42 54 77 36
250-400 42 53 61 92 46
500-800 51 64 73 109 54
Figure A4-3. Model CBW Space Requirements to Open Rear Door
BOILER HP A B C D E F G X Y
100 6 9 147 39-1/2 57-1/2 4 44-1/2 9-3/4 16-5/8
125 6 9 147 39-1/2 57-1/2 4 44-1/2 9-3/4 16-5/8
150 6 9 170 39-1/2 57-1/2 4 44-1/2 9-3/4 16-5/8
200 6 9 218 39-1/2 57-1/2 4 44-1/2 9-3/4 16-5/8
250 6 12 157 46 70 6 52-3/8 22 20-1/2
300 6 12 181 46 70 6 52-3/8 22 20-1/2
350 6 12 206 46 70 6 52-3/8 22 20-1/2
400 6 12 231 46 70 6 52-3/8 22 20-1/2
500 6 14 206 50 78 8 56 24 29
600 6 14 240 50 78 8 56 24 29
700-800 6 14 276 50 78 8 56 24 29
NOTE:
Figure A4-4. Model CBW Boiler Mounting Piers
A4-12
10-02
12-02

BOILER HP VIEW
A B C D E
100 Steam B 80 19 121 10 3
Hot Water B 80 19 121 10 3
125 Steam B 80 19 121 10 3
Hot Water B 80 19 121 10 3
150 Steam B 80 19 144 10 3
Hot Water B 80 19 144 10 3
200 Steam B 80 19 192 10 3
Hot Water B 80 19 192 10 3
250 Steam B 99 25 114 10 3
Hot Water B 99 25 114 10 3
300 Steam B 99 25 138 10 3
Hot Water B 99 25 138 10 3
350 Steam B 99 25 163 10 3
Hot Water B 99 25 163 10 3
400 Steam B 99 25 188 10 3
Hot Water B 99 25 188 10 3
500 Steam B 99 28 158 11 3
Hot Water B 99 28 158 11 3
600 Steam B 99 28 193 11 3
Hot Water B 99 28 193 11 3
700 Steam B 99 28 228 11 3

750
800 Hot Water B 99 28 228 11 3
NOTE: A, B and C Dimensions may vary by 1/2 inch.
Figure A4-5. Lifting Lug Location, Model CBW Boilers
A4-13
10-02
PERFORMANCE DATA
Efficiency
Efciency on Model CBW 3-pass wetback boilers will be
approximately 1-2% less than Model CB dryback boilers.
See Section A2 (Model CB Boiler) for efciency information
on four-pass dryback boilers. For specic fuel-to- steam ef-
ciency guarantees for Model CBW Firetube, contact your local
Cleaver-Brooks authorized representative.
Emissions
The emission data included in this section (Table A4-5) consist
of uncontrolled levels of nitrogen oxides (NOx) and carbon
monoxide (CO) for Cleaver-Brooks Model CBW Firetube
Boilers. The table includes typical emission levels.
The data in Table A4-5 represents typical emission levels only.
Guaranteed emission levels and emission levels for other pol-
lutants are available from your local Cleaver-Brooks autho-
Table A4-5. Model CBW Boiler Emission Data

ESTIMATED LEVELS - UNCONTROLLED
POLLUTANT
NATURAL GAS NO. 2 OILB NO. 6 OILC
CO ppmA 200 90 95
Lb/MMBtu 0.15 0.07 0.075
ppmA 100 185 502
NOx
Lb/MMBtu 0.12 0.25 0.67
ppmA 1 278 278
SOx
Lb/MMbtu 0.001 0.52 0.52
ppmA 40 50 70
HC/ VOCs
Lb/MMBtu 0.016 0.025 0.035
ppmA - - -
PM
Lb/MMBtu 0.01 0.025 0.160
A. ppm levels corrected to 3% O2, dry volume basis.
B. Based on fuel constituent levels of:

C. Based on fuel constituent levels of:
Conradson carbon residue = 16% by weight
A4-14
10-02
ENGINEERING DATA Table A4-6. Heating Surface, Model CBW Boilers

HEATING
The following engineering information is provided for Model BOILER SURFACE (SQ-FT)
CBW Firetube Boilers. Additional detail is available from HP
FIRESIDE
your local Cleaver-Brooks authorized representative. Refer to
100 500
Tables A4-6 through A4-10.
125 625
Blowdown Water Requirements 150 750

200 1000
250 1250
accordance with recommendations of the National Board of
Boiler and Pressure Vessel Inspectors. 300 1500
350 1750
The National Boards recommendations base the size of the
400 2000
blowdown tank on the removal of at least 4 inches of water
from the boiler. 500 2500
600 3000
Table A4-11 lists the approximate quantity of water repre-
700, 750, 800 3500
Cleaver-Brooks Power Boilers.
Table A4-7. Steam Volume and Disengaging Areas, Model CBW Boilers
STEAM RELIEVING AREA

STEAM VOLUME CU-FT SQ-IN
BOILER HP
HIGH PRESSUREA LOW PRESSUREB HIGH PRESSUREA LOW PRESSUREB
100 21.5 29.5 5856 6388
125 21.5 29.5 5856 6388
150 25.1 34.5 6850 7472
200 32.8 44.9 8925 9734
250 33.9 49.0 7732 8582

300 39.6 57.3 9043 10022
350 45.5 65.9 10396 11534
400 51.5 74.5 11750 13032
500 94.4 119.6 13809 14716
600 111.9 141.8 16387 17438
700, 750, 800 129.5 164.0 18950 20174

A4-15
10-02
Table A4-8. Water Circulation Rate and Temperature Drop for Hot Water Boilers
BOILER OUTPUT 10 20 30 40 50 60 70 80 90 100
HP (1000)
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
750 25105 5025 2513 1675 1258 1008 840 718 628 558 503
800 26780 5360 2680 1785 1340 1075 895 765 670 595 535
Notes:
1. See Section I2 for over-pressure requirements.
2. Minimum recommended return water temperature Model CBW Hot Water Boilers is 150 F. Minimum recommended outlet
temperature for Model CBW Hot Water Boilers is 170 F. Contact your local Cleaver-Brooks authorized representative for
special hot water application information.
Table A4-9. Recommended Steam Nozzle Size (to Maintain 4000 to 5000 fpm Nozzle Velocity)
BOILER HP
OPERATING
PRESSURE 100 125 150 200 250 300 350 400 500 600 700 750 800
PSIG
15 8 8 8 10 10 12 12 12 12 12 12 12 12
30 6 6 6 8 8 8 10 10 10 12 12 12 12
40 6 6 6 6 8 8 8 10 10 10 12 12 12
50 4 6 6 6 6 8 8 8 8 10 10 12 12
75 4 4 4 6 6 6 8 8 8 8 10 10 10
100 4 4 4 6 6 6 6 6 8 8 8 8 10
125 4 4 4 4 6 6 6 6 8 8 8 8 8
150 2.5 3 3 4 4 6 6 6 6 6 8 8 8
200 2.5 2.5 3 4 4 4 4 6 6 6 6 6 6
250 2 2.5 2.5 3 4 4 4 4 6 6 6 6 6
NOTE: Steam nozzle sizes given in inches.
A4-16
10-02
Table A4-10. Recommended Non-Return Valve Size

BOILER CA- OPERATING PRESSURES (PSIG)
BOILER PACITY
HP 50 75 100 125 150 175 200 250
(LBS/HR)
100 3450 3 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2
125 4313 4 3 3 3 3 2-1/2 2-1/2 2-1/2
150 5175 4 4 3 3 3 3 2-1/2 2-1/2
200 6900 4 4 4 3 3 3 3 3
250 8625 4 4 4 4 3 3 3 3
300 10350 6 4 4 4 4 4 4 3
350 12025 6 6 4 4 4 4 4 3
400 13800 6 6 4 4 4 4 4 4
500 17210 6 6 6 6 4 4 4 4
600 20700 8 8 6 6 6 4 4 4
700 24150 8 8 6 6 6 6 6 6
750 25875 8 8 6 6 6 6 6 6
800 27600 8 8 6 6 6 6 6 6
Test Method
Table A4-11. Blowdown Tank Sizing Information, CBW Boilers
The sound pressure levels in the following tables were obtained
BOILER HP WATER (GAL) from tests in accordance with the ABMA Test Code for the
Measurement of Sound from Packages Boilers. In accordance
100 115
with this code the sound pressure levels reported were mea-
125 115
150 137 bottom of the base rails and 3 feet horizontally in front of the
200 180 end of the blower motor or front surface of the electrical cabi-
250 161 net.
300 188
350 215 Sound Level Meter
400 243 The sound level meter used complies with ANSI S1.4, Type 1
500 258 (Precision). The readings are taken with the meter set for slow
600 306
response.
700, 750, 800 354
Sound Pressure
NOTE: Quantity of water removed from boiler (gal.) by lowering
normal water line 4". The large size boilers, the need for auxiliary equipment, and
the necessary interconnecting piping make it impractical (and
Sound Level sometimes impossible) to provide a boiler testing environment
Table A4-12 gives a summary of predicated sound pressure which is suitable for taking the data needed to develop Sound
levels for Model CBW boilers. Pressure Power levels.
Units Typical Values

The unit for Table A4-12 is dBA (decibels, measured on the A- Sound pressure levels (dBA) for the same boiler will vary
weighted scale) in reference to 0.0002 microbars. (20 micro- between boiler rooms. In addition, variations will occur
Newtons per square meter). They are standardly referenced in between different people using different sound meters on the
specifying and reporting sound pressure levels on industrial same boiler. And nally, no two boilers can be expected to give
equipment. precisely the same sound levels. For these reasons, we can only
A4-17
10-02
Table A4-12. Model CBW Boiler Sound Pressure Level Summary (100 - 800 hp)
BOILER HP 100 125 150 200 250 300 350 400 500 600 700 750 800
HFO, dbA 83 83 83 83 88 88 89 85 83 83 85 87 88
LFO, dbA 81 81 82 81 86 86 85 81 82 82 82 83 84
HFG, dbA 81 81 80 82 84 86 86 84 82 82 85 86 87
LFG, dbA 78 78 77 78 81 82 83 81 81 81 82 83 84
Sound Pressure levels measured on boilers operating in various locations and expressed in dBA are as follows:
ABBREVIATIONS:
HF = High Fire
LF = Low Fire
O = Oil
G = Gas
predict, but not guarantee, sound levels (dBA). Sound levels Table A4-15 shows conversion factors for gas pressure at ele-
can also change due to motor options and altitudes. vations over 700 ft above sea level.
Octave Band Table A4-16 shows regulated gas pressure with over and
undersized gas trains.
When predicting sound pressures in octave band (e.g., db at
125 Hz), even greater variations between boilers, between Gas Pressure Regulators
sound meters, and between operators can be expected. These
larger variations in the low and high frequencies make octave Pressure Rating: The regulator must have a pressure rating at
band levels a less reliable method of reporting than A-scale least equivalent to that of the gas distribution system.
sound levels. (Since A-scale sound levels are dominated by Capacity: The capacity can be determined by multiplying the
mid- frequency sounds, the A-scale sound levels between two maximum burning rate (CFH) by 1.15 (Table A4-17). This
boilers can be in reasonable agreement even through the low 15 percent over-capacity rating of the regulator provides for
and high frequencies of octave band measurement do not proper regulation. Table A4-17 shows maximum gas
closely correspond.) consumption for natural gas and propane vapor.
Spring Adjustment: The spring should be suitable for a range
Burner Information
pressure to 50 percent over.
Gas - Fired Burners
Sharp Lock-Up: The regulator should include this feature to
the boiler) from climbing when there is no gas ow.
NOTICE
A gas pressure regulator must be installed in the gas if the required gas volume is very large and if the pressure
piping to each Model CBW boiler. Gas pressure regu- drop must be kept to a minimum.
lators for Model CBW Firetube Boilers are sized and
selected on a job-by-job basis. Therefore, gas pres- Regulators in Series: This type of installation can be used if
sure requirements shown in Tables A4-13 through the available gas pressure is over 5, 10, or 20 psig.
A4-16 list regulated gas pressure. Regulated gas Depending on the regulator characteristics, one regulator
pressure is the pressure downstream of the gas pres- would reduce the pressure to 2 - 3 psig, and a second
sure regulator. Total gas pressure required for the regulator would reduce the pressure to the burner
boiler equals regulated gas pressure plus the pres- requirements.
sure drop of the selected gas pressure regulator. The Regulator Location: A straight run of gas line piping should
following items should be considered when selecting be used on both sides of the regulator to ensure proper
a regulator: regulator operation. This is particularly important when pilot
Table A4-13 shows regulated gas pressure requirements for operated regulators are used. The regulator can be located
Model CBW Boilers with standard or FM Gas Trains. close to the gas train connection, but 2 to 3 feet of straight
run piping should be used on the upstream side of the
Table A4-14 shows regulated gas pressure requirements for regulator.
Model CBW Boilers with IRI Gas Trains.
A4-18
10-02
Table A4-14. Model CBW Minimum Required Gas Pressure

at Entrance to Gas Trains Equipped with Industrial Risk (IRI)
Requirements (Downstream of Gas Pressure Regulator)
Table A4-13. Model CBW Minimum Required Gas Pressure at MODEL CBW
Entrance to Standard and FM Gas Trains (Downstream of Gas
BOILER HP MIN PRESS B
Pressure Regulator) CONN SIZE REQ'D
HTB MIN
(IN.) GAS PRESS
(IN WC) REQ'D
MODEL CBW
100 2 6.0 -
BOILER HP B 125 2.5 7.0 -
CONN SIZE MIN PRESS. HTB MIN
(IN.) REQ'D (IN. WC) PRESSURE
REQ'D 150 2.5 9.0 -
100 2 4.5 - 200 2.5 15.0 -
125 2.5 7.0 - 250 3 16.5 21.0
150 2.5 8.0 - 300 3 21.5 30.0
200 2.5 15.0 - 350 3 30.5 39.5
250 3 16.5 21.0 400 4 23.5 36.0
300 3 21.5 30.0 500 4 24.5 34.0
350 3 30.5 39.5 600 4 34.5 39.5
400 4 23.5 36.0 700 4 46.5 54.0
500 4 24.5 34.0 750 4 53.5 62.5
600 4 34.5 39.5 800 4 59.5 71.0
700 4 46.5 54.0 NOTES:

1. Pressures shown also apply to standard and FM gas trains for
750 4 53.5 62.5 Canada.
A. Based on 1000 Btu/cu-ft natural gas and elevation up to 700
800 4 59.5 71.0 feet.
NOTES:
1. For standard and FM gas pressure requirements for Canada,
refer to Table A4-14.
A. Based on 1000 Btu/cu-ft natural gas and elevation up to 700
feet.
Table A4-15. Minimum Required Gas Pressure Altitude

Conversion at 700 ft
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:
oz/sq-in x 1.732 = inches WC.
oz/sq-in x 0.0625 = psig.
psig x 27.71 = Inches WC.
psig x 16.0 = oz/sq-in.
A4-19
10-02
Table A4-16. Under and Oversized Standard, FM, and IRI Gas Trains, Model CBW Boilers, 100 - 800 hp
100 STD FM 100 IRI 125 150 200 250 300
SIZE REQD SIZE REQD SIZE REQD SIZE REQD SIZE REQD SIZE REQD SIZE (IN.) REQ
(IN.) (IN.) (IN.) (IN.) (IN.) (IN.)
1-1/2 17.5 1-1/2 19.0 2 10.5 2 15.0 2 25.5 2-1/2 31.5 2-1/2 42.5
2 4.5 2 6.0 2-1/2 7.0 2-1/2 9.0 2-1/2 15.0 3 21.0 3 30.0
2-1/2 3.5 2-1/2 4.0 3 5.0 3 7.0 3 12.0 4 15.0 4 21.5
3 2.5 3 3.0 4 4.0 4 5.5 4 8.5 4A 12.5 4 A 19.0
350 400 500 600 700 750 800
SIZE REQ SIZE REQD SIZE REQD SIZE REQD SIZE REQD SIZE REQD SIZE REQD
(IN.) (IN.) (IN.) (IN.) (IN.) (IN.) (IN.)
2-1/2 58.5 - - - - - - - - - - - -
3 38.5 3 50.5 3 58.0 3 73.5 3 NA 3 NA 3 NA
4 28.0 4 36.0 4 34.0 4 39.5 4 54.0 4 62.5 4 71.0
4A 24.5 4A 32.0 4A 26.5 4A 28.5 4A 38.0 4A 44.0 4A 51.0
NOTES: Pipe size in inches, and pressure required in inches WC.
B. Standard gas train size shown by shaded areas.
Table A4-17. Model CBW Boiler Maximum Consumption (CFH) for

Natural Gas and Propane Vapor
TYPE OF GAS AND HEAT CONTENT

BOILER
HP NATURAL GAS PROPANE GAS
1000 (Btu/cu-ft) 2550 (Btu/cu-ft)
100 4185 1640
125 5230 2050
150 6280 2465
200 8370 3280
250 10460 4105
300 12555 4925
350 14650 5745
400 16750 6570
500 20925 8205
600 25100 9845
700 29300 11480
750 31400 12310
800 33500 13140
A4-20
10-02
Gas pressure regulator selected for high turndown burners is No. 6 Oil Piping, Storage Tank Heating
critical at minimum ow rates. Consult your local Cleaver- If the oil viscosity exceeds 4,000 SSU at the pumping temper-
Brooks authorized representative for proper selection. ature, tank preheating is required.
If O2 trim is used, check for regulator compatibility. Based on the climate conditions for the job location, the mini-
Figure A4-6 shows standard gas train sizes and locations for mum pumping temperature can be predicted, and the viscosity
Model CBW Firetube Boilers. for the particular oil at this pumping temperature can be deter-
mined.
Figure A4-7 shows a typical gas train piping layout for a multi-
ple boiler application. It is recommended to provide for tank and/or line heating on
all No. 6 oil installations to ensure against high viscosities at
Figure A4-8 shows gas train components. decreased pumping temperatures. The following are two com-
mon methods:
Oil - Fired Burners
1. Provide a tank suction heater and bundling the steam or
Fuel oil consumption information is shown on the boiler rating water lines to the heater with the oil lines.
sheets in the Dimension and Rating Section.
2. Provide electric heating equipment on the oil lines and/or
Figure A4-9 shows the oil connection sizes and locations for in the storage tank.
Model CBW boilers ring No. 2 oil.
Figure A4-10 shows the oil connection sizes and locations for
CBW Boilers ring No. 6 oil. ! CAUTION
DANGER
Figures A4-11 through A4-16 show typical oil systems and
The temperature in the oil suction line should not ex-
layouts.
ceed 130 F as higher temperatures could cause va-
Figure A4-17 shows the detail of an oil transfer tank (day tank) por binding of the oil pump and decreased oil flow.
typically utilized to provide a storage reservoir between the oil See Figures A4-18 and A4-19 for an example of (No. 1 above)
system supply pump and the boiler oil pump. tank heating method. See Figure A4-20 for examples of pre-
heating systems.
MODEL CBW
HP SIZE DIMENSION
(IN.) (NPT) A (IN.)
100 2-1/2 67-1/2
125 2-1/2 67-1/2
150, 200 2-1/2 67-1/2
250, 300, 350 3 70-1/2
400, 500, 600, 700, 750, 800 4 109-1/2
Figure A4-6. Model CBW Standard Gas Train Connection Size and Location, IRI
A4-21
10-02
This figure illustrates the basic gas valve arrangement on Cleaver-Brooks Model CBW boiler and shows
the contractor's connection point. The valves and controls between the contractor connection point and
the gas main in the street are representative of a typical installation. Actual requirements may vary de-
pending on local codes or local gas company requirements which should be investigated prior to prepara-
tion of specifications and prior to construction.

C. Gas meter.

A4-22
10-02
ITEM DESCRIPTION
125- 300- 125- 300- 125- 125- 300-
BOILER HP 100 100 100 100
250 800 250 800 800 250 800
1 Pilot Shut Off Cock x x x x x x x x x x x
2 Pilot Shut Off Cock x x x x x
3 Shut Off Cock x x x x x x x x x x x
4 Shut Off Cock x x x x x x x x x x x
5 Pilot Pressure Regulator x x x x x x x x x x x
6 Pilot Pressure Gauge x x x x x x x x x x x
7 Gas Pilot Valve x x x x x x x x x x x
8 High Gas Pressure Switch x x x x x x x x x x x
9 Low Gas Pressure Switch x x x x x x x x x x x
10 Main Gas Valve with POC x x x x x x x x x
11 Main Gas Valve without POC x x x x x x x
13 Main Gas Valve without POC x x
14 Vent Valve x x x x x x x
15 Butterfly Valve x x x x x x x x x x x
Figure A4-8. Gas Train Components
A4-23
10-02
MODEL CBW
RECOMMENDED OIL LINE

A
SUPPLY SIZES
AND (STANDARD PIPE)
BOILER HP RETURN A (IN. - IPS)
CONNECTION (IN.) STORAGE
SIZES TANK TO PUMP RETURN
(IN.) (NPT) BOILER TO LINE TO
OR PUMP BOILER TANK
CONNECT
100, 125, 150, 3/4 12-1/2 1 1 1
200
250, 300, 350 3/4 34 1 1 1
400
400, 500, 600 3/4 36 1 1 1
700, 800 3/4 36 1 1 1
NOTE: See No. 2 Oil Line Sizing Instruction for systems with other con-
ditions.
A. For suction line condition with a maximum of 10 feet of lift and a total
of 100 feet of suction line
Figure A4-9. No. 2 Oil Connection Size, Location and Recommended Line Sizes
MODEL CBW
GAS PILOT RECOMMENDED OIL LINE
SUPPLY RETURN CONNECTION SIZES
CONNECTION CONNECTION 4-5" WC PRESS. (STANDARD PIPE)
BOILER HP REQD (IN.)
STORAGE
SIZE (IN.) A SIZE (IN.) B SIZE (IN.) C PUMP TO RETURN
TANK TO BOILER LINE TO
(NPT) (IN.) (NPT) (IN.) (NPT) (IN.) PUMP TANK
100 1-1/4 27-3/4 3/4 19-3/4 1/2 28 2 1-1/4 1-1/4
125, 150 1-1/4 49-1/2 1-1/4 39-1/2 1/2 38 2-1/2 1-1/2 2
200 1-1/4 65-1/2 1-1/4 39-1/2 1/2 38 2-1/2 1-1/2 2
250,300, 350 1-1/4 89-3/4 1-1/4 59-3/4 1/2 56 2-1/2 1-1/2 2
400, 500, 600,700, 800 1-1/4 63 1-1/4 48 1/2 54 3 2 2
NOTES:
2.For suction lines with a maximum of 10 feet of lift and a total of 100 feet of suction line.
Figure A4-10. No. 6 Oil Connection Size, Location and Recommended Line Size
A4-24
10-02

Remote Oil Pump

Remote Oil Pumps
A4-25
10-02

Oil Pumps
A4-26
10-02
Figure A4-15. No. 6 Oil Piping, Multiple Boiler Installation, Remote

Oil Pumps
A4-27
10-02
ITE
SIZE DESCRIPTION
M
1/2 Connection to off level

A
NPT switch
See
B Return line to tank
note
See Oil supply connection
C
note from transfer pump
1/2
D Tank drain connection
NPT
See
E FOS connection
note
1/8 Oil level test valve
F
NPT connection
See
G FOR connection
note Figure A4-17. No. 2 Oil Transfer Tank Detail
Figure A4-18. Typical Arrangement
A4-28
10-02
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 cover-
ing.
Note 2: When the bundle runs under driveways

or other traffic areas, a heavy duty outer jacket
of reinforced concrete, vitrified tile, or corrugated
steel is recommended.
Figure A4-19. Typical Cross Section of Bundled Lines
In order to properly preheat No. 6 oil, the minimum recommended boiler water temperature is 200 F. Some No. 6 oils must be preheated
up to 210 F, and higher boiler water temperatures are then desirable.
Although lower boiler water temperatures can be used, this condition means that the electric preheater will be doing more of the work. It is
more economical to use higher temperature boiler water for preheating than to use lower temperature water which increases the electric
preheating load.
To ensure the most trouble-free, dependable preheating system, a boiler water-to-water-to-oil preheating system is furnished as standard
equipment and is mounted, piped and wired on the boiler. This safety type system or double heat exchanger eliminates the possibility of
an oil leak fouling the boiler, oil heater, piping, control valves, and circulating pumps. Insurance companies recognize this as the best system
for the application.
The standard system does not have provisions for a hot water line to a storage tank heater.
Figure A4-20. Schematic of Standard Alstrom Hot Water Safety-Type Preheating System
A4-29
10-02
Boiler Room Information and cause variations in the quantity of combustion air.
This can result in unsatisfactory burner performance.
Figure A4-21 shows typical boiler room length requirements.
D. Under no condition should the total area of the air supply
Figure A4-22 shows typical boiler room width requirements. openings be less than (1) square foot.
Figure A4-23 shows typical breeching arrangements. E. Size the openings by using the formula:
Stack Support Capabilities Area (sq-ft) = CFM/FPM

Cleaver-Brooks Firetube CBW Boilers can support up to 2. Amount of air required (cfm).
2,000 lb without additional support.
A. Combustion Air = Rated bhp x 8 cfm/bhp.
Firetube boilers 250 hp through 800 hp can be reinforced to
support 3,000 lbs. B. Ventilation Air = Maximum bhp x 2 cfm/bhp
C. Total recommended air = 10 cfm/bhp - up to 1000 feet
Stack and Breeching Size Criteria elevation. Add 3 percent more per 1000 feet of added
elevation.
The design of the stack and breeching must provide the
required draft at each boiler ue gas outlet. Proper draft is crit- 3. Acceptable air velocity in boiler room (fpm).
ical to burner performance. A. From oor to (7) foot height - 250 fpm.
Although constant pressure at the ue gas outlet of the Model B. Above (7) foot height - 500 fpm.
CBW is not required, it is necessary to size the stack/breech-
ing to limit ue gas pressure variation. The allowable pressure Example: Determine the area of the boiler room air supply
range is 0.5" W.C. to +0.5" W.C. The maximum pressure openings for (1) 300 hp boiler at 800 feet altitude. The air
variation at any ring rate for the boiler is 0.5" W.C. openings are to be 5 feet above oor level.
For additional information, please review Section I4, General Air required: 300 x 10 = 3000 cfm (from 2B above).
Engineering Data (Stacks) and Section F, Stacks. Stack and Air velocity: Up to 7 feet = 250 fpm (from 3 above).
breeching sizes should always be provided by a reputable
stack supplier who will design the stack and breeching system Area Required: Area = cfm = 3000/250 = 12 Sq-ft total.
based on the above criteria. Your local Cleaver-Brooks autho- Area/Opening: 12/2 = 6 Sq-ft/Opening (2 required).
rized representative is capable of assisting in your evaluation
NOTICE
Boiler Room Combustion Air
When determining boiler room air requirements, the size of Consult local codes which may supersede these re-
the room, air ow, and velocity of air must be reviewed, as fol- quirements.
lows:
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
boiler.
protection, but they should not be covered with ne
mesh wire, as this type of covering has poor air ow
A4-30
10-02
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.
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.
Figure A4-21. Boiler Room Length, Typical Layout (CBW Boilers)
BOILER HP 100-200 250-400 500-800

Dimension A 87" 96" 106"
Dimension B 127" 151" 183"
NOTES:
1. Recommended Minimum Distance Between Boiler and
Wall. Dimension A allows for a clear 42" aisle between the
water column on the boiler and the wall. If space permits, this
aisle should be widened.
Dimension B between boilers allows for a clear
aisle of:
42" - 100 -200 hp
48" - 250-400 hp
60" - 500-800 hp
Figure A4-22. Boiler Room Width, Typical Layout (CBW Boilers)
A4-31
10-02
NOTE: These stack breeching arrangements for multi-

ple 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.
A4-32
10-02
SAMPLE SPECIFICATIONS
The following sample specications are provided by Cleaver-Brooks to assist you in meeting your customers specic needs and
application.
The detailed burner and control specications, and detailed control specications for CB780 Flame Safeguard control and the CB-
HAWK Flame Safeguard control, are provided. See Section D, Controls, for additional information on control options.
The sample specications are typically utilized as the base template for the complete boiler specication. Contact your local
equipment, or general assistance in completing the specication.
Model CBW Steam Boiler (100-800 hp, Steam 15-250 psig)

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

1.1 The Steam Boiler shall be Cleaver-Brooks Fuel Series ______ (100, 200, 400, 600, 700), ______ hp designed for ______ psig
(15, 150, 200, or other psig steam). The maximum operating pressure shall be _____ psig and the minimum operating pressure
shall be ______ psig.
1.2 The boiler shall have a maximum output of ______ Btu/hr, or ______ horsepower when wired with CS12-48 ______ oil and/or
natural gas, ______ Btu/cu-ft. Electrical power available shall be ______ Volt ______ Phase ______ Cycle.

2.1 The boiler shall be a three pass horizontal retube updraft boiler with ve (5) square feet of heating surface per rated boiler
NOTICE
2.1.1 The boiler shall be completely preassembled and re tested at the factory. The unit shall be ready for immediate mounting on
oor or simple foundation and ready for attachment of water, fuel, electrical, vent, and blowdown connections.
A4-33
10-02
2.1.2 The boiler shall be built to comply with the following insurance and codes ______________ (Factory Mutual, Industrial Risk
Insurance, ASME CSD-1).
2.2.2 The boiler shall be furnished with a manhole and handholes to facilitate boiler inspection and cleaning. Two lifting lugs must
be located on top of the boiler.
2.2.3 The front door shall be hinged or davited, the rear door shall be davited. Doors are to be sealed with berglass tadpole gaskets
and fastened tightly using heavy capscrews that thread into replaceable brass nuts.
2.2.4 The boiler tubes shall not include turbulators, swirlers, or other add-on appurtenances.
2.2.5 The rear door shall be insulated with a blanket material with a steel covering to give the surface a hard durable nish.
2.2.6 The exhaust gas vent shall be located at the rear of the boiler and be capable of supporting 2000 lbs. The boiler vent shall con-
tain a stack thermometer.
2.2.7 Observation ports for the inspection ame conditions shall be provided at each end of the boiler.
2.2.8 The boiler insulation shall consist of 2 inch blanket under a sectional preformed sheet metal lagging. The insulation must be
2.2.9 The entire boiler base frame and other components shall be factory painted before shipment, using a hard-nish enamel coat-
ing.

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.
feedwater pump to maintain the boiler water level within normal limits.
3.2 Auxiliary Low Water Cut-off
Auxiliary low water cut-off shall be included, piped to the vessel, and wired to the burner control circuit. A manual reset device
shall be used on this control.
3.4 Safety Valves
The steam pressure control to regulate burner operation shall be mounted near the water column. Controls shall be a high limit
(manual reset), operating limit (auto reset), and ring rate control.
A4-34
10-02

Burner operation shall be full modulation principle. The burner shall always return to low re position for ignition.
4.2 Blower
the re according to load demand. Potentiometer type position controls shall be provided to regulate operation of the damper con-
trol motor (remove this sentence when a CB-HAWK ame safeguard is used).
4.4 Fuel Specication and Piping
Fuel series 700 - Gas red (para 4.4.1).
Fuel series 100 - Light oil (No. 2) red (para 4.4.2).
Fuel series 200 - Light oil or gas red (para 4.4.3).
Fuel series 600 - No. 6 oil red (para 4.4.4).
Fuel series 400 - No. oil or gas red (para 4.4.5).
4.4.1.1 Burner Type - The burner shall be integral with the front head of the boiler and of high radiant annular gas entry on 100-200
hp and multi-port type gas entry on 250-800 hp. The burner shall be approved for operation on natural gas fuel.
pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include two manual shut-
power failure, ame failure, low water or any safety shutdown condition. A lubricating plug cock or buttery shutoff valve shall be
provided as a means for a tightness check of the primary shut off valve. An additional plug cock on buttery valve shall be fur-
A. 100 hp. High and low gas pressure switches shall be provided.
B. 125 through 250 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an
additional plugged leakage test connection shall be provided. A vent valve shall be located between the safety shutoff valves.
A. 100-200 hp. Turndown range of burner shall be 4:1 when ring natural gas.
B. 250-800 hp. Turndown range of the burner shall be 10:1 when ring natural gas. (Consult with Cleaver-Brooks Representa-
tive regarding high turndown capability based on available gas pressure.)
A4-35
10-02

tronic detector shall monitor the pilot so that the primary oil valve cannot open until ame has been established.
4.4.2.3 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. The motor
driven pump set, shipped loose, to be installed in a location favorable to the oil storage tank, shall be provided.
4.4.2.4 Oil Burner Piping
4.4.2.4.1 Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, solenoid shutoff valves,
pressure gauges and fuel strainer, all integrally mounted on the unit.
4.4.2.4.2 A fuel oil controller shall be provided to combine all of the fuel oil controls into a single casting which is mounted on the
front door of the unit. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. A low oil pressure
switch shall be included in the oil piping.
A. 100 through 400 hp. Belt driven air compressor, lubricating air tank, oil level indicator, inlet air lter, air pressure gauge,
B. 500 through 800 hp. Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch.
A. 100 through 200 hp. Turndown range shall be 4:1 when ring No. 2 oil.
B. 250 through 800 hp. Turndown range shall be 8:1 when ring No. 2 oil.
type for oil and high radiant annular gas entry on 100-200 hp and multi-port type gas entry on 250-800 hp. The burner shall be
approved for operation with either CS12-48 Commercial No. 2 Oil or natural gas.
so that the primary fuel valve cannot open until ame has been established. The pilot train shall include two manual shut-off
4.4.3.3 Oil Burner
4.4.3.3.1 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. The motor
A. 100 through 400 hp. Belt driven air compressor, lubricating air tank, oil level indicator, inlet air lter, air pressure gauge and
4.4.3.4 Gas Burner
provided as a means for a tightness check of the primary shut off valve. An additional plug cock or buttery valve shall be fur-
A4-36
10-02
C. 300-800 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus and addi-
A. 100 through 200 hp. Turndown range of the burner shall be 4:1.
B. 250 through 800 hp. Turndown range of the burner shall be 10:1 when ring natural gas and 8:1 on No. 2 oil. (Consult your
pilot so that the primary oil valve cannot open until pilot ame has been established. The pilot train shall include two manual shut-
purged of oil on each shutdown. A low oil pressure switch shall be included in the oil piping.
A. 100 through 400 hp. Belt driven air compressor, lubricating oil tank, oil level indicator, inlet air lter, air pressure gauge and
B. 500 through 800 hp. Separate air compressor modules mounted on boiler base rail with low atomizing air pressure switch.
4.4.4.6 Oil Preheat
NOTICE
15 psig only - 500 through 800 hp. Electric preheater size 10 kW.

A4-37
10-02
atomizing type for oil and high radiant annular gas entry on 100-200 hp and multi-port type gas entry on 250-800 hp. The burner
shall be approved for operation with either CS12-48 Commercial No. 6 oil or natural gas.
4.4.5.3 Oil Burner
piping and nozzle shall be purged of oil at each shutdown. A low oil pressure switch shall be included in the oil piping.
4.4.5.5 Oil Preheat - The oil shall be preheated by a steam heater and electric heater, each with thermostatic control. Both heaters
shall be installed in a single compact shell mounted, piped, and wired on the boiler. The thermostatic controls shall be sent to cut-
out the electric heater when steam is available. Select one of the following:
NOTICE
15 psig only - 500 through 800 hp Electric preheater size 10 kW.
4.4.5.6 Gas Burner

provided as means for a tightness check of the primary shutoff valve. An additional plug cock or buttery valve shall be furnished
4.5.1.1 Boilers with CB780 Control - Each boiler shall be factory equipped with ame safeguard controller providing technology
A4-38
10-02
Controller shall be computerized solid state having sequence and ame-on lights and alpha-numeric rst out fault indications of
ame safeguard trip functions. It shall include dynamic self-check logic. The controller shall have a xed operating sequence
cycles.
ing trip functions: pilot and main ame failure, high and low re proving switch faults, locking interlocks open, false ame signal
and run cycles for adjustments to ring rate motor, damper linkages and pilot ame for minimum turndown tests.
The panel shall contain the boiler ame safeguard controller, blower motor starter, indicating lights and selector switches.
The panel shall have a removable sub-base for mounting the ame safeguard controller, blower motor starter, and terminal blocks.
For combination gas-oil and heavy oil red boilers the panel shall contain the fuel selector and/or oil heater selector switch.
4.5.1.3 Lights
Red - low water.
Red - ame failure.
Burner On-Off.
Manual-Automatic.
4.5.1.5 Oil, heat and moisture resistant wire shall be used and identied with circuit numbers corresponding to the electrical wiring
diagram.
sequencing, ame supervision, and indications of system status, faults, and self-diagnostics.
The boiler controller shall consist of chassis, program module, keyboard display, and ame signal amplier. It shall be the non-
recycle type and have a xed operating sequence incapable of being manually altered. The sequence shall include standby, pre-
The system shall incorporate full modulating control of fuel and combustion air as well as ring rate control based on system
demand.
The boiler controller shall have a non-volatile memory that retains history les and sequence status after interruptions.
tures. Boiler ring rate shall also be displayed in addition to the last 6 lockouts and boiler operating information when the lockout
A4-39
10-02

The boiler controller shall incorporate a ve function run/test switch.
specic rate control program for precise load tracking that reduces on-off cycling due to load swings. The system shall also pro-
vide an integrated thermal stress protection program to prolong boiler life. An assured low re cutoff feature shall also be pro-
vided.
dynamic check of the gas pressure sensor shall be made prior to the main ame establishing period to ensure it is fully operational.
tion. Options such as Lead/Lag, Boiler Efciency, and Heating Boiler packages can be interfaced to this module without any
system.
The panel shall contain the boiler ame safeguard controller, indicating lights and selector switches.
Panel shall have a removable sub-base for mounting the ame safeguard controller, and terminal blocks. For combination gas-oil
and heavy oil red boilers the panel shall contain the fuel selector and/or oil heater selector switch.
4.5.2.2 Oil, heat, and moisture resistant wire shall be used and identied with circuit numbers corresponding to the electrical wiring
diagram.

5.1 The boiler must be guaranteed to operate at a minimum fuel-to-steam efciency of ____ percent at 100 percent of
rating when burning natural gas and ________ fuel-to-steam efciency at 100% ring rate when burning oil (Contact your local
Cleaver-Brooks authorized representative for efciency details).
6.0 Warranty
up or 18 months from date of shipment, whichever comes rst.
7.0 Execution
7.1 Shop Tests
A4-40
10-02
Model CBW Hot Water Boiler (100-800 hp, 30 and 125 psig)

1.1 The Hot Water Boiler shall be Cleaver-Brooks Model CBW, Fuel Series ______ (100, 200, 400, 600, 700), ______ hp designed
for ______ psig (30, 125, or other psig Hot Water). The maximum water temperature shall be ______ degree F, and the maximum
system temperature drop shall be ______ degree F.
1.2 The boiler shall have a maximum output of ______ Btu/hr, or ______ horsepower when red with CS12-48 ______ oil and/or
natural gas, ______ Btu/cu-ft. Electrical power available shall be ______ Volt ______ Phase _____ Cycle.

2.1 The boiler shall be a three pass horizontal retube updraft boiler with ve (5) square feet of heating surface per rated boiler
The complete packaged boiler approved as a unit by Underwriters Laboratories and shall bear the UL/ULC label.
oor or simple foundation and ready for attachment of water, fuel, electrical, vent, and blowdown connections.
2.1.2 The boiler shall be built to comply with the following insurance and codes _________________ (Factory Mutual, Industrial
Risk Insurance, ASME CSD-1).
prior to shipment. A copy of the inspection report shall be provided to the purchaser.
2.2.3 A dip tube shall be included as an integral part of the hot water outlet, and an air vent tapping shall be provided for removal of
entrained air.
2.2.4 The boiler shall be furnished with a manhole and handholes to facilitate boiler inspection and cleaning. Two lifting lugs shall
2.2.5 The front door shall be hinged or davited, rear door shall be davited. Doors are to be sealed with berglass tadpole gaskets
and fastened tightly using heavy capscrews that thread into replaceable brass nuts.
2.2.6 Front and rear tube sheets and all ues must be fully accessible for inspection or cleaning when the doors are swung open and
rear door access plug is removed.
2.2.7 The rear door shall be insulated with a blanket material a steel covering to give the surface a hard durable nish.
2.2.8 The exhaust gas vent shall be located at the rear of the boiler and be capable of supporting 2000 lbs. The boiler vent shall con-
tain a stack thermometer.
2.2.9 Observation ports for the inspection ame conditions shall be provided at each end of the boiler.
2.2.10 The boiler insulation shall consist of a 2 inch blanket under a sectional preformed sheet metal lagging. The insulation must
be readily removable and reinstalled, if required.
2.2.11 The entire boiler base fame and other components shall be factory painted before shipment, using a hard-nish enamel coat-
ing.

A4-41
10-02
Pressure and temperature gauges shall be mounted on the boiler with the temperature sensing element located adjacent to the hot
water outlet.
3.3 Relief Valves
to the hot water outlet. Controls shall be high limit (manual reset), operating limit (auto reset), and ring rate control.

Burner operation shall be full modulation principle. The burner shall always return to low re position for ignition.
4.2 Blower
the re according to load demand. Potentiometer type position controls shall be provided to regulate operation of the damper con-
trol motor (remove this sentence when a CB-HAWK ame safeguard is used).
Fuel series 600 - No. 6 oil red (para 4.4.4).
Fuel series 400 - No. oil or gas red (para 4.4.5).
4.4.1.1 Burner Type - The burner shall be integral with the front head of the boiler and of high radiant annular gas entry on 100-200
hp and multi-port type gas entry on 250-800 hp. The burner shall be approved for operation on natural gas fuel.
pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include two manual shut-
provided as a means for a tightness check of the primary shut off valve. An additional plug cock on buttery valve shall be fur-
A4-42
10-02
A. 100-200 hp. Turndown range of burner shall be 4:1 when ring natural gas.
B. 250-800 hp. Turndown range of the burner shall be 10:1 when ring natural gas. (Consult with Cleaver-Brooks Representa-
tive regarding high turndown capability based on available gas pressure.)
tronic detector shall monitor the pilot so that the primary oil valve cannot open until ame has been established.
4.4.2.3 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. The motor
4.4.2.4.1 Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, solenoid shutoff valves,
pressure gauges and fuel strainer, all integrally mounted on the unit.
4.4.2.4.2 A fuel oil controller shall be provided to combine all of the fuel oil controls into a single casting which is mounted on the
front door of the unit. A single tip retractable nozzle shall be used for the low pressure air atomizing burner. A low oil pressure
switch shall be included in the oil piping.
A. 100 through 400 hp. Belt driven air compressor, lubricating air tank, oil level indicator, inlet air lter, air pressure gauge,
A. 100 through 200 hp. Turndown range shall be 4:1 when ring No. 2 oil.
B. 250 through 800 hp. Turndown range shall be 8:1 when ring No. 2 oil.
type for oil and high radiant annular gas entry on 100-200 hp and multi-port type gas entry on 250-800 hp. The burner shall be
so that the primary fuel valve cannot open until ame has been established. The pilot train shall include two manual shut-off
4.4.3.3 Oil Burner
A. 100 through 400 hp. Belt driven air compressor, lubricating air tank, oil level indicator, inlet air lter, air pressure gauge and
A4-43
10-02
4.4.3.4 Gas Burner
provided as a means for a tightness check of the primary shut off valve. An additional plug cock or buttery valve shall be fur-
B. 125 through 250 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus
an additional plugged leakage test connection shall be provided.
C. 300 through 800 hp. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus
and additional plugged leakage test connection shall be provided. A vent valve shall be located between the safety shutoff
valves.
A. 100 through 200 hp. Turndown range of the burner shall be 4:1.
B. 250 through 800 hp. Turndown range of the burner shall be 10:1 when ring natural gas and 8:1 on No. 2 oil. (Consult your
The motor driven pump set shall be included shipped loose for location favorable to the oil storage tank.
purged of oil on each shutdown. A low oil pressure switch shall be included in the oil piping.
4.4.4.6 Oil Preheat
The oil shall be preheated by a safety type water-to-water-to-oil preheating system in conjunction with an electric heater, each with
thermostatic control. Both heaters shall be installed in a single compact shell mounted, piped, and wired on the boiler. Select one of
the following:
A4-44
10-02

4.4.5.3 Oil Burner
piping and nozzle shall be purged of oil at each shutdown. A low oil pressure switch shall be included in the oil piping.
4.4.5.5 Oil Preheat - The oil shall be preheated by a safety type water-to-water-to-oil preheating system in conjunction with an
electric heater, each with thermostatic control. Both heaters shall be installed in a single compact shell mounted, piped, and wired
on the boiler. Select one of the following:
4.4.5.6 Gas Burner

provided as means for a tightness check of the primary shutoff valve. An additional plug cock or buttery valve shall be furnished
4.5.1.1 Boilers with CB780 Control - Each boiler shall be factory equipped with ame safeguard controller providing technology
A4-45
10-02

Controller shall be computerized solid state having sequence and ame-on lights and alpha-numeric rst out fault indications of
ame safeguard trip functions. It shall include dynamic self-check logic. The controller shall have a xed operating sequence
cycles.
ing trip functions: pilot and main ame failure, high and low re proving switch faults, locking interlocks open, false ame signal
and run cycles for adjustments to ring rate motor, damper linkages and pilot ame for minimum turndown tests.
The panel shall contain the boiler ame safeguard controller, blower motor starter, indicating lights and selector switches.
The panel shall have a removable sub-base for mounting the ame safeguard controller, blower motor starter, and terminal blocks.
For combination gas-oil and heavy oil red boilers the panel shall contain the fuel selector and/or oil heater selector switch.
4.5.1.3 Lights
Red - low water.
Red - ame failure.
Burner On-Off.
Manual-Automatic.
4.5.1.5 Oil, heat and moisture resistant wire shall be used and identied with circuit numbers corresponding to the electrical wiring
diagram.
sequencing, ame supervision, and indications of system status, faults, and self-diagnostics.
The boiler controller shall consist of chassis, program module, keyboard display, and ame signal amplier. It shall be the non-
recycle type and have a xed operating sequence incapable of being manually altered. The sequence shall include standby, pre-
The system shall incorporate full modulating control of fuel and combustion air as well as ring rate control based on system
demand.
The boiler controller shall have a non-volatile memory that retains history les and sequence status after interruptions.
A4-46
10-02
tures. Boiler ring rate shall also be displayed in addition to the last 6 lockouts and boiler operating information when the lockout
The boiler controller shall incorporate a ve function run/test switch.
specic rate control program for precise load tracking that reduces on-off cycling due to load swings. The system shall also pro-
vide an integrated thermal stress protection program to prolong boiler life. An assured low re cutoff feature shall also be pro-
vided.
dynamic check of the gas pressure sensor shall be made prior to the main ame establishing period to ensure it is fully operational.
tion. Options such as Lead/Lag, Boiler Efciency, and Heating Boiler packages can be interfaced to this module without any
system.
The panel shall contain the boiler ame safeguard controller, indicating lights and selector switches.
Panel shall have a removable sub-base for mounting the ame safeguard controller, and terminal blocks. For combination gas-oil
and heavy oil red boilers the panel shall contain the fuel selector and/or oil heater selector switch.
4.5.2.2 Oil, heat, and moisture resistant wire shall be used and identied with circuit numbers corresponding to the electrical wiring
diagram.

5.1 The boiler must be guaranteed to operate at a minimum fuel-to-water efciency of ____ percent at 100 percent of
6.0 Warranty
A4-47
10-02
7.0 Execution
7.1 Shop Tests
7.2.1 After boiler installation is completed, the manufacturer shall provide the services of a eld representative for starting the unit
A4-48
10-02
Section A5
Model CBH Boilers
This product has been discontinued.
A5-1
02-02
Model CBH Boilers Firetube Boilers
Notes
A5-2
02-02
Section A6
MODEL CB OHIO SPECIAL BOILERS
CONTENTS
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-3
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-4
Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-11
Burner Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-13
Gas-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-13
Gas Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-16
Oil-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-17
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-25
ILLUSTRATIONS
Figure A6-1. Model CB Ohio Special Steam Boiler Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-6
Figure A6-2. Model CBW Ohio Special Steam Boiler Dimensions - Sheet 1of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-8
Figure A6-3. Space Required to Open Rear Head on Model CB and CBW Ohio Special Boilers Equipped with Davits A6-10
Figure A6-4. Model CB and CBW Ohio Special Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-10
A6-1
02-02
Ohio Special Boilers Firetube Boilers
Figure A6-5. Model CB Ohio Special Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-11

Figure A6-6. Secondary Air Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-13
Figure A6-7. Complete Linkage Assembly, Combination Gas and Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-14
Figure A6-8. Gas Modulating Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-15
Figure A6-9. Model CB and CBW Ohio Special Gas Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-18
Figure A6-11. Model CB and CBW Ohio Special Firetube Boilers Standard Gas Train Connection Size and Location . A6-20
Figure A6-12. CB and CBW Ohio Special Boilers, No. 2 Oil Connection Size, Location and Recommended Line Sizes A6-20
Figure A6-14. No. 2 Oil Piping, Multiple Boiler Installation, Remote Oil Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-21
Figure A6-17. Boiler Room Length (Typical Layouts), Model CB Ohio Special Shown . . . . . . . . . . . . . . . . . . . . . . . . . A6-24
Figure A6-18. Boiler Room Width (Typical Layout), Model CB Ohio Special Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-24
TABLES
Table A6-1. Model CB Ohio Special Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-5
Table A6-2. Model CBW Ohio Special Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-5
Table A6-3. Model CB and CBW Ohio Special Boilers Heating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-11
Table A6-4. Model CB Ohio Special Boilers Steam Volume and Disengaging Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-12
Table A6-5. Model CB and CBW Ohio Special Boilers Steam Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . . . A6-12
Table A6-6. Model CB and CBW Ohio Special Firetube Boilers Recommended Steam Nozzle Size
(To Maintain 4000 to 5000 fpm Nozzle Velocity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-12
Table A6-7. Model CB and CBW Ohio Special Firetube Boilers Recommended Non-Return Valve Size . . . . . . . . . . . . A6-13
Table A6-8. Model CB and CBW Ohio Special Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-13
Table A6-9. CB and CBW Ohio Special Firetube Boilers Minimum Required Gas Pressure at Entrance to
Standard and FM Gas Trains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-15
Table A6-10. CB and CBW Ohio Special Boilers Minimum Gas Pressure at Entrance to Gas Trains
Equipped with Industrial Risk Insurers (IRI) Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-16
Table A6-11. Model CB and CBW Ohio Special Boilers Under and Oversized Standard and FM Gas Trains . . . . . . . . A6-16
Table A6-12. Model CB and CBW Ohio Special Boilers Under and Oversized IRI Gas Trains, . . . . . . . . . . . . . . . . . . . A6-17
The following section contains information on Cleaver-Brooks Ohio Special Boilers.
A6-2
02-02
Firetube Boilers Ohio Special Boilers
FEATURES AND BENEFITS Boiler Options
The Cleaver-Brooks Ohio Special Firetube boiler is designed, Drain valves.

manufactured, and packaged by Cleaver-Brooks specifically Additional screwed or flanged trappings.
for operation in the state of Ohio, under the rules and regula-
tions for unattended units. The unique design of the Ohio Spe- Surge load baffles.
cial Boiler serves your steam needs and reduces unnecessary Seismic design.
labor costs. All units are factory fire tested and shipped as a
package, ready for quick connection to utilities. In addition to Blowdown valves.
the features provided on all Cleaver-Brooks Firetube boilers, Non-return valves.
the following features apply to the Ohio Specials.
Unique Dimple Tube Design: Special doors, davited, hinged, left swing.
Ensures high gas turbulence and increased efficiency without Special base rails.
turbulators, spinners, and other high maintenance devices.
Surface blowdown systems.
Dimple tubes also reduce the film coefficient on the gas side
to transfer more heat, thus achieving greater output with less Weather-proofing.
heating surface. Burner/Control Options
Special modulation controls.
358 Square Feet of Heating Surface:
Low NOx equipment.
The greatest amount offered in any packaged boiler for
unattended steam boiler operation in Ohio - means long life Optional flame safeguard controller.
and years of service at the high efficiencies.
Lead/lag system.
Low Furnace Location: Special insurance and code requirements (e.g., IRI, FM,
CSD1).
clearance from bottom of boiler, allowing proper circulation. Remote contacts.
Low furnace provides additional safety margin between Additional relay points and indicator lights.
furnace and water level.
Main disconnect.
Reduces water carryover, producing drier steam.
Elapsed time meter.
PRODUCT OFFERING Voltmeter/micro-ampmeter.

NEMA enclosures.
Cleaver-Brooks Ohio Special Firetube boilers are available
high pressure steam designs. Burners are available to fire natu- Low fired hold controls.
ral gas, light oil, or a combination of oil and gas.
Ohio Special Boilers include:
Circuit breaker.
Four-pass dryback design (100 hp).
Day/night controls.
Two-pass dryback design (125 - 225 hp).
Two-pass wetback design (125 - 200 hp).
Fuel Options
150, 200, and 250 psig high pressure steam
Available options: For option details, contact your local
Gas strainer.
Cleaver-Brooks authorized representative. In summary,
options include the following: Special fuel shut-off valves.
A6-3
02-02
Special pilot.
Alternate fuel firing.
Special oil pumps.

For dimension and rating information for Ohio Special boilers,
refer to the following tables and illustrations:
Table A6-1. Model CB Ohio Special Steam Boiler Ratings.
Table A6-2. Model CBW Ohio Special Boiler, Steam Boiler
Ratings.
Figure A6-1. Model CB Ohio Special Steam Boiler
Dimensions.
Figure A6-2. Model CBW Ohio Special Steam Boiler
Dimensions.
Figure A6-3. Space Required to Open Rear Head on Model
CB Ohio Special Boilers Equipped with Davits.
Figure A6-4. Lifting Lug Locations, Model CB Ohio Special
Boilers.
Figure A6-5. Model CB Ohio Special Boiler Mounting
Piers.
PERFORMANCE DATA
For efficiency and emission data for Ohio Special Boilers,
A6-4
02-02
A6-Text.fm Page 5 Tuesday, December 17, 2002 10:47 AM
Table A6-1. Model CB Ohio Special Steam Boiler Ratings

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 30 37.4 44.8 52.5 59.8 67.5
(140,000 Btu/gal)
Nat Gas CFH 4185 5230 6277 7323 8369 9415
(1000 Btu/cu-ft)
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
Air Compressor Motor hp 2
(Oil Fired Only) Air Compressor Belt Driven From Blower Motor
NOTES:
1. Standard Voltage is 230 or 460/3/60 Hz.
2. Burner control circuit Voltage is 115/1/60 Hz,1/2 kVA load.
3. Side mounted air compressor (3 hp motor) recommended for 200S and 225S.
Table A6-2. Model CBW Ohio Special Steam Boiler Ratings

BOILER HP 125S 150S 175S 200S
WEIGHT IN POUNDS
Normal Water Capacity 7000 7000 8500 8500
Approx Wt - 15 psig 11500 11500 13250 13350
Approx Wt - 150 psig 12500 12500 14300 14400
Approx Wt - 200 psig 13200 13200 15000 15100
Steam lbs/hr (212F) 4313 5175 6038 6900
Btu Output (1000 Btu/hr) 4184 5021 5858 6695
APROXIMATE FUEL CONSUMPTION AT RATED CAPACTIES
Light Oil gph 37.4 44.8 52.5 59.8
(140,000 Btu/gal)
Nat Gas CFH 5230 6277 7323 8369
(1000 Btu/cu-ft)
Nat Gas Therms/hr 52.3 62.8 73.2 83.7
POWER REQUIREMENTS - ELECTRIC (60 Hz)
Blower Motor hp (all models) 5 7-1/2 10 15
Oil Pump Motor hp No. 2 Oil 1/2 1/2 1/2 1/2
Air Compressor Motor hp Air Compressor Belt Driven From Blower Motor
(Oil Fired Only)
NOTES:
1. Standard Voltage is 230 or 460/3/60 Hz.
2. Burner control circuit voltage is 115/1/60 Hz; 1/2 kVA Load.
3. Side mounted air compressor (3 hp motor) recommended for 200S.
A6-5
02-02
RR/RF/RD
EE B
I FF
F
LL K
GG DD
L Y
D T E
Z
O
P J
OO
H
S
ELECTRICAL SERVICE
CONNECTIONS SIGHT PORT
KK (CONTROL CIRCUIT
Q 120/1/60) R
N NOTE: ALLOW 3 FEET 0.5
FOR DOOR SWING W W
M C
PER NEC
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 130 112 112 148 148 148
Front Head Extension (Approx) 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 A6-1. Model CB Ohio Special Steam Boiler Dimensions - Sheet 1 of 2
A6-6
02-02
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 Lagging L 27 33 33 33 33 33
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
Steam Nozzle (150 psig)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 RR 309 283 283 355 355 355
Removal
Min Room Length for Front Tube RF 299 236 236 308 308 308
Removal
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 A6-1. Model CB Ohio Special Steam Boiler Dimensions - Sheet 2 of 2
A6-7
02-02
NOTE: ALLOW 3 FEET

FOR DOOR SWING
PER NEC
Figure A6-2. Model CBW Ohio Special Steam Boiler Dimensions - Sheet 1of 2
A6-8
02-02
BOILER NO. DIM 125S 150S 175S 200S

LENGTHS
Overall A 195 195 222 226
Shell B 159 159 186 186
Base Frame C 151 151 170 175
Front Head Extension (Approx) D 31 31 32 36
Flange to Nozzle (15 psig) F 62 62 64 64
Flange to Nozzle (150 psig) F 64 64 64 64
WIDTHS
Overall I 85 85 85 85
ID Boiler J 60 60 60 60
Center to Water Column K 45 45 45 45
Center to Outside Hinge KK 35 35 35 35
Center to Lagging L 33 33 33 33
Center to Auxiliary Water Control LL 40 40 40 40
Base-Outside M 52-1/2 52-1/2 52-1/2 52-1/2
Base-Inside N 44-1/2 44-1/2 44-1/2 44-1/2
HEIGHTS
Overall OO 86 86 86 86
Base to Vent Outlet O 85 85 85 85
Base to Steam Outlet P 82-3/8 82-3/8 82-3/8 82-3/8
Base Frame Q 12 12 12 12
Base to Bottom Boiler R 16 16 16 16
CONNECTIONS
Chemical Feed H 1 1 1 1
Feedwater, Right & Left S 1-1/2 1-1/2 1-1/2 1-1/2
Auxiliary Connection Z 1 1 1 1
Steam Nozzle (15 psig)A Y 8 8 8 10
Steam Nozzle (150 psig)B Y 4 4 4 4
Drain-Front & Rear (15 psig only) W 1-1/2 1-1/2 2 2

Blowdown-Front & Rear (150 psig) W 1-1/2 1-1/2 1-1/2 1-1/2
Surface Blow (150 psig only) T 1 1 1 1
Vent Stack Dia. (Flanged) BB 16 16 16 16
Flange to Center Vent CC 9 9 9 9
MINIMUM CLEARANCE
Rear Door Swing DD 28 28 28 28
Front Door Swing EE 67 67 67 67
Tube Removal, Front only GG 89 89 116 116
Min Room Length for Front Tube Removal RF 276 276 328 328
Tube Removal thru Door RD 254 254 281 281
NOTE: Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension
prints.
A. Flanged 150 psig ANSI
B. Flanged 300 psig ANSI
Figure A6-2. Model CBW Ohio Special Steam Boiler Dimensions - Sheet 2 of 2
A6-9
02-02
DIMENSION (INCHES)
BOILER HP
A B C D E
CB 100S 27 48 38 60 26
CB 125S thru 225S 33 55 45 68 32
CBW 125S thru 200S 33 42 48 61 30
Figure A6-3. Space Required to Open Rear Head on Model CB and CBW Ohio Special Boilers Equipped with Davits
FRONT FLANGE B C D (HOLE DIA)
BOILER HP ALL DIMENSIONS IN INCHES

(CB) 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
BOILER HP ALL DIMENSIONS IN INCHES

(CBW)
A B C D
125S-150S 80 19 109 3
175S-225S 80 19 148 3
Figure A6-4. Model CB and CBW Ohio Special Boilers Lifting Lug Location
A6-10
02-02
CB 100S 6 8 130 26 42 4 29-5/8 8-1/4
CB 125S, 150S 6 9 112 39-1/2 57-1/2 4 44-1/2 10-1/4
CB 175S, 200S, 225S 6 9 148 39-1/2 57-1/2 4 44-1/2 10-1/4
CBW 125S, 150S 6 9 151 39-1/2 57-1/2 4 44-1/2 9-3/4 Front
26-3/4 Rear
CBW 175S, 200S 6 9 175 39-1/2 57-1/2 4 44-1/2 9-3/4 Front
26-3/4 Rear
NOTES:
2. 6-inch high mounting piers recommended for use beneath the boiler base frame. The use of these piers provides increased inspec-
tion accessibility to the piping beneath the boiler and added height for washing down the area beneath the boiler.
Figure A6-5. Model CB Ohio Special Boiler Mounting Piers
Table A6-5 lists quantity and outlet size for safety valves sup-
ENGINEERING DATA plied on Model CB and CBW Ohio Special Boilers.
The following engineering information is provided for the
Table A6-6 gives recommended steam nozzle sizes based on
Ohio Special Boilers. Ohio Special boilers are designated by
4000-5000 fpm steam velocity. Model CB and CBW Ohio
an S following the horsepower number. Additional detail is
Special Firetube Boilers.
available from your local Cleaver-Brooks authorized represen-
tative. Table A6-7 shows recommended non-return valve sizes for
Model CB and CBW Ohio Special Firetube Boilers.
Boiler Information
Table A6-3 shows heating surfaces for Model CB and CBW
Blowdown Water Requirements
Ohio Special Boilers. Some local codes require blowdown tanks to be constructed in
Table A6-4 shows steam volume and disengaging area for
Boiler and Pressure Vessel Inspectors.
Model CB Ohio Special Boilers.
The National Boards recommendations base the size of the
Table A6-3. Model CB and CBW Ohio Special Boilers Heating blowdown tank on the removal of at least 4 inches of water
Surface from the boiler.
BOILER HEATING SURFACE (SQ-FT) Table A6-8 lists the approximate quantity of water represented
HP FIRESIDE WATERSIDE by 4 inches of water at normal operating level for Model CB
and CBW Ohio Special Boilers.
100S 350 388
125S-150S 358 386
175S, 200S, 225S 358 384
A6-11
02-02
Table A6-4. Model CB Ohio Special Boilers Steam Volume and Disengaging Area
STEAM VOLUME CU-FT STEAM RELIEVING AREA SQ-IN
BOILER HP
HIGH PRESSURE
A B A B
LOW PRESSURE HIGH PRESSURE LOW PRESSURE
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 A6-5. Model CB and CBW Ohio Special Boilers Steam Boiler Safety Valve Openings
VALVE 15 PSIG STEAM 100 PSIG STEAM 125 PSIG STEAM 150 PSIG STEAM 200 PSIG STEAM 250 PSIG STEAM
SETTING
BOILER NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET
HP VALVES SIZE VALVES SIZE VALVES SIZE VALVES SIZE VALVES SIZE VALVES SIZE
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 2 1 1-1/2 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 A6-6. Model CB and CBW Ohio Special Firetube Boilers

Recommended Steam Nozzle Size
(To Maintain 4000 to 5000 fpm Nozzle Velocity)
BOILER HP
OPERATING
PRESSURE 100S 125S 150S 175S 200S 225S
PSIG
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.
A6-12
02-02
Table A6-7. Model CB and CBW Ohio Special Firetube Boilers Recommended Non-Return Valve Size
BOILER PACITY
HP 50 75 100 125 150 175 200
(LB/HR)
100S 3450 3 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2
125S 4313 4 3 3 3 3 2-1/2 2-1/2
150S 5175 4 4 3 3 3 3 2-1/2
175S 6900 4 4 3 3 3 3 2-1/2
200S 8625 4 4 4 3 3 3 3
225S 10350 4 4 4 3 3 3 3
Table A6-8. Model CB and CBW Ohio Special Blowdown Tank

Sizing Information
100S 80
125S-150S 87
175S-225S 118
NOTE: Quantity of water removed from boiler by lowering normal
water line 4"
Burner Information
The Ohio Special Firetube Boiler encompasses an integral
front head that includes the burner, combustion air fan, and
controls as part of the boiler package design.
The integral front head provides for burner/boiler design as a
single unit maximizing the compatibility between the boiler
and burner.
Figure A6-6 shows secondary air flow in the Ohio Special
Firetube Boiler. The rotary air damper design provides stan-
dard turn down of 4:1.
Figure A6-7 shows a typical linkage assembly. The single
point linkage layout allows for easy adjustment and maximum
repeatability of air/fuel ratios. Included on all Ohio Special
Boilers is an adjustable CAM assembly shown in Figure A6-8.
Gas-Fired Burners
NOTICE Figure A6-6. Secondary Air Flow Diagram

A gas pressure regulator must be installed in the gas Table A6-9 shows regulated gas pressure requirements for
piping to each boiler. Gas pressure regulators for Standard and FM gas trains for CB and CBW Ohio Special
Ohio Special Firetube Boilers are sized and selected Firetube Boilers.
on a job-by-job basis. Therefore, gas pressure re-
quirements shown in Tables A6-9, A6-10, A6-11, A6- Table A6-10 shows regulated gas pressure requirements for IRI
12, and A6-13 list regulated gas pressure. Regulat- Gas Trains for CB and CBW Ohio Special Boilers.
ed gas pressure is the pressure downstream of the Table A6-11 and A6-12 show regulated gas pressure with over
gas pressure regulator. Total gas pressure required and undersized gas trains for CB and CBW Ohio Special Fire-
for the boiler equals regulated gas pressure plus the tube Boilers.
pressure drop of the selected gas pressure regulator.
Table A6-13 shows minimum required gas pressure altitude
conversion.
A6-13
02-02
Figure A6-7. Complete Linkage Assembly, Combination Gas and Oil
A6-14
02-02
Figure A6-8. Gas Modulating Cam
Table A6-9. CB and CBW Ohio Special Firetube Boilers and FM Gas Trains
Minimum Required Gas Pressure at Entrance to Standard
BOILER HP CONN SIZE NET REGD BOILER HP CONN SIZE MIN PRESS
(IN.) PRESS. REQD (IN.) REQ'D
(IN. WC) (IN. WC)
100S 2 11.0 100S 2 12.0
125S 2-1/2 8.5 125S 2-1/2 8.5
150S 2-1/2 13.0 150S 2-1/2 13.0
175S 2-1/2 16.0 175S 2-1/2 16.0
200S 2-1/2 21.0 200S 2-1/2 21.0
225S 2-1/2 27.0 225S 2-1/2 27.0
NOTES: NOTES:
1. For standard and FM gas pressure require- 1. Pressures shown also apply to standard and
ments for Canada, refer to Table A6-10, IRI FM gas trains for Canada.
Trains. 2. Based on 1000 Btu/cu-ft natural gas and eleva-
2. Based on 1000 Btu/cu-ft natural gas and elevation up to 700 feet.
tions up to 700 feet.
A6-15
02-02
Table A6-10. CB and CBW Ohio Special Boilers Minimum Gas Pressure at Entrance to Gas Trains Equipped with Industrial Risk
Insurers (IRI) Requirements
100S 125S 150S 175S 200S 225S

1-1/2 24.0 2 14.5 2 19.0 2 23.5 2 31.0 2 39.0
2 11.0 2-1/2 8.5 2-1/2 13.0 2-1/2 16.0 2-1/2 21.0 2-1/2 27.0
2-1/2 9.5 3 7.5 3 11.0 3 12.5 3 15.5 3 20.0
3 8.5 4 6.5 4 9.0 4 10.0 4 12.5 4 16.0
NOTES:
1. Pipe size in inches, and pressure required in inches of WC.
2. Standard gas train shown by shaded area.
3. Pressure required is downstream of the gas pressure regulator.
Table A6-11. Model CB and CBW Ohio Special Boilers Under and Oversized Standard and FM Gas Trains
100S 125S 150S 175S 200S 225S
1-1/2 29.5 2 14.5 2 19.0 2 23.5 2 31.0 2 39
2 12.0 2-1/2 8.5 2-1/2 13.0 2-1/2 16.0 2-1/2 21.0 2-1/2 27
2-1/2 10.5 3 7.5 3 11.0 3 12.5 3 15.5 3 20
3 9.0 4 6.5 4 9.0 4 10.0 4 12.5 4 16
NOTES:
1. Pipe size in inches, and pressure required in inches WC.
2. Standard gas train shown by shaded areas.
3. Pressure required is downstream of the gas pressure regulator.
Table A6-12. Model CB and CBW Ohio Special Boilers Under Gas Pressure Regulator
and Oversized IRI Gas Trains,
The following items should be considered when selecting a
ALTITUDE CORRECTION ALTITUDE CORRECTION regulator:
1000 1.04 6000 1.25 Pressure Rating: The regulator must have a pressure rating at
2000 1.07 7000 1.30 least equivalent to that of the gas distribution system.
3000 1.11 8000 1.35 Capacity: The capacity can be determined by multiplying the
4000 1.16 9000 1.40 maximum burning rate (CFH) by 1.15, see Table A6-14. This
5000 1.21 - - 15 percent over-capacity rating of the regulator provides for
proper regulation.
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. Spring Adjustment: The spring should be suitable for a range
Oz/sq-in x 1.732 = Inches WC. of adjustment from 50 percent under the desired regulated
Oz/sq-in x 0.0625 = psig. pressure to 50 percent over.
Psig x 27.71 = Inches WC.
Psig x 16.0 = Oz/sq-in. Sharp Lock-Up: The regulator should include this feature to
the boiler) from climbing when there is no gas flow.
A6-16
02-02
Table A6-13. Minimum Required Gas Pressure Altitude Oil-Fired Burners

Conversion
Fuel oil consumption information is shown on the boiler rating
BOILER TYPE OF GAS AND HEAT CONTENT sheets in the Dimensions and Rating Section.
HP
NATURAL GAS PROPANE GAS Figure A6-12 shows the oil connection sizes and locations for
1000 (Btu/cu-ft) 2550 (Btu/cu-ft)
Ohio Special Boilers firing No. 2 oil.
100S 4185 1640
125S 5230 2050 Figures A6-13 through A6-15 show typical oil systems and
150S 6280 2465
layouts.
175S 7350 2870 Figure A6-16 shows the detail of an oil transfer tank (day tank)
200S 8370 3280 typically utilized to provide a storage reservoir between the oil
225S 9415 3690
system supply pump and the boiler oil pump.

if the required gas volume is very large and if the pressure
drop must be kept to a minimum.
Regulators in Series: This type of installation can be used if
the available gas pressure is over 5, 10, or 20 psig.
Depending on the regulator characteristics, one regulator
would reduce the pressure to 2 to 3 psig, and a second
regulator would reduce the pressure to the burner
requirements.
Regulator Location: A straight run of gas line piping should
be used on both sides of the regulator to ensure proper
regulator operation. This is particularly important when pilot
operated regulators are used. The regulator can be located
close to the gas train connection, but 2 to 3 feet of straight
run piping should be used on the upstream side of the
regulator.
Table A6-14 shows maximum gas consumption for natural gas
and propane vapor.
Figure A6-9 shows typical gas train components, and Figure
A6-10 shows typical gas train piping layouts for multiple
boiler applications.
Figure A6-11 shows standard gas train sizes and locations for
Model CB and CBW Ohio Special Firetube Boilers.
A6-17
02-02
ITEM DESCRIPTION 125S 150S 125S 150S 125S 150S 125S 150S
BOILER HP 100S 175S 200S 100S 175S 200S 100S 175S 200S 100S 175S 200S
225S 225S 225S 225S
1 Pilot Shut Off Cock X X X X X X X X
2 Pilot Shut Off Cock X X X X
3 Shut Off Cock X X X X X X X X
4 Shut Off Cock X X X X X X X X
5 Pilot Pressure Regulator X X X X X X X X
6 Pilot Pressure Gauge X X X X X X X X
7 Gas Pilot Valve X X X X X X X X
8 High Gas Pressure Switch X X X X X X X X
9 Low Gas Pressure Switch X X X X X X X X
10 Main Gas Valve with POC X X X X X X
11 Main Gas Valve without POC X X X X X X
12 Main Gas Valve without POC X X
13 Vent Valve X X X X
14 Butterfly Valve X X X X X X X X
Figure A6-9. Model CB and CBW Ohio Special Gas Train Components
A6-18
02-02
This figure illustrates the basic gas valve arrangement on Cleaver-Brooks boilers and shows the contractor's
connection point. The valves and controls between the contractor connection point and the gas main in the
street are representative of a typical installation. Actual requirements may vary depending on local codes
or local gas company requirements which should be investigated prior to preparation of specifications and
prior to construction.
MODEL CB & CBW

MODEL CB & CBW OHIO SPECIAL
OHIO SPECIAL BOILERS
BOILERS

C. Gas meter.

A6-19
02-02
MODEL CB& CBW

CONNEC-
BOILER LOCATION
TION
HP DIMENSION
SIZE A (IN.)
(IN.) (NPT)
100S 2 44
125S-225S 2-1/2 67-1/2
Figure A6-11. Model CB and CBW Ohio Special Firetube Boilers Standard Gas Train Connection Size and Location
RECOMMENDED OIL LINEA SIZES

BHP SUPPLY (STANDARD PIPE)
AND (IN.-IPS)
RETURN A STORAGE
CONN (IN.) TANK TO RETURN
SIZES (IN.) PUMP TO
BOILER OR LINE TO
(NPT) BOILER
PUMP TANK
CONNECT
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 A6-12. CB and CBW Ohio Special Boilers, No. 2 Oil Connection Size, Location and Recommended Line Sizes
A6-20
02-02
USE LAYOUT FOR: MODEL CB . . . . . . 100S - 225S

MODEL CBW . . . . 125 S- 200S

Oil Pump
USE LAYOUT FOR: MODEL CB . . 100S - 225S

MODEL CBW . . . 125S - 200S
Figure A6-14. No. 2 Oil Piping, Multiple Boiler Installation, Remote

Oil Pumps
A6-21
02-02
USE LAYOUT FOR: MODEL CB . . . . . . . 100S - 225S

MODEL CBW . . . . . 125S - 200S
ITEM SIZE DESCRIPTION
A 1/2 NPT Connection to oil level switch

B See note Return line to tank
C See note Oil supply connection from
transfer pump
D 1/2 NPT Tank drain connection
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 & Miller or
equal
NOTE: Connection should be sized using recom-
mended sizes in oil line sizing instruction.
A6-22
02-02
Boiler Room Information Example: Determine the area of the boiler room air supply
Figure A6-17 shows typical boiler room length requirements.
Air required: 200 x 10 = 2000 cfm (from 2B above).
Stack Support Capabilities Air velocity: Up to 7 feet = 250 fpm (from 3 above).
100 hp Ohio Special Boilers can support up to 1,000 lbs with- Area Required: Area = cfm = 2000/250 = 8 Sq-ft total.
out additional support. Area/Opening: 8/2 = 4 sq-ft/opening (2 required).
125-225 hp Ohio Special Boilers can support up to 2,000 lbs
without additional support.
NOTICE
Boiler Room Combustion Air Consult local codes, which may supersede these re-
When determining boiler room air requirements, the size of quirements.
the room, air flow, and velocity of air must be reviewed as fol-
lows: Stack/Breeching Size Criteria
1. Size (area) and location of air supply openings in boiler The design of the stack and breeching must provide the
room. required draft at each boiler flue gas outlet. Proper draft is crit-
A. Two (2) permanent air supply openings in the outer ical to burner performance.
walls of the boiler room are recommended. Locate (1) Although constant pressure at the flue gas outlet of the Ohio
at each end of the boiler room, preferably below a height Special is not required, it is necessary to size the stack/breech-
of 7 feet. This allows air to sweep the length of the ing to limit flue gas pressure variation. The allowable pressure
boiler. range is 0.25" W.C. to +0.25" W.C.
B. Air supply openings can be louvered for weather For additional information, please review Section I4, General
protection, but they should not be covered with fine Engineering Data (Stacks) and Section F, Stacks. Stack and
mesh wire, as this type of covering has poor air flow breeching sizes should always be provided by a reputable stack
qualities and is subject to clogging by dust or dirt. supplier who will design the stack and breeching system based
C. A vent fan in the boiler room is not recommended, as it on the above criteria. Your local Cleaver-Brooks authorized
could create a slight vacuum under certain conditions representative is capable of assisting in your evaluation of the
and cause variations in the quantity of combustion air. stack/breeching design.
D. Under no condition should the total area of the air
supply openings be less than (1) square foot.
E. Size the openings by using the formula:
Area (sq-ft) = cfm/fpm
2. Amount of air required (cfm).
A. Combustion air - rated bhp x 8 cfm/bhp.
B. Ventilation air - rated bhp x 2 cfm/bhp or a total of 10
cfm/bhp - up to 1000 feet elevation. Add 3 percent more
per 1000 feet of added elevation.
A. From floor to (7) foot height - 250 fpm.
B. Above (7) foot height - 500 fpm.
C. Duct from air supply to boiler - 1000 fpm.
A6-23
02-02
A6-Text.fm Page 24 Tuesday, December 17, 2002 12:19 PM
DWG A - MODEL CB & CBW
DWG B - MODEL CB & CBW

DWG C - MODEL CB ONLY
1. Shortest boiler room length (Dwg A) is obtained by allowing for possible future tube replacement through a window or doorway.
Allowance is only made for minimum door swing at each end of the boiler. This arrangement provides sufficient aisle space at the front
of the boiler but a tight space condition at the rear. If space permits, approximately 1.5 additional feet should be allowed at the rear for
additional aisle and working space.
Allowance is only made for minimum door swing at the rear. If space permits, approximately 1.5 additional feet should be allowed at the
rear for additional aisle and working space.
3. A slightly longer boiler room for Model CB (Dwg C) is obtained by allowing for possible future tube replacement from the rear of the
boiler. Allowance for door swing at the front provides sufficient aisle and working space at the front.
Figure A6-17. Boiler Room Length (Typical Layouts), Model CB Ohio Special Shown
BOILER HP 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.
Figure A6-18. Boiler Room Width (Typical Layout), Model CB Ohio Special Shown
A6-24
02-02
The following sample specifications are provided by Cleaver-Brooks to assist you in specifying your customer's specific needs and
application.
A separate specification for Ohio Special steam boilers Model CB and Model CBW is provided. When completing the specifica-
tion, begin with the boiler specification (CB or CBW). The boiler specification includes a place for burner and for controls. Fol-
lowing the boiler specification are the various detailed burner specifications organized by fuel type. Select the Burner specification
for the fuel utilized and insert it into the boiler specification.
Following the burner specifications are detailed control specifications for CB780 Flame Safeguard control and the CB-HAWK
Flame Safeguard control. Insert the appropriate detailed control specification into the boiler specification based on the project
requirements. See section 8, Boiler Controls, for additional information on control options.
Model CB Ohio Special Boiler

4.0 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-27
6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-30
7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-30
Model CBW Ohio Special Boiler

4.0 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-32
6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-35
7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-35
Model CB Ohio Special Steam Boiler (100-225 hp, Steam 15, 150, 200, or 250 psig)

1.1 The Steam Boiler shall be Cleaver-Brooks Model CB Ohio Special Fuel Series ____ (100, 200, 700), ____ hp designed for
____ psig (15 or ____ psig steam). The maximum operating pressure shall be ____ psig.
1.2 The boiler shall have a maximum output of ____ Btu/hr, or ____ horsepower when 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.

2.1 The boiler shall be a multi-pass horizontal firetube updraft boiler with 358 square feet of total heating surface. It shall be
mounted on a heavy steel frame with integral forced draft burner and burner controls.
NOTICE
A6-25
02-02
floor or simple foundation and ready for attachment of water, steam, fuel, electrical, vent, steam, and blowdown connections.
prior to shipment. A copy of the inspection report shall be furnished the purchaser.
2.2.4 Rear refractory and insulation shall be contained in the formed door which must swing open for inspection of brick work.
2.2.5 The boiler tubes shall not include swirlers, turbulators, or other add-on devices.
2.2.6 Front and rear tube sheets and all tubes must be fully accessible for inspection and cleaning when the doors are swung open.
A. 100 hp 1000 lbs. and shall contain a stack thermometer.
B. 125-225 hp 2000 lbs. and shall contain a stack thermometer.
2.2.9 Observation ports for the inspection of flame conditions shall be provided at each end of the boiler.
2.2.10 The boiler insulation shall consist of a 2 inch fiberglass blanket under a sectional preformed sheet metal lagging. This insu-
lation must be readily removable and capable of being reinstalled, if required.
2.2.11 The entire boiler base frame and other components shall be factory painted before shipment using a hard-finish enamel coat-
ing.

3.1 Water Column
valves.
3.2 Feedwater Pump Control
feedwater pump maintaining the boiler water level within normal limits.
Auxiliary low water cutoff shall be included, piped to the vessel, and wired to the burner control circuit. A manual reset device shall
be used on this control.
3.6 Safety Relief Valves
A6-26
02-02
The steam pressure control to regulate burner operation shall be mounted near the water column.
4.0 Burner
4.2 Forced Draft Blower
4.2.1 All air for combustion shall be supplied by a forced draft blower mounted in the front boiler door, above the burner, to elimi-
nate vibration and reduce noise level.
4.2.2 Maximum sound level of the boiler/burner package shall not exceed ____ dBA (when measured in accordance with ABMA
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 (para 4.4.1).
Fuel series 100 - light oil fired (para 4.4.2).
Fuel series 200 - light oil or gas fired (para 4.4.3).
4.4.1.1 Burner Type - The burner shall be integral with the front head of the boiler and of high radiantannular gas entry on 125-225
hp. and multi-port type gas entry on 100 hp. The burner shall be approved for operation on natural gas fuel.
closure switch and plugged leakage test connection. The valve is spring return to start or stop the gas burner and to close automat-
ically 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. Select one of the following:
A. 100 hp High and low gas pressure switches shall be provided.
B. 125-225 hp High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an addi-
4.4.1.4 Burner Turndown - Turndown range of the burner shall be 4:1 when firing natural gas.
4.4.2.3 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. A separate
A6-27
02-02
A. 100 hp. Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch shall be pro-
vided.
B. 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.
4.4.2.6 Burner Turndown - Turndown range of the burner shall be 4:1 when firing No. 2 oil.
type for oil and high radiant annular gas entry on 125-225 hp and multi-port type for gas entry om 100 hp. The burner shall be
4.4.3.3 Oil Burner
4.4.3.3.1 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. A separate
4.4.3.3.3 Low pressure Air Atomizing - Select one of the following:
A. 100 hp. Separate air compressor module mounted on boiler base rail with low atomizing air pressure switch shall be pro-
vided.
B. 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.
4.4.3.4 Gas Burner
closure switch and plugged leakage test connection. The valve is spring return to start or stop the gas burner and to close automat-
ically 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. Select one of the following:
A. 100 hp High and low gas pressure switches shall be provided.
B. 125-225 hp High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an addi-
4.4.3.5 Burner Turndown - Turndown range of the burner shall be 4:1.
See paragraphs 4.5.1 through 4.5.2 for boiler flame safeguard specification as indicated below.
4.5.1 CB780 Flame Safeguard Controller
Each boiler shall be factory equipped with flame safeguard controller providing technology and functions equal to the Cleaver-
Brooks Model CB780.
A6-28
02-02
cycles.
For combination gas-oil fired boilers, the panel shall contain the fuel selector switch.
4.5.1.2 Lights
Red - low water.
Burner On-Off.
Manual-Automatic.
diagram.
4.5.2 CB-HAWK Flame Safeguard Controller
4.5.2.1 Each boiler shall be factory equipped with a Boiler Management Control System providing technology and functions equal
to the Cleaver-Brooks Model CB-HAWK.
4.5.2.2 The system shall consist of a computer based boiler controller and solid state sensors totally integrated to provide automatic
burner sequencing, flame supervision, and indications of system status, faults, and self-diagnostics.
4.5.2.4 The boiler controller shall consist of chassis, program module, keyboard display, and flame signal amplifier. It shall be the
non-recycle type and have a fixed operating sequence incapable of being manually altered. The sequence shall include standby,
pre-purge, pilot, main fuel ignition, and run, and post-purge periods.
4.5.2.5 The system shall incorporate full modulating control of fuel and combustion air as well as firing rate control based on sys-
tem demand.
4.5.2.6 The boiler controller shall have a non-volatile memory that retains history files and sequence status after interruptions.
4.5.2.7 An 80 character, 2 line liquid crystal (LCD) display and keyboard shall be provided to adjust control settings and display 73
fault messages, 12 diagnostic messages, 38 historical messages as well as system status messages and operating pressures and tem-
peratures. Boiler firing rate shall also be displayed in addition to the last 6 lockouts and boiler operating information when the
lockout occurred. Provisions for a security access code shall be provided.
4.5.2.8 Separate status indicators will show:
A6-29
02-02
4.5.2.9 The boiler controller shall incorporate a five function run/test switch.
4.5.2.10 The system shall be characterized for each individual model boiler. The system shall also incorporate a tailored pre-purge
cycle that minimizes pre-purge energy losses, while maintaining the maximum required air changes. It shall permit the user to
select a specific rate control program for precise load tracking that reduces on-off cycling due to load swings. The system shall also
provide an integrated thermal stress protection program to prolong boiler life. An assured low fire cutoff feature shall also be pro-
vided.
4.5.2.11 The system shall monitor inputs from solid state sensor for gas pressure, oil pressure, and temperature. A single solid state
sensor shall be used for both on-off and proportioning control of the burner. The high/low limits and operating set points of all sen-
sors will be programmable from the keyboard display. The system shall be capable of detecting a jumpered or defective sensor. A
4.5.2.12 An optional 2 way communications module with built-in modem to allow for remote control of non-safety settings and
monitoring of up to 6 boilers shall also be available. Up to 3 pre-programmed telephone numbers shall be called in the event of a
fault condition. Options such as Lead/Lag, Boiler Efficiency, and Heating Boiler packages can be interfaced to this module without
any change to the existing system structure. The communications module shall be able to interface with an IBMTM PC or compat-
ible system.
4.5.3 Control Panel
4.5.3.1 The control panel shall be mounted on the front door of the boiler in a location convenient to the operator. The hinged metal
cabinet will have NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet key type lock.
4.5.3.2 The panel shall contain the boiler flame safeguard controller, blower motor starter, indicating lights and selector switches.
4.5.3.3 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.
diagram.

5.1 The boiler must be guaranteed to operate at a minimum fuel-to-steam efficiency of ____ percent from 25 to 100 percent of rat-
ing when burning natural gas and ________ fuel-to-steam efficiency at 100% firing rate when burning oil.
6.0 Warranty
7.0 Execution
7.1 Shop Tests
The packaged boiler must receive factory tests to check the construction, controls, and operation of the unit. All tests may be wit-
nessed by the purchaser, if desired.
and timing the operator at no additional costs.
A6-30
02-02
Model CBW Ohio Special Steam Boiler (125-200 hp, Steam 15, 150, 200, or 250 psig)

1.1 The Steam Boiler shall be Cleaver-Brooks Model CBW Ohio Special Fuel Series ____ (100, 200, 700), ____ hp designed for
____ psig (15 or ____ psig steam). The maximum operating pressure shall be ____ psig.
1.2 The boiler shall have a maximum output of ____ Btu/hr, or ____ horsepower when 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.

2.1 The boiler shall be a multi-pass horizontal firetube updraft boiler with 358 square feet of total heating surface. It shall be
mounted on a heavy steel frame with integral forced draft burner and burner controls. The complete packaged boiler is built as a
unit with Underwriters Laboratories listed components.
The boiler shall be completely preassembled and 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, steam, and blowdown connections.
2.2.4 Rear door must be insulated and be able to swing open for inspection.
2.2.5 The boiler tubes shall not include swirlers, turbulators, or other add-on devices.
2.2.6 The boiler shall be furnished with adequate handholes to facilitate boiler inspection and cleaning.
2.2.7 Boiler shall be supplied with a manhole.
2.2.8 The exhaust gas vent shall be located near the front of the boiler on the top center line and shall be capable of supporting 2000
lbs. and shall contain a stack thermometer.
2.2.10 The boiler insulation shall consist of a 2 inch fiberglass blanket under a sectional preformed sheet metal lagging. This insu-
lation must be readily removable and capable of being reinstalled, if required.
2.2.11 The entire boiler base frame and other components shall be factory painted before shipment using a hard-finish enamel coat-
ing.

3.1 Water Column
valves.
A6-31
02-02

Auxiliary low water cutoff shall be included, piped to the vessel, and wired to the burner control circuit. A manual reset device shall
The steam pressure control to regulate burner operation shall be mounted near the water column.
4.0 Burner
4.2 Forced Draft Blower
4.2.1 All air for combustion shall be supplied by a forced draft blower mounted in the front boiler door, above the burner, to elimi-
nate vibration and reduce noise level.
4.2.2 Maximum sound level of the boiler/burner package shall not exceed ____ dBA (when measured in accordance with ABMA
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 (para 4.4.1).
Fuel series 100 - light oil fired (para 4.4.2).
Fuel series 200 - light oil or gas fired (para 4.4.3).
4.4.1.1 Burner Type - The burner shall be integral with the front head of the boiler and of high radiant annular gas entry type for
gas. The burner shall be approved for operation on natural gas fuel.
4.4.1.3 Gas Burner Piping - Gas burner piping on all units shall include two (2) motorized gas shutoff valves, one (1) valve proof-
of-closure type, two (2) plugged leakage test connections, and high and low gas pressure switches. The main gas valves will be
wired to close automatically in the event of power failure, 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.
4.4.1.4 Burner Turndown - Turndown range of the burner shall be 4:1 when firing natural gas.
A6-32
02-02

4.4.2.3 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. A separate
4.4.2.5 Low pressure air atomizing system shall include belt driven air compressor, lubricating air tank, oil level indicator, inlet air
filter, air pressure gauge, and low atomizing air pressure switch.
4.4.2.6 Burner Turndown - Turndown range of the burner shall be 4:1 when firing No. 2 oil.
type for oil and high radiant annular gas entry type for gas. The burner shall be approved for operation with either CS12-48 Com-
mercial No. 2 Oil or natural gas.
4.4.3.3 Oil Burner
4.4.3.3.1 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. A separate
4.4.3.3.3 Low pressure air atomizing system shall include belt driven air compressor, lubricating air tank, oil level indicator, inlet
air filter, air pressure gauge and low atomizing air pressure switch.
4.4.3.4 Gas Burner
4.4.3.4.1 Gas Burner Piping - Gas burner piping on all units shall include two (2) motorized gas shutoff valves, one (1) valve proof-
of-closure type, two (2) plugged leakage test connections, and high and low gas pressure switches. The main gas valves will be
wired to close automatically in the event of power failure, 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.
4.4.3.5 Burner Turndown - Turndown range of the burner shall be 4:1.
See paragraphs 4.5.1 through 4.5.2 for boiler flame safeguard specification as indicated below.
4.5.1 CB780 Flame Safeguard Controller
4.5.1.1 Each boiler shall be factory equipped with flame safeguard controller providing technology and functions equal to the
Cleaver-Brooks Model CB780.
A6-33
02-02
4.5.1.2 Controller shall be computerized solid state having sequence and flame-on lights and digital first out fault code indica-
tions 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.
4.5.1.3 Controller shall be the non-recycle type for maximum safety that shall shutdown the burner and indicate as a minimum the
following trip functions: pilot and main 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).
4.5.1.4 The controller shall have a run/test switch. It shall allow interruptions to sequence just after pre-purge, during pilot ignition
trial and run cycles for adjustments to firing rate motor, damper linkages and pilot flame for minimum turndown tests.
4.5.1.6 Lights
Red - low water.
Burner On-Off.
Manual-Automatic.
diagram.
4.5.2 CB-HAWK Flame Safeguard Controller
4.5.2.1 Each boiler shall be factory equipped with a Boiler Management Control System providing technology and functions equal
to the Cleaver-Brooks Model CB-HAWK.
4.5.2.2 The system shall consist of a computer based boiler controller and solid state sensors totally integrated to provide automatic
burner sequencing, flame supervision, and indications of system status, faults, and self-diagnostics.
4.5.2.3 The boiler controller shall consist of chassis, program module, keyboard display, and flame signal amplifier. It shall be the
non-recycle type and have a fixed operating sequence incapable of being manually altered. The sequence shall include standby,
pre-purge, pilot, main fuel ignition, and run, and post-purge periods.
4.5.2.4 The system shall incorporate full modulating control of fuel and combustion air as well as firing rate control based on sys-
tem demand.
4.5.2.5 The boiler controller shall have a non-volatile memory that retains history files and sequence status after interruptions.
4.5.2.6 An 80 character, 2 line liquid crystal (LCD) display and keyboard shall be provided to adjust control settings and display 73
fault messages, 12 diagnostic messages, 38 historical messages as well as system status messages and operating pressures and tem-
A6-34
02-02
peratures. Boiler firing rate shall also be displayed in addition to the last 6 lockouts and boiler operating information when the
lockout occurred. Provisions for a security access code shall be provided.
4.5.2.7 Separate status indicators will show:
4.5.2.8 The boiler controller shall incorporate a five function run/test switch.
4.5.2.9 The system shall be characterized for each individual model boiler. The system shall also incorporate a tailored pre-purge
cycle that minimizes pre-purge energy losses, while maintaining the maximum required air changes. It shall permit the user to
select a specific rate control program for precise load tracking that reduces on-off cycling due to load swings. The system shall also
provide an integrated thermal stress protection program to prolong boiler life. An assured low fire cutoff feature shall also be pro-
vided.
4.5.2.10 The system shall monitor inputs from solid state sensor for gas pressure, oil pressure, and temperature. A single solid state
sensor shall be used for both on-off and proportioning control of the burner. The high/low limits and operating set points of all sen-
sors will be programmable from the keyboard display. The system shall be capable of detecting a jumpered or defective sensor. A
4.5.2.11 An optional 2 way communications module with built-in modem to allow for remote control of non-safety settings and
monitoring of up to 6 boilers shall also be available. Up to 3 pre-programmed telephone numbers shall be called in the event of a
fault condition. Options such as Lead/Lag, Boiler Efficiency, and Heating Boiler packages can be interfaced to this module without
any change to the existing system structure. The communications module shall be able to interface with an IBMTM PC or compat-
ible system.
4.5.2.13 The panel shall contain the boiler flame safeguard controller, blower motor starter, indicating lights and selector switches.
4.5.2.14 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.
4.5.2.15 Oil, heat, and moisture resistant wire shall be used and identified with circuit numbers corresponding to the electrical wir-
ing diagram.

5.1 The boiler must be guaranteed to operate at a minimum fuel-to-steam efficiency of ____ percent from 25 to 100 percent of rat-
ing when burning natural gas and ________ fuel-to-steam efficiency at 100% firing rate when burning oil.
6.0 Warranty
7.0 Execution
7.1 Shop Tests
A6-35
02-02

and timing the operator at no additional costs.
7.2.2 A factory approved and authorized start-up report shall be submitted to the customer/user at the time of start-up.
A6-36
02-02
Section A7
Model CBE Boilers
CONTENTS
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12
Boiler Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12
Blowdown Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-14
Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-14
Burner/Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-14
Burner Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-14
Gas Fired - Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-14
Fuel Connections - Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-14
Fuel Connections - Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-14
Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-19
Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-19
Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-19
Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-19
ILLUSTRATIONS
Figure A7-1. Model CBE Hot Water Boiler Dimensions (Page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-6
Figure A7-2. Model CBE Steam Boiler Dimensions (Page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-8
Figure A7-3. Space Required to Open Rear Head on Model CBE Boilers Equipped with Davits . . . . . . . . . . . . . . . . . . A7-10
A7-1
04-02
A7-text Page 2 Wednesday, December 11, 2002 9:45 AM
Model CBE Firetube Boilers
Figure A7-4. Model CBE Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-10

Figure A7-5. Model CBE Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-11
Figure A7-6 Typical Fuel Oil Supply Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-18
Figure A7-7. Boiler Room Length (Typical Layouts) - Model CBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-20
Figure A7-8.Boiler Room Width (Typical Layout) - Model CBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-20
TABLES
Table A7-1. Model CBE Hot Water Boiler Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-5
Table A7-2. Model CBE Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7- 5
Table A7-3. Predicted Fuel-to-Steam Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-12
Table A7-4. Heating Surface, Model CBE Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-13
Table A7-5.Model CBE Steam Volume and Disengaging Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-13
Table A7-6.Model CBE Steam Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-13
Table A7-7. Model CBE Hot Water Boiler Relief Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-15
Table A7-8.Model CBE Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm Nozzle Velocity) . . . . . . .A7-15
Table A7-9.Model CBE Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-16
Table A7-10. Model CBE Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-16
Table A7-11.Sound Pressure Levels in DbA (Profire F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-16
Table A7-12. Model CBE Burner Selections (Profire Burner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-17
Table A7-13. Minimum Required Gas Pressure Altitude Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-17
Table A7-14.Maximum Gas Consumption (CFH) for Natural Gas - Model CBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-17
Table A7-15.Minimum Required Gas Pressure at Entrance to Standard, FM and IRI Gas Trains -
Model CBE (Upstream of Gas Pressure Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7-18
The following information applies to the Cleaver-Brooks Model CBE Boiler.
A7-2
04-02
Firetube Boilers Model CBE
FEATURES AND BENEFITS 15 - 300 psig steam.

The Model CBE Boiler is available as a baseline alternative to
Full modulation, all sizes.
the Cleaver-Brooks Models CB or CBW Boilers. The Cleaver-
Brooks Model CBE Boiler line provides a quality product uti- Available options include the following (contact your local
lizing an economical boiler/burner design. Additionally, the Cleaver-Brooks authorized representative for option details).
boiler/burner packaged UL and cUL label is available on all
Boiler Options:
CBE sizes. The following features apply:
Drain valves.
Three-Pass Dryback Design: Additional screwed or flanged trappings.
Three-pass design provides high flue gas velocities and low Blowdown valves.
stack temperatures to maximize efficiency.
Non-return valves.
Dryback design provides full access to boiler tubes, tube
sheet, and furnace for ease of maintenance. Feedwater valves and regulators.
Dryback design includes single rear tube sheet construction, Surface blowdown systems
which reduces tube sheet stresses. Combustion relief door.
Five Square Feet of Heating Surface per Boiler Horsepower: Blend pump.
Good boiler efficiency. Surge load baffles.
Long boiler life. Seismic design.

Burner/Control Options:
Low Furnace Location:
Flame safeguard controllers.
clearance from bottom of boiler, allowing proper circulation. Lead/lag system.
Low furnace provides additional safety margin between High altitude design (up to 10,000 ft).
furnace and water level. Special insurance and code requirements (e.g., IRI, FM,
Reduces water carryover, producing drier steam. CSD1).
Alarm bell/silence switch.
Front and Rear Doors:
Davit, front and rear doors, all sizes.
Special purpose indicator lights.
Provides access to front and rear tube sheet and furnace.
Main disconnect.
Reduced maintenance costs.
Elapsed time meter.
Natural Gas, No. 2 Oil, or Combination Burners Available: Voltmeter/micro-ammeter.
Natural gas or No. 2 oil compatibility. NEMA enclosures.
Fuel changeover without burner adjustment. Low-fire hold control.
PRODUCT OFFERING
Circuit breaker.
Cleaver-Brooks Firetube Boilers are available in low pressure
steam, high pressure steam, and hot water designs. Burners are Day/night controls.
available to fire natural gas, No. 2 oil, or a combination of oil Special power requirements.
and gas. The CBE boiler is a baseline alternative to the Model
CB or CBW in the 60 - 350 hp range. Standard product offer- Stack thermometer.
ing is: Special indicating lights.
60 - 350 hp.
A7-3
04-02
Fuel Options
Air atomizing oil burner, 125 200 hp.
Gas strainer.
Gas pressure gauge.
Future gas conversion.

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

**No air compressor required (pressure atomized)
NOTE: All fractional hp motors will be single phase voltage; integral hp motors will be three-phase voltage.
Table A7-2. Model CBE Steam Boiler Ratings
BOILER HP 60 70 80 100 125 150 200 250 300 350
Rated Capacity (lbs/steam/hr

2070 2415 2760 3450 4313 5175 6900 8625 10350 12075
at 212 F)
Btu Output (1000 Btu/hr) 2009 2343 2678 3348 4184 5021 6695 8369 10043 11716
Light Oil GPH (140,000 Btu/

18 21 24 30 37.5 45 60 74.5 89.5 104.5
gal)
Gas CFH (1000 Btu) 2510 2930 3350 4185 5230 6280 8370 10460 12555 14650
Gas (Therm/hr) 25.1 29.3 33.5 41.9 52.3 62.8 83.7 104.6 125.5 146.5
Oil Pump Motor hp (No. 2 oil) * * * * * * * 1/2 3/4 3/4
Blower Motor - Series 100/200 3/4 3/4 1 2 2 3 7-1/2 5 7-1/2 10
Blower Motor - Series 700 3/4 1/2 3/4 1-1/2 2 3 5 5 7-1/2 10
Air Compressor Motor ** ** ** ** ** ** ** 3 3 3
BOILER DATA

NOTE: All fractional hp motors will be single phase voltage; integral hp motors will be three-phase voltage.
A7-5
04-02
LWCO
BOILER HP DIM 60 70 80 100 125 150 200 250 300 350
LENGTHS
Overall Length A 163-1/8 186-1/16 201-1/16 235-1/16 199-3/16 224-3/16 273-3/16 217-7/8 243-7/8 269-7/8
Shell Length B 123-5/8 141-5/8 157-5/8 191-5/8 151-5/8 176-5/8 225-5/8 161-5/8 187-5/8 213-5/8
Rear Frame Length C 133-3/8 152-3/8 173-9/16 207-9/16 162-9/16 187-9/16 236-9/16 177-3/16 203-3/16 229-3/16
Rear Head Extension E 7-7/8 7-7/8 7-7/8 7-7/8 8-3/8 8-3/8 8-3/8 9-3/8 9-3/8 9-3/8
Front Flange To Water Return F 70-1/4 88-1/4 104-1/4 129-1/4 72-1/4 97-1/4 146-1/4 78-1/4 104-1/4 130-1/4
Water Return To Water Supply G 24 24 24 24 36 36 36 36 36 36
Base Frame To Rear Head H 22-1/4 22-1/4 22-1/4 22-1/4 24-3/4 24-3/4 24-3/4 29-3/4 29-3/4 29-3/4
Water Supply To Vent Outlet R 20-1/2 20-1/2 20-1/2 29-1/2 34 34 34 35-1/2 35-1/2 35-1/2
WIDTHS
Overall Width I 53 53 53 53 66 66 66 84 84 84
Boiler Centerline To Lagging L 26-1/2 26-1/2 26-1/2 26-1/2 33 33 33 42 42 42
Base Outside M 37-3/4 37-3/4 37-3/4 37-3/4 52-1/2 52-1/2 52-1/2 64 64 64
Base Inside N 29-3/4 29-3/4 29-3/4 29-3/4 44-1/2 44-1/2 44-1/2 56 56 56
Figure A7-1. Model CBE Hot Water Boiler Dimensions (Page 1 of 2)
A7-6
04-02
BOILER HP DIM 60 70 80 100 125 150 200 250 300 350
HEIGHTS
Base To Boiler Centerline D 40 40 40 40 46 46 46 56 56 56
Boiler ID J 48 48 48 48 60 60 60 78 78 78
Base To Vent Outlet O 70-1/4 70-1/4 70-1/4 70-1/4 82-3/8 82-3/8 82-3/8 101-1/2 101-1/2 101-1/2
Base To Supply & Return Ports

P 62-1/4 62-1/4 62-1/4 62-1/4 82-3/8 82-3/8 82-3/8 101-1/2 101-1/2 101-1/2
(30 & 125 psig)
Base To Supply And Return

P 70-1/4 70-1/4 70-1/4 70-1/4 82-3/8 82-3/8 82-3/8 101-1/2 101-1/2 101-1/2
Ports (150 psig)
Base Frame Q 12 12 12 12 12 12 12 10 10 10
Base To Rear Davit T 72-5/8 72-5/8 72-5/8 72-5/8 88-3/8 88-3/8 88-3/8 107 107 107
Base To Lifting Lug AA 68-3/4 68-3/4 68-3/4 68-3/4 81 81 81 102-9/16 102-9/16 102-9/16
CONNECTIONS
Waterfill (Both Sides) S 1-1/4 1-1/4 1-1/4 1-1/4 1-1/2 1-1/2 2 2 2 2-1/2
Air Vent V 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2
Hot Water Supply & Return

U 4 4 4 4 6A 6A 6A 8A 8A 8A
(30 & 125 psig)
Hot Water Supply & Return

U 4B 4B 4B 4B 6B 6B 6B 8B 8B 8B
(150 psig)
Vent Outlet ID Y 10 12 12 12 16 16 16 20 20 20
Boiler Drain W 1-1/4 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2 2
Boiler Drain X
MISCELLANEOUS
Door Swing (Minimum Rear) DD 30 30 30 30 36 36 36 45 45 45
Tube Removal Rear FF 82 100 109 143 93 118 167 105 131 157
Tube Removal Front GG 90 108 124 158 110 135 184 116 142 168
Min. Boiler Room Length For

HH 244 280 312 380 298 348 446 323 375 427
Tube Removal Front

JJ 287 327 352 420 326 376 474 348 411 463
Tube Removal RearC
WEIGHTS
Normal Water Weight (lbs) - 4340 5195 5920 7455 8310 10050 13475 13495 16320 19130
Shipping Weight (30 psig) - 6505 7270 7755 9055 10810 12225 14690 17655 19765 23400
Shipping Weight (125 psig - 6705 7740 8420 9820 11735 13630 16400 20365 22870 26830
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 A7-1. Model CBE Hot Water Boiler Dimensions (Page 2 of 2)
A7-7
04-02
BOILER HP DIM 60 70 80 100 125 150 200 250 300 350
LENGTHS
Overall Length A 163-1/8 186-1/16 201-1/16 235-1/16 199-3/16 224-3/16 273-3/16 217-7/8 243-7/8 269-7/8
Shell Length B 123-5/8 141-5/8 157-5/8 191-5/8 151-5/8 176-5/8 225-5/8 161-5/8 187-5/8 213-5/8
Base Frame Length C 133-3/8 152-3/8 173-9/16 207-9/16 162-9/16 187-9/16 236-9/16 177-3/16 203-3/16 229-3/16
Rear Head Extension E 7-7/8 7-7/8 7-7/8 7-7/8 8-3/8 8-3/8 8-3/8 9-3/8 9-3/8 9-3/8
Front Flange To Steam Outlet F 49-1/4 60-1/4 70-1/4 91-1/4 57-1/4 73-1/4 97-1/4 66-1/4 88-1/4 89-1/4
Steam Outlet To Vent Outlet G 65-1/2 72-1/2 78-1/2 91-1/2 85 94 119 83-1/2 87-1/2 112-1/2
Base Frame To Rear Head H 22-1/4 22-1/4 22-1/4 22-1/4 24-3/4 24-3/4 24-3/4 29-3/4 29-3/4 29-3/4
WIDTHS
Overall Width I 73 73 73 73 85 85 85 103 103 103
Boiler Centerline To Water

K 39 39 39 39 45 45 45 54 54 54
Column
Boiler Centerline To Lagging L 26-1/2 26-1/2 26-1/2 26-1/2 33 33 33 42 42 42
Boiler Centerline To Aux. Water

LL 34 34 34 34 40 40 40 49 49 49
Column
Base Outside M 37-3/4 37-3/4 37-3/4 37-3/4 52-1/2 52-1/2 52-1/2 64 64 64
Base Inside N 29-3/4 29-3/4 29-3/4 29-3/4 44-1/2 44-1/2 44-1/2 56 56 56
Figure A7-2. Model CBE Steam Boiler Dimensions (Page 1 of 2)
A7-8
04-02
BOILER HP DIM 60 70 80 100 125 150 200 250 300 350
HEIGHTS
Base To Boiler Centerline D 40 40 40 40 46 46 46 56 56 56
Boiler ID J 48 48 48 48 60 60 60 78 78 78
Base To Vent Outlet O 70-1/4 70-1/4 70-1/4 70-1/4 82-3/8 82-3/8 82-3/8 101-1/2 101-1/2 101-1/2
Base To Steam Outlet (15 psig) P 70-1/4 70-1/4 70-1/4 70-1/4 82-3/8 82-3/8 82-3/8 101-1/2 101-1/2 101-1/2
Base To Steam Outlet (150 psig) P 67-7/8 67-7/8 67-7/8 70-1/4 82-3/8 82-3/8 82-3/8 101-1/2 101-1/2 101-1/2
Base Frame Q 12 12 12 12 12 12 12 10 10 10
Base To Rear Davit T 72-5/8 72-5/8 72-5/8 72-5/8 88-3/8 88-3/8 88-3/8 107 107 107
Base To Lifting Lug AA 68-3/4 68-3/4 68-3/4 68-3/4 81 81 81 102-9/16 102-9/16 102-9/16
CONNECTIONS
Chemical Feed R 1 1 1 1 1 1 1 1 1 1
Feedwater Inlet (Both Sides) S 1-1/4 1-1/4 1-1/4 1-1/4 1-1/2 1-1/2 2 2 2 2-1/2
Surface Blowoff (150 psig Only) V 1 1 1 1 1 1 1 1 1 1
Steam Outlet (15 psig) U 6A 6A 6A 8A 8A 8A 10 A 10 A 12 A 12 A
Steam Outlet (150 psig) U 3 3 3 4B 4B 4B 4B 6B 6B 6B
Vent Outlet ID Y 10 12 12 12 16 16 16 20 20 20
Boiler Blowdown (36 Dia Only) X - - - - - - - - - -
Boiler Blowdown (15 psig) W 1-1/4 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2 2
Boiler Blowdown (150 psig) W 1-1/4 1-1/4 1-1/4 1-1/4 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2
MISCELLANEOUS
Door Swing (Rear Minimum) DD 30 30 30 30 36 36 36 45 45 45
Tube Removal Rear FF 82 100 109 143 93 118 167 105 131 157
Tube Removal Front GG 90 108 124 158 110 135 184 116 142 168

HH 244 280 312 380 298 348 446 323 375 427
Tube Removal Front

JJ 287 327 352 420 326 376 474 348 411 463
Tube Removal RearC
WEIGHTS
Normal Water Weight - 3940 4720 5375 6770 7135 8625 11565 11530 13940 16350
NOTES:
1. All connections are threaded, except as noted.
2. Manway included on 125 - 350 hp.
A. 150 psig Flange.
B. 300 psig Flange.
C. Includes 4-foot clearance in front of boiler.
Figure A7-2. Model CBE Steam Boiler Dimensions (Page 2 of 2)
A7-9
04-02
DIMENSION (INCHES)
BOILER
HP
A B C D E
60 thru 100 27 45 38 61 30
125 thru 200 33 52 45 73 36
250 thru 350 42 61 58 90 45
Figure A7-3. Space Required to Open Rear Head on Model CBE Boilers Equipped with Davits
D NEAR SIDE FAR SIDE E (DIA OF HOLE)

D
B C

HP 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
100 68 14 155 10 2-1/2
125 80 19 106 10 3
150 80 19 131 10 3
200 80 19 180 10 3
250 99 18 110 10 3
300 99 18 136 10 3
350 99 18 162 10 3
Figure A7-4. Model CBE Boilers Lifting Lug Location
A7-10
04-02
A F F
G
X
B D B
C
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
100 6 8 211 25-3/4 41-3/4 4 29-5/8 8
125 6 9 166 44 62 4 44-1/2 8
150 6 9 191 44 62 4 44-1/2 8
200 6 9 249 44 62 4 44-1/2 8
250 6 10 181 50 70 4 56 9
300 6 10 207 50 70 4 56 9
350 6 10 233 50 70 4 56 9
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 added height for washing down the area beneath the boiler.
Figure A7-5. Model CBE Boiler Mounting Piers
A7-11
04-02
A7-text Page 12 Tuesday, December 17, 2002 11:07 AM
PERFORMANCE DATA 2. Efficiencies are based on ambient air temperature of 80 F,

Contact your local Cleaver-Brooks authorized representative flue gas.
for emissions or additional information.
3. Efficiencies are based on manufacturers published radiation
and convection losses. (For Cleaver-Brooks radiation and con-
Efficiency
vection losses, see Boiler Efficiency Facts Guide, publication
Table A7-3 shows predicted fuel-to-steam efficiencies (includ- number CB-7767).
ing radiation and convection losses) for Cleaver-Brooks Model
4. Any efficiency verification testing will be based on the stack
CBE Firetube boilers. For specific efficiencies on firetube
loss method.
boiler offerings not listed here, contact your local Cleaver-
Cleaver-Brooks offers an industry leading fuel-to-steam boiler
ENGINEERING DATA
efficiency guarantee for Model CBE Firetube Boilers. The The following engineering information is provided for Model
guarantee is based on the fuel-to-steam efficiencies shown in CBE Firetube Boilers. Additional detail is available from your
the efficiency tables and the following conditions. The effi- local Cleaver-Brooks authorized representative.
ciency percent number is only meaningful if the specific con-
ditions of the efficiency calculations are clearly stated in the Boiler Information
specification (see Cleaver-Brooks publication CB-7768 for a
detailed description of efficiency calculations). Table A7-4 shows heating surfaces for model CBE Firetube
boilers.
At the time of startup, the boiler will achieve fuel-to-steam
efficiency (as shown in Table A7-3) at 100% firing rate (add Table A7-5 shows steam volume and disengaging area for
efficiency guarantees at 50% of rating, if required). The speci- model CBE Firetube boilers.
fied boiler efficiency is based on the following conditions. Table A7-6 lists quantity and outlet size for safety valves sup-
1. Fuel specification used to determine boiler efficiency: plied on Model CBE steam boilers.
Natural Gas Table A7-7 lists quantity and outlet size for relief valves sup-
plied on Model CBE hot water boilers.
Carbon, % (wt) = 69.98
Hydrogen, % (wt) = 22.31 Tables A7-8 gives recommended steam nozzle sizes based on
Sulfur, % (wt) = 0.0 4000-5000 fpm steam velocity on Model CBE Boilers.
Heating value, Btu/lb = 21,830 Table A7-9 shows recommended non-return valve sizes for
No. 2 Oil Model CBE Firetube Boilers.
Carbon, % (wt) = 85.8

Sulfur, % (wt) = 0.2 Some local codes require blowdown tanks to be constructed in
Heating value, Btu/lb = 19,420 accordance with recommendations of the National Board of
Table A7-3. Predicted Fuel-to-Steam Efficiency
10 PSIG OPERATING PRESSURE 125 PSIG OPERATING PRESSURE
BOILER HP NATURAL GAS NO. 2 OIL NATURAL GAS NO. 2 OIL
50 % 100 % 50 % 100 % 50 % 100 % 50 % 100 %

60 82.8 81.6 86.2 85.1 80.3 80.0 83.7 83.2
70 84.0 82.5 87.5 86.0 81.4 80.3 84.8 83.8
80 84.3 82.9 87.7 86.3 81.7 80.7 85.1 84.1
100 84.8 83.8 88.2 87.2 82.1 81.5 85.5 84.9
125 83.2 81.8 86.6 85.2 80.5 80.0 84.0 83.0
150 84.2 82.8 87.6 86.3 81.4 80.3 84.8 83.7
200 85.0 84.2 88.4 87.6 82.1 81.5 85.5 84.9
250 83.8 81.8 87.2 85.3 81.2 80.0 84.6 83.2
300 84.3 82.9 87.8 86.4 81.6 80.6 85.1 84.1
350 84.7 83.7 88.2 87.2 81.9 81.2 85.3 84.6
A7-12
04-02
Table A7-4. Heating Surface, Model CBE Boilers Table A7-5. Model CBE Steam Volume and Disengaging Area
HEATING SURFACE (SQ-FT) BOILER STEAM VOLUME (CU-FT) STEAM RELIEVING AREA (SQ-IN)
BOILER
HP HIGH PRESSURE A LOW PRESSURE B HIGH PRESSURE A LOW PRESSURE B
HP FIRESIDE WATERSIDE
60 6.39 12.92 2936 3588
60 300 322
70 7.58 15.35 3486 4261
70 350 376
80 8.65 17.50 3974 4859
80 400 429
100 10.91 22.08 5014 6129
100 500 537
125 19.04 29.67 5121 5796
125 625 672
150 23.00 35.93 6202 7018
150 750 807 200 30.78 48.19 8319 9415
200 1000 1077 250 31.96 50.18 6872 7805
250 1250 1346 300 38.56 60.68 8309 9438
300 1500 1615 350 45.15 71.18 9747 11071
350 1750 1885 NOTE:
1. Based on normal water level.
2. Values are based on standard controls. Optional controls may result in different values.
Table A7-6. Model CBE Steam Boiler Safety Valve Openings

VALVE
SETTING
BOILER VALVES SIZE VALVES SIZE VALVES SIZE VALVES SIZE VALVES SIZE VALVES SIZE
HP REQ'D (IN.) REQ'D (IN.) REQ'D (IN.) REQ'D (IN.) REQ'D (IN.) REQ'D (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
100 1 2-1/2 1 2 1 2 1 1-1/2 1 1-1/2 1 1-1/4
(1) 1-1/2 (1) 1-1/2 (1) 1-1/4
125 1 3 2 1-1/2 2 2 2 2 1
(1) 1-1/4 (1) 1-1/4 (1) 1
(1) 2 (1) 1-1/2 (1) 1
150 1 3 2 2 1-1/2 2 2 1-1/4 2
(1) 1-1/2 (1) 1-1/4 (1) 1-1/4
(1) 2 (1) 1-1/2 (1) 1-1/4
200 2 2-1/2 2 2 2 2 1-1/2 2 2
(1) 1-1/2 (1) 1-1/4 (1) 1-1/2
(1) 2-1/2 (1) 2-1/2
250 2 2 2 2 2 2 2 1-1/2 2 1-1/2
(1) 3 (1) 2
(1) 2-1/2 (1) 2-1/2 (1) 2
300 2 3 2 2-1/2 2 2 2 2 1-1/2
(1) 2 (1) 2 (1) 1-1/2
(1) 2 (1) 2-1/2 (1) 2-1/2 (1) 1-1/2
350 3 3 2 2-1/2 2 2 2 2
(2) 3 (2) 2 (1) 2 (1)2
NOTE:
1.Valve manufacturers are Kunkle, Consolidated or Conbraco, depending on availability.
A7-13
04-02
The National Boards recommendations base the size of the Fuel Connections - Gas
blowdown tank on the removal of at least 4 inches of water
The local gas company should be consulted for requirements
from the boiler.
and authorization for installation and inspection of gas supply
Table A7-10 lists the approximate quantity of water repre- piping. Installation of gas supply piping and venting must be in
sented by 4 inches of water at normal operating level for accordance with all applicable engineering guidelines and reg-
Cleaver-Brooks Power Boilers. ulatory codes. All connections made to the boiler should be
arranged so that all components remain accessible for inspec-
Sound Level tion, cleaning and maintenance.
Table A7-11 summarizes predicted sound pressure levels for A drip leg should be installed in the supply piping before the
Model CBE Boilers. These values are based on standard connection to the gas pressure regulator. The drip leg should be
motors. Optional motor types and altitude conditions can at least as large as the inlet fitting supplied with the boiler.
increase sound levels. Consideration must be given to both volume and pressure
requirements when choosing gas supply piping size. Refer to
Units the boiler dimension diagram provided by Cleaver-Brooks for
The units for the sound level tables are dBA (decibels, mea- the particular installation. Connections to the burner gas train
sured on the A-weighted scale) in reference to 0.0002 should be made with a union, so that gas train components or
microbars (20 micro-Newtons per square meter). They are the burner may be easily disconnected for inspection or ser-
standardly referenced in specifying and reporting sound pres- vice. Upon completion of the gas piping installation, the sys-
sure levels on industrial equipment. tem should be checked for gas leakage and tight shutoff of all
valves.
Test Method
The sound pressure levels in the above table were obtained Fuel Connections - Oil
from tests in accordance with the "ABMA Test Code for the Oil-fired burners are equipped with an oil pump, which draws
Measurement of Sound from Packages Boilers." In accordance fuel from a storage tank and supplies pressurized oil to the
with this code, the sound pressure levels reported were mea- burner nozzle(s). The burner supply oil pump has a greater
sured on the boiler centerline 4-1/2 feet vertically above the capacity than the burner requires for the maximum firing rate.
bottom of the base rails and 3 feet horizontally in front of the Fuel not delivered to the nozzle is returned to the storage tank.
end of the blower motor or front surface of the electrical cabi- A two-pipe (supply and return) oil system is recommended for
net. all installations. Figure A7-6 shows a typical fuel oil supply
Sound Level Meter arrangement. Oil lines must be sized for the burner and burner
supply oil pump capacities.
The sound level meter used complies with ANSI S1.4, Type 1
(Precision). The readings are taken with the meter set for slow The burner supply oil pump suction should not exceed 10" Hg.
response. 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.
Burner/Control Information
A strainer must be installed in the supply piping upstream of
Burner Characteristics the burner supply pump in order to prevent entry of foreign
material into the pump, fuel control valves, or burner nozzle(s).
Burner information is shown in Table A7-12. Note that the The strainer must be sized for the burner supply pump capacity.
model selection may vary for actual application factors (alti- A strainer mesh of 150 microns (0.005") is recommended.
tude, gas pressure, etc.).
Install a check valve in the line to prevent draining of the oil
Gas Fired - Burners suction line when the burner is not in operation. Location of
the check valve varies with the system, but usually it is located
Table A7-13 shows conversion factors for gas pressure at ele- as close as possible to the storage tank.
vations over 700 ft above sea level.
Installation of a vacuum gauge in the burner supply line
Table A7-14 shows maximum gas consumption (CFH) for between the burner oil pump and the strainer is recommended.
Natural Gas. Regular observation and recording of the gauge indication will
Table A7-15 shows minimum and maximum gas pressure assist in determining when the strainer needs servicing.
requirements for Standard, FM and IRI CBE Boiler gas trains. Upon completion of the oil piping installation, the system
For oversized or undersized gas trains or altitude above 1,000 should be checked for oil or air leakage and tight shutoff of all
feet, contact your local Cleaver-Brooks authorized representa- valves.
tive.
A7-14
04-02
Table A7-7. Model CBE Hot Water Boiler Relief Valve Openings
VALVE SETTING 30 PSIG HW 60 PSIG HW 100 PSIG HW 125 PSIG HW

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
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
(1) 2-1/2
200 2 1 (1) 2-1/2 1 2 1 2
(1) 1-1/4
(1) 2
250 2 1 2-1/2 1 2-1/2 1 2
(1) 2-1/2
(1) 1
300 2 2-1/2 2 1 2-1/2 1 2-1/2
(1) 2-1/2
(2) 2-1/2 (1) 2-1/2
350 3 2 1 2-1/2 1 2-1/2
(1) 1 (1) 2
NOTES:
1.Hot water relief valves are Kunkle #537.
Table A7-8. Model CBE Recommended Steam Nozzle Size (To Maintain 4000 to 5000 fpm
Nozzle Velocity)
BOILER HP
OPERATING PRESSURE 60 70 80 100 125 150 200 250 300 350

PSIG
15 6 6 6 8 8 8 10 10 12 12
30 4 4 4 6 6 6 8 8 8 10
40 4 4 4 6 6 6 6 8 8 8
50 3 4 4 4 6 6 6 6 8 8
75 3 3 4 4 4 4 6 6 6 8
100 3 3 3 4 4 4 6 6 6 6
125 3 3 3 4 4 4 4 6 6 6
150 2.5 2.5 2.5 2.5 3 3 4 4 6 6
200 2.5 2.5 2.5 2.5 2.5 3 4 4 4 4
250 2 2 2 2 2.5 2.5 3 4 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, 10x8x48, and 12x8x48.
A7-15
04-02
A7-text Page 16 Tuesday, December 17, 2002 11:12 AM
Table A7-9. Model CBE Recommended Non-Return Valve Size

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

60 51
70 60
80 69
100 87
125 92
150 111
200 147
250 122
300 147
350 172
NOTE: Quantity of water removed from boiler by lowering normal
water line 4"
Table A7-11. Sound Pressure Levels in DbA (Profire F)
BOILER HP 60 70 80 100 125 150 200 250 300 350
GAS
HIGH FIRE 77.0 75.0 76.5 75.5 76.5 77.5 84.5 82.0 83.5 88.0
LOW FIRE 78.0 74.0 76.5 74.5 68.5 73.5 87.0 74.5 78.5 84.0
NO. 2 OIL
HIGH FIRE 77.0 74.0 76.5 76.0 79.0 80.0 83.0 83.0 84.5 89.0
LOW FIRE 75.5 72.0 76.0 75.0 76.0 76.0 85.0 78.0 80.5 84.0
A7-16
04-02
Table A7-12. Model CBE Burner Selections

(Profire Burner)
MAX ALTITIUDE
BOILER HP BURNER SIZE
(FT)
60 2000 1
70 3500 2
80 1500 2
100 1500 2
125 3500 3
150 2500 3
200 1500 3
250 2000 4
300 2500 4
350 1000 4
Table A7-13. Minimum Required Gas Pressure Altitude Table A7-14. Maximum Gas Consumption (CFH)
Conversion for Natural Gas - Model CBE
ALTITUDE CORRECTION ALTITUDE CORRECTION BOILER NATURAL GAS

(FT) FACTOR (FT) FACTOR HP 1000 (BTU/CU-FT)
1000 1.04 6000 1.25 60 2510
2000 1.07 7000 1.30 70 2930

80 3350
3000 1.11 8000 1.35
100 4185
4000 1.16 9000 1.40
125 5230
5000 1.21 - -
150 6280
To obtain minimum required gas pressure at altitudes above 700 feet, mul-
tiply the pressure by the listed factors:
inches WC x 0.577 = oz/sq-in. 200 8370
i inches WC x 0.0361= psig. 250 10460
psig x 16.0 = oz/sq-in. 300 12555
350 14650
A7-17
04-02
Table A7-15. Minimum Required Gas Pressure at Entrance to Standard, FM and IRI Gas Trains - Model CBE
(Upstream of Gas Pressure Regulator)
MAX 1 PSIG INLET, MIN SUPPLY MAX 10 PSIG INLET**, MIN SUPPLY
STD PIPE
BOILER PRESSURE (WC) PRESSURE (WC)
SIZE
HP
(Inches) 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
100 2* 16.0 16.0 17.0 22.0 22.0 23.0
125 2 12.5 12.5 12.5 16.0 16.0 16.0

150 2 18.5 18.5 18.5 23.0 23.0 23.0
200 2-1/2 19.5 19.5 19.5 22.5 22.5 22.5
250 2-1/2 23.5 23.5 23.5 27.5 27.5 27.5
300 2-1/2 N/A N/A N/A 39.0 39.0 39.0
350 3 N/A N/A N/A 41.5 41.5 41.5
* Gas pressure regulator is 1-1/2 inch.
** Use max 10 psig for all boilers destined for Canada.
Figure A7-6. Typical Fuel Oil Supply Arrangement
A7-18
04-02
Boiler Room Information openings are to be 5 feet above floor level.
Figure A7-7 shows typical boiler room length requirements. Air required: 300 x 10 = 3000 cfm (from 2B above).
Figure A7-8 shows typical boiler room width requirements. Air velocity: Up to 7 feet = 250 fpm (from 3 above).
Area Required: Area = cfm = 3000/250 = 12 Sq-ft total.
Stack Support Capabilities Area/Opening: 12/2 = 6 sq-ft/opening (2 required).
60-100 hp Model CBE Boilers can support up to 1000 lbs with-
out additional support.
125-350 hp Model CBE Boilers can support up to 2000 lbs NOTICE
without additional support.
quirements.
When determining boiler room air requirements, the size of the Stack/Breeching Size Criteria
room, air flow, and velocity of air must be reviewed as follows:
1. Size (area) and location of air supply openings in boiler required draft at each boiler flue gas outlet. Proper draft is crit-
room. ical to burner performance.
A. Two (2) permanent air supply openings in the outer walls Although constant pressure at the flue gas outlet of the Model
of the boiler room are recommended. Locate (1) at each CBE is not required, it is necessary to size the stack/breeching
end of the boiler room, preferably below a height of 7 to limit flue gas pressure variation. The allowable pressure
feet. This allows air to sweep the length of the boiler. range is 0.25" W.C. to +0.25" W.C.
B. Air supply openings can be louvered for weather For additional information, please review Section I4, General
protection, but they should not be covered with fine mesh Engineering Data (Stacks) and Section F, Stacks. Stack and
wire, as this type of covering has poor air flow qualities breeching sizes should always be provided by a reputable stack
and is subject to clogging by dust or dirt. supplier who will design the stack and breeching system based
representative is capable of assisting in your evaluation of the
stack/breeching design.
Area (sq-ft) = CFM/FPM
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.
A7-19
04-02
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.
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. Allow-
ance for door swing at the front provides sufficient aisle and working space at the front.
Figure A7-7. Boiler Room Length (Typical Layouts) - Model CBE
BOILER HP 60-100 125-200 250-350
Dimension A (inches) 78 82 93
Dimension B (inches) 105 115 141
NOTES:
1. Recommended Minimum Distance Between Boiler and Wall. Dimension A allows for a clear 42" aisle be-
tween the water column on the boiler and the wall. If space permits, this aisle should be widened.
42" - 60-200 hp
48" - 250-350 hp
Figure A7-8. Boiler Room Width (Typical Layout) - Model CBE
A7-20
04-02
A7-text Page 21 Wednesday, December 11, 2002 9:45 AM
The following sample specification are provided by Cleaver-Brooks to assist you in meeting your customers specific needs and
application.
Model CBE Steam Boiler (60-350 hp, Steam 15-300 psig)

6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-25
7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-25
Model CBE Hot Water Boiler (60-350 hp, 30 psig, 125 psig)
6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-29
7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-30
Model CBE Steam Boiler (60-350 hp, Steam 15-300 psig)

1.1 The Steam Boiler shall be Cleaver-Brooks Model CBE, Fuel Series ______ (100, 200, 700), _____ hp designed for _____ psig
(15, 150, 200, or other psig steam). The maximum operating pressure shall be _____ psig.
1.2 The boiler shall have a maximum output of _____ Btu/hr, or _____ horsepower when fired with CS 12-48 No. 2 oil and/or nat-
ural gas, _____ Btu/cu-ft. Electrical power available will be _____ Volt _____ Phase _____ Cycle and 115/1/160 for the control
circuit.

2.1 The boiler shall be a three 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 forced draft burner and burner controls.
2.1.1 Approvals: Underwriters Laboratories Inc. The complete boiler package shall be approved and listed as a unit by Underwrit-
ers Laboratories.
2.2.3 Front and rear doors on the boiler shall be davited.
A7-21
04-02
2.2.4 Refractory and insulation shall be contained in the rear smoke box and door; door shall swing open for inspection.
2.2.6 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.
2.2.7 For boilers over 100 horsepower, a manhole shall be provided.
2.2.8 The exhaust gas vent shall be located near the rear of the boiler on the top center line and shall be capable of supporting:
60-100 hp. 1000 lbs
125-350 hp. 2000 lbs
2.2.10 The boiler insulation shall consist of a 2 inch blanket under a sectional preformed sheet metal lagging. This insulation must
be readily removable and capable of being reinstalled, if required.
2.2.11 The entire boiler based frame and other components shall be factory painted before shipment using a hard finished enamel
coating.

3.1 Water Column
valves.
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.
4.2 Blower
4.2.1 All air for combustion shall be supplied by a forced draft blower mounted on the burner, to eliminate vibration and reduce
noise level.
A7-22
04-02
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.
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).
4.4.1.1 Burner Type - The burner shall be mounted at the front of the boiler and be of high radiant multi-port type for gas. The
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).
4.4.1.3 Gas Burner Piping - Select one of the following:
A. 60-100 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1)
motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure
switches. The gas valve shall be wired to close automatically in the event of power failure, 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) sole-
noid 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 and 350 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1)
solenoid and one (1) motorized gas valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test con-
nections, 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.
4.4.2.1 Burner Type - The burner shall be mounted at the front of the boiler, and shall be approved for operation with CS12-48,
Commercial No. 2 oil.
4.4.2.2 Ignition System - Select one of the following:
A. 60-100 hp. The burner shall employ a direct spark ignition system. A high voltage spark generated by a transformer shall be
used to ignite the main burner.
B. 125-350 hp. The burner shall employ a gas pilot ignition system. A separate pilot gas cock, gas pressure regulator, pilot and
safety shutoff gas valve.
the following:
A. 60-200 hp. Pump shall be an integral part of the burner and mechanically driven.
B. 250-350 hp. Pump shall be motor driven and shipped loose to be field installed near the oil storage tank. Oil pump motor
starter shall also be provided.
A7-23
04-02
4.4.2.4 Oil Burner Piping - Select one of the following:

A. 60 to 200 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid
oil shut-off valves, and pressure gauge all integrally mounted on the unit.
B. 250-350 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid
oil shut-off valves, low oil pressure switch, and pressure gauge all integrally mounted on the unit.
4.4.2.5 Oil Atomization Type-Select one of the following:
A. 60-200 hp. Burner shall include a complete mechanical oil atomizing system and be of the pressure atomizing type.
B. 250-350 hp. Burner shall be a low pressure air atomizing type, including a shipped loose air compressor assembly.
4.4.3.1 Burner Type - Select one of the following:
A. 60-200 hp. The burner, mounted at the front of the boiler, shall be a combination pressure atomizing type for oil and high
radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 oil or natu-
ral gas.
B. 250-350 hp. The burner, mounted at the front of the boiler, shall be a combination of low pressure air atomizing type for oil
and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 oil
or natural gas.
so that the primary fuel valve cannot open until flame has been established. The pilot train shall include one (1) manual shut-off
valve, solenoid valve, and pressure regulator.
4.4.3.3 Oil Burner
of the following:
4.4.3.3.2 Oil Burner Piping - Select one of the following:
A. 60-200 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil
shut-off valves, and pressure gauge all integrally mounted on the unit.
oil shut-off valves, low oil pressure switch and pressure gauge all integrally mounted on the unit.
4.4.3.3.3 Oil Atomization Type - Select one of the following:
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
gas pressure switches. The gas valve shall be wired to close automatically in the event of power failure, flame failure, low
A7-24
04-02
failure, flame failure, low water or any abnormal shutdown condition.
4.5 Control Panel and Flame Safeguard Controller
4.5.1 Control Panel
A factory prewired control panel shall be supplied with the boiler-burner package. Panel may be mounted on the burner or boiler.
4.5.2 The panel will have a NEMA 1A rating and contain the flame safeguard 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.
4.5.3 80-350 hp. The panel shall contain a control circuit transformer and fuse protection.
4.5.4 The flame safeguard controller shall be a CB110 flame monitor with EPD170 program module. Flame detector shall be ultra-
violet type.

5.1 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).
6.0 Warranty
7.0 Execution
7.1 Shop Tests
A7-25
04-02
Model CBE Hot Water Boiler (60-350 hp, 30 psig, 125 psig)

1.1 The Hot Water Boiler shall be Cleaver-Brooks Model CBE, Fuel Series ______ (100, 200, 700), _____ hp designed for _____
psig (30, 125, or other psig hot water). The maximum water temperature will be _____ degree F, and the maximum system temper-
ature drop will be _____ degree F.
ural gas, _____ Btu/cu-ft. Electrical power available will be _____ Volt _____ Phase _____ Cycle and 115/1/160 for the control
circuit.

2.1 The boiler shall be a three 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 forced draft burner and burner controls.
2.1.1 Approvals: Underwriters Laboratories Inc. The complete boiler package shall be approved and listed as a unit by Underwrit-
ers Laboratories.
2.2.5 Front and rear doors on the boiler shall be davited. Doors are to be sealed with Kaowool gaskets and fastened tightly using
heavy capscrews that thread into replaceable brass nuts.
2.2.6 Refractory and insulation shall be contained in the rear smoke box and door; door shall swing open for inspection.
2.2.9 For boilers over 100 horsepower, a manhole shall be provided.
2.2.10 The exhaust gas vent shall be located near the rear of the boiler on the top center line and shall be capable of supporting:
60-100 hp. 1000 lbs.
125-350 hp. 2000 lbs.
2.2.13 The entire boiler based frame and other components shall be factory painted before shipment using a hand finished enamel
coating.

3.1 Hot Water Connections
The hot water outlet and return connections shall be located on the top center line of the boiler. The internal design of these connec-
tions shall provide forced internal circulation, mixing return water with the hot water within the boiler.
A7-26
04-02
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.
to prevent burner operation if boiler water falls below a safe level. A manual reset device shall be used on this control.
outlet.
3.5 Relief Valves
to the hot water outlet.
4.0 Burner
4.2 Blower
noise level.
4.4.1.1 Burner Type - The burner shall be mounted at the front of the boiler and of high radiant multi-port type for gas. The burner
shall be approved for operation on natural gas fuel.
A7-27
04-02
switches. The gas valve shall be wired to close automatically in the event of power failure, flame failure, low water, or any
B. 125-250 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1)
failure, flame failure, low water, or any abnormal shutdown condition.
4.4.2.2 Ignition System - Select one of the following:
A. 60-100 hp. The burner shall employ a direct spark ignition system. A high voltage spark generated by a transformer shall be
used to ignite the main burner.
B. 125-350 hp. The burner shall employ a gas pilot ignition system. A separate pilot gas cock, gas pressure regulator, and pilot
safety shutoff gas valve.
the following:
oil shut-off valves, low oil pressure switch, and pressure gauge all integrally mounted on the unit.
4.4.2.5 Oil Atomization Type - Select one of the following:
A. 60-200 hp. The burner, mounted at the front of the boiler, shall be a combination pressure atomizing type for oil and high
ral gas.
B. 250-350 hp. The burner, mounted at the front of the boiler, shall be a combination of low pressure air atomizing type for oil
or natural gas.
A7-28
04-02
4.4.3.3 Oil Burner

of the following:
oil shut-off valves, low oil pressure switch and pressure gauge all integrally mounted on the unit.
motorized gas valve with proof of closure switch, two (2) plugged leakage test connection, and high and low gas pressure
gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, flame failure, low
failure, flame failure, low water or any abnormal shutdown condition.
4.5.1 Control Panel
A factory prewired control panel shall be supplied with the boiler-burner package. Panel may be mounted on the burner or boiler.
4.5.2 The panel will have a NEMA 1A rating and contain the flame safeguard 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.
4.5.3 80-350 hp. The panel shall contain a control circuit transformer and fuse protection.
violet type.

5.1 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).
6.0 Warranty
A7-29
04-02
7.0 Execution
7.1 Shop Tests
A7-30
04-02
Section A8
Model CEW Boilers
CONTENTS
Burner/Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-12
ILLUSTRATIONS
Figure A8-1. Model CEW Steam Boiler Dimensions (Page 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8- 6
Figure A8-2. Model CEW Hot Water Boiler Dimensions (Page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-8
Figure A8-3. Space Required to Open Rear Head on Model CEW Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-10
Figure A8-4. Model CEW Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-10
Figure A8-5. Model CEW Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-11
Figure A8-6. Typical Fuel Oil Supply Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-18
Figure A8-7. Boiler Room Length (Typical Layouts) - Model CEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-19
Figure A8-8. Boiler Room Width (Typical Layout) - Model CEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-19
A8-1
10-02
Model CEW Firetube Boilers
TABLES
Table A8-1. Model CEW Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A8-5
Table A8-2. Model CEW Hot Water Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A8-5
Table A8-3. Model CEW Steam Volume and Disengaging Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A8-14
Table A8-4. Model CEW Steam Boiler Safety Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A8-14
Table A8-5. Model CEW Hot Water Boiler Relief Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A8-15
Table A8-6. Model CEW Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A8-15
Table A8-7. Model CEW Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A8-16
Table A8-8. Model CEW Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A8-16
Table A8-9. Model CEW Standard Burner Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A8-17
Table A8-10. Altitude Correction for Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A8-17
Table A8-11. Model CEW Minimum and Maximum Required Gas Pressure at Entrance to Standard,
FM and IRI Gas Trains (Upstream of Gas Pressure Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A8-18
The following information applies to the Cleaver-Brooks Model CEW Boiler.
A8-2
10-02
Firetube Boilers Model CEW
FEATURES AND BENEFITS Seismic design.

The Cleaver-Brooks Model CEW Boiler line provides a qual-
ity product utilizing a baseline boiler/burner design. Addition-
ally, the boiler/burner packaged UL and cUL label is available Flame safeguard controllers.
on 125 - 800 hp. The following features apply:
Lead/lag system.
Three-Pass Wetback Design: High altitude design.

Three-pass design provides high ue gas velocities and low Special insurance and code requirements (e.g., IRI, FM,
stack temperatures to maximize efciency. CSD-1).
Five square feet of heating surface per boiler horsepower Alarm bell/silence switch.
(except for the 750 and 800 hp) provides guaranteed Special motor requirements (TEFC, high efciency).
efciency performance and long boiler life.
Special indicating lights.
Front and Rear Doors: Main disconnect.
Davit, front and rear doors, all sizes. Elapsed time meter.
Provides access to front and rear tube sheet. Voltmeter/micro-ammeter.
Large rear access plug for turnaround and furnace access. NEMA enclosures.
Rear door completely covers and insulates rear tube sheet. Low-re hold control.
Natural Gas, No. 2 Oil, or Combination Burners Available: Remote emergency shut-off (115V).
Combination gas/oil burners provide quick fuel changeover Circuit breakers.

without burner adjustment. Day/night controls.
PRODUCT OFFERING
Stack thermometer.
Cleaver-Brooks Model CEW Boilers are available in low pres-
sure steam, high pressure steam, and hot water designs. Burn- Fuel Options
ers are available to re natural gas, No. 2 oil, or a combination Air atomizing oil burner, 125 200 hp.
of oil and gas. Standard product offering is:
Gas strainer.
125 - 800 hp.
Gas pressure gauge.
15 - 250 psig steam.
Available options include the following (contact your local
Cleaver-Brooks authorized representative for option details).
Boiler Options:
Drain valves.
Additional screwed or anged trappings.
Blowdown valves.
Non-return valves.
Blend pump.
Surge load bafes.
A8-3
10-02

Dimensions and ratings for the Model CEW Boilers are shown
in the following tables and illustrations. The information is
subject to change without notice.
Table A8-1. Model CEW Steam Boiler Ratings
Table A8-2. Model CEW Hot Water Boiler Ratings
Figure A8-2. Model CEW Steam Boiler Dimensions
Figure A8-1. Model CEW Hot Water Boiler Dimensions
Figure A8-3. Model CEW Boiler Space Requirements to
Open Rear Door
Figure A8-4. Lifting Lug Location, Model CEW Boilers
Figure A8-5. Model CEW Boiler Mounting Piers
A8-4
10-02
A8-TEXT Page 5 Friday, December 13, 2002 2:42 PM
Table A8-1. Model CEW Steam Boiler Ratings

BOILER HP 125 150 200 250 300 350 400 500 600 700 750 800
Rated Capacity (lbs-steam/hr from

4313 5175 6900 8625 10350 12075 13800 17250 20700 24150 25875 27600
and at 212 F)
Btu Output (1000 Btu/hr) 4184 5021 6695 8369 10043 11716 13390 16738 20085 23433 25106 26780
Light Oil gph (140,000 Btu/gal) 37.5 45 60 74.5 89.5 104.5 119.5 149.5 179.5 209 224 239
Gas CFH (1000 Btu) 5230 6280 8370 10460 12555 14650 16750 20925 25100 29300 31385 33500
Gas (Therm/hr) 52.3 62.8 83.7 104.6 125.5 146.5 167.5 209.3 251.0 293.0 313.9 335.0
Oil Pump Motor hp (oil firing only) * * * 1/2 3/4 3/4 3/4 3/4 3/4 1 1 1
Blower Motor - Series 100/200A 2 3 7-1/2 5 7-1/2 10 20 25 30 40 60 60
Blower Motor - Series 700A 2 3 5 5 7-1/2 10 20 25 30 40 60 60
Air Comp. Motor (oil firing only) ** ** ** 3 3 3 5 5 7-1/2 7-1/2 7-1/2 7-1/2
Oil Meter. Pump Mtr (oil firing only) N/A N/A N/A N/A N/A N/A 1/2 3/4 3/4 3/4 3/4 3/4
BOILER DATA
Heating Surface sq-ft (Fireside) 625 750 1000 1250 1500 1750 2000 2500 3000 3500 3500 3500

NOTE:All fractional hp motors will be single phase voltage except oil metering pump motor(3-phase); integral hp motors will be 3-phase voltage.
A. For altitudes over 1000 ft. contact your local Cleaver-Brooks representative for verification of motor hp.
Table A8-2. Model CEW Hot Water Boiler Ratings
BOILER HP 125 150 200 250 300 350 400 500 600 700 750 800
Btu Output (1000 Btu/hr) 4184 5021 6695 8369 10043 11716 13390 16738 20085 23433 25106 26780
Gas CFH (1000 Btu) 5230 6280 8370 10460 12555 14650 16750 20925 25100 29300 31385 33500
Gas (Therm/hr) 52.3 62.8 83.7 104.6 125.5 146.5 167.5 209.3 251 293 313.8 335
Oil Pump Motor hp (oil firing only) * * * 1/2 3/4 3/4 3/4 3/4 3/4 1 1 1
Blower Motor - Series 100/200A 2 3 7-1/2 5 7-1/2 10 20 25 30 40 60 60
Blower Motor - Series 700A 2 3 5 5 7-1/2 10 20 25 30 40 60 60
Air Comp. Motor (oil firing only) ** ** ** 3 3 3 5 5 7-1/2 7-1/2 7-1/2 7-1/2
Oil Meter. Pump Mtr (oil firing only) N/A N/A N/A N/A N/A N/A 1/2 3/4 3/4 3/4 3/4 3/4
BOILER DATA

NOTE:All fractional hp motors will be single phase voltage except oil metering pump motor(3-phase); integral hp motors will be 3-phase voltage.
A8-5
10-02
RF/RD
I DD
LL GG B 4"
L K BB
E Y T CC
J
O OA
P
G
(NEARSIDE)
S
(BOTH SIDES)
D
Q R
N W W
M C H
A
FRONT VIEW RIGHT SIDE VIEW
BOILER HP DIM 125 150 200 250 300 350 400 500 600 700 750 800
LENGTHS
Overall A 201-3/4 224-3/4 272-3/4 216-7/16 240-7/16 265-7/16 300 282-1/2 319 354 356-7/8 359
Shell B 158 181 229 168 192 217 242 219-3/4 254-3/4 289-3/4 289-3/4 289-3/4
Base Frame C 166-3/4 189-3/4 237-3/4 179-1/2 203-1/2 228-1/2 225-7/8 203-3/4 238-3/4 273-3/4 273-3/4 273-3/4
Base Frame to Rear Flange H 19-1/8 19-1/8 19-1/8 22 22 22 22 22 22 22 22 22
Flange to Steam Nozzle E 56 72 108 70 90 108 118 100-3/4 110-3/4 127-1/4 127-1/4 127-1/4
WIDTHS
OverallC I 85 85 85 103 103 103 103 121 121 121 121 121
I. D. Boiler J 60 60 60 78 78 78 78 96 96 96 96 96
Center to Water Column K 45 45 45 54 54 54 54 63 63 63 63 63
Center to Auxil.iary LWCO LL 40 40 40 49 49 49 49 58 58 58 58 58
Base Outside M 52-1/2 52-1/2 52-1/2 64 64 64 64 71-7/8 71-7/8 71-7/8 71-7/8 71-7/8
Base Inside N 44-1/2 44-1/2 44-1/2 56 56 56 56 58-7/8 58-7/8 58-7/8 58-7/8 58-7/8
Figure A8-1. Model CEW Steam Boiler Dimensions (Page 1 of 2)
A8-6
10-02
12-02
BOILER HP DIM 125 150 200 250 300 350 400 500 600 700 750 800
HEIGHTS
Base To Boiler Centerline D 46 46 46 56 56 56 56 67 67 67 67 67
Base To Vent Outlet O 85 85 85 106 106 106 106 126 126 126 126 126
Base to Rear Door Davit OA 86-1/2 86-1/2 86-1/2 106 106 106 106 126 126 126 126 126
Base To Steam Outlet P 82-3/8 82-3/8 82-3/8 101-1/2 101-1/2 101-1/2 101-1/2 122 122 122 122 122
Base Frame Q 12 12 12 10 10 10 10 12 12 12 12 12
Base to Bottom Boiler R 16 16 16 17 17 17 17 19 19 19 19 19
CONNECTIONS
Chemical Feed G 1 1 1 1 1 1 1 1 1 1 1 1
Feedwater Inlet (Both Sides) S 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 2-1/2
Steam Nozzle (15 psig)A Y 8 8 10 10 12 12 12 12 12 12 12 12
B
Steam Nozzle (150 psig) Y 4 4 4 6 6 6 6 8 8 8 8 8
Drain - Front & Rear (15 psig) W 1-1/2 1-1/2 2 2 2 2 2 2 2 2 2 2
Blowdown - Front & Rear (150

W 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2 2 2 2
psig)
Surface Blowoff T 1 1 1 1 1 1 1 1 1 1 1 1
Vent Stack Diameter (Flanged) BB 16 16 16 20 20 20 20 24 24 24 24 24
Flange to Center Vent CC 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 12-5/8
MISCELLANEOUS
Rear Door Swing DD 36 36 36 46 46 46 46 54 54 54 54 54
Tube Removal - Front Only GG 124 147 195 128 152 177 202 171 206 242 242 242

RF 318 364 460 342 390 440 490 445 515 586 586 586
Tube Removal Front

RD 270 293 341 295 319 344 378 369 405 440 443 445
WEIGHTS
Normal Water Weight 6600 8050 11000 11394 13466 15861 17936 21353 25531 29835 29835 29835
Shipping Weight (15 psig) 12150 12950 15600 20300 22450 25250 27650 35800 40950 47850 48250 48250
NOTES:
Accompanying dimensions, while sufciently accurate for layout purposes, must be conrmed for actual option requirements.
A. 150 psig Flange.
B. 300 psig Flange.
C. Overall width may increase with the addition of electrical options due to control panel mounting.
Figure A8-1. Model CEW Steam Boiler Dimensions (Page 2 of 2)
A8-7
10-02
12-02
RF/RD
I GG B DD
F 4"
E
L K BB
LWCO T U Y CC
LWCO
J
O OA P
S
(BOTH SIDES)
D
Q R
N W W
M C H
A
BOILER HP DIM 125 150 200 250 300 350 400 500 600 700 750 800
LENGTHS
Overall A 201-3/4 224-3/4 272-3/4 216-7/16 240-7/16 265-7/16 300 282-1/2 319 354 356-7/8 359
Shell B 158 181 229 168 192 217 242 219-3/4 254-3/4 289-3/4 289-3/4 289-3/4
Base Frame C 166-3/4 189-3/4 237-3/4 179-1/2 203-1/2 228-1/2 225-7/8 203-3/4 238-3/4 273-3/4 273-3/4 273-3/4
Base Rail to Rear Flange H 19-1/8 19-1/8 19-1/8 22 22 22 22 22 22 22 22 22
Flange To Return E 100 123 171 108 132 157 182 133-3/4 156-3/4 203-3/4 203-3/4 203-3/4
Flange to Outlet F 125 148 196 134 158 183 208 169-3/4 192-3/4 239-3/4 239-3/4 239-3/4
WIDTHS
OverallB I 70 70 70 88 88 88 88 106 106 106 106 106
I. D. Boiler J 60 60 60 78 78 78 78 96 96 96 96 96
Center to LWCO Controller K 37 37 37 46 46 46 46 55 55 55 55 55
Base-Outside M 52-1/2 52-1/2 52-1/2 64 64 64 64 71-7/8 71-7/8 71-7/8 71-7/8 71-7/8
Base-Inside N 44-1/2 44-1/2 44-1/2 56 56 56 56 58-7/8 58-7/8 58-7/8 58-7/8 58-7/8
Figure A8-2. Model CEW Hot Water Boiler Dimensions (Page 1 of 2)
A8-8
10-02
12-02
BOILER HP DIM 125 150 200 250 300 350 400 500 600 700 750 800
HEIGHTS
Base to Return/Outlet P 82-1/2 82-1/2 82-1/2 101-1/2 101-1/2 101-1/2 101-1/2 122 122 122 122 122
Base Frame Q 12 12 12 10 10 10 10 12 12 12 12 12
CONNECTIONS
Waterll (Both Sides) S 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 2-1/2
Water Return U 6 6 6 8 8 8 10 10 12 12 12 12
Water OutletA Y 6 6 6 8 8 8 10 10 12 12 12 12
Drain - Front & Rear W 1-1/2 1-1/2 2 2 2 2 2 2 2 2 2 2
Air Vent T 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2 2 2
Vent Stack Dia (Flanged) BB 16 16 16 20 20 20 20 24 24 24 24 24
Flange to Center Vent CC 9 9 9 10-1/2 10-1/2 10-1/2 10-1/2 12-5/8 12-5/8 12-5/8 12-5/8 12-5/8
MISCELLANEOUS
Min. Room Length for: Front

RF 318 364 460 342 390 440 490 445 515 586 586 586
Tube Removal
Min. Room Length for: Tube

RD 270 293 341 295 319 344 378 369 405 440 443 445
Removal thru Door
WEIGHTS
Normal Water Weight (lbs) 8625 10310 13960 14170 16770 19640 22140 28200 33690 39215 39215 39215
Shipping Weight (125 psig 13050 14100 16950 21850 24400 26600 28850 38900 44300 51900 52000 52000
NOTES:
Accompanying dimensions, while sufciently accurate for layout purposes, must be conrmed for actual option requirements.
B. Overall width may increase with the addition of electrical options, due to control panel mounting.
Figure 8-2. Model CEW Hot Water Boiler Dimensions (Page 2 of 2)
A8-9
10-02
12-02
DIMENSION (INCHES)
BOILER
HP
A B C D E
125-200 33 42 54 77 36
250-400 42 53 61 92 46
500-800 51 64 73 109 54
Figure A8-3. Space Required to Open Rear Head on Model CEW Boilers

HP A B C D E
Steam
125 80 19 121 10 3
Hot Water
Steam
150 80 19 144 10 3
Hot Water
Steam
200 80 19 192 10 3
Hot Water
Steam
250 99 25 114 10 3
Hot Water
Steam
300 99 25 138 10 3
Hot Water
Steam
350 99 25 163 10 3
Hot Water
Steam
400 99 25 188 10 3
Hot Water
Steam
500 119 29 158 11 3
Hot Water
Steam
600 119 29 193 11 3
Hot Water
700,750, Steam 119 29 228 11 3
800 Hot Water
NOTE: A, B and C dimensions may vary by 1 inch.
Figure A8-4. Model CEW Boilers Lifting Lug Location

A8-10
10-02
12-02
125 6 9 170 39-1/2 57-1/2 4 44-1/2 9-1/2
150 6 9 193 39-1/2 57-1/2 4 44-1/2 9-1/2
200 6 9 241 39-1/2 57-1/2 4 44-1/2 9-1/2
250 6 9 183 51 69 4 56 10-1/2
300 6 9 207 51 69 4 56 10-1/2
350 6 9 232 51 69 4 56 10-1/2
400 6 9 229 51 69 4 56 10-1/2
500 6 12 207 53-3/8 77-3/8 6-1/2 58-7/8 13-1/2
600 6 12 242 53-3/8 77-3/8 6-1/2 58-7/8 13-1/2
700, 750, 800 6 12 277 53-3/8 77-3/8 6-1/2 58-7/8 13-1/2
NOTE:
All numbers in table are in inches.
6-inch high mounting piers recommended for use beneath the boiler base frame. The use of these piers provides increased
Figure A8-5. Model CEW Boiler Mounting Piers
PERFORMANCE DATA Boiler Information

Contact your local Cleaver-Brooks authorized representative Table A8-3 shows steam volume and disengaging area for
for efciencies or additional information. model CEW boilers.
Cleaver-Brooks CEW boilers are available with the standard Table A8-4 lists quantity and outlet size for safety valves
burner package, or optional induced ue gas recirculation. supplied on Model CEW steam boilers.
Refer to the Model CEW-LN in Section A9. Table A8-5 lists quantity and outlet size for relief valves sup-
plied on Model CEW hot water boilers.
ENGINEERING DATA Table A8-6 gives recommended steam nozzle sizes on Model
The following engineering information is provided for CEW Boilers.
Model CEW Boilers. Additional detail is available from your Table A8-7 shows recommended non-return valve sizes for
local Cleaver-Brooks authorized representative. Model CEW Boilers.
A8-11
10-02
Blowdown Water Requirements Fuel Connections - Oil

Some local codes require blowdown tanks to be constructed in Oil-red burners are equipped with an oil pump, which draws
accordance with recommendations of the National Board of fuel from a storage tank and supplies pressurized oil to the
Boiler and Pressure Vessel Inspectors. burner nozzle(s). The burner supply oil pump has a greater
capacity than the burner requires for the maximum ring rate.
The National Boards recommendations base the size of the Fuel not delivered to the nozzle is returned to the storage tank.
blowdown tank on the removal of at least 4 inches of water A two-pipe (supply and return) oil system is recommended for
from the boiler. all installations. Figure A8-6 shows a typical fuel oil supply
Table A8-8 lists the approximate quantity of water represented arrangement. Oil lines must be sized for the burner and burner
by 4 inches of water at normal operating level for Cleaver- supply oil pump capacities.
Brooks Model CEW Boilers. The burner supply oil pump suction should not exceed 10" Hg.
If a transfer pump is used, it must have a pumping capacity at
Burner/Control Information least equal to that of the burner pump(s). Supply pressure to the
Burner Characteristics A strainer must be installed in the supply piping upstream of
Maximum altitude for standard burners is shown in Table A8- the burner supply pump in order to prevent entry of foreign
10. Note that altitude correction and burner changes are material into the pump, fuel control valves, or burner nozzle(s).
required for higher altitudes which may alter dimensions, The strainer must be sized for the burner supply pump capacity.
motor hp and gas pressures. A strainer mesh of 150 microns (0.005") is recommended.
Gas-Fired Burners suction line when the burner is not in operation. Location of the
Table A8-10 shows correction factors for gas pressure at eleva- check valve varies with the system, but usually it is located as
tions over 700 ft above sea level. close as possible to the storage tank.
Table A8-11 shows minimum and maximum gas pressure Installation of a vacuum gauge in the burner supply line
requirements for Standard, FM and IRI CEW Boiler gas trains between the burner oil pump and the strainer is recommended.
upstream of the gas pressure regulator. Regular observation and recording of the gauge indication will
assist in determining when the strainer needs servicing.
For oversized or undersized gas trains or altitude above 2,000
feet, contact your local Cleaver-Brooks authorized representa- Upon completion of the oil piping installation, the system
tive. should be checked for oil or air leakage and tight shutoff of all
valves.
Fuel Connections - Gas
The local gas company should be consulted for requirements Boiler Room Information
and authorization for installation and inspection of gas supply Figure A8-7 shows typical boiler room length requirements.
piping. Installation of gas supply piping and venting must be
in accordance with all applicable engineering guidelines and
regulatory codes. All connections made to the boiler should be
arranged so that all components remain accessible for inspec- Stack Support Capabilities
tion, cleaning and maintenance. 125 - 800 hp Model CEW Boilers can support up to 2000 lbs
A drip leg should be installed in the supply piping before the without additional support.
connection to the gas pressure regulator. The drip leg should 125 - 800 hp Model CEW Boilers can be reinforced to support
be at least as large as the inlet tting supplied with the boiler. up to 3000 lbs.
Consideration must be given to both volume and pressure
the boiler dimension diagram provided by Cleaver-Brooks for Boiler Room Combustion Air
the particular installation. Connections to the burner gas train When determining boiler room air requirements, the size of the
should be made with a union, so that gas train components or room, air ow, and velocity of air must be reviewed as follows:
the burner may be easily disconnected for inspection or ser-
vice. Upon completion of the gas piping installation, the sys-
room.
tem should be checked for gas leakage and tight shutoff of all
valves. A. Two (2) permanent air supply openings in the outer walls
of the boiler room are recommended. Locate one (1) at
A8-12
10-02
each end of the boiler room, preferably below a height For additional information, please review Section I4, General
of 7 feet. This allows air to sweep the length of the Engineering Data (Stacks) and Section F, Stacks. Stack and
boiler. breeching sizes should always be provided by a reputable stack
supplier who will design the stack and breeching system based
representative is capable of assisting in your evaluation of the
mesh wire, as this type of covering has poor air ow
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.
A. From oor to (7) foot height - 250 fpm.
openings are to be 5 feet above oor level.
Area Required: Area = cfm/fpm = 3000/250 = 12 Sq-ft total.
NOTICE
quirements.
Stack/Breeching Size Criteria

required draft at each boiler ue gas outlet. Proper draft is crit-
ical to burner performance.
Although constant pressure at the ue gas outlet of the Model
CEW is not required, it is necessary to size the stack/breeching
to limit ue gas pressure variation. The allowable pressure
range is 0.25 W.C. to +0.25 W.C.
A8-13
10-02
Table A8-3. Model CEW Steam Volume and Disengaging Areas
STEAM VOLUME (CU-FT) STEAM RELIEVING AREA (SQ-IN)

BOILER
HP HIGH PRESSURE LOW PRESSURE HIGH PRESSURE LOW PRESSURE
(A) (B) (A) (B)
125 21.5 29.5 5856 6388
150 25.1 34.5 6850 7472
200 32.8 44.9 8925 9734
250 33.9 49.0 7732 8582
300 39.6 57.3 9043 10022
350 45.5 65.9 10396 11534
400 51.5 74.5 11750 13032
500 94.4 119.6 13809 14716
600 111.9 141.8 16387 17438
700,750, 129.5 164.0 18950 20174
800
NOTE:
Based on normal water level.
Values are based on standard controls. Optional controls may result in different values.
Table A8-4. Model CEW Steam Boiler Safety Valve Outlet Size
VALVE
15 PSIG STEAM 150 PSIG STEAM 200 PSIG STEAM 250 PSIG STEAM
SETTING
(1) 1-1/2 (1) 1-1/4
125 1 3 2 2 2 1
(1) 1-1/4 (1) 1
(1) 1-1/2 (1) 1
150 1 3 2 2 1-1/4 2
(1) 1-1/4 (1) 1-1/4
(1) 1-1/2
200 2 2-1/2 2 1-1/2 2 2 1-1/4
(1) 1-1/4
(1) 2-1/2 (1) 2 (1) 1-1/2
250 2 2 2 1-1/2 2
(1) 3 (1)1-1/2 (1) 1-1/4
(1) 2
300 2 3 2 2 2 2 1-1/2
(1) 1-1/2
(1) 2 (1) 2-1/2 (1) 1-1/2
350 3 2 2 2 2
(2) 3 (1) 2 (1)2
(2) 3 (1) 2-1/2 (1) 1-1/2
400 3 2 2 2 2
(1) 2-1/2 (1) 2 (1) 2
(1) 2-1/2
500 3 3 2 2-1/2 2 2 2
(1) 2
(3) 3 (2) 2-1/2 (1) 2
600 4 3 2 2-1/2 2
(1) 2-1/2 (1) 2 (1) 2-1/2
700,750, (3) 3 (2) 2-1/2
5 3 2 2-1/2 2 2-1/2
800 (2) 2-1/2 (1) 2
NOTE:
Valve requirements can vary with special pressure settings.
A8-14
10-02
Table A8-5. Model CEW Hot Water Boiler Relief Valve Outlet Size
VALVE SETTING 30 PSIG HW 125 PSIG HW 150 PSIG HW
NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET
BOILER VALVES SIZE VALVES SIZE VALVES SIZE
HP REQ'D (IN.) REQ'D (IN.) REQ'D (IN.)
125 1 2-1/2 1 1-1/4 1 1-1/4
150 1 2-1/2 1 2 1 1-1/4
(1) 2-1/2
200 2 1 2 1 2
(1) 1-1/4
(1) 2
250 2 1 2 1 2
(1) 2-1/2
300 2 2-1/2 1 2-1/2 1 2
(2) 2-1/2
350 3 1 2-1/2 1 2-1/2
(1) 1
(1) 2
400 3 1 2-1/2 1 2-1/2
(2) 2-1/2
(1) 1 (1) 1
500 4 2 1 2-1/2
(3) 2-1/2 (1) 2-1/2
(3) 2-1/2 (1) 1-1/4 (1) 1
600 4 2 2
(1) 2 (1) 2-1/2 (1) 2-1/2
(1) 1 (1) 2-1/2 (1) 1-1/4
700,750,800 5 2 2
(4) 2-1/2 (1) 2 (1) 2-1/2
NOTES:
Hot water relief valves are Kunkle #537.
Table A8-6. Model CEW Recommended Steam Nozzle Size
BOILER HP
OPERATING PRESSURE 125 150 200 250 300 350 400 500 600 700 750 800
PSIG
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 8 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 2.5 3 4 4 4 4 6 6 6 6 6
NOTES:
Steam nozzle sizes given in inches.
Spool pieces (300 psig flanges) are available in the following sizes (in inches): 3x2-1/2x30, 4x3x30, 6x4x36, 8x6x48, 10x8x48, and
12x8x48.
All standard steam nozzle sizes for the 150 psig design pressure or greater are the same as 125 psig operating pressure on the
above table. To increase or decrease the standard size, request the change with your local Cleaver-Brooks authorized represen-
tative.
A8-15
10-02
Table A8-7. Model CEW Recommended Non-Return Valve Size

HP (LBS/HR) 50 75 100 125 150 175 200 250
125 4313 4 3 3 3 3 2-1/2 2-1/2 2-1/2
150 5175 4 4 3 3 3 3 2-1/2 2-1/2
200 6900 4 4 4 3 3 3 3 3
250 8625 4 4 4 4 3 3 3 3
300 10350 6 4 4 4 4 4 4 3
350 12025 6 6 4 4 4 4 4 3
400 13800 6 6 4 4 4 4 4 4
500 17210 6 6 6 6 4 4 4 4
600 20700 8 8 6 6 6 4 4 4
700 24150 8 8 6 6 6 6 6 6
750 25875 8 8 6 6 6 6 6 6
800 27600 8 8 6 6 6 6 6 6
Table A8-8. Model CEW Blowdown Tank Sizing Information

125 115
150 137
200 180
250 161
300 188
350 215
400 243
500 258
600 306
700,750,800 354
NOTE: Quantity of water removed from boiler by lowering normal wa-
ter line 4".
Optional level controls can alter water quantities.
A8-16
10-02
Table A8-9. Model CEW Standard Burner Altitude
MAX ALTITIUDE
BOILER HP
(FT)
125 3500
150 2500
200 1500
250 2000
300 2500
350 1000
400 2000
500 2000
600 2000
700 2000
750 2000
800 2000
Note: Altitude correction and burner

changes required for higher altitude.
Table A8-10. Altitude Correction for Gas

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 - -
inches WC x 0.577 = oz/sq-in.
i inches WC x 0.0361= psig.
A8-17
10-02
Table A8-11. Model CEW Minimum and Maximum Required Gas Pressure at Entrance to Standard, FM and
IRI Gas Trains (Upstream of Gas Pressure Regulator)
PRESSURE REQUIRED
BOILER PIPE SIZE ( WC)
HP (Inches)
Minimum Maximum
125 2 12.5 27.7
150 2 18.0 27.7
200 2-1/2 19.5 27.7
250 2-1/2 23.5 27.7
300 2-1/2 37.5 277.0
350 3 41.5 277.0
400 3 91.0 140.0
500 3 75.0 210.0
600 3 115.0 160.0
700 3 135.0 175.0
750 3 145.0 225.0
800 3 185.0 277.0
Note: For undersized or oversized gas trains or altitudes above
1,000 feet, contact your local Cleaver-Brooks representative.
A8-18
10-02
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.
Figure A8-7. Boiler Room Length (Typical Layouts) - Model CEW
BOILER HP 125-200 250-400 500-800
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" - 250-400 hp
60 - 500-800 hp
Figure A8-8. Boiler Room Width (Typical Layout) - Model CEW
A8-19
10-02
Notes
A8-20
10-02
A8-TEXT Page 21 Tuesday, December 17, 2002 9:57 AM
application.
Model CEW Steam Boiler (125 - 800 hp, 15 - 250 psig)

6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-25
7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-25
Model CEW Hot Water Boiler (125 - 800 hp, 30 psig, 125 psig)
6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-29
7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8-30

1.1 The Steam Boiler shall be Cleaver-Brooks Model CEW, Fuel Series ______ (100, 200, 700), _____ hp designed for _____ psig
(15, 150, 200, 250 psig steam). The maximum operating pressure shall be _____ psig.
ural gas, _____ Btu/cu-ft. Electrical power available will be _____ Volt _____ Phase _____ Cycle and 115/1/60 for the control cir-
cuit.

2.1 The boiler shall be a three pass wetback horizontal firetube updraft boiler with five (5) square feet of heating surface per rated
boiler horsepower (except for the 750 and 800 hp). It shall be mounted on a heavy steel frame with forced draft burner and burner
controls.
2.1.1 Approvals: The complete burner/boiler package shall be approved as a unit by Underwriters Laboratories Inc. and bear the
UL, cUL label.
A8-21
10-02
2.2.4 The rear door shall be insulated with a blanket material and a steel covering to give the surface a hard durable nish.
2.2.6 The boiler shall be furnished with a manhole and handholes to facilitate boiler inspection and cleaning.
2.2.7 The exhaust gas vent shall be located near the rear of the boiler on the top center line and shall be capable of supporting 2000lbs.
2.2.8 Observation ports for the inspection of ame conditions shall be provided at each end of the boiler.
2.2.9 The boiler insulation shall consist of a 2 inch blanket under a sectional preformed sheet metal lagging. This insulation must be
2.2.10 The entire boiler based frame and other components shall be factory painted before shipment using a hard nish enamel coat-
ing.

3.1 Water Column
valves.
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.

Burner operation shall be the full modulation principle. The burner shall always return to low re position for ignition.
4.2 Blower
4.2.1 All air for combustion shall be supplied by a forced draft blower mounted on the burner, to eliminate vibration and reduce noise
level.
4.2.2 Maximum sound level of the boiler/burner package shall not exceed _____ dBA (when measured in accordance with ABMA
4.2.3 The impeller shall be fabricated aluminum with radial blade, carefully balanced, and directly connected to the blower motor
shaft.
A8-22
10-02

Combustion air damper and fuel control valve (125-350 hp) or cam operated fuel metering valve (400-800 hp) shall be operated by
a single damper control motor that regulates the ame according to load demand. Potentiometer type position controls shall be pro-
vided to regulate operation of the damper control motor.
pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include one (1) shut-off
A. 125 - 250 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1)
solenoid and one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and
low gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low
B. 300 - 350 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1)
failure, ame failure, low water, or any abnormal shutdown condition.
C. 400 - 800 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, two (2)
motorized gas valves and one (1) valve with proof of closure switch, main gas vent valve, two (2) plugged leakage test connec-
tions, and high and low gas pressure switches. The gas valves shall be wired to close automatically in the event of power fail-
ure, ame failure, low water, or any abnormal shutdown condition.
the following:
A. 125 - 200 hp. Pump shall be an integral part of the burner and mechanically driven.
B. 250 - 800 hp. Pump shall be motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor
A. 125 - 200 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid
B. 250 - 350 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid oil
shut-off valves, atomizing air proving switch, low oil pressure switch, and pressure gauge all integrally mounted on the unit.
A8-23
10-02
C. 400 - 800 hp. Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one (1)
motorized oil valve with proof of closure switch, pressure relief valve, atomizing air proving switch, and low oil pressure
switch all integrally mounted on the unit.
A. 125 - 200 hp. Burner shall include a complete mechanical oil atomizing system and be of the pressure atomizing type.
B. 250 - 800 hp. Burner shall be a low pressure air atomizing type, including a shipped loose air compressor assembly.
A. 125 - 200 hp. The burner, mounted at the front of the boiler, shall be a combination pressure atomizing type for oil and high
ral gas.
B. 250 - 800 hp. The burner, mounted at the front of the boiler, shall be a combination of low pressure air atomizing type for oil
or natural gas.
so that the primary fuel valve cannot open until ame has been established. The pilot train shall include one (1) manual shut-off
4.4.3.3 Oil Burner
of the following:
B. 250 - 350 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2) solenoid
oil shut-off valves, atomizing air proving switch, low oil pressure switch and pressure gauge all integrally mounted on the unit.
A8-24
10-02
ure, ame failure, low water or any abnormal shutdown condition.
4.5.1 Control Panel
A factory prewired control panel shall be supplied with the boiler/burner package. Panel may be mounted on the burner or boiler.
4.5.2 The panel will have a NEMA 1A rating and contain the ame safeguard controller, burner motor starter, air compressor motor
starter, oil metering pump motor starter, control circuit transformer and fuses, selector switches, indicating lights and terminal
strips. Lights shall indicate load demand, ame failure, low water, and fuel valve open.
4.5.3 The panel shall contain fuse protection for the burner motor, air compressor motor, and oil metering pump.
4.5.4 The ame safeguard controller shall be a CB110 ame monitor with EPD170 program module. Flame detector shall be ultra-
violet type.

5.1 The boiler must be guaranteed to operate at a minimum fuel-to-steam efciency of ____ percent at 100 percent of rating when
burning natural gas and ________ fuel-to-steam efciency at 100% ring rate when burning oil (Contact your local Cleaver-
Brooks authorized representative for efciency details).
6.0 Warranty
7.0 Execution
7.1 Shop Tests
A8-25
10-02
Model CEW Hot Water Boiler (125 - 800 hp, 30 psig, 125 psig)

1.1 The Hot Water Boiler shall be Cleaver-Brooks Model CEW, Fuel Series ______ (100, 200, 700), _____ hp designed for _____
psig (30, 125, or other psig hot water). The maximum water temperature will be _____ degree F, and the maximum system temper-
ature drop will be _____ degree F.
1.2 The boiler shall have a maximum output of _____ Btu/hr, or _____ horsepower when red with CS 12-48 No. 2 oil and/or nat-
cuit.

2.1 The boiler shall be a three pass wetback horizontal retube updraft boiler with ve (5) square feet of heating surface per rated
boiler horsepower (except for the 750 and 800 hp.) It shall be mounted on a heavy steel frame with forced draft burner and burner
controls.
UL, cUL label.
oor or simple foundation and ready for attachment of water, steam, fuel, electrical, vent and blowdown connections.
2.2.2 The hot water return and outlet connections shall be located on the top center line of the boiler. The boiler shall be designed to
rapidly mix the return water with the boiler water. Forced internal circulation shall be used.
2.2.8 The boiler shall be furnished with a manhole and handholes to faciliate boiler inspection and cleaning.
2.2.9 The exhaust gas vent shall be located near the rear of the boiler on the top center line and shall be capable of supporting 2000
lbs.
2.2.12 The entire boiler based frame and other components shall be factory painted before shipment using a hard nish enamel
coating.

3.2 Dip Tube
The dip tube, an integral part of the hot water outlet, and an air vent tapping in the boiler shell must be provided for removal of air.
A8-26
10-02

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.
outlet.
3.5 Relief Valves
The temperature controls to regulate burner operation shall be mounted on the unit with temperature sensing elements located adja-
cent to the hot water outlet.

4.2 Blower
noise level.
shaft.
Combustion air damper and fuel control valve (125-350 hp) or cam operated fuel metering valve (400-800 hp) shall be operated by
a single damper control motor that regulates the ame according to load demand. Potentiometer type position controls shall be pro-
vided to regulate operation of the damper control motor.
Fuel series 700 - Gas red (4.4.1).
Fuel series 100 - Light oil (No. 2) red (4.4.2).
Fuel series 200 - Light oil or gas red (4.4.3).
A8-27
10-02
the following:
oil shut-off valves, atomizing air proving switch, low oil pressure switch, and pressure gauge all integrally mounted on the
unit.
A. 125 - 200 hp. The burner, mounted at the front of the boiler, shall be a combination pressure atomizing type for oil and high
ral gas.
B. 250 - 800 hp. The burner, mounted at the front of the boiler, shall be a combination of low pressure air atomizing type for oil
or natural gas.
4.4.3.3 Oil Burner
A8-28
10-02
of the following:
oil shut-off valves, atomizing air proving switch, low oil pressure switch and pressure gauge all integrally mounted on the unit.
4.5.1 Control Panel
4.5.2 The panel will have a NEMA 1A rating and contain the ame safeguard controller, burner motor starter, air compressor
4.5.3 The panel shall contain fuse protection for the burner motor, air compressor motor, and the oil metering pump.
violet type.

6.0 Warranty
A8-29
10-02
start-up or 18 months from date of shipment, whichever comes rst.
7.0 Execution
7.1 Shop Tests
A8-30
10-02
Section A9
Model CEW-LN Boilers
CONTENTS
Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-12
Burner/Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-12
BURNER CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-12
GAS FIRED - BURNERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-12
FUEL CONNECTIONS - GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-12
FUEL CONNECTIONS - OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-12
ILLUSTRATIONS
Figure A9-1. Model CEW-LN Steam Boiler Dimensions (Page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-6
Figure A9-2. Model CEW-LN Hot Water Boiler Dimensions (Page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-8
Figure A9-3. Space Required to Open Rear Head on Model CEW-LN Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-10
Figure A9-4. Model CEW-LN Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-10
A9-1
10-02
12-02
Model CEW-LN Firetube Boilers
Figure A9-5. Model CEW-LN Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-11

Figure A9-6 Typical Fuel Oil Supply Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-18
Figure A9-7. Boiler Room Length (Typical Layouts) - Model CEW-LN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-19
Figure A9-8. Boiler Room Width (Typical Layout) - Model CEW-LN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-19
TABLES
Table A9-2. Model CEW-LN Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-5
Table A9-1. Model CEW-LN Hot Water Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-5
Table A9-3. Model CEW-LN Steam Volume and Disengaging Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-14
Table A9-4. Model CEW-LN Steam Boiler Safety Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-14
Table A9-5 .Model CEW-LN Hot Water Boiler Relief Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-15
Table A9-6. Model CEW-LN Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-15
Table A9-7. Model CEW-LN Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-16
Table A9-8. Model CEW-LN Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-16
Table A9-9. Sound Pressure Levels in dBA at 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-16
Table A9-10. Model CEW-LN Standard Burner Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A9-17
Table A9-11. Altitude Correction for Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-17
Table A9-12. Model CEW LN Minimum and Maximum Required Gas Pressure at Entrance to Standard,
FM and IRI Gas Trains (Upstream of Gas Pressure Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-18
Available as an option to the model CEW firetube wetback boiler (125-800 hp), the low NOx option provides maximum NOx
reduction at all firing rates while maintaining top of the line boiler performance.
The low NOx option is for 30 ppm on natural gas corrected to 3% O2
A9-2
10-02
Firetube Boilers Model CEW-LN
FEATURES AND BENEFITS

The Cleaver-Brooks Model CEW-LN Boiler line provides a
quality product utilizing a baseline boiler/burner design. In
addition to the features of the Model CEW Boiler, the low
NOx option of the CEW-LN provides the following:
Burner Low NOx Package:

UL and cUL approval.
Guaranteed low nitrogen oxide (NOx) performance.
PRODUCT OFFERING
The Low NOx option currently is available on:
125 - 800 hp.
Natural gas, No. 2 oil, and combination red.
For available option details contact your local Cleaver-Brooks
authorized representative.

Dimensions and ratings for the Model CEW-LN Boilers are
shown in the following tables and illustrations. The informa-
tion is subject to change without notice.
Table A9-1. Model CEW-LN Steam Boiler Ratings
Table A9-2. Model CEW-LN Hot Water Boiler Ratings
Figure A9-1. Model CEW-LN Steam Boiler Dimensions
Figure A9-2. Model CEW-LN Hot Water Boiler Dimensions
Figure A9-3. Model CEW-LN Boiler Space Requirements to
Open Rear Head.
Figure A9-4. Lifting Lug Location, Model CEW-LN Boilers
Figure A9-5. Model CEW-LN Boiler Mounting Piers
A9-3
10-02
Notes
A9-4
10-02
Table A9-1. Model CEW-LN Steam Boiler Ratings
BOILER HP 125 150 200 250 300 350 400 500 600 700 750 800
Rated Capacity (lbs-steam/hr from

4312 5175 6900 8625 10350 12075 13800 17250 20700 24150 25875 27600
and at 212 F)
Btu Output (1000 Btu/hr) 4184 5021 6695 8369 10043 11716 13390 16738 20085 23433 25106 26780
Light Oil GPH (140,000 Btu/gal) 37.5 45 60 74.5 89.5 104.5 119.5 149.5 179.5 209 224 239
Gas CFH (1000 Btu/cu-ft) 5230 6280 8370 10460 12555 14650 16750 20925 25100 29300 31385 33500
Gas (Therm/hr) 52.3 62.8 83.7 104.6 125.5 146.5 167.5 209.3 251.0 293.0 313.9 335.0
Oil Pump Motor hp (oil firing only) 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4 1 1 1
A
Blower Motor 5 7-1/2 10 15 15 20 25 30 40 60 60 60
Air Compressor Motor (oil firing

1 1 1 2 2 5 5 5 7-1/2 7-1/2 7-1/2 15
only)
Oil Meter. Pump Mtr (oil firing only) N/A N/A N/A N/A N/A 1/2 1/2 3/4 3/4 3/4 3/4 1
BOILER DATA
NOTE:All fractional hp motors will be single phase voltage except oil meter pump motor(3-phase); integral hp motors will be 3-phase voltage.
Table A9-2. Model CEW-LN Hot Water Boiler Ratings

BOILER HP 125 150 200 250 300 350 400 500 600 700 750 800
Btu Output (1000 Btu/hr) 4184 5021 6695 8369 10043 11716 13390 16738 20085 23433 25106 26780
Gas CFH (1000 Btu/cu-ft.) 5230 6280 8370 10460 12555 14650 16750 20925 25100 29300 31385 33500
Gas (Therm/hr) 52.3 62.8 83.7 104.6 125.5 146.5 167.5 209.3 251 293 313.8 335
Oil Pump Motor hp (oil firing only) 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4 1 1 1
A
Blower Motor 5 7-1/2 10 15 15 20 25 30 40 60 60 60
Air Compressor Motor (oil firing

1 1 1 2 2 5 5 5 7-1/2 7-1/2 7-1/2 15
only)
Oil Meter. Pump Mtr (oil firing only) N/A N/A N/A N/A N/A 1/2 1/2 3/4 3/4 3/4 3/4 1
BOILER DATA
NOTE:All fractional hp motors will be single phase voltage except oil meter pump motor(3-phase); integral hp motors will be 3-phase voltage.
A9-5
12-02
10-02
I
RF/RD KK
DD LL K
4" B GG L
BB
CC T Y E
J OO
P O OA
G
(FAR SIDE)
S
(BOTH SIDES)
D
V Q
W R
W N
H C M
A
LEFT SIDE VIEW FRONT VIEW
BOILER HP DIM 125 150 200 250 300 350 400 500 600 700 750 800
LENGTHS
Overall A 206 229-1/2 272-1/2 223 247 275 305 284 319 356-7/8 359 364-1/2
Shell B 158 181 229 168 192 217 242 219-3/4 254-3/4 289-3/4 289-3/4 289-3/4
Base Frame C 144-3/4 167-3/4 215-3/4 151-7/8 175-7/8 200-7/8 225-7/8 203-3/4 238-3/4 273-3/4 273-3/4 273-3/4
Base Frame to Rear Flange H 19-1/8 19-1/8 19-1/8 22 22 22 22 22 22 22 22 22
Flange to Nozzle E 56 72 108 70 90 108 118 100-3/4 110-3/4 127-1/4 127-1/4 127-1/4
WIDTHS
C
Overall I 92 92 92 110-1/2 111-1/2 111-1/2 111-1/2 132-1/2 133-1/2 133-1/2 133-1/2 133-1/2
I. D. Boiler J 60 60 60 78 78 78 78 96 96 96 96 96
Center to Control Panel K 47 47 47 56 56 56 56 65 65 65 65 65
Center to Outside FGR Pipe KK 45 45 45 54-1/2 55-1/2 55-1/2 55-1/2 67-1/2 68-1/2 68-1/2 68-1/2 68-1/2
FGR Duct Size V 6 6 6 6 8 8 8 8 10 10 10 10
Center to Auxiliary LWCO LL 40 40 40 49 49 49 49 58 58 58 58 58
Base Outside M 52-1/2 52-1/2 52-1/2 64 64 64 64 71-7/8 71-7/8 71-7/8 71-7/8 71-7/8
Base Inside N 44-1/2 44-1/2 44-1/2 56 56 56 56 58-7/8 58-7/8 58-7/8 58-7/8 58-7/8
Figure A9-1. Model CEW-LN Steam Boiler Dimensions (Page 1 of 2)
A9-6
10-02 12-02
BOILER HP DIM 125 150 200 250 300 350 400 500 600 700 750 800
HEIGHTS
Base to rear Door Davit OA 86-1/2 86-1/2 86-1/2 106 106 106 106 126 126 126 126 126
Base to Vent Extension OO 99 99 99 123 123 123 123 146 146 146 146 146
Base To Steam Outlet P 82-3/8 82-3/8 82-3/8 101-1/2 101-1/2 101-1/2 101-1/2 122 122 122 122 122
Base Frame Q 12 12 12 10 10 10 10 12 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 1-1/2 1-1/2 2 2 2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2
Steam Nozzle (15 psig)A Y 8 8 10 10 12 12 12 12 12 12 12 12
Steam Nozzle (150 psig)B Y 4 4 4 6 6 6 6 8 8 8 8 8
Drain - Front & Rear (15 psig) W 1-1/2 1-1/2 2 2 2 2 2 2 2 2 2 2

W 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2 2 2 2
psig)
Surface Blow (150 lb only) T 1 1 1 1 1 1 1 1 1 1 1 1
Vent Stack Diameter (Flanged) BB 16 16 16 20 20 20 20 24 24 24 24 24
Flange to Center Vent CC 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 12-5/8
MISCELLANEOUS

RF 318 364 460 342 390 440 490 445 515 586 586 586
Tube Removal Front

RD 274 298 341 301 325 353 383 370 405 443 445 451
WEIGHTS
Normal Water Weight 6600 8050 11000 11394 13466 15861 17936 21353 25531 29835 29835 29835
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.
Figure A9-1. Model CEW-LN Steam Boiler Dimensions (Page 2 of 2)
A9-7
12-02
10-02
RF/RD I
DD
4" B KK K
GG L
F
BB E
CC T LWCO
Y U
J OO
P O OA
(BOTH SIDES)
S
D
R V Q
W
W N
H C M
A
LEFT SIDE VIEW FRONT VIEW
BOILER HP DIM 125 150 200 250 300 350 400 500 600 700 750 800
LENGTHS
Overall A 206 229-1/2 272-1/2 223 247 275 305 284 319 356-7/8 359 364-1/2
Shell B 158 181 229 168 192 217 242 219-3/4 254-3/4 289-3/4 289-3/4 289-3/4
Base Frame C 144-3/4 167-3/4 215-3/4 151-7/8 175-7/8 200-7/8 225-7/8 203-3/4 238-3/4 273-3/4 273-3/4 273-3/4
Base Rail to Rear Flange H 19-1/8 19-1/8 19-1/8 22 22 22 22 22 22 22 22 22
Flange To Return E 100 123 171 108 132 157 182 133-3/4 156-3/4 203-3/4 203-3/4 203-3/4
Flange to Outlet F 125 148 196 134 158 183 208 169-3/4 192-3/4 239-3/4 239-3/4 239-3/4
WIDTHS
Overall WidthB I 92 92 92 110-1/2 111-1/2 111-1/2 111-1/2 132-1/2 133-1/2 133-1/2 133-1/2 133-1/2
I. D. Boiler J 60 60 60 78 78 78 78 96 96 96 96 96
Center to Control Panel K 47 47 47 56 56 56 56 65 65 65 65 65
Center to Outside FGR Pipe KK 45 45 45 54-1/2 55-1/2 55-1/2 55-1/2 67-1/2 68-1/2 68-1/2 68-1/2 68-1/2
FGR Duct Size V 6 6 6 6 8 8 8 8 10 10 10 10
Base-Outside M 52-1/2 52-1/2 52-1/2 64 64 64 64 71-7/8 71-7/8 71-7/8 71-7/8 71-7/8
Base-Inside N 44-1/2 44-1/2 44-1/2 56 56 56 56 58-7/8 58-7/8 58-7/8 58-7/8 58-7/8
Figure A9-2. Model CEW-LN Hot Water Boiler Dimensions (Page 1 of 2)
A9-8
10-02 12-02
BOILER HP DIM 125 150 200 250 300 350 400 500 600 700 750 800
HEIGHTS
Base to Vent Extension OO 99 99 99 123 123 123 123 146 146 146 146 146
Base to Return/Outlet P 82-1/2 82-1/2 82-1/2 101-1/2 101-1/2 101-1/2 101-1/2 122 122 122 122 122
Base Frame Q 12 12 12 10 10 10 10 12 12 12 12 12
CONNECTIONS
Waterfill (Both Sides) S 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 2-1/2
Water Return U 6 6 6 8 8 8 10 10 12 12 12 12
Water OutletA Y 6 6 6 8 8 8 10 10 12 12 12 12
Drain - Front & Rear W 1-1/2 1-1/2 2 2 2 2 2 2 2 2 2 2
Air Vent T 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2 2 2
Vent Stack Dia (Flanged) BB 16 16 16 20 20 20 20 24 24 24 24 24
Flange to Center Vent CC 9 9 9 10-1/2 10-1/2 10-1/2 10-1/2 12-5/8 12-5/8 12-5/8 12-5/8 12-5/8
MISCELLANEOUS
Min. Room Length for: Front

RF 318 364 460 342 390 440 490 445 515 586 586 586
Tube Removal
Min. Room Length for: Tube

RD 274 298 341 301 325 353 383 370 405 443 445 451
Removal thru Door
WEIGHTS
Normal Water Weight (lbs) 8625 10310 13960 14170 16770 19640 22140 28200 33690 39215 39215 39215
Shipping Weight (125 psig 13050 14100 16950 21850 24400 26600 28850 38900 44300 51900 52000 52000
NOTES:
B. Overall width may increase with the addition of electrical options, due to control panel mounting.
Figure A9-1. Model CEW-LN Hot Water Boiler Dimensions (Page 2 of 2)
A9-9
12-02
10-02
DIMENSION (INCHES)
BOILER
HP
A B C D E
125-200 33 42 54 77 36
250-400 42 53 61 92 46
500-800 51 64 73 109 54
Figure A9-3. Space Required to Open Rear Head on Model CEW-LN Boilers

HP A B C D E
Steam
125 80 19 121 10 3
Hot Water
Steam
150 80 19 144 10 3
Hot Water
Steam
200 80 19 192 10 3
Hot Water
Steam
250 99 25 114 10 3
Hot Water
Steam
300 99 25 138 10 3
Hot Water
Steam
350 99 25 163 10 3
Hot Water
Steam
400 99 25 188 10 3
Hot Water
Steam
500 119 29 158 11 3
Hot Water
Steam
600 119 29 193 11 3
Hot Water
700,750, Steam 119 29 228 11 3
800 Hot Water
NOTE: A, B and C dimensions may vary by 1 inch.
Figure A9-4. Model CEW-LN Boilers Lifting Lug Location
A9-10
10-02 12-02
125 6 9 148 39-1/2 57-1/2 4 44-1/2 9-1/2
150 6 9 171 39-1/2 57-1/2 4 44-1/2 9-1/2
200 6 9 219 39-1/2 57-1/2 4 44-1/2 9-1/2
250 6 9 155 51 69 4 56 10-1/2
300 6 9 179 51 69 4 56 10-1/2
350 6 9 204 51 69 4 56 10-1/2
400 6 9 229 51 69 4 56 10-1/2
500 6 12 207 53-3/8 77-3/8 6-1/2 58-7/8 13-1/2
600 6 12 242 53-3/8 77-3/8 6-1/2 58-7/8 13-1/2
700-800 6 12 277 53-3/8 77-3/8 6-1/2 58-7/8 13-1/2
NOTE:
All numbers in table are in inches.
Figure A9-5. Model CEW-LN Boiler Mounting Piers
PERFORMANCE DATA Table A9-5 lists quantity and outlet size for relief valves sup-
plied on Model CEW-LN hot water boilers.
Contact your local Cleaver-Brooks authorized representative
for efciencies or additional information. Table A9-6 gives recommended steam nozzle sizes based on
4000-5000 fpm steam velocity on Model CEW-LN Boilers.
ENGINEERING DATA Table A9-7 shows recommended non-return valve sizes for
Model CEW-LN Boilers.
The following engineering information is provided for
Model CEW-LN Firetube Boilers. Additional detail is avail-
able from your local Cleaver-Brooks authorized representa- Blowdown Water Requirements
tive. Some local codes require blowdown tanks to be constructed
in accordance with recommendations of the National Board
Boiler Information of Boiler and Pressure Vessel Inspectors.
Table A9-3 shows steam volume and disengaging area for The National Boards recommendations base the size of the
model CEW-LN boilers. blowdown tank on the removal of at least 4 inches of water
from the boiler.
Table A9-4 lists quantity and outlet size for safety valves
supplied on Model CEW-LN steam boilers. Table A9-8 lists the approximate quantity of water repre-
Cleaver-Brooks Model CEW-LN Boilers.
A9-11
10-02
Sound Level tion, cleaning and maintenance.

Table A9-9 summarizes predicted sound pressure levels for A drip leg should be installed in the supply piping before the
Model CEW-LN Boilers. These values are based on standard connection to the gas pressure regulator. The drip leg should be
motors. Optional motor types and altitude conditions can at least as large as the inlet tting supplied with the boiler.
increase sound levels. Consideration must be given to both volume and pressure
Units
the boiler dimension diagram provided by Cleaver-Brooks for
The units for the sound level tables are dBA (decibels, mea- the particular installation. Connections to the burner gas train
sured on the A-weighted scale) in reference to 0.0002 should be made with a union, so that gas train components or
microbars (20 micro-Newtons per square meter). They are the burner may be easily disconnected for inspection or ser-
standardly referenced in specifying and reporting sound pres- vice. Upon completion of the gas piping installation, the sys-
sure levels on industrial equipment. tem should be checked for gas leakage and tight shutoff of all
valves.
Test Method
The sound pressure levels in the above table were obtained Fuel Connections - Oil
from tests in accordance with the "ABMA Test Code for the
Oil-red burners are equipped with an oil pump, which draws
Measurement of Sound from Packages Boilers. In accordance
fuel from a storage tank and supplies pressurized oil to the
with this code, the sound pressure levels reported were mea-
burner nozzle(s). The burner supply oil pump has a greater
bottom of the base rails and 3 feet horizontally in front of the
Fuel not delivered to the nozzle is returned to the storage tank.
end of the blower motor or front surface of the electrical cabi-
A two-pipe (supply and return) oil system is recommended for
net.
all installations. Figure A9-6 shows a typical fuel oil supply
Sound Level Meter arrangement. Oil lines must be sized for the burner and burner
The sound level meter used complies with ANSI S1.4, Type 1
(Precision). The readings are taken with the meter set for slow The burner supply oil pump suction should not exceed 10" Hg.
response. If a transfer pump is used, it must have a pumping capacity at
Burner/Control Information burner pump should not exceed 3 psig.
Burner Characteristics the burner supply pump in order to prevent entry of foreign
Burner altitude limits for standard conguration is shown in material into the pump, fuel control valves, or burner nozzle(s).
Table A9-10. Higher altitudes may require different congura- The strainer must be sized for the burner supply pump capacity.
tions, including dimensions, motor hp and gas pressures. A strainer mesh of 150 microns (0.005") is recommended.
Gas Fired - Burners suction line when the burner is not in operation. Location of the
check valve varies with the system, but usually it is located as
Table A9-11 shows conversion factors for gas pressure at ele-
close as possible to the storage tank.
vations over 700 ft. above sea level.
Table A9-12 shows maximum and minimum gas consumption
between the burner oil pump and the strainer is recommended.
(CFH) for Natural Gas.
Regular observation and recording of the gauge indication will
For oversized or undersized gas trains or altitude above 1,000 assist in determining when the strainer needs servicing.
feet, contact your local Cleaver-Brooks authorized representa-
Upon completion of the oil piping installation, the system
tive.
should be checked for oil or air leakage and tight shutoff of all
valves.
The local gas company should be consulted for requirements Boiler Room Information
piping. Installation of gas supply piping and venting must be Figure A9-7 shows typical boiler room length requirements.
in accordance with all applicable engineering guidelines and Figure A9-8 shows typical boiler room width requirements.
A9-12
10-02
Stack Support Capabilities Area/Opening: 12/2 = 6 sq-ft./opening (2 required).

125 - 800 hp Model CEW-LN Boilers can support up to 2000
lbs without additional support.
NOTICE
125 - 800 hp Model CEW-LN Boilers can be reinforced to
support up to 3000 lbs. Consult local codes, which may supersede these require-
ments.
When determining boiler room air requirements, the size of
the room, air ow, and velocity of air must be reviewed as fol- The design of the stack and breeching must provide the
lows: required draft at each boiler ue gas outlet. Proper draft is
critical to burner performance.
room. Although constant pressure at the ue gas outlet of the
Model CEW-LN is not required, it is necessary to size the
A. Two (2) permanent air supply openings in the outer stack/breeching to limit ue gas pressure variation. The
walls of the boiler room are recommended. Locate one allowable pressure range is 0.25 W.C. to +0.25 W.C.
(1) at each end of the boiler room, preferably below a
height of 7 feet. This allows air to sweep the length of For additional information, please review Section I4, Gen-
the boiler. eral Engineering Data (Stacks) and Section F, Stacks.
Stack and breeching sizes should always be provided by a
B. Air supply openings can be louvered for weather reputable stack supplier who will design the stack and
protection, but they should not be covered with ne breeching system based on the above criteria. Your local
mesh wire, as this type of covering has poor air ow Cleaver-Brooks authorized representative is capable of
qualities and is subject to clogging by dust or dirt. assisting in your evaluation of the stack/breeching design.
Area (sq-ft.) = CFM/FPM
Area Required: Area = cfm/fpm = 3000/250 = 12 Sq-ft. total.
A9-13
10-02
Table A9-3. Model CEW-LN Steam Volume and Disengaging Areas
STEAM VOLUME (CU-FT) STEAM RELIEVING AREA (SQ-IN)

BOILER
HP HIGH PRESSURE LOW PRESSURE HIGH PRESSURE LOW PRESSURE
(A) (B) (A) (B)
125 21.5 29.5 5856 6388
150 25.1 34.5 6850 7472
200 32.8 44.9 8925 9734
250 33.9 49.0 7732 8582
300 39.6 57.3 9043 10022
350 45.5 65.9 10396 11534
400 51.5 74.5 11750 13032
500 94.4 119.6 13809 14716
600 111.9 141.8 16387 17438
700,750, 129.5 164.0 18950 20174
800
NOTE:
Table A9-4. Model CEW-LN Steam Boiler Safety Valve Outlet Size
VALVE
SETTING

(1) 1-1/2 (1) 1-1/4

125 1 3 2 2 2 1
(1) 1-1/4 (1) 1
(1) 1-1/2 (1) 1
150 1 3 2 2 1-1/4 2
(1) 1-1/4 (1) 1-1/4
(1) 1-1/2
200 2 2-1/2 2 1-1/2 2 2 1-1/4
(1) 1-1/4
(1) 2-1/2 (1) 2 (1) 1-1/2
250 2 2 2 1-1/2 2
(1) 3 (1)1-1/2 (1) 1-1/4
(1) 2
300 2 3 2 2 2 2 1-1/2
(1) 1-1/2
(1) 2 (1) 2-1/2 (1) 1-1/2
350 3 2 2 2 2
(2) 3 (1) 2 (1)2
(2) 3 (1) 2-1/2 (1) 1-1/2
400 3 2 2 2 2
(1) 2-1/2 (1) 2 (1) 2
(1) 2-1/2
500 3 3 2 2-1/2 2 2 2
(1) 2
(3) 3 (2) 2-1/2 (1) 2
600 4 3 2 2-1/2 2
(1) 2-1/2 (1) 2 (1) 2-1/2
700,750, (3) 3 (2) 2-1/2
5 3 2 2-1/2 2 2-1/2
800 (2) 2-1/2 (1) 2
NOTE:
A9-14
10-02
Table A9-5. Model CEW-LN Hot Water Boiler Relief Valve Outlet Size

NO. OF OUTLET NO. OF OUTLET NO. OF OUTLET
BOILER VALVES SIZE VALVES SIZE VALVES SIZE
HP REQ'D (IN.) REQ'D (IN.) REQ'D (IN.)
125 1 2-1/2 1 1-1/4 1 1-1/4
150 1 2-1/2 1 2 1 1-1/4
(1) 2-1/2
200 2 1 2 1 2
(1) 1-1/4
(1) 2
250 2 1 2 1 2
(1) 2-1/2
300 2 2-1/2 1 2-1/2 1 2
(2) 2-1/2
350 3 1 2-1/2 1 2-1/2
(1) 1
(1) 2
400 3 1 2-1/2 1 2-1/2
(2) 2-1/2
(1) 1 (1) 1
500 4 2 1 2-1/2
(3) 2-1/2 (1) 2-1/2
(3) 2-1/2 (1) 1-1/4 (1) 1
600 4 2 2
(1) 2 (1) 2-1/2 (1) 2-1/2
(1) 1 (1) 2-1/2 (1) 1-1/4
700,750,800 5 2 2
(4) 2-1/2 (1) 2 (1) 2-1/2
NOTES:
Hot water relief valves are Kunkle #537.
Table A9-6. Model CEW-LN Recommended Steam Nozzle Size
BOILER HP
OPERATING PRESSURE 125 150 200 250 300 350 400 500 600 700 750 800
PSIG
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 8 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 2.5 3 4 4 4 4 6 6 6 6 6
NOTE:
Spool pieces (300 psig flanges) are available in the following sizes (in inches): 3x2-1/2x30, 4x3x30, 6x4x36, 8x6x48, 10x8x48, and
12x8x48.
A9-15
10-02
Table A9-7. Model CEW-LN Recommended Non-Return Valve Size

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

125 115
150 137
200 180
250 161
300 188
350 215
400 243
500 258
600 306
700,750,800 354
ter line 4".
Table A9-9. Sound Pressure Levels in dBA at 3
BOILER HP 125 150 200 250 300 350 400 500 600 700 750 800
GAS
HIGH FIRE 87 88 88 89 89 90 90 91 91 93 93 93
LOW FIRE 80 81 82 81 81 81 81 81 82 83 83 85
NO. 2 OIL
HIGH FIRE 87 89 89 90 90 91 91 92 92 93 93 95
LOW FIRE 81 81 80 81 81 82 82 82 83 83 84 86
A9-16
10-02
Table A9-10. Model CEW-LN Standard Burner Altitude
MAX ALTITIUDE
BOILER HP
(FT)
125 2000
150 2000
200 2000
250 2000
300 2000
350 2000
400 2000
500 2000
600 2000
700 2000
750 2000
800 2000
Note: Altitude correction and burner

changes required for higher altitude.

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 - -
A9-17
10-02
Table A9-12. Model CEW LN Minimum and Maximum Required Gas Pressure at Entrance to Standard, FM
and IRI Gas Trains (Upstream of Gas Pressure Regulator)
PRESSURE REQUIRED
BOILER PIPE SIZE (WC)
HP (Inches)
Minimum Maximum
125 2 35.0 138.0

150 2-1/2 23.0 27.7
200 3 42.0 138.0
250 3 25.0 27.7
300 3 41.0 138.0
350 3 51.0 138.0
400 3 44.0 138.0
500 3 51.0 138.0
600 3 115.0 166.0
700 3 132.0 221.0
750 3 176.0 263.0
800 3 191.0 277.0
Note: For undersized or oversized gas trains or altitudes
above 1,000 feet, contact your local Cleaver-Brooks rep-
resentative.
A9-18
10-02
Figure A9-7. Boiler Room Length (Typical Layouts) - Model CEW-LN
BOILER HP 125-200 250-400 500-800
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" - 250-400 hp
60 - 500-800 hp
Figure A9-8. Boiler Room Width (Typical Layout) - Model CEW-LN

A9-19
10-02
Notes
A9-20
10-02
The following sample specication is provided by Cleaver-Brooks to assist you in meeting your customers specic needs and
application.
The Sample Specication is typically utilized as the base template for the complete boiler specication. The LN option includes
information on the Low NOx package for 30 ppm NOx (dry volume basis and corrected to 3% O2) when ring natural gas. Contact
your local Cleaver-Brooks authorized representative for information on special insurance requirements, special code requirements,
optional equipment, or general assistance in completing the specication.
Model CEW-LN Steam Boiler (125 - 800 hp, 15 - 250 psig)
6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-25
7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-25
Model CEW-LN Hot Water Boiler (125 - 800 hp, 30 psig, 125 psig)
6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-29
7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9-29

1.1 The Steam Boiler shall be Cleaver-Brooks Model CEW-LN, Fuel Series ______ (100, 200, 700), _____ hp designed for _____
psig (15, 150, 200, 250 psig steam). The maximum operating pressure shall be _____ psig.
cuit.

boiler horsepower (except for the 750 and 800 hp). It shall be mounted on a heavy steel frame with forced draft burner and burner
controls.
2.1.1 Approvals: The complete burner/ boiler Low NOx package shall be approved as a unit by Underwriters Laboratories Inc. and
bear the UL/cUL label.
A9-21
10-02
2.2.7 The exhaust gas vent shall be located near the rear of the boiler on the top centerline and shall be capable of supporting 2000
lbs.
coating.
2.3.1 Boiler shall be equipped with a low emission (LN) option for guaranteed NOx performance at 30 ppm, dry volume basis and
corrected to 3% O2 when ring natural gas.
2.3.2 The low emission (LN) option shall include a burner and boiler package to provide NOx reduction through an induced ue
gas recirculation system using the burner blower assembly, a control valve, a shutoff valve, electrical interlocks, and ue gas recir-
culation piping. Boiler fuel-to-steam efciency and rated boiler capacity shall be guaranteed while the boiler is operating at the low
NOx performance levels.
2.3.3 Burner, boiler and low NOx system shall be manufactured as a package by a single manufacturer. The Low Nox option to the
Cleaver-Brooks boiler shall include factory testing as a package, and the burner shall bear the UL or CSA label.

3.1 Water Column
valves.

A9-22
10-02
4.2 Blower
noise level.
shaft.
Combustion air damper and fuel control valve shall be operated by a single damper control motor that regulates the ame according
B. 300 - 800 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, two (2)
valve, solenoid vale, pressure regulator, and one (1) plugged leakage test connection (Canada only).
4.4.2.3 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Pump shall be
motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided.
A. 125 - 350 hp. Fuel oil piping on the unit shall include oil metering system, two (2) solenoid oil shut-off valves, pressure
relief valve, and atomizing air proving switch all integrally mounted on the unit.
A9-23
10-02
B. 400 - 800 hp. Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one (1)
A. 125 - 300 hp. Burner shall be a low pressure air atomizing type, including a burner mounted integral air compressor.
4.4.3.1 Burner Type - The burner, mounted at the front of the boiler, shall be a combination of low pressure air atomizing type for
oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 oil
or natural gas.
4.4.3.3 Oil Burner
4.4.3.3.1 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Pump shall
be motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided.
4.5.1 Control Panel
4.5.3 The panel shall contain fuse protection for blower motor, air compressor, and oil metering pump.
violet type.
A9-24
10-02

6.0 Warranty
7.0 Execution
7.1 Shop Tests
A9-25
10-02
Model CEW-LN Hot Water Boiler (125 - 800 hp, 30 psig, 125 psig)

1.1 The Hot Water Boiler shall be Cleaver-Brooks Model CEW-LN, Fuel Series ______ (100, 200, 700), _____ hp designed for
cuit.

boiler horsepower (except for the 750 and 800 hp.) It shall be mounted on a heavy steel frame with forced draft burner and burner
controls.
2.1.1 Approvals: The complete burner/ boiler Low NOx package shall be approved as a unit by Underwriters Laboratories Inc. and
2.2.8 The boiler shall be furnished with a manhole and handholes to faciliate boiler inspection and cleaning.
2.2.9 The exhaust gas vent shall be located near the rear of the boiler on the top centerline and shall be capable of supporting 2000
lbs.
coating.
corrected to 3% O2 when ring natural gas.
2.3.2 The low emission (LN) option shall include a burner and boiler package to provide NOx reduction through an induced ue
gas recirculation system using the burner blower assembly, a control valve, a shutoff valve, electrical interlocks, and ue gas recir-
culation piping. Boiler fuel-to-water efciency and rated boiler capacity shall be guaranteed while the boiler is operating at the low
A9-26
10-02
2.3.3 Burner, boiler and low NOx system shall be manufactured as a package by a single manufacturer. The Low NOx option to the
Cleaver-Brooks boiler shall include factory testing as a package, and the burner shall bear the UL or CSA label.

3.2 Dip Tube
outlet.
3.5 Relief Valves
The temperature controls to regulate burner operation shall be mounted on the unit with temperature sensing elements located adja-
cent to the hot water outlet.

4.2 Blower
noise level.
shaft.
Combustion air damper and fuel control valve shall be operated by a single damper control motor that regulates the ame according
Fuel series 700 - Gas red (4.4.1).
Fuel series 100 - Light oil (No. 2) red (4.4.2).
Fuel series 200 - Light oil or gas red (4.4.3).
A9-27
10-02
4.4.2.3 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Pump shall be
motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided.
or natural gas.
4.4.3.3 Oil Burner
4.4.3.3.1 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Pump shall
be motor driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided.
A9-28
10-02
B. 400 - 800 hp. Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one (1) oil
4.5.1 Control Panel
4.5.3 The panel shall contain fuse protection for blower motor, air compressor motor, and oil metering pump.
violet type.

6.0 Warranty
start-up or 18 months from date of shipment, whichever comes rst.
7.0 Execution
7.1 Shop Tests
A9-29
10-02
Notes
A9-30
10-02
Section A10
Model CEW Ohio Special Boilers
CONTENTS
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-4
Blowdown Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-10
Burner/Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-10
BURNER CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-10
GAS - FIRED BURNERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-10
FUEL CONNECTIONS - GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-10
FUEL CONNECTIONS - OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-10
Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-10
Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-10
Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-10
Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-11
SAMPLE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-17
ILLUSTRATIONS
Figure A10-1. Model CEW Ohio Special Steam Boiler Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-6
Figure A10-2. Space Required to Open Rear Head on Model CEW Ohio Special Boilers . . . . . . . . . . . . . . . . . . . . . . . A10-8
Figure A10-3. Model CEW Ohio Special Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-8
Figure A10-4. Model CEW Ohio Special Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-9
A10-1
02-02
A10-CEW_OS.FM Page 2 Wednesday, December 11, 2002 10:09 AM
Model CEW Ohio Special Firetube Boilers
Figure A10-5. Typical Fuel Oil Supply Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-15

Figure A10-6. Boiler Room Length (Typical Layouts) - Model CEW Ohio Special . . . . . . . . . . . . . . . . . . . . . . . . . . A10-16
Figure A10-7. Boiler Room Width (Typical Layout) - Model CEW Ohio Special . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-16
TABLES
Table A10-1. Model CEW Ohio Special Steam Boiler Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-5
Table A10-2. Model CEW Ohio Special Steam Volume and Disengaging Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-12
Table A10-3. Model CEW Ohio Special Steam Boiler Safety Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-12
Table A10-4. Model CEW Ohio Special Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-13
Table A10-5. Model CEW Ohio Special Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-13
Table A10-6. Model CEW Ohio Special Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-14
Table A10-7. Altitude Correction for Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-14
Table A10-8. Model CEW Ohio Special Minimum and Maximum Required Gas Pressure at Entrance to Standard,
FM and IRI Gas Trains (Upstream of Gas Pressure Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-15
The following information applies to the Cleaver-Brooks Model CEW Ohio Special Boiler.
A10-2
02-02
Firetube Boilers Model CEW Ohio Special
FEATURES AND BENEFITS Surge load bafes.

The Model CEW Ohio Special Firetube boiler is designed,
Seismic design.
manufactured, and packaged by Cleaver-Brooks specically
for operation in the state of Ohio, under the rules and regula- Burner/Control Options:
tions for unattended units. The unique design of the Ohio Spe-
cial Boiler serves your steam needs and reduces unnecessary
labor costs. All units are factory re tested and shipped as a Lead/lag system.
package, ready for quick connection to utilities. In addition to
Special insurance and code requirements (e.g., IRI, FM,
the features provided on all Cleaver-Brooks Firetube boilers,
CSD-1).
the following features apply to the Model CEW Ohio Specials.
Less than 360 Square Feet of Heating Surface: Special motor requirements (TEFC, high efciency).
The greatest amount offered in any packaged boiler for Special indicating lights.
unattended steam boiler operation in Ohio - means long life
and years of service at the high efciencies. Main disconnect.
Elapsed time meter.
NEMA enclosures.
Davited, front and rear doors, all sizes.
Low-re hold control.
Provides access to front and rear tube sheet.
Large rear access plug for turnaround and furnace access.
Circuit breakers.
Rear door completely covers and insulates rear tube sheet.
Day/night controls.
Natural Gas, No. 2 Oil, or Combination Burners Available: Special power requirements.
Combination gas/oil burners provide quick fuel changeover Stack thermometer.
without burner adjustment.
Fuel Options:
PRODUCT OFFERING Gas strainer.
Cleaver-Brooks Model CEW Ohio Special Boilers are avail- Gas pressure gauge.
able in low pressure steam and high pressure steam designs. Future gas conversion.
Burners are available to re natural gas, No. 2 oil, or a combi-
nation of oil and gas. Standard product offering is: Oversized/undersized gas trains.
100 - 225 hp.

Three pass wetback design.
Boiler Options:
Drain valves.
Additional screwed or anged tappings.
Blowdown valves.
Non-return valves.
A10-3
02-02

Dimensions and ratings for the Model CEW Ohio Special
Boilers are shown in the following tables and illustrations. The
information is subject to change without notice.
Table A10-1. Model CEW Ohio Special Steam Boiler
Ratings
Figure A10-1. Model CEW Ohio Special Steam Boiler
Dimensions
Figure A10-2. Model CEW Ohio Special Boiler Space
Requirements to Open Rear Door
Figure A10-3. Lifting Lug Location, Model CEW Ohio
Special Boilers
Figure A10-4. Model CEW Ohio Special Boiler Mounting
Piers
A10-4
02-02
A10-CEW_OS.FM Page 5 Friday, December 13, 2002 2:52 PM
Table A10-1. Model CEW Ohio Special Steam Boiler Ratings
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
3
Gas CFH (1000 Btu/ft ) 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& combination) 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.
A10-5
02-02
RF/RD
I DD
LL GG B 4"
L K BB
E Y T CC
J
O OA
P
G
(NEARSIDE)
S
(BOTH SIDES)
D
R
Q
N W W
M C H
A
100S- 175S-
DIM
150S 225S
BOILER HP
(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
C I 85 85
Overall
I. D. Boiler J 60 60
Center to Water Column K 45 45
Center to Lagging L 33 33
Center to Auxilliary LWCO LL 40 40
Base Outside M 52-1/2 52-1/2
Base Inside N 44-1/2 44-1/2
Figure A10-1. Model CEW Ohio Special Steam Boiler Dimensions (Page 1 of 2)
A10-6
12-02
02-02
100S- 175S-
DIM
150S 225S
BOILER HP
(inches)
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
Steam Nozzle (15 psig)A Y 8 10
B
Steam Nozzle (150 psig) Y 4 4
Drain - Front & Rear (15 psig) W 1-1/2 2

W 1-1/2 1-1/2
psig)
Surface Blowoff (150 psig) T 1 1
Surface Blowoff (15 psig) T 1-1/2 1-1/2
Vent Stack Diameter

BB 16 16
(Flanged)
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

RF 318 344
Tube Removal Front

RD 276 297
NOTES:
Accompanying dimensions, while sufciently accurate for layout
purposes, must be conrmed for actual option requirements.
A. 150 psig Flange.
B. 300 psig Flange.
C. Overall width may increase with the addition of electrical
options due to control panel mounting.
Figure A10-1. Model CEW Ohio Special Steam Boiler Dimensions (Page 2 of 2)
A10-7
02-02
12-02
A10-CEW_OS.FM Page 8 Friday, December 13, 2002 1:22 PM
DIMENSION (INCHES)
BOILER
HP
A B C D E
100S-225S 33 42 54 77 36
Figure A10-2. Space Required to Open Rear Head on Model CEW Ohio Special Boilers

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
Figure A10-3. Model CEW Ohio Special Boilers Lifting Lug Location
A10-8
12-02
02-02
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
NOTE:
All dimensions are in inches.
Figure A10-4. Model CEW Ohio Special Boiler Mounting Piers
PERFORMANCE DATA Boiler Information

Contact your local Cleaver-Brooks authorized representative Table A10-2 shows steam volume and disengaging area for
for efciencies or additional information. Model CEW Ohio Special boilers.
Table A10-3 lists quantity and outlet size for safety valves
ENGINEERING DATA supplied on Model CEW Ohio Special boilers.
The following engineering information is provided for Table A10-4 gives recommended steam nozzle sizes on
Model CEW Ohio Special Boilers. Model CEW Ohio Spe- Model CEW Ohio Special Boilers.
cial Boilers are designated by an S following the horse- Table A10-5 shows recommended non-return valve sizes for
power number. Additional detail is available from your local Model CEW Ohio Special Boilers.
A10-9
02-02
Blowdown Water Requirements Fuel Connections - Oil

Some local codes require blowdown tanks to be constructed in Oil-red burners are equipped with an oil pump, which draws
accordance with recommendations of the National Board of fuel from a storage tank and supplies pressurized oil to the
Boiler and Pressure Vessel Inspectors. burner nozzle(s). The burner supply oil pump has a greater
The National Boards recommendations base the size of the Fuel not delivered to the nozzle is returned to the storage tank.
blowdown tank on the removal of at least 4 inches of water A two-pipe (supply and return) oil system is recommended for
from the boiler. all installations. Figure A10-5 shows a typical fuel oil supply
Table A10-6 lists the approximate quantity of water repre- arrangement. Oil lines must be sized for the burner and burner
sented by 4 inches of water at normal operating level for supply oil pump capacities.
Cleaver-Brooks Model CEW Ohio Special Boilers. The burner supply oil pump suction should not exceed 10" Hg.
Burner/Control Information least equal to that of the burner pump(s). Supply pressure to the
Burner Characteristics A strainer must be installed in the supply piping upstream of
Note that altitude correction and burner changes are required the burner supply pump in order to prevent entry of foreign
for higher altitudes which may alter dimensions, motor hp and material into the pump, fuel control valves, or burner nozzle(s).
gas pressures. The strainer must be sized for the burner supply pump capacity.
A strainer mesh of 150 microns (0.005") is recommended.
Gas-Fired Burners Install a check valve in the line to prevent draining of the oil
Table A10-7 shows correction factors for gas pressure at eleva- suction line when the burner is not in operation. Location of the
tions over 700 ft above sea level. check valve varies with the system, but usually it is located as
close as possible to the storage tank.
Table A10-8 shows minimum and maximum gas pressure
requirements for Standard, FM and IRI CEW Ohio Special Installation of a vacuum gauge in the burner supply line
Boiler gas trains upstream of the gas pressure regulator. between the burner oil pump and the strainer is recommended.
For oversized or undersized gas trains or altitude above 1,000 assist in determining when the strainer needs servicing.
tive. Upon completion of the oil piping installation, the system
Fuel Connections - Gas valves.

and authorization for installation and inspection of gas supply Boiler Room Information
piping. Installation of gas supply piping and venting must be Figure A10-6 shows typical boiler room length requirements.
tion, cleaning and maintenance. Stack Support Capabilities
A drip leg should be installed in the supply piping before the 100 - 225 hp Model CEW Ohio Special Boilers can support up
connection to the gas pressure regulator. The drip leg should to 2000 lbs without additional support.
be at least as large as the inlet tting supplied with the boiler. 100 - 225 hp Model CEW Ohio Special Boilers can be rein-
Consideration must be given to both volume and pressure forced to support up to 3000 lbs.
the particular installation. Connections to the burner gas train Boiler Room Combustion Air
should be made with a union, so that gas train components or When determining boiler room air requirements, the size of the
the burner may be easily disconnected for inspection or ser- room, air ow, and velocity of air must be reviewed as follows:
vice. Upon completion of the gas piping installation, the sys-
room.
valves.
A. Two (2) permanent air supply openings in the outer walls
of the boiler room are recommended. Locate one (1) at
A10-10
02-02
each end of the boiler room, preferably below a height Stack/Breeching Size Criteria
boiler. The design of the stack and breeching must provide the
required draft at each boiler ue gas outlet. Proper draft is crit-
B. Air supply openings can be louvered for weather ical to burner performance.
mesh wire, as this type of covering has poor air ow Although constant pressure at the ue gas outlet of the Model
qualities and is subject to clogging by dust or dirt. CEW Ohio Special is not required, it is necessary to size the
stack/breeching to limit ue gas pressure variation. The allow-
C. A vent fan in the boiler room is not recommended, as it able pressure range is 0.25 W.C. to +0.25 W.C. and up to
could create a slight vacuum under certain conditions +0.5 at high re, when an economizer is used.
This can result in unsatisfactory burner performance. The maximum pressure variation at any ring rate for the
boiler is 0.25" W.C.
supply openings be less than one (1) square foot. For additional information, please review Section I4, General
E. Size the openings by using the formula: breeching sizes should always be provided by a reputable stack
Area (sq-ft) = CFM/FPM supplier who will design the stack and breeching system based
2. Amount of air required (cfm). representative is capable of assisting in your evaluation of the
A. Combustion Air = Rated bhp x 8 cfm/bhp. stack/breeching design.

Area Required: Area = cfm/fpm = 3000/250 = 12 Sq-ft total.
NOTICE
quirements.
A10-11
02-02
Table A10-2. Model CEW Ohio Special Steam Volume and Disengaging Areas
BOILER STEAM VOLUME (CU-FT) STEAM RELIEVING AREA (SQ-IN)

HP 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:
Table A10-3. Model CEW Ohio Special Steam Boiler Safety Valve Outlet Size
VALVE
SETTING
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
2-1/2
225S 2 2-1/2 1 1 2 N/A N/A
NOTE:
A10-12
02-02
Table A10-4. Model CEW Ohio Special Recommended Steam Nozzle Size
BOILER HP
OPERATING PRESSURE 100S 125S 150S 175S 200S 225S

PSIG
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:
Spool pieces (300 psig flanges) are available in the following sizes (in inches):
3x2-1/2x30, 4x3x30, 6x4x36, 8x6x48, 10x8x48, and 12x8x48.
All standard steam nozzle sizes for the 150 psig design pressure or greater are
the same as 125 psig operating pressure on the above table. To increase or de-
crease the standard size, request the change with your local Cleaver-Brooks au-
thorized representative.
Table A10-5. Model CEW Ohio Special Recommended Non-Return Valve Size

BOILER PACITY
HP 50 75 100 125 150 175 200
(LB/HR)
100S 3450 3 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2
125S 4313 4 3 3 3 3 2-1/2 2-1/2
150S 5175 4 4 3 3 3 3 2-1/2
175S 6900 4 4 3 3 3 3 2-1/2
200S 8625 4 4 4 3 3 3 3
225S 10350 4 4 4 3 3 3 3
A10-13
02-02
Table A10-6. Model CEW Ohio Special Blowdown Tank Sizing Information

100S-150S 110
175S-225S 120
ter line 4".

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 - -
A10-14
02-02
Table A10-8. Model CEW Ohio Special Minimum and Maximum Required Gas Pressure at Entrance to
Standard, FM and IRI Gas Trains (Upstream of Gas Pressure Regulator)
PRESSURE REQUIRED (WC)

BOILER PIPE SIZE
HP (Inches) MAX 1 PSIG INLET, MIN SUPPLY MAX 10 PSIG INLET, MIN SUPPLY
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.
A10-15
02-02
Figure A10-6. Boiler Room Length (Typical Layouts)
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.

A10-16
02-02
The following sample specication is provided by Cleaver-Brooks to assist you in meeting your customers specic needs and
application.
The Sample Specications are typically utilized as the base template for the complete boiler specication. Contact your local
equipment, or general assistance in completing the specication.
Model CEW Ohio Special Steam Boiler (100 - 225 hp, 15 - 250 psig)
1.0 Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-17
2.0 General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-17
3.0 Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-18
4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-18
5.0 Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-20
6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-20
7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10-20

1.1 The Steam Boiler shall be Cleaver-Brooks Model CEW Ohio Special, Fuel Series ______ (100, 200, 700), _____ hp designed
for _____ psig (15, 150, 250 psig steam). The maximum operating pressure shall be _____ psig.
cuit.

2.1 The boiler shall be a three pass wetback horizontal retube updraft boiler with less than 360 square feet of total heating surface.
It shall be mounted on a heavy steel frame with forced draft burner and burner controls. The complete packaged boiler is built as a
unit with Underwriters Laboratories listed controls.
2.2.7 The exhaust gas vent shall be located near the rear of the boiler on the top center line and shall be capable of supporting
2000lbs.
2.2.10 The entire boiler base frame and other components shall be factory painted before shipment using a hard nish enamel coat-
ing.
A10-17
02-02

3.1 Water Column
valves.

4.2 Blower
4.2.1 All air for combustion shall be supplied by a forced draft blower mounted on the burner, to eliminate vibration and reduce noise
level.
shaft.
Combustion air damper and fuel control valve shall be operated by a single damper control motor that regulates the ame according to
load demand. Potentiometer type position controls shall be provided to regulate operation of the damper control motor.
A10-18
02-02

pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include one (1) shutoff
A. 100 hp. Gas burner piping on all units shall include two (2) manual shutoff valves, gas pressure regulator, one (1) motorized
gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches. The
gas valve shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal shut-
down condition.
B. 125 - 225 hp. Gas burner piping on all units shall include two (2) manual shutoff valves, gas pressure regulator, one (1) sole-
noid, one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas
pressure switches. The gas valve shall be wired to close automatically in the event of power failure, ame failure, low water, or
any abnormal shutdown condition.
pilot so that the primary gas valve cannot open until pilot ame has been established. The pilot train shall include one (1) shutoff
4.4.2.3 Oil Pump - An oil pump with a capacity sufcient for the maximum burning rate shall be included. Pump shall be motor
driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided.
4.4.2.4 Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2)
solenoid oil shutoff valves, atomizing air proving switch, low oil pressure switch, and pressure gauge all integrally mounted on the
unit.
4.4.2.5 Oil Atomization Type - Burner shall be a low pressure air atomizing type, including a shipped loose air compressor
assembly.
or natural gas.
so that the primary fuel valve cannot open until pilot ame has been established. The pilot train shall include one (1) manual shut-
off valve, solenoid valve, and pressure regulator.
4.4.3.3 Oil Burner
4.4.3.3.1 Oil Pump - An oil pump with a capacity sufcient for the maximum burning rate shall be included. Pump shall be motor
driven and shipped loose to be eld installed near the oil storage tank. Oil pump motor starter shall also be provided.
4.4.3.3.2 Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2)
solenoid oil shutoff valves, atomizing air proving switch, low oil pressure switch and pressure gauge all integrally mounted on the
unit.
4.4.3.3.3 Oil Atomization Type - Burner shall be a low pressure air atomizing type, including a shipped loose air compressor
assembly.
A10-19
02-02

A. 100 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) motor-
ized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches.
The gas valve shall be wired to close automatically in the event of power failure, ame failure, low water, or any abnormal
shutdown condition.
solenoid, one (1) motorized gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low
gas pressure switches. The gas valves shall be wired to close automatically in the event of power failure, ame failure, low
4.5.1 Control Panel
A factory prewired control panel shall be supplied with the boiler/burner package. Panel will be mounted on the burner.
starter, control circuit transformer and fuses, selector switches, indicating lights and terminal strips. Lights shall indicate load
demand, ame failure, low water, and fuel valve open.
4.5.3 The panel shall contain fuse protection for the burner motor and air compressor motor.
violet type.

6.0 Warranty
7.0 Execution
7.1 Shop Tests
A10-20
02-02
Section A11
Model CBL
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-3
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-4
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-9
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-10
Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-10
Blowdown Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-10
Burner/Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-10
Burner Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-10
Gas-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-10
Fuel Connections - Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-10
Fuel Connections - Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-10
Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-11
Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-11
Boiler Room Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-11
Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-11
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-19
Model CBL Steam Boiler (800-1500 hp, Steam 15-250 psig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-19
A11-1
02-02
A11_CBL Page 2 Tuesday, December 17, 2002 12:40 PM
Model CBL Firetube Boilers
ILLUSTRATIONS
Figure A11-1. Model CBL Steam Boiler Dimensions, 4 Pass (Page 1 of 2) (4 pass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-6
Figure A11-2. Space Required to Open Rear Doors on Model CBL Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-8
Figure A11-3. Model CBL Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-8
Figure A11-4. Model CBL Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-9
Figure A11-5. No. 2 Oil Piping, Single Boiler Installation, Oil Pump Integral With Boiler . . . . . . . . . . . . . . . . . . . . . . A11-17
Figure A11-6. No. 6 Oil Piping, Single Boiler Installation, Remote Oil Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-17
Figure A11-7. Boiler Room Length (Typical Layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-18
Figure A11-8. Boiler Room Width (Typical Layouts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-18
TABLES
Table A11-1. Model CBL Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-5
Table A11-2. Heating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-5
Table A11-3. Predicted Fuel-to-Steam Efficiencies (%) Model CBL Boilers- 125 psig,
Natural Gas, 5sq. ft./BHP, 4 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-13
No. 2 Oil, 5sq. ft./BHP, 4 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-13
No. 6 Oil, 5sq. ft./BHP, 4 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-13
Natural Gas, 4 sq. ft./BHP, 3 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-14
No. 2 Oil, 4 sq. ft./BHP, 3 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-14
No. 6 Oil, 4 sq. ft./BHP, 3 Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-14
Table A11-9. Model CBL Steam Boiler Safety Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-15
Table A11-10. Model CBL Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-15
Table A11-11. Model CBL Steam Volume and Disengaging Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-16
Table A11-12. Model CBL Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-16
Table A11-13. Model CBL Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-16
Table A11-14. Altitude Correction for Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-16
The following information applies to the Cleaver-Brooks Model CBL Boiler.
A11-2
02-02
Firetube Boilers Model CBL
FEATURES AND BENEFITS Feedwater valves and regulators.

The Model CBL Firetube boiler is designed, manufactured, Surface blowdown systems.
and packaged by Cleaver-Brooks. All units are factory fire
tested and shipped as a package, ready for quick connection to Surge load baffles.
utilities. In addition to the features provided on all Cleaver- Seismic design.
Brooks Firetube boilers, the following features apply to the
Model CBL. Burner/Control Options:
Three Pass or Four Pass Design:
Lead/lag system.
The packaged boiler offers high efficiency, flexibility,
reliability, safety and ease of operation.
NFPA8501).
Front and Rear Doors: Alarm bell/silence switch.
Davited, front and rear doors, all sizes. Special motor requirements (TEFC, high efficiency).
Provides access to front tube sheet and furnace. Special indicating lights.
Large rear access plug for turnaround and furnace access. Main disconnect.
Rear door completely covers and insulates rear tube sheet. Elapsed time meter.
NEMA enclosures.
Natural Gas, No. 2 Oil, No. 6 Oil, or Combination Burners
Available: Remote emergency shut-off (115V).
Combination gas/oil burners provide quick fuel changeover Circuit breakers.
without burner adjustment. Day/night controls.
PRODUCT OFFERING
Low NOx Equipment.
Cleaver-Brooks Model CBL Boilers are available in high pres-
sure steam designs. Burners are available to fire natural gas, CB HAWK
No. 2 oil, No. 6 oil, or a combination of oil and gas. Standard
Fuel Options:
product offering is:
Gas strainer.
800 - 1500 hp.
Gas pressure gauge.
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.
Optional Oil Pumps.
30 & 125 psig hot water in most sizes.
Boiler Options:
Additional screwed or flanged tappings.
Blowdown valves.
Non-return valves.
A11-3
02-02

Dimensions and ratings for the Model CBL Boilers are shown
in the following tables and illustrations. The information is
subject to change without notice.
Table A11-1. Model CBL Steam Boiler Ratings
Table A11-2. Heating Surface
Figure A11-1. Model CBL Steam Boiler Dimensions
Figure A11-2. Model CBL Boiler Space Requirements to
Open Rear Door
Figure A11-3. Lifting Lug Location, Model CBL Boilers
Figure A11-4. Model CBL Boiler Mounting Piers
A11-4
02-02
A11_CBL Page 5 Tuesday, December 17, 2002 11:15 AM
Table A11-1. Model CBL Steam Boiler Ratings
BOILER HP 800 900 1000 1100 1200 1300 1400 1500
RATINGS - SEA LEVEL TO 1000 FT B
Rated Capacity (lbs-steam/hr from and at 212 F) 27600 31050 34500 37950 41400 44850 48300 51750
Btu Output (1000 Btu/hr) 26780 30125 33475 36820 40170 43515 46865 50210
Blower Motor, hp A(Gas and Oil) 60 60 60 75 75 75 75 75
Oil Pump Motor hp (#2 oil) 1 1 1 1 1-1/2 1-1/2 NA NA
Oil Pump Motor hp (#6 oil) 1 1 1 1 1 1 NA NA
Air Comp. Motor, hp (#2 oil) 7-1/2 15 15 15 15 15 NA NA
Oil heater Kw (#6 oil) 10 10 10 15 15 15 NA NA
NOTE:
A. 1400 and 1500 hp blower motor is for natural gas only.
B. Ratings based on nominal 80% efficiency.
C. Ratings based on 60 hertz, please verify 50 hertz ratings with factory.
Table A11-2. Heating Surface
Boiler Square Foot

Heating Surface
4000 4500 5000 5500 6000
Approximate Fuel Consumption D
5 sq.ft./bhp 800 900 1000 1100 1200
Natural Gas A (cfh) 33475 37660 41845 46025 50215
No. 2 Oil B (gph) 239.3 269.0 299.0 329.0 359.0
No. 6 Oil C (gph) 223.4 251.1 279.0 307.0 335.0
4 sq.ft./bhp 1000 1100 1200 1300 1400 1500
Natural Gas A (cfh) 41845 46025 50215 54395 58585 62765
No. 2 Oil B (gph) 299.0 329.0 359.0 388.5 NA NA
No. 6 Oil C(gph) 279.0 307.0 335.0 363.0 NA NA
Note:
A. Natural gas based on heating value of 1000 BTU/cu.ft
B. No. 2 oil based on heating value of 140,000 BTU/gal.
C. No. 6 oil based on heating value of 150,000 BTU/gal.
D. Ratings based on nominal 80% efficiency.
A11-5
02-02
I BB
RF/RD
J GG B
L
K E Y T
CC
P S
F
G
O
N R W
M C H
W
BOILER SQUARE FOOT

DIM 4000 4500 5000 5500 6000 6500D 7000D 7500D
HEATING SURFACE
Boiler Horsepower@ 5 ft2/bhp 800 900 1000 1100 1200 1300 1400 1500
Boiler Horsepower @ 4 ft2/bhp 1000 1100 1200 1300 1500 - - -
LENGTHS
Overall * 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
Figure A11-1. Model CBL Steam Boiler Dimensions, 4 Pass (Page 1 of 2) (4 pass)
A11-6
02-02
A11_CBL Page 7 Tuesday, December 17, 2002 12:39 PM
BOILER SQUARE FOOT

DIM 4000 4500 5000 5500 6000 6500D 7000D 7500D
HEATING SURFACE
Boiler Horsepower@ 5 ft2/bhp 800 900 1000 1100 1200 1300 1400 1500
Boiler Horsepower @ 4 ft2/bhp 1000 1100 1200 1300 1500 - - -
HEIGHTS
Base to piping
F 146 146 158 158 158 171 171 171
connections
Base to Boiler Centerline D 77-1/2 77-1/2 83-3/4 83-3/4 83-3/4 89 3/4 89 3/4 89 3/4
Base to Vent Outlet O 141 141 153-1/2 153-1/2 153-1/2 165 1/2 165 1/2 165 1/2
Base to Steam Outlet P 141 141 153-1/2 153-1/2 153-1/2 165 1/2 165 1/2 165 1/2
Base Frame Q 12 12 12 12 12 12 12 12
Base to Bottom Boiler R 20 20 20 20 20 20 20 20
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 NozzleA (5 ft2/bhp) Y 8 10 10 10 10 10 12 12
Steam NozzleA (4 ft2/bhp) Y 10 10 10 10 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
c AA - - - - - - - -
Rear Door Swing
Tube Removal - Front Only GG 246 276 217 241 264 233 252 271

RF 537 597 538 586 632 665 703 741
Tube Removal Front

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
Approx. Wt. 200 psig (Lbs.) 73500 80200 88600 95200 101500 107800 N/A N/A
Approx. Wt. 250 psig (Lbs.) 81300 89000 97200 104500 N/A N/A N/A N/A
NOTES:
A. 300 psig Flange. See recommended steam nozzle size chart for operating pressure greater than 125 psig.
B. Add 11 1/2 inches to dimension B for a three pass boiler.
C. Reference Figure A11-2.
D. 6500, 7000 & 7500 square foot boiler are for a 30ppm option on natural gas.
Figure A11-1. Model CBL Steam Boiler Dimensions, 4 Pass (Page 2 of 2) (4 pass)
A11-7
02-02
3-PASS BOILER SHOWN.

4 PASS VENT STUB ON
"D" OPPOSITE END.
"B"
"A"
BOILER DIMENSION (INCHES)
ID A B C D E
114" 60 72 39 82 22 "E"
REAR DOOR "C"
126" 66 78 52 93 33
138" 72 84 66 105 45
MAXIMUM REAR MINIMUM REAR
MINIMUM SIDE MAXIUM SIDE
Figure A11-2. Space Required to Open Rear Doors on Model CBL Boilers
BOILER SQUARE FOOT BHP

A B C D E
OF HEATING SURFACE 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 - 1300 162 47 216 12 3
7000 - 1400 162 47 235 12 3
7500 - 1500 162 47 254 12 3
Figure A11-3. Model CBL Boilers Lifting Lug Location
A11-8
02-02
H
E
BOILER SQUARE FOOT BHP

A B C D E F G H
OF HEATING SURFACE 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 - 1300 6 12 * 76 100 8 80 15
7000 - 1400 6 12 * 76 100 8 80 15
7500 - 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 acces-
sibility 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.
Figure A11-4. Model CBL Boiler Mounting Piers
PERFORMANCE DATA CB-7767 for a detailed description of efficiency calcula-

tions).
Efficiency The boiler manufacturer shall guarantee that, at the time of
startup, the boiler will achieve fuel-to-steam efficiency (as
Tables A11-3, A11-4, A115, A11-6, A117, and A11-8 show shown in the tables listed above) at 100% firing rate (add
predicted fuel-to-steam efficiencies (including radiation and efficiency guarantees at 25%, 50%, and 75% of rating, if
convection losses) for Cleaver-Brooks Model CBL Firetube required). If the boiler(s) fail to achieve the corresponding
boilers. For specific efficiencies on firetube boiler offerings guaranteed efficiency as published, the boiler manufacturer
not listed here, contact your local Cleaver-Brooks authorized will rebate, to the ultimate boiler owner, five thousand dol-
representative. lars ($5,000) for every full efficiency point (1.0%) that the
Cleaver-Brooks offers an industry leading fuel-to-steam actual efficiency is below the guaranteed level. The specified
boiler efficiency guarantee for Model CBL Firetube Boilers. boiler efficiency is based on the following conditions.
The guarantee is based on the fuel-to-steam efficiencies 1. Fuel specification used to determine boiler efficiency:
shown in the efficiency tables and the following conditions.
The efficiency percent number is only meaningful if the spe- Natural Gas
cific conditions of the efficiency calculations are clearly Carbon,% (wt) = 69.98
stated in the specification (see Cleaver-Brooks publication
A11-9
02-02
Hydrogen,% (wt) = 22.31 Burner/Control Information
Sulfur,% (wt) = 0.0
Heating value, Btu/lb = 21,830 Burner Characteristics
No. 2 Oil Note that altitude correction and burner changes are required
Carbon,% (wt) = 85.8 for higher altitudes which may alter dimensions, motor hp and
Hydrogen,% (wt) = 12.7 gas pressures. Also 50 Hz applications and low NOx options
Sulfur,% (wt) = 0.2 should be reviewed by the Cleaver-Brooks authorized repre-
Heating value, Btu/lb = 19,420 sentative.
No. 6 Oil
Gas-Fired Burners
Carbon,% (wt) = 86.6 Table A11-13 shows correction factors for gas pressure at ele-
Hydrogen,% (wt) = 10.9 vations over 700 ft. above sea level.
Sulfur,% (wt) = 2.09
Heating value, Btu/lb = 18,830 For oversized or undersized gas trains or altitude above 1,000
2. Efficiencies are based on ambient air temperature of 80 F, tive.
flue gas.
3. Efficiencies are based on the following radiation and con-
vection losses. Firing rate of 25% - 1.2%, 50% - 0.6%, 75% -
0.4%, and 100% - 0.3%.
piping. Installation of gas supply piping and venting must be in
accordance with all applicable engineering guidelines and reg-
ENGINEERING DATA ulatory codes. All connections made to the boiler should be
The following engineering information is provided for Model
tion, cleaning and maintenance.
CBL Boilers. Additional detail is available from your local
Cleaver-Brooks authorized representative. A drip leg should be installed in the supply piping before the
connection to the gas pressure regulator. The drip leg should be
Boiler Information at least as large as the inlet fitting supplied with the boiler.
Table A11-11 shows steam volume and disengaging area for requirements when choosing gas supply piping size. Refer to
Model CBL boilers. the boiler dimension diagram provided by Cleaver-Brooks for
Table A11-9 lists quantity and outlet size for safety valves sup- the particular installation. Connections to the burner gas train
plied on Model CBL boilers. should be made with a union, so that gas train components or
Table A11-10 gives recommended steam nozzle sizes on vice. Upon completion of the gas piping installation, the sys-
Model CBL Boilers. tem should be checked for gas leakage and tight shutoff of all
Table A11-12 shows recommended non-return valve sizes for valves.
Model CBL Boilers.
Fuel Connections - Oil
Blowdown Water Requirements Oil-fired burners are equipped with an oil pump, which draws
Some local codes require blowdown tanks to be constructed in fuel from a storage tank and supplies pressurized oil to the
accordance with recommendations of the National Board of burner nozzle(s). The burner supply oil pump has a greater
Boiler and Pressure Vessel Inspectors. capacity than the burner requires for the maximum firing rate.
Fuel not delivered to the nozzle is returned to the storage tank.
The National Boards recommendations base the size of the A two-pipe (supply and return) oil system is recommended for
blowdown tank on the removal of at least 4 inches of water all installations. Figure A11-6 shows a typical fuel oil supply
from the boiler. arrangement. Oil lines must be sized for the burner and burner
Table A11-13 lists the approximate quantity of water repre- supply oil pump capacities.
sented by 4 inches of water at normal operating level for The burner supply oil pump suction should not exceed 10" Hg.
Cleaver-Brooks Model CBL Boilers. If a transfer pump is used, it must have a pumping capacity at
A11-10
02-02
A strainer must be installed in the supply piping upstream of C. A vent fan in the boiler room is not recommended, as it
the burner supply pump in order to prevent entry of foreign could create a slight vacuum under certain conditions
material into the pump, fuel control valves, or burner noz- and cause variations in the quantity of combustion air.
zle(s). The strainer must be sized for the burner supply pump This can result in unsatisfactory burner performance.
capacity. A strainer mesh of 150 microns (0.005") is recom-
mended.
openings be less than one (1) square foot.
suction line when the burner is not in operation. Location of
the check valve varies with the system, but usually it is located Area (sq-ft) = CFM/FPM
as close as possible to the storage tank.
Regular observation and recording of the gauge indication will B. Ventilation Air = Maximum bhp x 2 cfm/bhp or a total
assist in determining when the strainer needs servicing. of 10 cfm/bhp - up to 1000 feet elevation. Add 3 percent
Upon completion of the oil piping installation, the system
should be checked for oil or air leakage and tight shutoff of all 3. Acceptable air velocity in Boiler Room (fpm).
valves.
Boiler Room Information B. Above (7) foot height - 500 fpm.
Figure A11-7 shows typical boiler room length requirements. Example: Determine the area of the boiler room air supply
Figure A11-8 shows typical boiler room width requirements. openings are to be 5 feet above floor level.
Stack Support Capabilities
Model CBL Boilers can support up to 2000 lbs. without addi-
tional support. Area Required: Area = cfm/fpm = 10000/250 = 40 Sq-ft total.
Model CBL Boilers can be reinforced to support up to 3000 Area/Opening: 40/2 = 20 sq-ft/opening (2 required).
lbs.
Boiler Room Combustion Air NOTICE

When determining boiler room air requirements, the size of Consult local codes, which may supersede these re-
the room, air flow, and velocity of air must be reviewed as fol- quirements.
lows:
1. Size (area) and location of air supply openings in boiler Stack/Breeching Size Criteria
room.
A. Two (2) permanent air supply openings in the outer required draft at each boiler flue gas outlet. Proper draft is crit-
walls of the boiler room are recommended. Locate one ical to burner performance.
height of 7 feet. This allows air to sweep the length of
CBL is not required, it is necessary to size the stack/breeching
the boiler.
to limit flue gas pressure variation. The allowable pressure
B. Air supply openings can be louvered for weather range is 0.50 W.C. to +0.50 W.C. The maximum pressure
protection, but they should not be covered with fine variation at any firing rate for the boiler is 0.50" W.C.
A11-11
02-02
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 0.25W.C.
For additional information, please review Section I4, General
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 autho-
rized representative is capable of assisting in your evaluation
A11-12
02-02
Table A11-3. Predicted Fuel-to-Steam Efficiencies (%) Model CBL

Boilers- 125 psig, Natural Gas, 5sq. ft./BHP, 4 Pass
BOILER FIRING RATE (%)

HP 25 50 75 100
800 82.7 83.1 83.1 83.0
900 82.8 83.2 83.2 83.1
1000 82.7 83.1 83.1 83.0
1100 82.8 83.2 83.2 83.1
1200 82.8 83.2 83.2 83.2
Table A11-4. Predicted Fuel-to-Steam Efficiencies (%) Model

CBL Boilers- 125 psig, No. 2 Oil, 5sq. ft./BHP, 4 Pass

HP 25 50 75 100
800 86.2 86.5 86.5 86.4
900 86.2 86.6 86.6 86.5
1000 86.2 86.5 86.5 86.4
1100 86.2 86.6 86.6 86.5
1200 86.2 86.6 86.7 86.6

CBL Boilers- 125 psig, No. 6 Oil, 5sq. ft./BHP, 4 Pass

HP 25 50 75 100
800 86.5 86.9 86.9 86.8
900 86.6 87.0 87.0 86.9
1000 86.5 86.9 86.9 86.8
A11-13
02-02

CBL Boilers- 125 psig, Natural Gas, 4 sq. ft./BHP, 3 Pass

HP 25 50 75 100
1000 82.4 82.4 82.0 81.5
1100 82.5 82.6 82.4 82.0
1200 82.4 82.4 82.0 81.6
1300 82.5 82.6 82.3 81.9
1400 82.5 82.6 82.3 82.0
1500 82.5 82.7 82.5 82.1

CBL Boilers- 125 psig, No. 2 Oil, 4 sq. ft./BHP, 3 Pass

HP 25 50 75 100
1000 85.8 85.8 85.4 85.0
1100 85.9 86.0 85.8 85.4
1200 85.8 85.8 85.5 85.0
1300 85.9 86.0 85.7 85.4

CBL Boilers- 125 psig, No. 6 Oil, 4 sq. ft./BHP, 3 Pass

HP 25 50 75 100
1000 86.2 86.2 85.8 85.3
A11-14
02-02
Table A11-9. Model CBL Steam Boiler Safety Valve Outlet Size
VALVE
SETTING
HP REQ'D (FPT) REQ'D (FPT) REQ'D (FPT) REQ'D (FPT)
1-3 1 - 2 1/2
800 - - 2 2 2 2 1/2
1-4 1-3
1-3 1 - 2 1/2
900 - - 2 2 3 2
1-4 1-3
1 - 2 1/2
1000 7 4 2 4 2 3 2 1-3
1-3
1100 8 4 2 4 2 2 3
1-4
1-3
1200 8 4 2 4 2 2 3
1-4
2-3 1 - 2 1/2
1300 - - 3 3 - -
1-4 2-3
1-3
1400 - - 3 3 3 - -
2-4
1-3
1500 - - 3 3 3 - -
2-4
NOTES:
Table A11-8 only applies to 5 Sq Ft/BHP units.
Valve manufacture is Kunkle.
Table A11-10. Model CBL Recommended Steam Nozzle Size
BOILER HP
OPERATING PRESSURE 800 900 1000 1100 1200 1300 1400 1500
PSIG
12 18 18 20 20 24 24 24 24
30 14 16 16 16 18 18 18 20
50 12 12 12 14 16 16 16 16
75 10 10 12 12 12 12 12 14
100 10 10 10 10 12 12 12 12
125 8 10 10 10 10 10 12 12
150 8 8 8 10 10 10 10 10
200 8 8 8 8 8 NA NA NA
225 6 8 8 8 8 NA NA NA
NOTES:
All standard steam nozzle sizes for the 150 psig design pressure or greater are the same as 125
psig operating pressure on the above table. To increase or decrease the standard size, request
the change with your local Cleaver-Brooks authorized representative.
A11-15
02-02
Table A11-11. Model CBL Steam Volume and Disengaging Areas

STEAM VOLUME STEAM RELIEVING AREA
BOILER SQUARE FOOT OF BHP (CU-FT) (SQ-IN)
HEATING SURFACE
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 - 1300 352 28918
7000 - 1400 379 31079
7500 - 1500 405 33242
NOTE:
Table A11-12. Model CBL Recommended Non-Return Valve Size
BOILER CAPACITY OPERATING PRESSURE

HP LBS.PER HR. 50 75 100 125 150 175 200 225
800 27600 8 8 8 6 6 6 6 6
900 31050 8 8 8 6 6 6 6 6
1000 34500 8 8 8 6 6 6 6 6
1100 37950 8 8 8 8 6 6 6 6
1200 41400 10 8 8 8 8 8 8 6
1300 44850 10 8 8 8 8 8 N/A N/A
1400 48300 10 10 8 8 8 8 N/A N/A
1500 51750 10 10 10 8 8 8 N/A N/A
Table A11-13. Model CBL Blowdown Tank Sizing Information Table A11-14. Altitude Correction for Gas
BOILER SQUARE BHP WATER ALTITUDE CORRECTION ALTITUDE CORRECTION

FOOT OF HEATING (GAL) (FT) FACTOR (FT) FACTOR
SURFACE 4 SQ.FT. 5 SQ.FT.
1000 1.04 6000 1.25

4000 1000 800 356
4500 1100 900 400 2000 1.07 7000 1.30
5000 1200 1000 418 3000 1.11 8000 1.35
5500 1300 1100 460 4000 1.16 9000 1.40
6000 1500 1200 500 5000 1.21 - -
6500 - 1300 500

7000 - 1400 538 inches WC x 0.577 = oz/sq-in.
inches WC x 0.0361= psig.
7500 - 1500 575 oz/sq-in x 0.0625 = psig.
ter line 4".
A11-16
02-02

Oil Pump Integral With Boiler

Remote Oil Pumps
A11-17
02-02
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.
BOILER SQUARE FOOT OF BHP A B

HEATING SURFACE 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 - 1300 642 515
7000 - 1400 680 534
7500 - 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 A11-7. Boiler Room Length (Typical Layout)
Boiler Square Foot of 4000-4500 5000-6000 6500-7500

Heating Surface
For reference to Boiler Horsepower per square foot see A11-7
Figure A11-8. Boiler Room Width (Typical Layouts)
A11-18
02-02
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 pro-
vided. See Section D, Controls, for additional information on control options.
Model CBL Steam Boiler (800 - 1500 hp, 15 - 250 psig)

6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-24
7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11-24
Model CBL Steam Boiler (800-1500 hp, Steam 15-250 psig)

1.1 The Steam Boiler shall be Cleaver-Brooks Fuel Series ______ (100, 200, 400, 600, 700), ______ hp designed for ______ psig
(15, 150, 200, or 250 psig steam). The maximum operating pressure shall be _____ psig and the minimum operating pressure shall
be ______ psig.
1.2 The boiler shall have a maximum output of ______ Btu/hr, or ______ horsepower when fired with CS12-48 ______ oil and/or
natural gas, ______ Btu/cu-ft. Electrical power available shall be ______ Volt ______ Phase ______ Cycle.

2.1 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.
floor or simple foundation and ready for attachment of water, fuel, electrical, vent, and blowdown connections.
2.1.2 The boiler shall be built to comply with the following insurance and codes ______________ (Factory Mutual, Industrial Risk
Insurance, ASME, NFPA 8501).
2.2.2 The boiler shall be furnished with a manhole and handholes to facilitate boiler inspection and cleaning. Two lifting lugs must
A11-19
02-02
2.2.3 The front door shall be davited and the rear door shall be davited. Doors are to be sealed with fiberglass tadpole gaskets and fas-
2.2.4 The boiler tubes shall not include turbulators, swirlers, or other add-on appurtenances.
2.2.5 The rear door shall be insulated with a blanket material with a steel covering to give the surface a hard durable finish.
2.2.6 The exhaust gas vent shall be located at the front or rear of the boiler and be capable of supporting 2000 lbs. The boiler vent
shall contain a stack thermometer.
2.2.7 Observation ports for the inspection flame conditions shall be provided at each end of the boiler.
2.2.8 The boiler insulation shall consist of 2 inch blanket under a sectional pre-formed sheet metal lagging. The insulation must be
2.2.9 The entire boiler base frame and other components shall be factory-painted before shipment, using a hard-finish enamel coating.

3.1 Water Column
A water column shall be located on the right-hand side of the boiler complete with gauge glass set, and water column blowdown
valves.
3.1.1 Modulating feedwater Control
The boiler modulating feedwater control and valve shall be included to automatically maintain the boiler water level within normal
limits.
The low water cutoff shall be included and wired into the burner control circuit to prevent burner operation if the boiler water level
falls below a safe level.
3.2 Auxiliary Low Water Cut-off
Auxiliary low water cut-off shall be included, piped to the vessel, and wired to the burner control circuit. A manual reset device shall
3.4 Safety Valves
The steam pressure control to regulate burner operation shall be mounted near the water column. Controls shall be a high limit (man-
ual reset), operating limit (auto reset), and firing rate control.

4.1.1 Burner operation shall be full modulation principle. The burner shall always return to low fire position for ignition.
4.1.2 A low fire hold control is mounted and wired on the boiler.
4.2 Blower
4.2.1 Air for combustion shall be supplied by a forced draft blower mounted on the burner, to eliminate vibration and reduce noise
level.
A11-20
02-02
4.2.3 The impeller shall be cast aluminum with radial blade, carefully balanced, and directly connected to the blower motor shaft.
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.
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).
Fuel series 600 - No. 6 oil-fired (para 4.4.4).
Fuel series 400 - No. 6 oil or gas-fired (para 4.4.5).
4.4.1 Fuel Series 700 - Gas-Fired
4.4.1.1 Burner Type - The burner shall be mounted at the front of the boiler and of high radiant multi-port type gas entry. The
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).
4.4.1.3 Gas Burner Piping - Gas burner piping on all units shall include a gas pressure regulator, a primary gas shutoff valve, motor
operated with proof of closure switch and plugged leakage test connection. The main gas valves shall be wired to close automati-
cally in the event of power failure, flame failure, low water or any safety shutdown condition. A lubricating plug cock shall be pro-
vided as a means for a tightness check of the primary shutoff valve. An additional plug cock shall be furnished at entrance to gas
train. High and low gas pressure switches shall be provided. A second motorized safety shutoff valve, plus an additional plugged
leakage test connection shall be provided. A vent valve shall be located between the safety shutoff valves.
4.4.1.4 Burner Turndown: Turndown range of the burner shall be 10:1 when firing natural gas. (Consult with Cleaver-Brooks Rep-
resentative regarding high turndown capability based on available gas pressure.)
4.4.2 Fuel Series 100 - Light Oil-Fired
4.4.2.1 Burner Type - The burner shall be mounted at the front of the boiler, and shall be a low pressure air atomizing type approved
for operation with CS12-48, Commercial No. 2 oil.
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).
4.4.2.3 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. The motor-
4.4.2.4.1 Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, low oil pressure switch, two
(2) motorized oil valves and pressure gauges, all integrally mounted on the unit.
4.4.2.5 Low Pressure Air Atomizing: Separate air compressor module, shipped loose with burner mounted low atomizing air
pressure switch.
A11-21
02-02
4.4.2.6 Turndown range shall be 8:1 when firing No. 2 oil.

4.4.3 Fuel Series 200 - Light Oil or Gas-Fired
4.4.3.1 Burner Type - The burner shall be mounted at the front of the boiler and shall be a combination of the low pressure air atom-
izing 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.
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).
4.4.3.3 Oil Burner
4.4.3.3.1 Oil Pump - An oil pump with a capacity of approximately twice the maximum burning rate shall be included. The motor-
driven pump set, shipped loose, shall be provided, to be installed in a location favorable to the oil storage tank.
4.4.3.3.2 Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, low oil
pressure switch, one (1) solenoid shutoff valve, one (1) motorized oil valve, and pressure gauges all integrally mounted on the unit.
4.4.3.3.3 Low pressure Air Atomizing - Separate air compressor module, shipped loose with burner-mounted low-atomizing air
pressure switch.
4.4.3.3.4 Burner Turndown - Turndown range shall be 8:1 when firing No. 2 oil.
4.4.3.4 Gas Burner
4.4.3.4.1 Gas Burner Piping - Gas burner piping on all units shall include a gas pressure regulator, and a primary gas shutoff valve,
motor-operated with proof-of-closure switch and plugged leakage test connection. The main gas valves shall be wired to close
automatically in the event of power failure, 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.
4.4.3.4.2 Burner Turndown - Turndown range shall be 10:1 when firing natural gas.
4.4.4 Fuel Series 600 - No. 6 Oil-Fired
4.4.4.1 Burner Type - The burner shall be mounted at the front of the boiler and low pressure air atomizing type approved for oper-
ation with CS12-48, Commercial No. 6 Oil.
pilot so that the primary oil valve cannot open until pilot 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 (Canada only).
The motor driven pump set, shipped loose, to be installed in a location favorable to the oil storage tank shall be provided.
4.4.4.4 Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, low oil
pressure switch, one (1) solenoid shutoff valve, one (1) motorized oil valve and pressure gauges all integrally mounted on the unit.
4.4.4.5 Low Pressure Air-Atomizing - Separate air compressor module, shipped loose with the burner-mounted low-atomizing
air pressure switch.
4.4.4.6 Oil Preheat
single compact shell; mounted, piped, and wired. The thermostatic controls shall be set to cut-out the electric heater when steam is
available.
4.4.4.7 Burner Turndown - Turndown range will be 4:1 when firing No. 6 oil.
4.4.5 Fuel Series 400 - No. 6 Oil or Gas-Fired
A11-22
02-02
4.4.5.1 Burner Type - The burner shall be mounted at the front the boiler and shall be a combination of the low pressure atomizing
type for oil and multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 6 oil or
natural gas.
pilot so that the primary oil valve cannot open until pilot 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.)
4.4.5.3 Oil Burner
driven pump set, shipped loose, shall be provided to be installed in a location favorable to the oil storage tank.
4.4.5.3.2 Oil Burner Piping - Fuel oil piping on the unit shall include oil pressure regulating devices, oil metering controls, low oil
pressure switch, two (2) motorized oil valves, and pressure gauges all integrally mounted on the unit.
4.4.5.4 Low Pressure Air-Atomizing: Separate air compressor module shipped loose with burner mounted low atomizing air
pressure switch.
4.4.5.5 Oil Preheat - The oil shall be preheated by a steam heater and electric heater, each with thermostatic control. Both heaters
shall be installed in a single compact shell mounted, piped, and wired. The thermostatic controls shall be sent to cut-out the electric
heater when steam is available.
4.4.5.6 Burner Turndown - Turndown range will be 4:1 when firing No. 6 oil.
4.4.5.7 Gas Burner
4.4.5.7.1 Gas Burner Piping - Gas burner piping on all units shall include a gas pressure regulator, and a primary gas shutoff valve,
motor-operated with proof-of-closure switch and plugged leakage test connection. The main gas valves shall be wired to close
automatically in the event of power failure, 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.
4.4.5.7.2 Burner Turndown - Turndown range shall be 4:1 when firing natural gas.
4.5.1 CB100E Flame Safeguard
4.5.1.1 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.
4.5.2 Control Panel
4.5.3 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.
A11-23
02-02

5.1 The boiler must be guaranteed to operate at a minimum fuel-to-steam efficiency of ____ percent at 100 percent of
Cleaver-Brooks authorized representative for efficiency details).
6.0 Warranty
up, or 18 months from date of shipment; whichever comes first.
7.0 Execution
7.1 Shop Tests
7.2.1.1 A factory-approved and authorized start-up report shall be submitted to the customer/user at the time of start-up.
A11-24
02-02
Section A12
Model ICB
CONTENTS
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-3
Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-3
Dimensions and Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-4
Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-13
Engineering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-13
Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-13
Sample Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-20
A12-1
12-02
Model ICB Firetube Boilers
ILLUSTRATIONS
Figure A12-1. Model ICB Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-7
Figure A12-2. Model ICB Hot Water Boiler Dimensions, 4-Pass and 3-Pass (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-9
Figure A12-3. Space Required to Open Rear Head on Model ICB Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-11
Figure A12-4. Model ICB Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-11
Figure A12-5. Model ICB Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-12
Figure A12-6. Typical Fuel Oil Supply Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-18
Figure A12-7. Boiler Room Length (Typical Layouts) Model ICB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-19
Figure A12-8. Boiler Room Width (Typical Layout) Model ICB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-19
TABLES
Table A12-1. Model ICB Steam Boiler Ratings, 4-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-5
Table A12-2. Model ICB Steam Boiler Ratings, 3-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-5
Table A12-3. Model ICB Hot Water Boiler Ratings, 4-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-6
Table A12-4. Model ICB Hot Water Boiler Ratings, 3-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-6
Table A12-5. Model ICB Steam Boiler Dimensions, 4-Pass and 3-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-8
Table A12-6. Model ICB Hot Water Boiler Dimensions, 4-Pass and 3-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-10
Table A12-7. Model ICB Steam Volume and Disengaging Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-15
Table A12-8. Model ICB Steam Boiler Safety Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-15
Table A12-9. Model ICB Hot Water Boiler Relief Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-16
Table A12-10. Model ICB Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-16
Table A12-11. Model ICB Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-17
Table A12-12. Model ICB Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-17
Table A12-13. Altitude Correction for Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-17
Table A12-14. Sound Levels in dBA for 4-Pass ICB Boilers at High Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-17
Table A12-15. Model ICB, Standard, Minimum Required Gas Pressure at Entrance to Standard,
FM & IRI Gas Trains (Upstream of Gas Pressure Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-18
The following information applies to the Cleaver-Brooks Model ICB Boiler.
A12-2
12-02
Firetube Boilers Model ICB
FEATURES AND BENEFITS Available options include the following (contact your local
Cleaver-Brooks Authorized Representative for option details).
The Cleaver-Brooks Model ICB Boiler line provides a quality
product utilizing a baseline boiler/burner design. Additionally, Boiler Options:
the boiler/burner package has the UL/cUL label. The following Three-pass design.
features apply:
Drain valves.
Four-Pass Intercooled Design:
Blowdown valves.
Four-pass design provides high flue gas velocities and low
stack temperatures to maximize efficiency. Non-return valves.
Three-Pass Intercooled Design (optional): Surface blowdown systems.
Versatile design offered with choice of three or four-pass Blend pump.
construction to meet application needs. Surge load baffles.
Seismic design.
Intercooled Rear Turnaround:
Rear furnace turnaround area is fluid cooled and has a
davited access opening for full accessibility to 2nd pass Flame safeguard controllers.
tubes and furnace. It eliminates confined space issues and Lead/lag system.
provides for ease of maintenance. All tubes can be removed
High altitude design.
from either the front or rear of the boiler.
CSD-1).
Rear door completely covers and insulates rear tube sheet. Main disconnect.
Elapsed time meter.
Natural Gas, No. 2 Oil, or Combination Burners Available:
Combination gas/oil burners provide quick fuel changeover NEMA enclosures.
Low-fire hold control.
PRODUCT OFFERING
Circuit breakers.
Cleaver-Brooks Model ICB Boilers are available in low Day/night controls.
pressure steam, high pressure steam, and hot water designs.
Burners are available to fire natural gas, No. 2 oil, or a Special power requirements.
combination of oil and gas. Standard product offering is: Stack thermometer.
100 800 hp. Fuel Options
30 and 125 psig hot water. Air atomizing oil burner, 200 800 hp.
15 300 psig steam. Pressure atomizing oil burner, 100 150 hp.
Full modulation, all sizes. Gas strainer.
Gas pressure gauge.
A12-3
12-02

Dimensions and ratings for the Model ICB Boilers are shown in the following tables and illustrations. The information is subject to
change without notice.
Table A12-1. Model ICB Steam Boiler Ratings, 4-Pass
Table A12-2. Model ICB Steam Boiler Ratings, 3-Pass (Optional)
Table A12-3. Model ICB Hot Water Boiler Ratings, 4-Pass
Table A12-4. Model ICB Hot Water Boiler Ratings, 3-Pass (Optional)
Figure A12-1. Model ICB Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional)
Table A12-5. Model ICB Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional)
Figure A12-2. Model ICB Hot Water Boiler Dimensions, 4-Pass and 3-Pass (Optional)
Table A12-6. Model ICB Hot Water Boiler Dimensions, 4-Pass and 3-Pass (Optional)
Figure A12-3. Space Required to Open Rear Head on Model ICB Boilers
Figure A12-4. Model ICB Boilers Lifting Lug Location
Figure A12-5. Model ICB Boiler Mounting Piers
A12-4
12-02

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 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
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 87.5 102.1 116.6 145.8 175.0 204.1 233.3
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
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 5 5 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
* = 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.

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 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

A12-5
12-02

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 D145P D175P D210P D252P D300P D336P D378P

Btu Output (1000 Btu/hr) 3348 4184 5021 6695 8369 10043 11716 13390 16738 20085 23433 26780

Light Oil gph (140,000 Btu/gal) 29.2 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 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 5 5 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 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

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

A12-6
12-02
4-PASS ICB STANDARD STEAM BOILERS
3-PASS ICB STANDARD STEAM BOILERS
Figure A12-1. Model ICB Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional)
A12-7
12-02
Table A12-5. Model ICB Steam Boiler Dimensions, 4-Pass and 3-Pass
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"
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
NOTE: Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for actual option requirements.
A12-8
12-02
4-PASS ICB STANDARD HOT WATER BOILERS
3-PASS ICB STANDARD HOT WATER BOILERS
Figure A12-2. Model ICB Hot Water Boiler Dimensions, 4-Pass and 3-Pass (Optional)
A12-9
12-02
Table A12-6. Model ICB Hot Water Boiler Dimensions, 4-Pass and 3-Pass
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 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 2" 2" 2" 2"
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
A12-10
12-02
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
Figure A12-3. Space Required to Open Rear Head on Model ICB Boilers
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
NOTE: A, B, and C dimensions may vary by 1 inch.
Figure A12-4. Model ICB Boilers Lifting Lug Location
A12-11
12-02
" E"
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
NOTE: 6-inch high mounting piers recommended for use beneath the boiler base frame. The use of these piers pro-
vides increased inspection accessibility to the boiler and added height for washing down the area beneath the boiler.
Figure A12-5. Model ICB Boiler Mounting Piers
A12-12
12-02
PERFORMANCE DATA Gas-Fired Burners

Table A12-13 lists minimum required gas pressure for altitude
Contact your local Cleaver-Brooks Authorized Representative correction.
for efficiencies or additional information.
Cleaver-Brooks ICB boilers are available with the standard requirements for Standard, FM and IRI ICB Boiler gas trains
burner package, or optional induced flue gas recirculation, upstream of the gas pressure regulator.
refer to the Model ICB-LN in Section A13.
For oversized or undersized gas trains or altitude above 700
feet, contact your local Cleaver-Brooks Authorized
ENGINEERING DATA Representative.
The following engineering information is provided for Model
ICB Boilers. Additional detail is available from your local Fuel Connections Gas
Cleaver-Brooks Authorized Representative. The local gas company should be consulted for requirements
Boiler Information piping. Installation of gas supply piping and venting must be in
Table A12-7 shows steam volume and disengaging area for accordance with all applicable engineering guidelines and
Model ICB Boilers. regulatory codes. All connections made to the boiler should be
arranged so that all components remain accessible for
Table A12-8 lists quantity and outlet size for safety valves inspection, cleaning and maintenance.
supplied on Model ICB Steam Boilers.
A drip leg should be installed in the supply piping before the
Table A12-9 lists quantity and outlet size for relief valves connection to the gas pressure regulator. The drip leg should be
supplied on Model ICB Hot Water Boilers. at least as large as the inlet fitting supplied with the boiler.
Table A12-10 gives recommended steam nozzle sizes on Consideration must be given to both volume and pressure
Model ICB Boilers. requirements when choosing gas supply piping size. Refer to
Table A12-11 shows recommended non-return valve sizes for the particular installation. Connections to the burner gas train
Model ICB Boilers. should be made with a union, so that gas train components or
the burner may be easily disconnected for inspection or
Blowdown Water Requirements service. Upon completion of the gas piping installation, the
Some local codes require blowdown tanks to be constructed in system should be checked for gas leakage and tight shutoff of
accordance with recommendations of the National Board of all valves.
Fuel Connections Oil
The National Boards recommendations base the size of the Oil-fired burners are equipped with an oil pump, which draws
blowdown tank on the removal of at least 4 inches of water fuel from a storage tank and supplies pressurized oil to the
from the boiler. burner nozzle(s). The burner supply oil pump has a greater
Table A12-12 lists the approximate quantity of water capacity than the burner requires for the maximum firing rate.
represented by 4 inches of water at normal operating level for Fuel not delivered to the nozzle is returned to the storage tank.
Cleaver-Brooks Model ICB Boilers. A two-pipe (supply and return) oil system is recommended for
Burner/Control Information arrangement. Oil lines must be sized for the burner and burner
Burner Characteristics
The burner supply oil pump suction should not exceed 10" Hg.
Maximum altitude for standard burners is 700 feet. Contact
your local Cleaver-Brooks Authorized Representative for
least equal to that of the burner pump(s). Supply pressure to
higher altitude availability. Note that altitude correction and
the burner pump should not exceed 3 psig.
burner changes are required for higher altitudes which may
alter dimensions, motor hp and gas pressures.
A12-13
12-02
A strainer must be installed in the supply piping upstream of D. Under no condition should the total area of the air
the burner supply pump in order to prevent entry of foreign supply openings be less than one (1) square foot.
material into the pump, fuel control valves, or burner E. Size the openings by using the formula:
nozzle(s). The strainer must be sized for the burner supply
pump capacity. A strainer mesh of 150 microns (0.005") is
recommended. 2. Amount of air required (cfm).
Install a check valve in the line to prevent draining of the oil A. Combustion Air = Rated bhp x 8 cfm/bhp.
suction line when the burner is not in operation. Location of B. Ventilation Air = Maximum bhp x 2 cfm/bhp or a total
the check valve varies with the system, but usually it is located of 10 cfm/bhp up to 1000 feet elevation. Add 3 percent
as close as possible to the storage tank. more per 1000 feet of added elevation.
Installation of a vacuum gauge in the burner supply line 3. Acceptable air velocity in Boiler Room (fpm).
between the burner oil pump and the strainer is recommended. A. From floor to (7) foot height 250 fpm.
Regular observation and recording of the gauge indication will B. Above (7) foot height 500 fpm.
Upon completion of the oil piping installation, the system openings for (1) 300 hp boiler at 800 feet altitude. The air
should be checked for oil or air leakage and tight shutoff of all openings are to be 5 feet above floor level.
valves.
Boiler Room Information Air velocity: Up to 7 feet = 250 fpm (from 3 above).
Figure A12-7 shows typical boiler room length requirements. Area Required: Area = cfm/fpm = 3000/250 = 12 sq-ft total.
Figure A12-8 shows typical boiler room width requirements. Area/Opening: 12/2 = 6 sq-ft/opening (2 required).

100 800 hp Model ICB Boilers can support up to 2000 lbs NOTICE
without additional support. Consult local codes, which may supersede these
requirements.
100 800 hp Model ICB Boilers can be reinforced to support
up to 3000 lbs.
Boiler Room Combustion Air 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.
room, air flow, and velocity of air must be reviewed as follows:
ICB is not required, it is necessary to size the stack/breeching
room.
to limit flue gas pressure variation. The allowable pressure
A. Two (2) permanent air supply openings in the outer range is 0.25" W.C. to +0.25" W.C.
walls of the boiler room are recommended. Locate one
(1) at each end of the boiler room, preferably below a For additional information, please review Section I4, General
height of 7 feet. This allows air to sweep the length of Engineering Data (Stacks) and Section F, Stacks. Stack and
the boiler. 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
A12-14
12-02
Table A12-7. Model ICB Steam Volume and Disengaging Areas

HIGH LOW HIGH LOW

BOILER PRESSURE PRESSURE PRESSURE PRESSURE
HP (A) (B) (A) (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:
Table A12-8. Model ICB Steam Boiler Safety Valve Outlet Size
VALVE SETTING 15 PSIG STEAM 150 PSIG STEAM 200 PSIG STEAM 250 PSIG STEAM
NO. OF NO. OF NO. OF NO. OF

VALVES OUTLET VALVES OUTLET VALVES OUTLET VALVES OUTLET
BOILER HP REQD SIZE (IN.) REQD SIZE (IN.) REQD SIZE (IN.) REQD 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 2 (1) 1-1/4 2 1
(1) 1-1/4 (1) 1
150 1 3 2 (1) 1-1/2 2 1-1/4 2 (1) 1
(1) 1-1/4 (1) 1-1/4
200 2 2-1/2 2 1-1/2 2 (1) 1-1/2 2 1-1/4
(1) 1-1/4
250 2 (1) 2-1/2 2 (1) 2 2 1-1/2 2 (1) 1-1/2
(1) 3 (1) 1-1/2 (1) 1-1/4
300 2 3 2 2 2 (1) 2 2 1-1/2
(1) 1-1/2
350 3 (1) 2 2 (1) 2-1/2 2 2 2 (1) 1-1/2
(2) 3 (1) 2 (1) 2
400 3 (2) 3 2 (1) 2-1/2 2 2 2 (1) 1-1/2
(1) 2-1/2 (1) 2 (1) 2
500 3 3 2 2-1/2 2 (1) 2-1/2 2 2
(1) 2
600 4 (3) 3 3 (2) 2-1/2 2 2-1/2 2 (1) 2
(1) 2-1/2 (1) 2 (1) 2-1/2
700, 800 5 (3) 3 3 (2) 2-1/2 2 2-1/2 2 2-1/2
(2) 2-1/2 (1) 2
A12-15
12-02
Table A12-9. Model ICB Hot Water Boiler Relief Valve Outlet Size
NO. OF NO. OF NO. OF

VALVES OUTLET VALVES OUTLET VALVES OUTLET
BOILER HP REQD SIZE (IN.) REQD SIZE (IN.) REQD 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 2 2 2
(1) 1-1/4
250 2 (1) 2 1 2 2 (1) 2
(1) 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 2-1/2 2 (1) 2-1/2
(1) 1 (1) 3
400 3 (1) 2 1 2-1/2 2 (1) 2-1/2
(2) 2-1/2 (1) 3
500 4 (1) 1 2 (1) 1 2 3
(3) 2-1/2 (1) 2-1/2
600 4 (3) 2-1/2 2 (1) 1-1/4 3 (2) 3
(1) 2 (1) 2-1/2 (1) 2-1/2
700, 800 5 (1) 1 2 (1) 2-1/2 3 3
(4) 2-1/2 (1) 2
NOTE: Relief valve is Kunkle #537 for 30# & 125#(Section IV) boiler and is Kunkle #927 for 150# HTHW (Section I) boiler.
Table A12-10. Model ICB Recommended Steam Nozzle Size

OPERATING
PRESSURE 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 8 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 2.5 3 4 4 4 4 6 6 6 6
NOTES:
2. Recommended steam nozzle sizes based on 4000 to 5000 fpm steam velocity.
A12-16
12-02
Table A12-11. Model ICB Recommended Non-Return Valve Size

BOILER OPERATING PRESSURE (PSIG)
BOILER CAPACITY
HP (LBS/HR) 50 75 100 125 150 175 200 250
100 3450 3 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2
125 4313 4 3 3 3 3 2-1/2 2-1/2 2-1/2
150 5175 4 4 3 3 3 3 2-1/2 2-1/2
200 6900 4 4 4 3 3 3 3 3
250 8625 4 4 4 4 3 3 3 3
300 10350 6 4 4 4 4 4 4 3
350 12025 6 6 4 4 4 4 4 3
400 13800 6 6 4 4 4 4 4 4
500 17210 6 6 6 6 4 4 4 4
600 20700 8 8 6 6 6 4 4 4
700 24150 8 8 6 6 6 6 6 6
800 27600 8 8 6 6 6 6 6 6
NOTE: Valve sizes (300 psig flanges) given in inches.
Table A12-12. Model ICB Blowdown Tank Sizing Information Table A12-14. Sound Levels in dBA for
4-Pass ICB Boilers at High Fire
100 75 Sound Level dBA
125 94 BHP ICB
150 102 100 80.0
200 135 125 84.5
250 125 150 84.5
300 150 200 84.5
350 174 250 84.5
400 191 300 91.0
500 206 350 94.0
600 248 400 91.5
700 266 500 93.5
800 297 600 93.5
NOTE: Quantity of water removed from boiler by lowering normal water line 4". 700 93.7
800 93.7
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:

oz/sq-in x 1.732 = Inches WC.
Inches WC x 0.0361 = psig.
A12-17
12-02
Table A12-15. Model ICB, Standard, Minimum Required Gas Pressure at Entrance to Standard,
FM & IRI Gas Trains (Upstream of Gas Pressure Regulator)
STD PIPE PRESSURE REQUIRED, PRESSURE REQUIRED,
SIZE 3-PASS ("WC) 4-PASS ("WC)
BOILER
HP (Inches) Minimum Maximum Minimum Maximum
100 2 8.5 27.7 10.5 27.7
125 2 13.5 27.7 16 27.7
150 2 17 27.7 21 27.7
200 2-1/2 20 27.7 26 138.5
250 2-1/2 32.5 138.5 33 138.5
300 2-1/2 45 138.5 45.5 138.5
350 3 46 138.5 46.5 138.5
400 3 38 138.5 43.5 138.5
500 3 56 138.5 56 138.5
600 3 120 277 120 277
700 3 138.5 277 138.5 277
800 3 86 277 86 277
NOTE: For undersized or oversized gas trains or altitudes above 700 feet, contact your local Cleaver-Brooks
Authorized Representative.
A12-18
12-02
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.
Figure A12-7. Boiler Room Length (Typical Layouts) 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:
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" 100-200 hp
48" 250-400 hp
60 500-800 hp
Figure A12-8. Boiler Room Width (Typical Layout) Model ICB
A12-19
12-02
application.
Cleaver-Brooks Authorized Representative for information on special insurance requirements, special code requirements, optional
Model ICB Steam Boiler (100 800 hp, 15 300 psig)

1.0 Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-20
2.0 General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-20
3.0 Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-21
4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-22
5.0 Efficiency Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-25
6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-25
7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-25
Model ICB Hot Water Boiler (100 800 hp, 30 psig, 125 psig)
3.0 Hot Water Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-27
6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-30
7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12-30
Model ICB Steam Boiler (100 800 hp, 15 300 psig)

1.1 The Steam Boiler shall be Cleaver-Brooks Model ICB, Fuel Series ______ (100, 200, 700), _____ hp designed for _____ psig
(15, 150, 200, 250, 300 psig steam). The maximum operating pressure shall be _____ psig.
1.2 The boiler shall have a maximum output of _____ Btu/hr, or _____ horsepower when 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.

2.1 Number of Passes Select one of the following:
A. (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.
B. (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.
UL/cUL label.
A12-20
12-02

2.2.4 The rear door shall be insulated with a blanket material and a steel covering to give the surface a hard durable finish.
2.2.7 Exhaust Vent Select one of the following:
A. (Four-Pass) The exhaust gas vent shall be located near the front of the boiler on the top center line and shall be capable of
supporting 2000 lbs.
B. (Three-Pass) The exhaust gas vent shall be located at the rear of the boiler on the top center line and shall be capable of
2.2.10 The entire boiler based frame and other components shall be factory painted before shipment using a hard finish enamel
coating.
2.2.11 An inner rear turnaround access opening shall swing on a davit, to allow full accessibility to the 2nd pass tubes and furnace.
2.2.12 Tubes shall be removable from either the front or rear of the boiler.

3.1 Water Column
valves.
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.
A12-21
12-02

4.2 Blower
noise level.
shaft.
4.3 Combustion Air Control Select one of the following:
A. (Four-Pass) Combustion air damper and fuel control valve (100 250 hp) or cam operated fuel metering valve
(300 800 hp) shall be operated by a single damper control motor that regulates the flame according to load demand.
Potentiometer type position controls shall be provided to regulate operation of the damper control motor.
B. (Three-Pass) Combustion air damper and fuel control valve (100 350 hp) or cam operated fuel metering valve
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).
4.4.1 FUEL SERIES 700 GAS FIRED
4.4.1.1 Burner Type The burner shall be mounted at the front of the boiler and be of high radiant multi-port type for gas. The
4.4.1.2 Gas Pilot The gas pilot shall be a premix type with automatic electric ignition. An electronic detector shall monitor the
4.4.1.3 Gas Burner Piping Select one of the following:
A. 100 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, one (1) motorized
gas valve with proof of closure switch, two (2) plugged leakage test connections, and high and low gas pressure switches.
The gas valves shall be wired to close automatically in the event of power failure, 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 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.
A12-22
12-02
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
4.4.2 FUEL SERIES 100 LIGHT OIL FIRED
4.4.2.1 Burner Type The burner shall be mounted at the front of the boiler, and shall be approved for operation with CS12-48,
4.4.2.3 Oil Pump An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Pump shall
be motor driven and shipped loose to be field installed near the oil storage tank. Oil pump motor starter shall also be provided.
A. Four-Pass Select one of the following:
a. 100 150 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2)
solenoid oil shut-off valves, and pressure gauge all integrally mounted on the unit.
b. 200 250 hp. Fuel oil piping on the unit shall include oil pressure regulating device, oil metering controls, two (2)
solenoid oil shut-off valves, atomizing air proving switch, low oil pressure switch, and pressure gauge all integrally
mounted on the unit.
c. 300 800 hp. Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one (1)
B. Three-Pass Select one of the following:
4.4.2.5 Oil Atomization Type Select one of the following:
A. 100 150 hp. Burner shall include a complete mechanical oil atomizing system and be of the pressure atomizing type.
B. 200 800 hp. Burner shall be a low pressure air atomizing type, including a shipped loose air compressor assembly.
4.4.3 FUEL SERIES 200 LIGHT OIL OR GAS FIRED
4.4.3.1 Burner Type Select one of the following:
A. 100 150 hp. The burner, mounted at the front of the boiler, shall be a combination pressure atomizing type for oil and high
radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 oil or
natural gas.
B. 200 800 hp. The burner, mounted at the front of the boiler, shall be a combination of low pressure air atomizing type for
oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No.
2 oil or natural gas.
4.4.3.2 Gas Pilot The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the
pilot so that the primary fuel valve cannot open until flame has been established. The pilot train shall include one (1) manual shut-
off valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only).
A12-23
12-02
4.4.3.3 Oil Burner

4.4.3.3.1 Oil Pump An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Pump
shall be motor driven and shipped loose to be field installed near the oil storage tank. Oil pump motor starter shall also be provided.
4.4.3.3.2 Oil Burner Piping
solenoid oil shut-off valves, atomizing air proving switch, low oil pressure switch and pressure gauge all integrally
4.4.3.3.3 Oil Atomization Type Select one of the following:
shutdown condition.
power failure, flame failure, low water or any abnormal shutdown condition.
A12-24
12-02

4.5.1 Control Panel
violet type.

Brooks Authorized Representative for efficiency details).
6.0 Warranty
7.0 Execution
7.1 Shop Tests
7.2 Start-Up Service
A12-25
12-02
Model ICB Hot Water Boiler (100 800 hp, 30 psig, 125 psig)

1.1 The Hot Water Boiler shall be Cleaver-Brooks Model ICB, Fuel Series ______ (100, 200, 700), _____ hp designed for _____
psig (30, 125, or other psig hot water). The maximum water temperature will be _____ degree F, and the maximum system
circuit.

UL/cUL label.
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
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
coating.
A12-26
12-02

The hot water outlet and return connections shall be located on the top center line of the boiler. The internal design of these
connections shall provide forced internal circulation, mixing return water with the hot water within the boiler.
3.2 Dip Tube
outlet.
3.5 Relief Valves
The temperature controls to regulate burner operation shall be mounted on the unit with temperature sensing elements located
adjacent to the hot water outlet.

4.2 Blower
noise level.
shaft.
4.3 Combustion Air Control Select one of the following:
A. (Four-Pass) Combustion air damper and fuel control valve (100 250 hp) or cam operated fuel metering valve
B. (Three-Pass) Combustion air damper and fuel control valve (100 350 hp) or cam operated fuel metering valve
A12-27
12-02

4.4.1.1 Burner Type The burner shall be mounted at the front of the boiler and of high radiant multi-port type for gas. The burner
shutdown condition.
4.4.2.2 Gas Pilot The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the pilot
4.4.2.3 Oil Pump An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Pump shall be
motor driven and shipped loose to be field installed near the oil storage tank. Oil pump motor starter shall also be provided.
A12-28
12-02
4.4.2.5 Oil Atomization Type Select one of the following:
4.4.3.1 Burner Type Select one of the following:
A. 100 150 hp. The burner, mounted at the front of the boiler, shall be a combination pressure atomizing type for oil and high
radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No. 2 oil or
natural gas.
B. 200 800 hp. The burner, mounted at the front of the boiler, shall be a combination of low pressure air atomizing type for
oil and high radiant multi-port type for gas. The burner shall be approved for operation with either CS12-48 Commercial No.
2 oil or natural gas.
4.4.3.3 Oil Burner
4.4.3.3.1 Oil Pump An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Pump shall
4.4.3.3.2 Oil Burner Piping
4.4.3.3.3 Oil Atomization Type Select one of the following:
A12-29
12-02

shutdown condition.
4.5.1 Control Panel
4.5.2 The panel will have a NEMA 1A rating and contain the flame safeguard controller, burner motor starter, air compressor
violet type.

Cleaver-Brooks Authorized Representative for efficiency details).
6.0 Warranty
7.0 Execution
7.1 Shop Tests
A12-30
12-02
Section A13
Model ICB-LN
CONTENTS
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-3
Dimensions and Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-4
Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-13
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-13
Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-13
Sample Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-20
A13-1
12-02
Model ICB-LN Firetube Boilers
ILLUSTRATIONS
Figure A13-1. Model ICB-LN Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-7
Figure A13-2. Model ICB-LN Hot Water Boiler Dimensions, 4-Pass and 3-Pass (Optional) . . . . . . . . . . . . . . . . . . . . . . . . A13-9
Figure A13-3. Space Required to Open Rear Head on Model ICB-LN Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-11
Figure A13-4. Model ICB-LN Boilers Lifting Lug Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-11
Figure A13-5. Model ICB-LN Boiler Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-12
Figure A13-6. Typical Fuel Oil Supply Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-18
Figure A13-7. Boiler Room Length (Typical Layouts) Model ICB-LN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-19
Figure A13-8. Boiler Room Width (Typical Layout) Model ICB-LN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-19
TABLES
Table A13-1. Model ICB-LN Steam Boiler Ratings, 4-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-5
Table A13-2. Model ICB-LN Steam Boiler Ratings, 3-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-5
Table A13-3. Model ICB-LN Hot Water Boiler Ratings, 4-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-6
Table A13-4. Model ICB-LN Hot Water Boiler Ratings, 3-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-6
Table A13-5. Model ICB-LN Steam Boiler Dimensions, 4-Pass and 3-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-8
Table A13-6. Model ICB-LN Hot Water Boiler Dimensions, 4-Pass and 3-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-10
Table A13-7. Model ICB-LN Steam Volume and Disengaging Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-15
Table A13-8. Model ICB-LN Steam Boiler Safety Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-15
Table A13-9. Model ICB-LN Hot Water Boiler Relief Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-16
Table A13-10. Model ICB-LN Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-16
Table A13-11. Model ICB-LN Recommended Non-Return Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-17
Table A13-12. Model ICB-LN Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-17
Table A13-13. Altitude Correction for Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-17
Table A13-14. Sound Pressure Levels in dBA for ICB Boilers at High Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-17
Table A13-15. Model ICB-LN, Standard, Minimum Required Gas Pressure at Entrance to Standard,
FM & IRI Gas Trains (Upstream of Gas Pressure Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-18
The following information applies to the Cleaver-Brooks Model ICB-LN Boiler.
A13-2
12-02
Firetube Boilers Model ICB-LN
FEATURES AND BENEFITS Available options include the following (contact your local
Cleaver-Brooks Authorized Representative for option details).
The Cleaver-Brooks Model ICB Boiler line provides a quality
product utilizing a baseline boiler/burner design. Additionally, Boiler Options:
the boiler/burner package has the UL/cUL label. The following Three-pass design.
features apply:
Drain valves.
Four-Pass Intercooled Design:
Blowdown valves.
Four-pass design provides high flue gas velocities and low
stack temperatures to maximize efficiency. Non-return valves.
Three-Pass Intercooled Design (optional): Surface blowdown systems.
Versatile design offered with choice of three or four-pass Blend pump.
construction to meet application needs. Surge load baffles.
Seismic design.
Intercooled Rear Turnaround:
Rear furnace turnaround area is fluid cooled and has a
davited access opening for full accessibility to 2nd pass Flame safeguard controllers.
tubes and furnace. It eliminates confined space issues and Lead/lag system.
provides for ease of maintenance. All tubes can be removed
High altitude design.
from either the front or rear of the boiler.
CSD-1).
Rear door completely covers and insulates rear tube sheet. Main disconnect.
Elapsed time meter.
Natural Gas, No. 2 Oil, or Combination Burners Available:
Combination gas/oil burners provide quick fuel changeover NEMA enclosures.
Low-fire hold control.
PRODUCT OFFERING
Circuit breakers.
Cleaver-Brooks Model ICB Boilers are available in low Day/night controls.
pressure steam, high pressure steam, and hot water designs.
Burners are available to fire natural gas, No. 2 oil, or a Special power requirements.
combination of oil and gas. Standard product offering is: Stack thermometer.
100 800 hp. Fuel Options
30 and 125 psig hot water. Air atomizing oil burner, 100 800 hp.
15 300 psig steam. Gas strainer.
Full modulation, all sizes. Gas pressure gauge.
A13-3
12-02

Dimensions and ratings for the Model ICB-LN Boilers are shown in the following tables and illustrations. The information is sub-
ject to change without notice.
Table A13-1. Model ICB-LN Steam Boiler Ratings, 4-Pass
Table A13-2. Model ICB-LN Steam Boiler Ratings, 3-Pass (Optional)
Table A13-3. Model ICB-LN Hot Water Boiler Ratings, 4-Pass
Table A13-4. Model ICB-LN Hot Water Boiler Ratings, 3-Pass (Optional)
Figure A13-1. Model ICB-LN Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional)
Table A13-5. Model ICB-LN Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional)
Figure A13-2. Model ICB-LN Hot Water Boiler Dimensions, 4-Pass and 3-Pass (Optional)
Table A13-6. Model ICB-LN Hot Water Boiler Dimensions, 4-Pass and 3-Pass (Optional)
Figure A13-3. Space Required to Open Rear Head on Model ICB-LN Boilers
Figure A13-4. Model ICB-LN Boilers Lifting Lug Location
Figure A13-5. Model ICB-LN Boiler Mounting Piers
A13-4
12-02

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

Rated Capacity (lbs-steam/hr 3450 4313 5175 6900 8625 10350 12075 13800 17250 20700 24150 27600
from and at 212F)
Btu Output (1000 Btu/hr) 3348 4184 5021 6695 8369 10043 11716 13390 16738 20085 23433 26780

Light Oil gph 29.2 36.4 43.7 58.3 72.9 87.5 102.1 116.6 145.8 175.0 204.1 233.3
(140,000 Btu/gal)
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 5 5 7-1/2 7-1/2 7-1/2 15 15
Motor hp (Oil only)
Integral Oil/Air Motor hp 1 1 1 1 2
(Oil only)
Oil Metering Pump Motor hp 1/2 3/4 3/4 3/4 3/4 1 1
(Oil only)
Circulating Oil Pump 1/2 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4 1 1
Motor hp (Oil only)
BOILER DATA
Heating Surface sq-ft. 353 438 555 729 885 1055 1384 1522 1734 2094 3244 3641
(Fireside)

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

Rated Capacity (lbs-steam/hr 3450 4313 5175 6900 8625 10350 12075 13800 17250 20700 24150 27600
from and at 212F)
Btu Output (1000 Btu/hr) 3348 4184 5021 6695 8369 10043 11716 13390 16738 20085 23433 26780

Light Oil gph 29.9 37.5 45.0 60.0 74.5 89.5 104.5 119.5 149.5 179.5 209 239
(140,000 Btu/gal)
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 5 5 7-1/2 7-1/2 7-1/2 15
Motor hp (Oil only)
Integral Oil/Air Motor hp 1 1 1 1 2 2
(Oil only)
Oil Metering Pump Motor hp 1/2 3/4 3/4 3/4 3/4 1
(Oil only)
Motor hp (Oil only)
BOILER DATA
(Fireside)
A13-5
12-02

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 29.2 36.4 43.7 58.3 72.9 87.5 102.1 116.6 145.8 175.0 204.1 233.3
(140,000 Btu/gal)
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 5 5 7-1/2 7-1/2 7-1/2 15 15
Motor hp (Oil only)
Integral Oil/Air Motor hp 1 1 1 1 2
(Oil only)
Oil Metering Pump Motor hp 1/2 3/4 3/4 3/4 3/4 1 1
(Oil only)
Motor hp (Oil only)
BOILER DATA
(Fireside)

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 29.9 37.5 45.0 60.0 74.5 89.5 104.5 119.5 149.5 179.5 209 239
(140,000 Btu/gal)
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 5 5 7-1/2 7-1/2 7-1/2 15
Motor hp (Oil only)
Integral Oil/Air Motor hp 1 1 1 1 2 2
(Oil only)
Oil Metering Pump 1/2 3/4 3/4 3/4 3/4 1
Motor hp (Oil only)
Circulating Oil Pump Motor 1/2 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4 1 1
hp (Oil only)
BOILER DATA
(Fireside)
A13-6
12-02
4-PASS ICB LOW NOx STEAM BOILERS
3-PASS ICB LOW NOx STEAM BOILERS
Figure A13-1. Model ICB-LN Steam Boiler Dimensions, 4-Pass and 3-Pass (Optional)
A13-7
12-02
Table A13-5. Model ICB-LN Steam Boiler Dimensions, 4-Pass and 3-Pass
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 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"
(3-Pass Only)
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"
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
A13-8
12-02
4-PASS ICB LOW NOx HOT WATER BOILERS
3-PASS ICB LOW NOx HOT WATER BOILERS
Figure A13-2. Model ICB-LN Hot Water Boiler Dimensions, 4-Pass and 3-Pass (Optional)
A13-9
12-02
Table A13-6. Model ICB-LN Hot Water Boiler Dimensions, 4-Pass and 3-Pass
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 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"
(3-Pass Only)
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 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 2" 2" 2" 2"
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
A13-10
12-02
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
Figure A13-3. Space Required to Open Rear Head on Model ICB-LN Boilers
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
NOTE: A, B, and C dimensions may vary by 1 inch.
Figure A13-4. Model ICB-LN Boilers Lifting Lug Location
A13-11
12-02
" E"
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
NOTE: 6-inch high mounting piers recommended for use beneath the boiler base frame. The use of these piers pro-
vides increased inspection accessibility to the boiler and added height for washing down the area beneath the boiler.
Figure A13-5. Model ICB-LN Boiler Mounting Piers
A13-12
12-02
PERFORMANCE DATA Gas-Fired Burners

Table A13-13 lists minimum required gas pressure for altitude
Contact your local Cleaver-Brooks Authorized Representative correction.
for efficiencies or additional information.
requirements for Standard, FM and IRI ICB Boiler gas trains
ENGINEERING DATA upstream of the gas pressure regulator.
The following engineering information is provided for Model For oversized or undersized gas trains or altitude above 700
ICB-LN Boilers. Additional detail is available from your local feet, contact your local Cleaver-Brooks Authorized
Cleaver-Brooks Authorized Representative. Representative.
Boiler Information Fuel Connections Gas
Table A13-7 shows steam volume and disengaging area for The local gas company should be consulted for requirements
Model ICB-LN Boilers. and authorization for installation and inspection of gas supply
Table A13-8 lists quantity and outlet size for safety valves piping. Installation of gas supply piping and venting must be in
supplied on Model ICB-LN Steam Boilers. accordance with all applicable engineering guidelines and
Table A13-9 lists quantity and outlet size for relief valves arranged so that all components remain accessible for
supplied on Model ICB-LN Hot Water Boilers. inspection, cleaning and maintenance.
Table A13-10 gives recommended steam nozzle sizes on A drip leg should be installed in the supply piping before the
Model ICB-LN Boilers. connection to the gas pressure regulator. The drip leg should be
Table A13-11 shows recommended non-return valve sizes for at least as large as the inlet fitting supplied with the boiler.
Model ICB-LN Boilers. Consideration must be given to both volume and pressure
Blowdown Water Requirements 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
The National Boards recommendations base the size of the system should be checked for gas leakage and tight shutoff of
blowdown tank on the removal of at least 4 inches of water all valves.
from the boiler.
Fuel Connections Oil
Table A13-12 lists the approximate quantity of water Oil-fired burners are equipped with an oil pump, which draws
represented by 4 inches of water at normal operating level for fuel from a storage tank and supplies pressurized oil to the
Cleaver-Brooks Model ICB-LN Boilers. burner nozzle(s). The burner supply oil pump has a greater
capacity than the burner requires for the maximum firing rate.
Burner/Control Information Fuel not delivered to the nozzle is returned to the storage tank.
Burner altitude limits for standard configuration is 700 feet.
arrangement. Oil lines must be sized for the burner and burner
Contact your local Cleaver-Brooks Authorized
Representative for higher altitude availability. Note that
higher altitudes may require different configurations, The burner supply oil pump suction should not exceed 10" Hg.
including dimensions, motor hp and gas pressures. 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.
A13-13
12-02
A strainer must be installed in the supply piping upstream of D. Under no condition should the total area of the air
the burner supply pump in order to prevent entry of foreign supply openings be less than one (1) square foot.
material into the pump, fuel control valves, or burner E. Size the openings by using the formula:
nozzle(s). The strainer must be sized for the burner supply
pump capacity. A strainer mesh of 150 microns (0.005") is
recommended. 2. Amount of air required (cfm).
Install a check valve in the line to prevent draining of the oil A. Combustion Air = Rated bhp x 8 cfm/bhp.
suction line when the burner is not in operation. Location of B. Ventilation Air = Maximum bhp x 2 cfm/bhp or a total
the check valve varies with the system, but usually it is located of 10 cfm/bhp up to 1000 feet elevation. Add 3 percent
as close as possible to the storage tank. more per 1000 feet of added elevation.
Installation of a vacuum gauge in the burner supply line 3. Acceptable air velocity in Boiler Room (fpm).
between the burner oil pump and the strainer is recommended. A. From floor to (7) foot height 250 fpm.
Regular observation and recording of the gauge indication will B. Above (7) foot height 500 fpm.
Upon completion of the oil piping installation, the system openings for (1) 300 hp boiler at 800 feet altitude. The air
should be checked for oil or air leakage and tight shutoff of all openings are to be 5 feet above floor level.
valves.
Boiler Room Information Air velocity: Up to 7 feet = 250 fpm (from 3 above).
Figure A13-7 shows typical boiler room length requirements. Area Required: Area = cfm/fpm = 3000/250 = 12 sq-ft total.
Figure A13-8 shows typical boiler room width requirements. Area/Opening: 12/2 = 6 sq-ft/opening (2 required).

100 800 hp Model ICB-LN Boilers can support up to 2000 NOTICE
lbs without additional support.
Consult local codes, which may supersede these
100 800 hp Model ICB-LN Boilers can be reinforced to requirements.
support up to 3000 lbs.
Boiler Room Combustion Air The design of the stack and breeching must provide the
When determining boiler room air requirements, the size of the required draft at each boiler flue gas outlet. Proper draft is
room, air flow, and velocity of air must be reviewed as follows: critical to burner performance.
1. Size (area) and location of air supply openings in boiler Although constant pressure at the flue gas outlet of the Model
room. ICB-LN is not required, it is necessary to size the stack/
A. Two (2) permanent air supply openings in the outer breeching to limit flue gas pressure variation. The allowable
walls of the boiler room are recommended. Locate one pressure range is 0.25" W.C. to +0.25" W.C.
(1) at each end of the boiler room, preferably below a For additional information, please review Section I4, General
height of 7 feet. This allows air to sweep the length of Engineering Data (Stacks) and Section F, Stacks. Stack and
the boiler. breeching sizes should always be provided by a reputable stack
B. Air supply openings can be louvered for weather supplier who will design the stack and breeching system based
protection, but they should not be covered with fine on the above criteria. Your local Cleaver-Brooks Authorized
mesh wire, as this type of covering has poor air flow Representative is capable of assisting in your evaluation of the
qualities and is subject to clogging by dust or dirt. stack/breeching design.
A13-14
12-02
Table A13-7. Model ICB-LN Steam Volume and Disengaging Areas

HIGH LOW HIGH LOW

BOILER PRESSURE PRESSURE PRESSURE PRESSURE
HP (A) (B) (A) (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:
Table A13-8. Model ICB-LN Steam Boiler Safety Valve Outlet Size
VALVE SETTING 15 PSIG STEAM 150 PSIG STEAM 200 PSIG STEAM 250 PSIG STEAM
NO. OF NO. OF NO. OF NO. OF

VALVES OUTLET VALVES OUTLET VALVES OUTLET VALVES OUTLET
BOILER HP REQD SIZE (IN.) REQD SIZE (IN.) REQD SIZE (IN.) REQD 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 2 (1) 1-1/4 2 1
(1) 1-1/4 (1) 1
150 1 3 2 (1) 1-1/2 2 1-1/4 2 (1) 1
(1) 1-1/4 (1) 1-1/4
200 2 2-1/2 2 1-1/2 2 (1) 1-1/2 2 1-1/4
(1) 1-1/4
250 2 (1) 2-1/2 2 (1) 2 2 1-1/2 2 (1) 1-1/2
(1) 3 (1) 1-1/2 (1) 1-1/4
300 2 3 2 2 2 (1) 2 2 1-1/2
(1) 1-1/2
350 3 (1) 2 2 (1) 2-1/2 2 2 2 (1) 1-1/2
(2) 3 (1) 2 (1) 2
400 3 (2) 3 2 (1) 2-1/2 2 2 2 (1) 1-1/2
(1) 2-1/2 (1) 2 (1) 2
500 3 3 2 2-1/2 2 (1) 2-1/2 2 2
(1) 2
600 4 (3) 3 3 (2) 2-1/2 2 2-1/2 2 (1) 2
(1) 2-1/2 (1) 2 (1) 2-1/2
700, 800 5 (3) 3 3 (2) 2-1/2 2 2-1/2 2 2-1/2
(2) 2-1/2 (1) 2
A13-15
12-02
Table A13-9. Model ICB-LN Hot Water Boiler Relief Valve Outlet Size
NO. OF NO. OF NO. OF

VALVES OUTLET VALVES OUTLET VALVES OUTLET
BOILER HP REQD SIZE (IN.) REQD SIZE (IN.) REQD 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 2 2 2
(1) 1-1/4
250 2 (1) 2 1 2 2 (1) 2
(1) 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 2-1/2 2 (1) 2-1/2
(1) 1 (1) 3
400 3 (1) 2 1 2-1/2 2 (1) 2-1/2
(2) 2-1/2 (1) 3
500 4 (1) 1 2 (1) 1 2 3
(3) 2-1/2 (1) 2-1/2
600 4 (3) 2-1/2 2 (1) 1-1/4 3 (2) 3
(1) 2 (1) 2-1/2 (1) 2-1/2
700, 800 5 (1) 1 2 (1) 2-1/2 3 3
(4) 2-1/2 (1) 2
NOTE: Relief valve is Kunkle #537 for 30# & 125#(Section IV) boiler and is Kunkle #927 for 150# HTHW (Section I) boiler.
Table A13-10. Model ICB-LN Recommended Steam Nozzle Size

OPERATING
PRESSURE 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 8 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 2.5 3 4 4 4 4 6 6 6 6
NOTES:
2. Recommended steam nozzle sizes based on 4000 to 5000 fpm steam velocity.
A13-16
12-02
Table A13-11. Model ICB-LN Recommended Non-Return Valve Size

BOILER OPERATING PRESSURE (PSIG)
BOILER CAPACITY
HP (LBS/HR) 50 75 100 125 150 175 200 250
100 3450 3 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2
125 4313 4 3 3 3 3 2-1/2 2-1/2 2-1/2
150 5175 4 4 3 3 3 3 2-1/2 2-1/2
200 6900 4 4 4 3 3 3 3 3
250 8625 4 4 4 4 3 3 3 3
300 10350 6 4 4 4 4 4 4 3
350 12025 6 6 4 4 4 4 4 3
400 13800 6 6 4 4 4 4 4 4
500 17210 6 6 6 6 4 4 4 4
600 20700 8 8 6 6 6 4 4 4
700 24150 8 8 6 6 6 6 6 6
800 27600 8 8 6 6 6 6 6 6
NOTE: Valve sizes (300 psig flanges) given in inches.
Table A13-12. Model ICB-LN Blowdown Tank Sizing Table A13-14. Sound Pressure Levels in dBA for
Information ICB Boilers at High Fire
BOILER HP WATER (GAL) Sound Level dBA
100 75 BHP ICB-LN
125 94 100 83.1
150 102 125 89.5
200 135 150 88.6
250 125 200 90.0
300 150 250 91.0
350 174 300 94.0
400 191 350 91.5
500 206 400 93.5
600 248 500 93.5
700 266 600 93.7
800 297 700 93.7
NOTE: Quantity of water removed from boiler by lowering normal water line 4". 800 93.5

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:

oz/sq-in x 1.732 = Inches WC.
Inches WC x 0.0361 = psig.
A13-17
12-02
Table A13-15. Model ICB-LN, Standard, Minimum Required Gas Pressure at Entrance to Standard,
FM & IRI Gas Trains (Upstream of Gas Pressure Regulator)
STD PIPE PRESSURE REQUIRED, PRESSURE REQUIRED,
SIZE 3-PASS ("WC) 4-PASS ("WC)
BOILER
HP (Inches) Minimum Maximum Minimum Maximum
100 2 13 27.7 15 27.7
125 2 19.5 27.7 17.5 27.7
150 2 20 27.7 21.5 27.7
200 2-1/2 27 27.7 32.5 138.5
250 2-1/2 30 138.5 35.5 138.5
300 2-1/2 43 138.5 47.5 138.5
350 3 45 138.5 49.5 138.5
400 3 40.5 138.5 42.5 138.5
500 3 53.5 138.5 58.5 138.5
600 3 120 277 120 277
700 3 138.5 277 138.5 277
800 3 86 277 86 277
NOTE: For undersized or oversized gas trains or altitudes above 700 feet, contact your local Cleaver-Brooks
Authorized Representative.
A13-18
12-02
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.
Figure A13-7. Boiler Room Length (Typical Layouts) Model ICB-LN
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:
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" 100-200 hp
48" 250-400 hp
60 500-800 hp
Figure A13-8. Boiler Room Width (Typical Layout) Model ICB-LN
A13-19
12-02
application.
The Sample Specification is typically utilized as the base template for the complete boiler specification. The LN option includes
information on the Low NOx package for 30 ppm NOx (dry volume basis and corrected to 3% O2) when firing natural gas. Contact
your local Cleaver-Brooks Authorized Representative for information on special insurance requirements, special code
requirements, optional equipment, or general assistance in completing the specification.
Model ICB-LN Steam Boiler (100 800 hp, 15 300 psig)

1.0 Boiler Characteristics (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-20
3.0 Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-21
6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-24
7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-24
Model ICB-LN Hot Water Boiler (100 800 hp, 30 psig, 125 psig)
3.0 Hot Water Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-26
6.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-28
7.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13-28
Model ICB-LN Steam Boiler (100 800 hp, 15 300 psig)

1.1 The Steam Boiler shall be Cleaver-Brooks Model ICB-LN, Fuel Series ______ (100, 200, 700), _____ hp designed for _____
psig (15, 150, 200, 250, 300 psig steam). The maximum operating pressure shall be _____ psig.
circuit.

2.1.1 Approvals: The complete burner/boiler Low NOx package shall be approved as a unit by Underwriters Laboratories Inc. and
A13-20
12-02
A. (Four-Pass) The exhaust gas vent shall be located near the front of the boiler on the top centerline and shall be capable of
B. (Three-Pass) The exhaust gas vent shall be located at the rear of the boiler on the top centerline and shall be capable of
coating.
corrected to 3% O2 when firing natural gas.
2.3.2 The low emission (LN) option shall include a burner and boiler package to provide NOx reduction through an induced flue
gas recirculation system using the burner blower assembly, a control valve, a shut-off valve, electrical interlocks, and flue gas recir-
culation piping. Boiler fuel-to-steam efficiency and rated boiler capacity shall be guaranteed while the boiler is operating at the low
Cleaver-Brooks boiler shall include factory testing as a package, and the burner shall bear the UL, cUL label.

3.1 Water Column
valves.
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.
A13-21
12-02


4.2 Blower
noise level.
shaft.
4.4.1.1 Burner Type The burner shall be mounted at the front of the boiler and be of high radiant multi-port type for gas. The
shutdown condition.
A13-22
12-02
C. 300 800 hp. Gas burner piping on all units shall include two (2) manual shut-off valves, gas pressure regulator, two (2)
4.4.2.3 Oil Pump An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Pump shall
4.4.2.4 Oil Burner Piping Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one
(1) motorized oil valve with proof of closure switch, pressure relief valve, atomizing air proving switch, and low oil pressure switch
all integrally mounted on the unit.
4.4.2.5 Oil Atomization Type Burner shall be a low pressure air atomizing type, including a shipped loose air compressor
assembly.
4.4.3.1 Burner Type The burner, mounted at the front of the boiler, shall be a combination of low pressure air atomizing type for
or natural gas.
4.4.3.2 Gas Pilot The gas pilot shall be premix type with automatic electric ignition. An electronic detector shall monitor the
pilot so that the primary fuel valve cannot open until flame has been established. The pilot train shall include one (1) manual shut-
off valve, solenoid valve, pressure regulator, and one (1) plugged leakage test connection (Canada only).
4.4.3.3 Oil Burner
4.4.3.3.1 Oil Pump An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Pump
shall be motor driven and shipped loose to be field installed near the oil storage tank. Oil pump motor starter shall also be provided.
4.4.3.3.2 Oil Burner Piping Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one
4.4.3.3.3 Oil Atomization Type Burner shall be a low pressure air atomizing type, including a shipped loose air compressor
assembly.
shutdown condition.
A13-23
12-02

4.5.1 Control Panel
violet type.

Brooks Authorized Representative for efficiency details).
6.0 Warranty
7.0 Execution
7.1 Shop Tests
A13-24
12-02
Model ICB-LN Hot Water Boiler (100 800 hp, 30 psig, 125 psig)

1.1 The Hot Water Boiler shall be Cleaver-Brooks Model ICB-LN, Fuel Series ______ (100, 200, 700), _____ hp designed for
circuit.

2.1.1 Approvals: The complete burner/boiler Low NOx package shall be approved as a unit by Underwriters Laboratories Inc. and
2.2.2 The hot water return and outlet connections shall be located on the top centerline of the boiler. The boiler shall be designed to
A. (Four-Pass) The exhaust gas vent shall be located near the front of the boiler on the top centerline and shall be capable of
B. (Three-Pass) The exhaust gas vent shall be located at the rear of the boiler on the top centerline and shall be capable of
coating.
A13-25
12-02

corrected to 3% O2 when firing natural gas.
2.3.2 The low emission (LN) option shall include a burner and boiler package to provide NOx reduction through an induced flue
gas recirculation system using the burner blower assembly, a control valve, a shut-off valve, electrical interlocks, and flue gas recir-
culation piping. Boiler fuel-to-water efficiency and rated boiler capacity shall be guaranteed while the boiler is operating at the low
Cleaver-Brooks boiler shall include factory testing as a package, and the burner shall bear the UL, cUL label.

The hot water outlet and return connections shall be located on the top centerline of the boiler. The internal design of these
connections shall provide forced internal circulation, mixing return water with the hot water within the boiler.
3.2 Dip Tube
outlet.
3.5 Relief Valves
The temperature controls to regulate burner operation shall be mounted on the unit with temperature sensing elements located
adjacent to the hot water outlet.

4.2 Blower
noise level.
shaft.
A13-26
12-02

4.4.1.1 Burner Type The burner shall be mounted at the front of the boiler and of high radiant multi-port type for gas. The burner
shutdown condition.
so that the primary fuel valve cannot open until 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).
4.4.2.3 Oil Pump An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Pump shall be
motor driven and shipped loose to be field installed near the oil storage tank. Oil pump motor starter shall also be provided.
4.4.2.4 Oil Burner Piping Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one (1)
motorized oil valve with proof of closure switch, pressure relief valve, atomizing air proving switch, and low oil pressure switch all
integrally mounted on the unit.
4.4.2.5 Oil Atomization Type Burner shall be a low pressure air atomizing type, including a shipped loose air compressor
assembly.
4.4.3.1 Burner Type The burner, mounted at the front of the boiler, shall be a combination of low pressure air atomizing type for
or natural gas.
A13-27
12-02
4.4.3.3 Oil Burner

4.4.3.3.1 Oil Pump An oil pump with a capacity of approximately twice the maximum burning rate shall be included. Pump shall
4.4.3.3.2 Oil Burner Piping Fuel oil piping on the unit shall include oil metering system, one (1) solenoid oil shut-off valve, one
4.4.3.3.3 Oil Atomization Type Burner shall be a low pressure air atomizing type, including a shipped loose air compressor
assembly.
shutdown condition.
4.5.1 Control Panel
4.5.2 The panel will have a NEMA 1A rating and contain the flame safeguard controller, burner motor starter, air compressor
violet type.
Cleaver-Brooks Authorized Representative for efficiency details).
6.0 Warranty
7.0 Execution
7.1 Shop Tests
A13-28
12-02
Section B
COMMERCIAL BOILERS
Model FLX Boilers B1
Model 4 Boilers B2
Model 5 Boilers B3
Electric Boilers B4
Truefire Boilers B5
Clearfire Boilers B6
B-a
02-02
General Commercial Boilers
B-b
Section B1
FLEXIBLE WATERTUBE BOILERS
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-3
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-4
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-4
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-5
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-11
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-11
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-11
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-11
Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-11
Burner/Control Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1-13
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1-18
Steam Boiler Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-18
Hot Water Boiler Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-22
B1-1
04-02
Flexible Watertube Boilers Commercial Boilers
ILLUSTRATIONS
Figure B1-1. Model FLX Hot Water Boiler Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-7
Figure B1-2. Model FLX Steam Boiler Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-9
Figure B1-3. Model FLX Tube Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-13
Figure B1-4. Model FLX Oil Burner Supply Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-15
Figure B1-5. Model FLX Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-16
Figure B1-6.Model FLX Breeching Arrangement - Single or Multiple Boiler Installation . . . . . . . . . . . . . . . . . . . . . . . B1-17
TABLES
Table B1-1. Model FLX Watertube Boiler Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-4
Table B1-2. Model FLX Hot Water Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-6
Table B1-3.Model FLX Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-6
Table B1-4. Expected Emissions (ppm, corrected to 3% O2), Natural Gas Fired Boiler . . . . . . . . . . . . . . . . . . . . . . . . . B1-11
Table B1-5. Model FLX Hot Water Boiler Flow Rates and Pressure Drops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-11
Table B1-6. Model FLX Circulating Rates, Hot Water Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-12
Table B1-7. Model FLX Minimum Over Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-12
Table B1-8. Model FLX Boiler Heat Release Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-12
Table B1-9. Model FLX Burner Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-14
Table B1-10. Model FLX Minimum Required Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-14
Table B1-11. Model FLX Sound Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-16
Table B1-12. Model FLX Combustion Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-17
This section contains information on the Flexible Watertube boiler. The product model name is FLX
for factory-assembled boilers, and FLE for 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.
B1-2
04-02
Commercial Boilers Flexible Watertube Boilers
FEATURES AND BENEFITS NOx reduction to 20 ppm available.

Meets stringent emission requirements with no loss in
Patented Vessel and Tube Design: operating performance.
Ensures that all tubes are subject to radiant heat from the
burner flame. ASME Construction:
Creates high water-flow-rates at all loads, and increases heat Ensures high quality design and manufacturing standards.
transfer throughout the boiler. Ensures safety and reliability.
Large Downcomer, Located Outside the Fire Zone: Cleaver-Brooks Forced Draft Burner:
Guarantees positive natural internal circulation, minimizing Provides high pressure drop for low CO and maximum
the impact of exterior pumping conditions. combustion performance.
Reduces stack draft requirements.
True Tangent-Wall Design:
No fins or strips to substitute for tubes. Optimum fuel and air mixing.
Ensures maximum cooling and uniform heat transfer Long-life reverse curve impeller.
throughout the boiler. Ensures maximum combustion efficiency, as low as 10%
excess air.
Five-Pass Boiler Design:
Burner/Boiler by single manufacturer.
Creates high flue gas velocities to rapidly and efficiently
transfer heat to the water. Removable Side Panels
Higher efficiencies compared to other tangent-tube designs. Provides easy access for inspection.
1.5-Inch Diameter Tube Design:
Ensures containment of furnace gases.
Eliminates possible damage from thermal shock stresses.
Rugged construction for durability.
Prolongs equipment life. 20-Year Pressure Vessel Warranty:
Guaranteed to last.
Swedge-Fitted Tube Attachment:
Backed by Cleaver-Brooks.
Eliminates the need for rolling or welding tubes.
Lessens repair or replacement requirements. Field Erectable (Optional):
Ease of tube replacement reduces downtime. Complete package for ease of assembly.
Pieces fit through standard doorway.
Burner Supported by the Front Door:
No crane/hoist is required to remove burner and components
for inspection.
PRODUCT OFFERING
Information in this section applies to steam and hot water
Provides easy inspection access.
boiler sizes ranging from 1.5 to 12 MMBtu/hr input, as shown
Reduces maintenance costs. in Table B1-1.
The Flexible Watertube Boiler is a five-pass steel boiler with
Insulated Construction: flexible tubes formed and arranged to direct the flow of com-
Reduces thermal losses. bustion gases through the boiler. The pressure vessel conforms
to Section I or Section IV of the ASME Code, and consists of
Increases efficiency. the formed tubes and the external downcomer connected to the
top and bottom drums. The heated area of the pressure vessel is
Low NOx Capability: contained within a gas-tight, insulated casing that is composed
of removable, formed-steel panels. The boiler/burner package
B1-3
04-02
Table B1-1. Model FLX Watertube Boiler Sizes C. Pressure gauge for steam boilers.
CAPACITY D. Operating and limit controls:
HEAT OUTPUT EQUIV
MODEL INPUT
BTU/HR HP 1). High limit control - manual reset.
BTU/HR
FLX-150 1,500,000 1,200,000 36 2). Operating limit control - automatic reset.

FLX-200 2,000,000 1,600,000 48
3). Modulating or proportional controller.
FLX-250 2,500,000 2,000,000 60
FLX-300 3,000,000 2,400,000 72 E. Low water cutoff:
FLX-350 3,500,000 2,800,000 84
1). Probe type - hot water.
FLX-400 4,000,000 3,200,000 96
FLX-450 4,500,000 3,600,000 108 2). Float type main and probe type auxiliary- steam.
FLX-500 5,000,000 4,000,000 119
F. Pump Control - steam boilers.
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 NOTICE
FLX-900 9,000,000 7,200,000 215
Hot water boilers with design pressures up to 150
FLX-1000 10,000,000 8,000,000 239
psig, and with design temperatures less than 250 F,
FLX-1100 11,000,000 8,800,000 263
are constructed under Section IV of the ASME Code,
FLX-1200 12,000,000 9,600,000 287
and H stamped for low- pressure heating boilers.
NOTES:
1. Design Pressure: 150 psig Hot Water, 15 psig Steam, 150 psig
Steam.
2. Also available in Model FLE (field erectable). NOTICE
is manufactured by Cleaver-Brooks and UL/cUL approved as Steam boilers with design pressure of 30 psig, and
a package. maximum allowable operating pressure of 15 psig,
are constructed under Section IV of the ASME Code,
Standard Equipment and H stamped for low pressure heating boilers.
Equipment described below is for the standard boiler offering.
1. Boiler: NOTICE
A. All boilers are designed and constructed in accordance
with the ASME Code and are mounted on an integral Steam boilers with design pressure of 150 psig are
frame. All refractories for boiler and burner are constructed under Section I of the ASME code and
installed. S stamped for high pressure steam boilers.
4. Altitude: Standard boilers attain full ratings at altitudes up
B. Factory fire test.
to 1,500 feet. Altitude compensation for most models is
2. Cleaver-Brooks ProFire Forced Draft Burner: available for altitudes up to 11,000 ft above sea level.
A. Mounted on a hinged backing plate for easy access to
furnace. Optional Equipment
B. Pressure atomizing type for No. 2 oil burner. This For option details, contact your local Cleaver-Brooks autho-
includes the oil pump. rized representative. In summary, options include the follow-
ing:
C. Stainless steel flame-retention type combustion head for
gas, with UV scanner, and gas pressure regulator. A. Boiler Options
D. External access to flame scanner for ease of Auxiliary low water cut-off (hot water).
maintenance. Stack thermometer.
3. Water/Steam Controls: Insulated downcomer(s).
A. ASME safety relief valve(s). Drain valves.
B. Pressure and temperature gauges for hot water boilers. Additional screwed tappings.
B1-4
04-02
Packaged for field erection. DIMENSIONS AND RATINGS

B. Burner/Control Options Ratings for steam and hot water boilers are shown in Tables
Special burner modulation controls. B1-2 and B1-3. Dimensions for steam and hot water boilers
are shown in Figures B1-1and B1-2.
Low NOx burner.
Optional flame safeguard controller.
Lead/lag system.
High altitude design, up to 11,000 ft.
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).
C. Fuel Options
Oversized gas trains.
Gas strainer.
Remote oil pump set.
Special pilot.
Direct spark oil ignition.
B1-5
04-02
Table B1-2. Model FLX Hot Water Boiler Ratings
MODEL NO. 150 200 250 300 350 400 450 500 550 600 700 800 900 1000 1100 1200
Fuel Consumption .......Gas (cfh)A 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 7000 8000 9000 10000 11000 12000
Oil (gph)B 10.7 14.3 17.9 21.4 25.0 28.6 32.1 35.7 39.3 42.9 50.0 57.2 64.3 71.4 78.6 85.7
Output (MBH) ..............Gas Firing 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800 5600 6400 7200 8000 8800 9600
Oil Firing 1245 1660 2075 2490 2905 3320 3735 4150 4565 4980 5810 6640 7470 8300 9130 9960
Approximate bhp 36 48 60 72 84 96 108 119 131 143 167 191 215 239 263 287
Natural Gas Input: CFH (1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 7000 8000 9000 10000 11000 12000
Btu)
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 1/3A 1/2 3/4 1/2A 3/4A 1-1/2 1-1/2A 2 3 3 5 5 5A 5A 7 1/2 10
1/2B 3/4B 1B 2B 7-1/2B 7-1/2B
NOTES: 212F Feedwater.

A. Natural Gas @ 1000 Btu/cu-ft.
B. No. 2 Oil @ 140,000 Btu/gal.
Table B1-3. Model FLX Steam Boiler Ratings
MODEL NO. 150 200 250 300 350 400 450 500 550 600 700 800 900 1000 1100 1200
Fuel Consumption ...Gas(h)A 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 7000 8000 9000 10000 11000 12000
Oil (gph)B 10.7 14.3 17.9 21.4 25.0 28.6 32.2 35.7 39.3 42.9 50.0 57.2 64.3 71.4 78.6 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 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800 5600 6400 7200 8000 8800 9600
Oil Firing 1245 1660 2075 2490 2905 3320 3735 4150 4565 4980 5810 6640 7470 8300 9130 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 85 85 85 95 95 140 140 140 140 140 210 210 210 252 252 252
(US gal)
Blower Motor hp 1/3A 1/2 3/4 1/2A 3/4A 1-1/2 1-1/2A 2 3 3 5 5 5A 5A 7 1/2 10
1/2B 3/4B 1B 2B 7-1/2B 7-1/2B
NOTES: 212 F feedwater.

A. Natural Gas @ 1000 Btu/cu-ft.
B. No. 2 Oil @ 140,000 Btu/gal.
B1-6
04-02
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
NOTES: 4. Contact your local Cleaver-Brooks authorized representative regarding total
1. Measurements in inches. length for altitude-compensated boilers.
2. Rear drain connection on Model 600 and larger specification subject to chang
without notice. 5. Inlet and outlet flanges: Model 150 thru 900 - studded flange.
3. Models 150 thru 350 supplied with one front drain only. Models 1000 thru 1200 - nozzle flange.
Figure B1-1. Model FLX Hot Water Boiler Dimensions (1 of 2)
B1-7
04-02
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
Figure1-1. Model FLX Hot Water Boiler Dimensions (2 of2)

B1-8
04-02
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 60 60 60 64 64 67 67 67 67 67
Drum
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 64 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 54 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) (2) (2) (2) (2)
1-1/4 1-1/4 1-1/4 1-1/4 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 of2)
B1-9
04-02
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) 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 (2of2)
B1-10
04-02
PERFORMANCE DATA Emissions

Expected emissions for natural gas fired FLX boilers are
Efficiency shown in Table B1-4.
Fuel-to-steam (fuel-to-water) efficiency is based on specific

operating conditions (fuel, pressure, temperature). Nominal
ENGINEERING DATA
efficiency on all FLX hot water and low pressure steam boilers
is 81% firing natural gas, and 84% firing No. 2 oil. For high Boiler Information
pressure steam applications, contact your local Cleaver-
Brooks representative for expected efficiencies. 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
Table B1-4. Expected Emissions (ppm, corrected to 3% O2), temperature drop.
Natural Gas Fired Boiler Table B1-6 can be used to determine the maximum gpm
circulating rate in relation to full boiler output and system tem-
FLUE GAS HIGH-FIRE LEVELA LOW-FIRE LEVELB perature drop. The maximum gpm can be determined by
COMPONENT PPMV PPMV
knowing the boiler size and expected system temperature drop.
CO 0- 50 0 - 50
System Operating Parameters (Hot Water)
NOx 40 - 60 30 - 60
System over pressure requirements are shown in Table B1-7.
NOTE: NOx levels based on standard product offering.
A. Based on 12% excess air.
B. Based on 15% excess air.
Table B1-5. Model FLX Hot Water Boiler Flow Rates and Pressure Drops
T = 20F T = 40F T = 60F T = 80F T = 100F

MODEL
NO.
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
B1-11
04-02
Table B1-6. Model FLX Circulating Rates, Hot Water Boiler

SYSTEM TEMPERATURE DROP F
MODEL NO. (HP) 10 20 30 40 50 60 70 80 90 100
MAXIMUM CIRCULATING RATE - GPM
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 B1-8. Model FLX Boiler Heat Release Information
FURNACE FURNACE
FURNACE FURNACE
MODEL HEAT HEAT
PROJECTED VOLUME
NO. RELEASE RELEASE BTU/
AREA (FT2) (FT3)
BTU/HR (FT3) HR (FT2)
FLX-150 38.4 24.2 61,983 39,063

FLX-200 38.4 24.2 82,645 52,083
Table B1-7. Model FLX Minimum Over
FLX-250 38.4 24.2 103,306 65,104
Pressure Requirements
FLX-300 48.7 34.9 85,960 61,602
FLX-350 48.7 34.9 100,287 71,869
MAXIMUM
MINIMUM SYSTEM FLX-400 70.6 54.7 73,126 56,657
OUTLET
PRESSURE
TEMPERATURE FLX-450 70.6 54.7 82,267 63,739
(PSIG)
(F) FLX-500 70.6 54.7 91,408 70,822
180 12 FLX-550 70.6 54.7 100,548 77,904
190 15 FLX-600 70.6 54.7 109,689 84,986
200 18 FLX-700 104.6 94.6 73,996 66,922
210 21 FLX-800 104.6 94.6 84,567 76,482
220 24 FLX-900 104.6 94.6 95,137 86,042
230 27 FLX-1000 128.9 116.5 85,837 77,580
240 30 FLX-1100 128.9 116.5 94,421 85,337
FLX-1200 128.9 116.5 103,004 93,095
B1-12
04-02
Minimum return water temperature is 120 F; minimum sup- Fuel Connections - Gas
ply (boiler outlet) water temperature is 150 F in order to pre- The local gas company should be consulted for requirements
vent fireside corrosion. and authorization for installation and inspection of gas supply
piping. Installation of gas supply piping and venting must be in
System Operating Parameters (Steam Boilers) accordance with all applicable engineering guidelines and reg-
The following operating limitations must be observed for opti- ulatory codes. All connections made to the boiler should be
mum operation of the boiler: arranged so that all components remain accessible for inspec-
tion, cleaning and maintenance.
1. Minimum make-up temperature 60 F.
A drip leg should be installed in the supply piping before the
2. Maximum make-up rate (for on/off make-up control) 2.0 connection to the gas pressure regulator. The drip leg should be
times the evaporation rate. at least as large as the inlet fitting supplied with the boiler. Con-
3. Minimum operating pressure 6 psig. on low pressure steam sideration must be given to both volume and pressure require-
and 40 psig. on high pressure steam. ments when choosing gas supply piping size. Refer to the
boiler dimension diagram provided by Cleaver-Brooks for the
4. Maximum operating pressure 12 psig. on low pressure particular installation. Connections to the burner gas train
steam. should be made with a union, so that gas train components or
5. Maximum load tracking rate 0 - 100% load or 100% - 0 the burner may be easily disconnected for inspection or service.
load, 30 seconds on low pressure steam and 20% per Upon completion of the gas piping installation, the system
minute on high pressure steam. should be checked for gas leakage and tight shutoff of all
valves.
Maximum boiler water chemistry parameters: Silica: 150
ppm; specific conductance: 3500 mho/cm un-neutralized;
Fuel Connections - Oil
total alkalinity: 300 ppm as CaCO3; hardness: 0; oxygen: 7
ppb; pH: 7 - 10; total iron: 0.05 ppm; oil matter: 1 ppm. Oil-fired burners are equipped with an oil pump, which draws
fuel from a storage tank and supplies pressurized oil to the
Boiler Heat Release Information burner nozzle(s). The burner supply oil pump has a greater
capacity than the burner requires for the maximum firing rate.
Boiler heat release information is shown in Table B1-8. Fuel not delivered to the nozzle is returned to the storage tank.
Tube Attachment all installations. Figure B1-4 shows a typical fuel oil supply
Construction of the Flexible Watertube Boiler includes a spe- arrangement. Oil lines must be sized for the burner and burner
cial tube-to-drum attachment that requires no welding or roll- supply oil pump capacities.
ing (see Figure B1-3). The tube is fitted with a tapered ferrule, The burner supply oil pump suction should not exceed 10" Hg.
which is press-fit into the tube hole in the drum. The ferrule is If a transfer pump is used, it must have a pumping capacity at
welded to the tube at the factory for both new and replacement least equal to that of the burner pump(s). Supply pressure to the
tubes, so no field welding is required. The tube is held in place burner pump should not exceed 3 psig.
with a keeper plate.
This tube attachment design reduces repair and maintenance the burner supply pump in order to prevent entry of foreign
costs, and also reduces the cost of field erection of new units.
Burner/Control Information
Burner information is shown in Table B1-9. Note that the
model selection may vary for actual application factors (alti-
tude, 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
tive. Figure B1-3. Model FLX Tube Attachment
B1-13
04-02
Table B1-9. Model FLX Burner Characteristics Table B1-10. Model FLX Minimum Required Gas Pressure
BOILER STD GAS

MIN GAS
MAXIMUM BURNER MOTOR 3450 RPM MODEL TRAIN BURNER
MODEL NO. PRESSURE
INPUT MODEL VOLTAGE NO. SIZE MODEL
(IN. WC)
MBH (IN.)
FLX-150 1500 GP-200-1-1.5 120-60-1 FLX-150 2.0 3.7 GP-700-1-1.5

FLX-200 2000 GP-200-1-2.0 120-60-1 FLX-200 2.0 6.3 GP-700-1-2.0
FLX-250 2500 GP-200-1-2.5 120-60-1 FLX-250 2.0 8.1 GP-700-1-2.5
FLX-300 3000 GP-200-2-3.0 120-60-1 FLX-300 2.0 8.0 GP-700-2-3.0
FLX-350 3500 GP-200-2-3.5 240-60-3 FLX-350 2.0 11.0 GP-700-2-3.5
FLX-400 4000 GP-200-2-4.0 240-60-3 FLX-400 2.0 13.3 GP-700-2-4.0
FLX-450 4500 GP-200-2-4.5 240-60-3 FLX-450 2.0 16.9 GP-700-2-4.5
FLX-500 5000 GP-200-3-5.0 240-60-3 FLX-500 2.0 21.4 GP-700-3-5.0
FLX-550 5500 GP-200-3-5.5 240-60-3 FLX-550 2.0 19.0 GP-700-3-5.5
FLX-600 6000 GP-200-3-6.0 240-60-3 FLX-600 2.0 17.7 GP-700-3-6.0
FLX-700 7000 GP-200-3-7.0 240-60-3 FLX-700 2.0 23.8 GP-700-3-7.0
FLX-800 8000 GP-200-3-8.0 240-60-3 FLX-800 2.0 38.4 GP-700-3-8.0
FLX-900 9000 GP-200-3-9.0 240-60-3 FLX-900 2.0 48.3 GP-700-3-9.0
FLX-1000 10,000 GP-200-4-10.0 240-60-3 FLX-1000 2-1/2 31.2 GP-700-4-10.0
FLX-1100 11,000 GP-200-4-11.0 240-60-3 FLX-1100 2-1/2 37.9 GP-700-4-11.0
FLX-1200 12,000 GP-200-4-12.0 240-60-3 FLX-1200 3 37.2 GP-700-4-12.0
NOTES: NOTES:
1. Burner model selection shown is subject to change based on 1. Table is based on 1,000 Btu/cu-ft natural gas and ele-
actual application (altitude, gas pressure, etc.). vation up to 1,000 ft.
2. Standard voltage in Canada is 575/3/60. 2. Minimum gas pressure also applies to 200 fuel series
3. All burners feature full mod operation, with high-low-high avail- burner.
able as an option. 3. Standard regulators suitable for 1 psig maximum inlet
4. Burner models shown are for gas/oil burners. pressure.
material into the pump, fuel control valves, or burner noz- trols which reset the boiler water outlet temperature below 150
zle(s). The strainer must be sized for the burner supply pump F, or the utilization of the boiler as a system thermostat.
capacity. A strainer mesh of 150 microns (0.005") is recom-
mended. Boiler Room Information
Install a check valve in the line to prevent draining of the oil The boiler must be installed on a non-combustible floor. If the
suction line when the burner is not in operation. Location of floor is not level, piers, or a raised pad, slightly larger in length
the check valve varies with the system, but usually it is located and width than the boiler base dimensions, will make boiler
as close as possible to the storage tank. 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 addi-
tional equipment installed with it. Approximate operating
weights for Model FLX series steam and hot water boilers are
Upon completion of the oil piping installation, the system shown in Dimensions and Ratings.
After the boiler is in place it must be leveled. Both side-to-side
valves.
and front-to-back level can be verified using the vertical con-
nection between the upper and lower drums at the back of the
Sound Levels (dBA) boiler. If shims are required to level the boiler, the weight of
Refer to Table B1-11 for sound level information. the boiler must be evenly distributed at all points of support.
The boiler must be installed so that all components remain
Outdoor Reset Control accessible for inspection, cleaning, or maintenance. Field-
Cleaver-Brooks does not recommend the use of outdoor con-
B1-14
04-02
Figure B1-4. Model FLX Oil Burner Supply Pump Installation
installed piping and electrical connections to the burner and Breechings

boiler must be arranged to allow removal of the casing panels, For single boiler installations, use breeching of the same diam-
and swinging of the burner. eter as the vent outlet on the boiler. For multiple boiler installa-
Minimum clearances to walls or other obstructions and com- tions, and when a number of boilers of the same size (input)
bustible materials are shown in Figure B1-5. The top view are to be connected to a common breeching, use the table on
shaded sections in Figure B1-5 show areas that must be kept Figure B1-6 to size the breeching diameter. For more informa-
clear of field installed connections to the boiler for access or tion on breechings and stacks, refer to Stacks, Section F.
maintenance purposes.
A positive means of supplying a volume of outside air for
complete fuel combustion is required. Proper ventilation of the Flextube boilers can support up to 200 lbs without additional
boiler room must be provided. The amount of air required, support.
and the required duct and air supply opening areas, are deter-
mined by the maximum fuel input rating of the burner and the
altitude of the installation. Refer to Table B1-12. Air inlets
must be sized in accordance with applicable engineering
guidelines and regulatory code.
B1-15
04-02
Table B1-11. Model FLX Sound Levels
MODEL NO.
SOUND LEVEL
FIRING RATE
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 88
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.
SIDES TOP FRONT REAR

MODEL NO.
A B C D
FLX-150 - 250 28 18 48 24
FLX-300 - 350 32 18 48 24
FLX-400 - 600 34 18 48 24
FLX-700 - 1200 40 18 48 24
NOTE: Top Dimension from boiler to top of stack based

on stack selection.
Figure B1-5. Model FLX Clearance Requirements
B1-16
04-02
Table B1-12. Model FLX Combustion Air Requirements
MODEL NO. 150 200 250 300 350 400 450 500 550 600 700 800 900 1000 1100 1200
Gas (scfh) 15480 20640 25800 30960 36120 41280 46440 51600 56760 61920 72240 82560 92280 103200 113520 123840
Comb (lb/hr) 1207 1609 2012 2414 2817 3219 3621 4024 4426 4828 5633 6438 7243 8048 8853 9657
Air
(Dry) Oil (scfh) 17050 22733 28414 34098 39782 45463 51146 56831 62514 68196 79562 90928 102294 113662 125028 136394
(lb/hr) 1269 1692 2115 2538 2961 3384 3807 4231 4654 5077 5923 6769 7640 8462 9308 10154
Gas (scfh) 17520 23360 29200 35040 40880 46720 52560 58400 64240 70080 81760 93440 105120 116800 128480 140160
Flue (lb/hr) 1278 1704 2130 2556 2983 3409 3835 4261 4687 5113 5965 6817 7669 8521 9373 10225
Gas
(Dry) Oil (scfh) 17915 23886 29855 35827 41799 47769 53740 59713 65684 71655 83598 95541 107484 119427 131370 143312
(lb/hr) 1357 1809 2261 2714 3166 3618 4070 4523 4975 5427 6330 7237 8142 9047 9951 10856
NOTES:
1. Natural gas @ 1000 Btu/cu-ft.
2. No. 2 oil @ 140,000 Btu/gal.
Figure B1-6. Model FLX Breeching Arrangement - Single or Multiple Boiler Installation
B1-17
04-02
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.
Steam Boiler Package

1.0 Boiler Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-16
2.0 General Boiler Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-16
3.0 Hot Water Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-17
4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-17
5.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-19
6.0 Field Erectable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-19
Hot Water Boiler Package

1.0 Boiler Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-20
2.0 General Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-20
3.0 Steam Boiler Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-20
4.0 Burner and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-20
5.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-23
6.0 Field Erectable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-23
Steam Boiler Package
1.0 Boiler Capacity

The _____ (low or high) pressure steam boiler shall be Cleaver-Brooks Model FLX (FLE for field erected) designed for _______
(15 or 150) psig steam.
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.
2.0 General Design

2.1 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.
2.2 The boiler pressure vessel shall be constructed in accordance with ASME Boiler Code, and must receive authorized boiler
inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser. The complete packaged boiler -
burner unit shall be listed by Underwriters Laboratories, and shall have the UL/cUL label affixed to the front head.
2.2.1 The boiler drums shall be furnished with handholes to facilitate boiler inspection and cleaning.
2.2.2 Boiler tubes shall be 1.5" diameter, 0.095" wall thickness, and shall be easy to remove and replace without expanding or
welding the tube attachment to the drums.
2.2.3 The boiler shall have sufficiently sized downcomers to provide positive natural internal circulation.
2.2.4 The burner shall be mounted on a hinged backing plate for easy access to furnace.
2.3 Observation ports for the inspection of flame conditions shall be provided at rear end of the boiler and in the burner assembly at
the front end.
2.4 The tangent wall tubes shall be covered with 1-1/2 inches of insulation under a gas-tight, 16-gauge inner casing. There shall be
2 inches of insulation between the inner and outer casing. The outer casing shall be 20 gauge. The boiler base frame and other com-
ponents shall be factory-painted before shipment, using a hard enamel finish.
B1-18
04-02

The following items shall be installed on the boiler:
3.1 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.
3.2 Feedwater Pump Control - The boiler feedwater pump control switch shall be included. It shall provide automatic actuation of
a motor-driven feedwater pump, or solenoid valve, to maintain the boiler water level within normal limits.
3.3 Steam Pressure Controls - A minimum of three controls shall be provided: one auto reset type for burner on-off control, one for
burner firing rate, and one manual reset type for burner cutout in excessive steam pressure conditions.
3.4 Miscellaneous - A pressure gauge shall be mounted to the boiler. Pressure controls (for regulation of burner operation) shall be
mounted to the boiler. Steam relief valves shall be of a type and size to comply with ASME Code requirements (shipped loose).

The boiler shall be provided with a UL/cUL approved fuel burning system in full accordance with the requirements of state, pro-
vincial and local codes, the local gas utility, and other applicable regulatory bodies. The boiler shall be a Cleaver-Brooks Profire
burner.
Option (specify as required)
A. The complete fuel burning system shall further be in full accordance with Factory Mutual (FM) requirements.
B. The complete fuel burning system shall further be in full accordance with Industrial Risk Insurers (IRI) requirements.
4.1 Burner Description
4.1.1 Option (specify A, B, or C)
A. The burner shall include a gas burner having rated capacity to burn ________ MMBtu/hr of ______ Btu/cu-ft of
__________ gas at a pressure of _______ (lbs/sq-inch) (inches of water column) at the inlet of the burner gas control train.
B. The burner shall include an oil burner having rated capacity to burn ______ gph of No. 2 fuel oil.
C. The burner shall include a combination gas-oil burner having rated capacity to burn _______ MMBtu/hr of _____ Btu/cu-ft
gas at a pressure of _________ lbs/sq-inch (inches of water column) at the inlet to the burner gas control train (or _______ gph
of No. 2 fuel).
4.1.2 The burner shall be forced draft type with full 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.
A. 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% O2) 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% O2) NOx emissions.
B. 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.
C. The gas-oil 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% O2) 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% O2) NOx emissions.
4.1.4 Primary-secondary air control shall be a design function of the combustion head. Combustion heads requiring an internal
adjustment shall not be acceptable.
4.1.5 The burner shall be equipped with an aluminum reverse curve fan for lower fan motor hp requirements and self-cleaning char-
acteristics.
B1-19
04-02
4.1.6 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.
4.1.7 Supply voltage available shall be ______ Volts, ______ phase, 60 Hz. All motors shall be suitable for use on this voltage. All
burner controls are to be for use on 120 volts, 1 phase, 60 hz.
4.1.8 The burner shall be factory fire-tested to ensure proper operation before shipment.
4.2 Pilot Gas Train for Each Burner (Mounted, Piped, and Wired)
A separate pilot gas cock, gas pressure regulator, and pilot safety shutoff gas valve shall be provided for the ignition gas supply.
4.3 Oil Burner
4.3.1 The oil burner shall be of the mechanical pressure atomizing type.
4.3.2 A two-stage oil pump shall be provided for each burner as an integral part of the burner.
4.3.3Two approved automatically operated safety shutoff valve(s) shall be provided in the oil supply line to the burner valves to be
piped in series but wired parallel.
4.3.4 Supply an oil pressure gauge to indicate the discharge oil pump pressure.
4.3.5 Install a manual valve, fuel oil filter, or strainer and vacuum gauge on the suction side of the oil pump (optional).
4.3.6 Install a fusible-link-actuated oil safety shutoff valve in the oil supply line between the oil tank and the manual gate valve at
the oil pump (optional).
4.3.7 Oil pressure monitoring shall be provided by an approved pressure switch interlocked to accomplish a non-recycling safety
shutdown in the event of low oil pressure (optional).
4.4 Gas Valve Train for Each Burner
4.4.1 Provide a pressure gauge to indicate the gas burner manifold pressure (optional).
4.4.2 Furnish and install one manually operated, ________ inch, ball valve upstream of all valves.
4.4.3 Provide one _______ inch, main gas pressure regulator (of tight shutoff type) with vent to outside atmosphere, in accordance
with local codes.
NOTICE
Specify a tight shutoff type gas pressure regulator when the inlet gas pressure exceeds 1-1/2 psig.
4.4.4 Provide one ________ inch, automatically operated motorized safety gas valve.
One safety shutoff valve shall be proven closed during pre- ignition by proof of valve closure interlock switch on valve.
4.4.5 Provide a second _______ inch, automatically operated gas safety shutoff valve to operate simultaneously with the above gas
valve.
4.4.6 A manually operated gas valve shall be located downstream of both automatic gas valves to permit leakage testing of the
valves.
4.4.7 Gas pressure monitoring shall be provided by approved pressure switches interlocked to accomplish a non-recycling safety
shutdown in the event of either high or low gas pressure (optional on sizes 150-250).
4.5 Burner Controls
4.5.1 The full modulation of the burner shall be controlled by steam pressure by means of a pressure control.
4.5.2 An additional high limit safety pressure control of the manual reset type shall be provided to control the burner.
4.5.3 Pre-purge and post-purge operation of the burner fan shall be provided per current UL/cUL requirements.
4.5.4 The burner shall utilize a Fireye E110 type flame safeguard programmer incorporating 7 LED indicator lights to annunciate
the current operating status of the burner.
4.5.5 A manual restart of the burner shall be necessary in the event of shutdown due to flame failure.
B1-20
04-02
4.5.6 All three-phase motors shall be controlled and protected by an automatic starter with thermal overload protection. The starter
shall be inter-locked to prevent burner operation when over-load relays are tripped out.
4.5.7 Supply a burner-mounted diaphragm air flow switch to prevent the energization of the main fuel valves in the event of insuffi-
cient combustion air, or to provide safety shutdown in the event of combustion air interruption.
4.5.8 A factory-wired control cabinet shall be supplied and mounted on the burner. The control cabinet shall house the flame safe-
guard control, programming timer, burner motor starter, fuses, control circuit transformer, control switches, indicating lamps and
relays as required.
4.5.9 Provide four individual lights with nameplates on the control cabinet to indicate call for heat, main fuel valve on, low
water, and main flame failure.
4.5.10 Option (specify A or B)
A. The changing from one fuel to the other shall be manual by means of a fuel selector switch. No burner adjustments shall be
required to switch from one fuel to the other.
B. Changing from one fuel to the other shall be automatically controlled by the outdoor temperature switch, or other external
device. No burner adjustment shall be required to switch from one fuel to the other.
4.5.11 The burner shall be equipped with suitable fuel and air controls to assure smooth main flame ignition. The burner shall uti-
lize 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.
4.5.12 Fuel-air control shall be synchronized. The fuel air drive unit shall be provided with a position indicating switch interlocked
with the 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.
4.5.13 Pre-ignition pure air flow rate shall not be less than 60% maximum firing rate air flow. Interlocks shall be provided to moni-
tor and prove 60% air flow purge when air inlet louvers are automatically opened to obtain this rate.
4.5.14 Full modulation of fuel input shall be provided. A modulating pressure control shall be supplied to modulate a burner
mounted damper motor controlling both fuel and air supply by means of direct mechanical linkage.
4.5.15 Electronic safety combustion controls shall be supplied, complete with ultra-violet 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.
5.0 Warranty
All equipment is to be guaranteed against defects in material and/or workmanship for a period of 12 months from the date of 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.
6.0 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.
B1-21
04-02
Hot Water Boiler Package
1.0 Boiler Capacity (Hot Water)

1.1 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.
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.

2.1 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.
2.2 The boiler pressure vessel must be constructed in accordance with ASME Boiler Code, and must receive authorized boiler
inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser. The complete packaged boiler -
burner unit shall be listed by Underwriters Laboratories, and shall have the UL/cUL label affixed to the front head.
2.2.1 The boiler drums shall be furnished with handholes to facilitate boiler inspection and cleaning.
2.2.2 Boiler tubes shall be 1.5" diameter, with 0.095" wall thickness, and shall be easy to remove and replace without expanding or
welding the tube attachment to the drums.
2.2.3 The boiler shall have a sufficiently sized downcomer to provide natural internal circulation.
2.2.4 The burner shall be mounted on a hinged backing plate for easy access to the furnace.
2.3 Observation ports for the inspection of flame conditions shall be provided at the rear of the boiler, and in the burner assembly at
the front.
2.4 The tangent wall tubes shall be covered with 1-1/2 inches of insulation under a gas-tight, 16-gauge inner casing. There shall be
2 inches of insulation between the inner and outer casing. The outer casing shall be 20 gauge. The boiler base frame and other com-
ponents shall be factory-painted before shipment, using a hard enamel finish.

The following items will be installed on the boiler.
3.1 Low Water Cut-Off: A probe-type, low water cut-off control shall be mounted in the upper drum. It is to be wired to the burner
control circuit to prevent burner operation if the boiler water falls below a safe level.
3.2 Miscellaneous: A combustion temperature and pressure gauge shall be mounted on the boiler. Temperature controls, for regula-
tion 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.

The boiler shall be provided with a UL/cUL approved fuel burning system in full accordance with the requirements of state, pro-
vincial and local codes, the local gas utility, and other applicable regulatory bodies. The burner shall be a Cleaver-Brooks ProFire
burner or approved equal.
Option (specify A or B, as required)
A. The complete fuel burning system shall be in full accordance with Factory Mutual (FM) requirements.
B. The complete fuel burning system shall be in full accordance with Industrial Risk Insurers (IRI) requirements.
A. The boiler shall include a gas burner having rated capacity to burn ________ MMBtu/hr of ______ Btu/cu-ft of
B1-22
04-02
__________ gas at a pressure of _______ (lbs/sq-in.) (inches of water column) at the inlet of the burner gas control train.
B. The boiler shall include an oil burner having rated capacity to burn ______ gph of No. 2 fuel oil.
C. The boiler shall include a combination gas-oil burner having rated capacity to burn _______ MMBtu/hr of Btu/cu-ft ______
gas at a pressure of _________ (lbs/sq-in.) (inches of water column) at the inlet to the burner gas control train or _______ gph
of No. 2 fuel.
4.1.2 The burner shall be forced draft type with full 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.
than 15% excess air and less than 50 ppm (corrected to 3% O2) 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% O2) NOx emissions.
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% O2) NOx emissions.
4.1.5 The burner shall be equipped with an aluminium reverse curve fan for lower fan motor hp requirements and self-cleaning
characteristics.
burner controls are to be for use on 120 volts, 1 phase, 60 Hz.
A separate pilot gas cock, gas pressure regulator, and pilot safety shutoff gas valve, shall be provided for the ignition gas supply.
4.3. Oil Burner
4.3.3 Two approved automatically operated safety shutoff valve(s) shall be provided in the oil supply line to the burner valves to be
B1-23
04-02
with local codes.
NOTICE
4.4.4 Provide one ________ inch, automatically operated motorized safety gas valve. One safety shutoff valve shall be proven
closed during pre- ignition by proof of valve closure interlock switch on valve.
valve.
valves.
shutdown in the event of either high or low gas pressure (optional on sizes 150-250).
4.5 Burner Controls
4.5.1 The full modulation of the burner shall be controlled by water temperature by means of a temperature control.
4.5.2 An additional high limit safety temperature control of the manual reset type shall be provided to control the burner.
4.5.3 Pre- and post- operation of the burner fan shall be provided per current UL/cUL requirements.
4.5.4 The burner shall utilize a Fireye type flame safeguard programmer, incorporating 7 LED indicator lights to annunciate the
current operating status of the burner.
4.5.7 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.
guard control, programming timer, burner motor starter, fuses, control circuit transformer, control switches, indicating lamps, and
relays as required.
4.5.10 Option (specify A or B)
A. The changing from one fuel to the other shall be manual by means of a fuel selector switch. No burner adjustments shall be
B. Changing from one fuel to the other shall be automatically controlled by an outdoor temperature switch, or other external
device. No burner adjustment shall be required to switch from one fuel to the other.
B1-24
04-02

4.5.14 Full modulation of fuel input shall be provided. A modulating temperature control shall be supplied to modulate a burner
mounted damper motor, controlling both fuel and air supply by means of direct mechanical linkage.
5.0 Warranty
All equipment is to be guaranteed against defects in material and/or workmanship for a period of 12 months from the date of 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.
6.0 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.
B1-25
04-02
NOTES
B1-26
04-02
Section B2
MODEL 4 BOILERS
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-3
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-3
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-4
Special Insurance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-5
Added Equipment for IRI Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-5
Added Equipment for FM Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-5
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-5
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-12
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-12
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-12
Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-12
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-12
Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-12
Stack Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-12
Steam Boiler Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-17
Hot Water Boiler Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2-23
B2-1
04-02
Model 4 Boilers Commercial Boilers
ILLUSTRATIONS
Figure B2-1. Model 4 Boiler Standard Gas Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-7
Figure B2-2. Model 4 Hot Water Boiler Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-8
Figure B2-3. Model 4 Steam Boiler Dimensions Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-10
Figure B2-4. Model 4 Boiler Over Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-16
TABLES
Table B2-1. Model 4 Boiler Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-3
Table B2-2. Model 4 Hot Water Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6
Table B2-3. Model 4 Steam Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2- 6
Table B2-4. Model 4 Boiler Emission Data - Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-12
Table B2-5. Model 4 Boiler Emission Data - No. 2 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-12
Table B2-6. Model 4 Gas Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-13
Table B2-7. Model 4 Steam Boiler Minimum Pressure Vessel Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-14
Table B2-8. Model 4 Boiler Fuel, Air, and Flue Gas Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-14
Table B2-9. Model 4 Hot Water Boiler Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-15
Table B2-10. Model 4 Hot Water Boiler Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-15
Table B2-11. Model 4 Boiler Recommended Steam Nozzle Size at Reduced Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . B2-16
Table B2-12. Model 4 Sound Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-16
This section contains information on the Model 4 Commercial Watertube Boiler product line for low and high pressure steam and
hot water applications. Sizes range from 1.5 to 6 MMBtu/hr. The Model 4 Boiler is an excellent choice where high outputs and
space limitations exist. The model number designation is 1500 through 6000, representing Btu/hr input (1,500,000 to 6,000,000
Btu/hr).
Fuel series designation is as follows:
Series 100: No. 2 oil 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, an
M4W-700-2500-140HW boiler designates a gas-fired, 2,500,000 Btu/hr, 140 psig, hot water boiler.
B2-2
04-02
Commercial Boilers Model 4 Boilers
FEATURES AND BENEFITS Steam Design Pressures to 500 psig:
The following features and benefits apply to the Model 4 High performance in a compact design.
Boiler product line. Proven vessel design for high design pressure applications.
Higher pressures available.
33" Cased Width:
Boiler fits through most standard doorways.
PRODUCT OFFERING
Reduced installation costs.
Information in this section applies to Cleaver-Brooks Model 4
watertube boilers in sizes ranging from 1.5 to 6 MMBtu/hr
Direct Driven, Vibration-Free Centrifugal Impeller: input, as shown in Table B2-1. Model numbers represent input
Quiet operation. (1,000 Btu/hr).
Sound levels below 80 dBA. The Model 4 Boiler is a compact, packaged, all-steel- mem-
braned waterwall watertube boiler. It is a three-pass boiler with
Ideal for noise critical areas such as hospitals, churches, etc.
watertubes and membranes formed to direct the flow of com-
bustion gases through the boiler. The pressure vessel is con-
Minimum Refractory: structed to conform with Sections I or IV of the ASME Codes,
Membrane waterwalls reduce the need for refractory by for hot water, low-pressure steam, and high-pressure steam
95%. boilers.
Reduced maintenance costs and refractory repair The vessel consists of formed membrane tubes and downcom-
requirements. ers, connected to the upper and lower drums. The boiler vessel
is gas tight, insulated on the outside, and covered by casing
Membrane Waterwalls: constructed of removable, formed steel panels. The standard
boiler/burner package is UL approved in hot water, low- pres-
Enhanced heat transfer area in compact design. sure steam, and high-pressure steam (150 psig design) when
Sealed combustion chamber improves heat transfer for high fueled by No. 2 oil and/or natural gas.
efficiency.
Standard Equipment
Small Boiler Footprint: Equipment described below is for standard boiler offerings.
Savings of up to 50% in floor space.
The Cleaver-Brooks Model 4 Boiler is a packaged watertube,
steel boiler consisting of pressure vessel, oil or gas burner,
Weighs up to 40% less than Comparable Boilers: burner controls, forced draft fan, and integral air damper con-
Lower freight and rigging costs. trol assembly.
Reduced structural requirements.
Standard Built-in Soot Washers: Table B2-1. Model 4 Boiler Sizes

Boiler cleaning without shutdown.
MODEL INPUT HEAT EQUIV STEAM SHIPPING
Maintains peak boiler performance. NO. MBH OUTPUT HP OUTPUT WEIGHT
MBH LB/HR LBS
Packaged Forced Draft Burner: 1500 1500 1200 35 1237 3100
High pressure drop design. 2000 2000 1600 47 1649 3100

2500 2500 2000 59 2062 3700
Optimum fuel and air mixing. 3000 3000 2400 71 2474 3700
Improved combustion efficiency. 3500 3500 2800 83 2887 4100
4000 4000 3200 95 3299 4100
Front Door Davit: 4500 4500 3600 107 3711 4700
5000 5000 4000 119 4124 4700
Easy access to furnace.
6000 6000 4800 143 4949 5400
Reduced maintenance costs. NOTE: Steam output from and at 212 F.
B2-3
04-02
1. Boiler D. Low water cutoff with pump control.

A. Designed, constructed, and hydrostatically tested in E. Auxiliary low water cutoff with manual reset.
accordance with the ASME Boiler and Pressure Vessel
F. Water column gauge glass set and fittings.
Code.
G. Combustion air proving switch.
B. Refractories for the boiler and burner are installed.
5. Electrical Control Panel
C. Fully insulated under a preformed, sectional sheet
metal jacket. A. Mounted at eye level on the front head of the boiler.
D. Mounted on an integral steel heavy base frame. B. NEMA rating 1A with gasket dust seal.
E. Factory painted using a hard-finish enamel. C. Contains electronic program relay, switches and four
indicating lights (low water, flame failure, load demand,
2. Forced Draft Burner
and fuel valve).
A. Integral with front head of boiler (factory mounted and
6. Miscellaneous
tested).
A. The boiler is (UL) listed and bears packaged
B. Combustion air fan and motor are integral with front
boiler/burner UL listing label.
head of boiler.
B. Motorized gas valves.
C. Pressure atomizing type for No. 2 oil burner includes
oil pump.
Optional Equipment
D. High radiant multi-port type burner for gas includes
gas train and gas pressure regulator. For more detailed information on optional equipment, contact
your local Cleaver-Brooks authorized representative. In sum-
E. Burner operation uses low-high-low principle. mary, options include the following:
F. Ultra-violet type flame scanner. 1. Boiler Options
3. Hot Water Boiler Control Standard Equipment (140 psig) Auxiliary low water cut-off (hot water).
A. ASME safety relief valve(s). Pressure gauges and temperature guages.
B. Temperature and pressure gauges. Drain valves.
C. Temperature controls: Feed valves.
High limit control-manual reset. Additional screwed tappings.
Operating limit control. High pressure designs.
High-low fire rate control. Surface blow-off valve.
D. Low water cutoff-probe type with manual reset. High altitude design.
E. Return water blend pump. 2. Burner/Control Options
F. Low fire hold time delay. Full modulation on gas.
G. Combustion air proving switch. Optional flame safeguard controller.
4. Steam Boiler Control Standard Equipment (15 to 150 psig) Lead/Lag system.
A. ASME safety relief valve(s). Remote emergency shut-off.
B. Steam pressure gauge. Day-night controls.
C. Pressure controls: Low fire hold control.
High limit control-manual reset. Alarm bell/silence switch.
Operating limit control. Special motor requirements (TEFC, High efficiency).
High-low fire control. Remote contacts.
B2-4
04-02
Additional relay points and indicator lights. Added Equipment for FM Compliance
Main disconnect (fusible/circuit breaker). 1. Oil Fired
Control circuit transformer. Low oil pressure switch.
Elapsed time meter. Alarm bell mounted for non-recycling shutdowns.
Voltmeter/micro-ammeter. 2. Combination Oil and Gas Fired
Optional NEMA enclosure. Low oil pressure switch.
High stack temperature control. Alarm bell mounted for non-recycling shutdowns.
3. Fuel Options High and low gas pressure switches. Sizes 1500-2500.
Automatic fuel changeover. 3. Gas Fired
Special gas pressure regulator. High and low gas pressure switches. Sizes 1500-2500.
Oversized/undersized gas trains. Alarm bell mounted for non-recycling shutdowns.
Gas strainer.
Dimension and rating information for Model 4 boilers, is
Remote oil pump set. shown in Tables B2-2 and B2-3, and Figures B2-1 through
Dual pilots (gas and oil). B2-3.
Direct spark oil ignition.
Propane fuel firing.
Special Insurance Requirements
Added Equipment for IRI Compliance

1. All fuels
Alarm bell mounted for non-recycling shutdowns.
High fire switch for purge timing.
2. Oil Fired
Low oil pressure switch.
Gas pilot.
3. Gas fired
High and low gas pressure switches. Sizes 1500-2500.
Two motorized main gas valves with vent valve. Sizes
1500-2500.
Second motorized main gas valve with vent valve. Sizes
3000-5000.
Main gas vent valve. Size 6000.
B2-5
04-02
Table B2-2. Model 4 Hot Water Boiler Ratings
BOILER MODEL 1500 2000 2500 3000 3500 4000 4500 5000 6000
Rated Capacity Btu Output (1,000 Btu/hr) 1200 1600 2,000 2400 2800 3200 3600 4000 4,800
Boiler Horsepower 35 47 59 71 83 95 107 119 143
EDR Water Gross, sq-ft 8000 10667 13333 16000 18667 21333 24000 26667 32000
Blower Motor Gas Only (hp) 3/4 1 1-1/2 2 2 3 3 3 5
Blower Motor Oil or Combination (hp) 1-1/2 1-1/2 2 2 3 5 3 3 5
Control Circuit Transformer kVA 1 1 1 1 1 1 1 1 1
Oil Pump Belt Driven From Blower Motor
Flooded Water Weight 908 908 1200 1200 1466 1466 1766 1766 2033
Approximate Shipping Weight 3100 3100 3700 3700 4100 4100 4700 4700 5400
NOTE: Ratings are sea level to1000 ft.
Table B2-3. Model 4 Steam Boiler Ratings
BOILER MODEL 1500 2000 2500 3000 3500 4000 4500 5000 6000
Rated Capacity in lbs Steam/hr (212 F) 1237 1649 2062 2474 2887 3299 3711 4124 4949
EDR Steam Gross, sq-ft 5000 6667 8333 10000 11667 13333 15000 16667 20000
Blower Motor Gas Only (hp) 3/4 1 1-1/2 2 2 3 3 3 5
Blower Motor Oil or Combination (hp) 1-1/2 1-1/2 2 2 3 5 3 3 5
Control Circuit Transformer kVA 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2
Operating Water Weight 658 658 866 866 1075 1075 1291 1291 1500
NOTE: Ratings are at sea level to 1000 ft.
B2-6
04-02
SIZES
ITEM PART DESCRIPTION
INCHES
1 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
3 4 Size 3000
2
6 7 3 Pilot Gas Regulator 1/2
5 5
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
4
2 3 2 Pilot Shutoff Cock 1/2
7 8 9
6
5 5 Manual Shutoff Valve 2
5
6 Main Gas Regulator 2
8 Motorized Valve with P.O.C. 2
Size 6000
1 Butterfly Valve 2
3 4 4 Pilot Solenoid Valve 1/2
2
5 Manual Shutoff Valve 2
7 9 10
6 8 7 Low Gas Pressure Switch 1/4
5 5
8 Solenoid Valve 2
9 Motorized Valve with P.O.C. 2
Figure B2-1. Model 4 Boiler Standard Gas Train
B2-7
04-02
Q2
Figure B2-2. Model 4 Hot Water Boiler Dimensions - Sheet 1 of 2
B2-8
04-02
BOILER MODEL 1500 2000 2500 3000 3500 4000 4500 5000 6000
A - Overall 91-1/2 91-1/2 107-5/8 107-5/8 123-1/4 123-1/4 142-5/8 142-5/8 158-1/4
B - Cased Boiler 60-3/4 60-3/4 76-7/8 76-7/8 92-1/4 92-1/4 108-7/8 108-7/8 124-1/2
C - Base Frame 54 54 69-5/8 69-5/8 85-1/4 85-1/4 100-7/8 100-7/8 116-1/2
C1 - Base to Front Head 9-5/8 9-5/8 9-5/8 9-5/8 9-5/8 9-5/8 10 10 10
C2 - Base Frame Anchor Holes 51-1/2 51-1/2 67-1/8 67-1/8 82-3/4 82-3/4 98-3/8 98-3/8 114
D - Front Head Extension 20-1/8 20-1/8 20-1/8 20-1/8 21-7/8 21-7/8 24-5/8 24-5/8 24-5/8
E - Front Casing to Outlet 23-1/4 23-1/4 32-1/4 32-1/4 32-3/4 32-3/4 37-3/8 37-3/8 45-1/4
F - Outlet to Relief Valve 25-1/2 25-1/2 32-5/8 32-5/8 47-1/2 47-1/2 59-1/2 59-1/2 67-1/4
G - Relief Valve to Relief Valve 30 psig Only - - - - - - - - 35-7/8
H - Rear Casing to Air Vent 5-1/2 5-1/2 5-1/2 5-1/2 5-1/2 5-1/2 5-1/2 5-1/2 5-1/2
J - Outside Casing to Ent. Box 38-3/16 38-3/16 38-3/16 38-3/16 38-3/16 38-3/16 38-3/16 38-3/16 38-3/16
K - Center to Outside Casing 16-3/8 16-3/8 16-3/8 16-3/8 16-3/8 16-3/8 16-3/8 16-3/8 16-3/8
L - Base, Inside 20 20 20 20 20 20 20 20 20
M - Base, Outside 28 28 28 28 28 28 28 28 28
N - Center to Soot Washer Drain 5-1/4 5-1/4 5-1/4 5-1/4 5-1/4 5-1/4 5-1/4 5-1/4 5-1/4
O - Center to Base Center 12 12 12 12 12 12 12 12 12
P - Center to Soot Washer 10-11/16 10-11/16 10-11/16 10-11/16 10-11/16 10-11/16 10-11/16 10-11/16 10-11/16
QQ - Overall (Base to Vent Outlet) 79 79 79 79 79 79 79 79 79
Q - Base to Outlet 78 78 78 78 78 78 78 78 78
Q1 - Base to Smoke Box 77-13/16 77-13/16 77-13/16 77-13/16 77-13/16 77-13/16 77-13/16 77-13/16 77-13/16
Q2 - Base to Top of Control Box 83-1/4 83-1/4 83-1/4 83-1/4 83-1/4 83-1/4 83-1/4 83-1/4 83-1/4
R - Base to Soot Washer 55-1/2 55-1/2 55-1/2 55-1/2 55-1/2 55-1/2 55-1/2 55-1/2 55-1/2
S - Height of Base 4 4 4 4 4 4 4 4 4
T - Base to Return 9-1/4 9-1/4 9-1/4 9-1/4 9-1/4 9-1/4 9-1/4 9-1/4 9-1/4
U - Base to Soot Washer Drain 1-13/16 1-13/16 1-13/16 1-13/16 1-13/16 1-13/16 1-13/16 1-13/16 1-13/16
OS - Base to Oil Supply 27-3/4 27-3/4 27-3/4 27-3/4 27-3/4 27-3/4 27-3/4 27-3/4 27-3/4
OR - Base to Oil Return 25-3/4 25-3/4 25-3/4 25-3/4 25-3/4 25-3/4 25-3/4 25-3/4 25-3/4
BB - Diameter (Sleeve Connection) 12 12 12 12 12 12 16 16 16
CC - Rear Casing to Vent CL 25-13/16 25-13/16 26-1/4 26-1/4 26-1/4 26-1/4 30-3/8 30-3/8 30-3/8
W - Soot Washers (Two) 1/4 1/4 1/4 1/4 1/4 1/4 1/4 1/4 1/4
X - Soot Washer Drains (Two) 2 2 2 2 2 2 2 2 2
Y - Bottom Drain (One) 1-1/4 1-1/4 1-1/4 1-1/4 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2
HS - Water OutletA 3 3 3 3 4 4 4 4 4
HR - Water ReturnA 3 3 3 3 4 4 4 4 4
FF - Air Vent 1 1 1 1 1 1 1 1 1
GG - Oil Supply and Return 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2
HH - Relief Valve Outlet 125 psig Setting 1 1 1 1-1/4 1-1/4 2 2 2 2
DD - Front Door Swing 33 33 33 33 33 33 33 33 33
EE - Tube Removal Each Side 30 30 30 30 30 30 30 30 30
RF - Allowance for Front Door Swing and 30" 124 124 140 140 155 155 172 172 187
Rear Aisle Space
RD - Allowance for Tube Removal Each Side and 93 93 93 93 93 93 93 93 93
Front Door Swing
NOTES:
1. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified prints.
2. Allow sufficient clearance at rear of boiler for soot washer lance removal.
3. Furnace access opening, 13" x 21" located behind front head.
4. Circulating pump standard on ASME Section IV boilers (Max. 250 F and 160 psig). Section I high-temp hot water applications will not include circulator.
A. Male pipe thread.
B2-9
04-02
O2
Figure B2-3. Model 4 Steam Boiler Dimensions Sheet 1 of 2
B2-10
04-02
BOILER MODEL 1500 2000 2500 3000 3500 4000 4500 5000 6000
A - Overall 84-1/4 84-1/4 100-1/4 100-1/4 117-3/8 117-3/8 136-3/4 136-3/4 152-3/8
B- Cased Boiler 61 61 77 77 92-3/8 92-3/8 109 109 124-5/8
C - Base Frame 54 54 69-5/8 69-5/8 85-1/4 85-1/4 101 101 116-1/2
C1 - Base to Front Head 9-5/8 9-5/8 9-5/8 9-5/8 9-5/8 9-5/8 10 10 10
C2 - Base Frame Anchor Holes 51-1/2 51-1/2 67-1/8 67-1/8 82-3/4 82-3/4 98-3/8 98-3/8 114
DD - Front Casing to Steam Nozzle CL 17-1/4 17-1/4 25-1/4 25-1/4 30-3/4 30-3/4 37-3/8 37-3/8 45-1/4
HH - Steam Nozzle to Safety Valve 15 psig 8 8 12 12 11-1/2 11-1/2 13 13 17
II - Steam Nozzle to Safety Valve 150 psig 8 8 12 12 17 17 17 17 17
E - Overall 59 59 59 59 59 59 59 59 59
F - Center to Water Column 32-7/16 32-7/16 32-7/16 32-7/16 32-7/16 32-7/16 32-7/16 32-7/16 32-7/16
G - Center to Opt. Aux. Water Control 26-9/16 26-9/16 26-9/16 26-9/16 26-9/16 26-9/16 26-9/16 26-9/16 26-9/16
H - Center to Outside Casing 16-3/8 16-3/8 16-3/8 16-3/8 16-3/8 16-3/8 16-3/8 16-3/8 16-3/8
I - Base Frame Inside 20 20 20 20 20 20 20 20 20
J - Base Outside 28 28 28 28 28 28 28 28 28
K - Soot Washer Centers 21-3/8 21-3/8 21-3/8 21-3/8 21-3/8 21-3/8 21-3/8 21-3/8 21-3/8
L - Center to Soot Washer 10-11/16 10-11/16 10-11/16 10-11/16 10-11/16 10-11/16 10-11/16 10-11/16 10-11/16
M - CL Base Rail to Center 12 12 12 12 12 12 12 12 12
N - Center to Soot Drain 5-1/4 5-1/4 5-1/4 5-1/4 5-1/4 5-1/4 5-1/4 5-1/4 5-1/4
OO - Overall (Base to Vent Outlet) 78-3/4 78-3/4 78-3/4 78-3/4 78-3/4 78-3/4 78-3/4 78-3/4 78-3/4
O - Base to Steam Nozzle 150 psig 74-3/4 74-3/4 74-3/4 74-3/4 74-3/4 74-3/4 78 78 78
O - Base to Steam Nozzle 15 psig 75 75 75 75 78-1/4 78-1/4 78-1/4 78-1/4 78-1/4
O1 - Base to Smoke Box 77-13/16 77-13/16 77-13/16 77-13/16 77-13/16 77-13/16 77-13/16 77-13/16 77-13/16
O2 - Base to Top of Control Box 83-1/4 83-1/4 83-1/4 83-1/4 83-1/4 83-1/4 83-1/4 83-1/4 83-1/4
P - Base to Surface Blow Off 59-1/4 59-1/4 59-1/4 59-1/4 59-1/4 59-1/4 59-1/4 59-1/4 59-1/4
Q - Base to Feedwater Inlet 57-1/4 57-1/4 57-1/4 57-1/4 57-1/4 57-1/4 57-1/4 57-1/4 57-1/4
R - Base to Soot Washer 55-1/2 55-1/2 55-1/2 55-1/2 55-1/2 55-1/2 55-1/2 55-1/2 55-1/2
S - Height of Base 4 4 4 4 4 4 4 4 4
OR - Base to Oil Return . 25-3/4 25-3/4 25-3/4 25-3/4 25-3/4 25-3/4 25-3/4 25-3/4 25-3/4
T - Bottom Drum Blow Down 15 # (one) 1-1/4 1-1/4 1-1/4 1-1/4 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2
T1 - Bottom Drum Blow Down 150 # (one) 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 - Steam Nozzle 15 psig 4A 4A 4A 4A 6B 6B 6B 6B 6B
V - Steam Nozzle 150 psig 2-1/2A 2-1/2A 3A 3A 3A 3A 4B 4B 4B
W - Soot Washer Drains (Two) 2 2 2 2 2 2 2 2 2
X - Surface Blow Off (One) 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4
Y - Feedwater Inlet (One) 1 1 1 1 1 1 1 1 1
Z - Soot Washers (Two) 1/4 1/4 1/4 1/4 1/4 1/4 1/4 1/4 1/4
GG - Oil Supply & Return 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2
JJ - Relief Valve Outlet 15 psig 2 2 2 2 2 2-1/2 2-1/2 2-1/2 3
JJ - Relief Valve Outlet 150 psig 1 1-1/4 1-1/4 1-1/4 1-1/2 1-1/2 1-1/2 1-1/2 2
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
RF - Allowance for Front Door Swing and 30" 124 124 140 140 155 155 172 172 187
Rear Aisle Space
Front Door Swing
NOTES:
1. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by
certified prints. For 200 psig design pressure or higher, contact factory for certified prints.
2. Allow sufficient space for soot washer lance removal at rear of boiler.
3. Furnace access opening, 13" x 21" located behind front head.
A. Female pipe thread.
B. Flg 150 psig FF.
Figure B2-3. Model 4 Steam Boiler Dimensions Sheet 2 of 2
B2-11
04-02
Table B2-11 shows steam nozzle sizes at various operating
PERFORMANCE DATA pressures.
Table B2-12 shows maximum sound levels when firing oil or
Efficiency
natural gas.
Efficiency data provided is based on hot water or low pressure
steam operation. Nominal boiler efficiency is: Stack Support Capabilities
Gas - 80 percent. Model 4 Boilers can support up to 200 lbs without additional
Oil - 83 percent. support.
For high pressure steam applications, contact your local

Cleaver-Brooks authorized representative for expected effi- Stack Breeching Size Criteria
ciency data. A constant pressure at the flue gas outlet of a Model 4 Boiler is
not required. The high static pressure developed in the wind-
Emissions box by the forced draft fan, and high pressure drop type burner,
provides a safety margin for pressure changes at the boiler out-
The emission data included in this section consist of uncon- let.
trolled nitrogen oxides (NOx) and carbon monoxide (CO) for
Cleaver-Brooks Model 4 Boilers. The following tables include However, it is necessary to size the stack breeching to limit the
typical emission levels and a range of actual emissions. Emis- flue gas pressure variation. The allowable pressure range is
sion data is presented in Table B2-4 for natural gas, and for 0.25 WC to +0.25 WC.
No. 2 oil in Table B2-5.
Table B2-4. Model 4 Boiler Emission Data - Natural Gas
NOTICE POLLUTANT UNCONTROLLED
ppm xx200
The data in these tables represents typical emission CO
lb/MMBtu 0.15
levels only. Please contact your local Cleaver-Brooks
ppm 100
authorized representative if an emission guarantee is NOx
required, or for emission level information not shown lb/MMBtu 0.12
in these tables. ppm 1

SOx
lb/MMBtu 0.001
Fuels ppm 40
HC/VOCs
Fuel requirements for the Model 4 Boiler are shown in Table lb/MMBtu 0.016
B2-6. ppm
PM
lb/MMBtu 0.01
ENGINEERING DATA
Engineering data for Model 4 Boilers are shown in Tables Table B2-5. Model 4 Boiler Emission Data - No. 2 Oil
B2- 7 through B2-12. POLLUTANT UNCONTROLLED
Table B2-7 shows the steam boiler pressure vessel thicknesses, ppm 90
CO
and Table B2-8 shows fuel, combustion air, and flue gas flow lb/MMBtu 0.07
rates at rated boiler capacity. ppm 187
NOx
Flow rates and pressure drops are shown in Table B2-9. This lb/MMBtu 0.248
table can be utilized to determine the boiler pressure drop in ppm 270
relation to the full boiler output and system temperature drop. SOx
lb/MMBtu 0.515
Table B2-10 can be used to determine the maximum circulat- ppm 50
ing rate in relation to the full boiler output and system temper- HC/VOCs
lb/MMBtu 0.025
ature drop. The maximum circulation rate can be determined
ppm
by determining the boiler size and expected system drop. PM
lb/MMBtu 0.025
For information on over pressure requirements for Model 4 NOTES:
Boilers refer to Figure B2-4. Based on fuel oil constituent levels:
Fuel bound nitrogen = 0.05% (max) by weight.
Sulfur = 0.5% (max) by weight.
For more information on hot water boiler over pressure Ash = 0.01% (max) by weight.
requirements refer to Section I2, Hot Water Systems.
B2-12
04-02
Table B2-6. Model 4 Gas Fuel Requirements

NATURAL GAS PROPANE VAPOR
MINIMUM REQUIRED MINIMUM REQUIRED

PRESSURES PRESSURES
BOILER SIZE TRAIN SIZE USAGE USAGE
(INCHES OF WC) (INCHES OF WC)
SCFH) (SCFH)
STANDARD & STANDARD &
IRI IRI
FM FM
1500 1.5A 4.4 5.3 1500 6.7 7.1 600

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

Vessel Thickness
PRESSURE 20" UPPER 8"LOWER

2" TUBES
(PSIG) DRUM DRUM
15 0.375 0.322 0.095
150 0.375 0.322 0.095
250 0.593 0.322 0.095
350 0.812 0.322 0.095
500 1.031 0.500 0.095
NOTE: All thicknesses are in inches.
Table B2-8. Model 4 Boiler Fuel, Air, and Flue Gas Flow Rates
SIZE & INPUT 1500 2000 2500 3000 3500 4000 4500 5000 6000
Gas (cfh)A 1500 2000 2500 3000 3500 4000 4500 5000 6000
Fuel Consumption
Oil (gph)B,C 10.72 14.29 17.86 21.43 25.0 28.57 32.14 35.71 42.85
Gas (scfh) 15480 20640 25800 30960 36120 41280 46440 51600 61920
(lb/h) 1207 1609 2012 2414 2817 3219 3621 4024 4828
Combustion Air
Oil (scfh) 17049 22733 28414 34098 39782 45463 51147 56831 68196
(lb/h) 1269 1692 2115 2538 2961 3384 3808 4231 5077
Gas (scfh) 17520 23360 29200 35040 40880 46720 52560 58400 70080
(lb/h) 1278 1704 2130 2556 2983 3409 3835 4261 5113
Flue Gas
Oil (scfh) 17914 23886 29855 35827 41799 47769 53741 59713 71655
(lb/h) 1357 1809 2261 2714 3166 3618 4070 4523 5427
Notes:
A. Gas Consumption based on 1000 Btu/cu-ft.
B. Oil consumption based on 140,000 Btu/gal.
C. Oil supply lines to be sized for 125 gph pumping rate. Oil pump suction pressure to be -10 Hg to 3 psig.
B2-14
04-02
Table B2-9. Model 4 Hot Water Boiler Pressure Drop
T = 20 T = 30 T = 40 T = 50
OUTLET OUTLET OUTLET OUTLET

BOILER
P P P P
SIZE
VELOCITY FLOW VELOCITY FLOW VELOCITY FLOW VELOCITY FLOW
PSIG FT/S GPM PSIG FT/S GPM PSIG FT/S GPM PSIG FT/S GPM
INLET/OUTLET CONNECTION - 3 NPT
1500 0.54 5.38 123 0.24 3.58 83 0.14 2.69 62 0.09 2.16 50
2000 0.96 7.17 165 0.43 4.79 110 0.24 3.58 83 0.16 2.88 66
2500 1.49 8.96 206 0.67 5.98 138 0.38 4.48 103 0.24 3.60 83
3000 2.13 10.75 248 0.95 7.17 165 0.54 5.38 124 0.343 4.30 99
3500 1.32 7.28 289 0.59 4.86 193 0.34 3.65 145 0.22 2.92 116
4000 1.72 8.34 331 0.77 5.55 220 0.44 4.17 166 0.28 3.34 132
4500 2.18 9.38 372 0.97 6.26 248 0.55 4.69 186 0.35 3.76 149
5000 2.68 10.42 413 1.20 6.95 275 0.68 5.21 207 0.43 4.17 165
6000 3.86 12.50 496 1.72 8.34 330 0.97 6.26 248 0.63 5.01 198
NOTE: Based on 200F outlet temperature
Table B2-10. Model 4 Hot Water Boiler Flow Rates

BOILER SYSTEM TEMPERATURE DROP
SIZE
(BHP) 10 20 30 40 50 60 70 80 90 100
1500 (35) 247 123 83 62 50 41 35 31 28 25
2000 (47) 330 165 110 83 66 55 47 41 37 33
2500 (59) 413 206 138 103 83 69 59 52 46 41
3000 (71) 494 248 165 124 99 83 71 62 55 50
3500 (83) 578 289 193 145 116 97 83 72 64 58
4000 (95) 661 331 220 166 132 110 95 83 74 66
4500 (107) 740 372 248 186 149 124 106 93 83 74
5000 (119) 826 413 275 207 165 138 118 103 92 83
6000 (143) 992 496 330 248 198 166 142 124 110 99
B2-15
04-02
Table B2-11. Model 4 Boiler Recommended Steam Nozzle Size at Reduced Pressure
OPERATING BOILER SIZE

PRESSURE
(PSIG) 1500 2000 2500 3000 3500 4000 4500 5000 6000
15A 4 4 4 4 6 6 6 6 6
20 3 4 4 4 6 6 6 6 6
40 2-1/2 3 3 4 4 4 6 6 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
95-125B 2-1/2 2-1/2 3 3 3 3 4 4 4

NOTE: All dimensions are in inches.
A. Standard Nozzle Size for 15 lb DP Units.
B. Same Nozzle Size as 150 lb DP Units.
Table B2-12. Model 4 Sound Levels

BOILER SIZE (BHP)
SOUND LEVEL
FIRING RATE 1500 2000 2500 3000 3500 4000 4500 5000 6000
(35) (47) (59) (71) (83) (95) (107) (119) (143)
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
decibal ratings on the A-weighted scale, and were registered without the addition of sound attenuators, mufflers,
or silencers.
Figure B2-4. Model 4 Boiler Over Pressure Requirements

B2-16
04-02
Steam Boiler Specifications

1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-17
2.0 Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-17
3.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-22
Hot Water Boiler Specifications

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

2.3.1 Pressure Vessel
2.3.1.1 The upper drum shall have a 20" OD, manufactured from SA53 Gr. B seamless pipe, with a minimum wall thickness of
.375".
2.3.1.2 The lower drum shall have an 85/8" OD, manufactured from SA53 Gr. B seamless pipe, with a minimum wall thickness
of .322".
2.3.1.3 The generating tubes shall be 2" OD, manufactured from SA178 Gr. A tubing, with a minimum wall thickness of .095".
2.3.1.4 The boiler shall have two downcomers, located at the rear of the boiler, and be totally insulated from the generating tubes.
These shall be a minimum of 21/2" OD, manufactured from SA178 Gr. A tubing, with a minimum wall thickness of .105".
2.3.1.5 The upper drum shall have an inspection opening, located at the rear of the unit, to allow internal inspection, and shall be a
minimum of 4"x6".
2.3.1.6 The lower drum shall have inspection openings, located at the front of the unit, to allow internal inspection, and shall be a
minimum of 47/8"x57/8".
2.3.1.7 The boiler shall have inspection openings in the convection area.
2.3.1.8 The hot water outlet shall be located on the top centerline of the boiler and the return water connection shall be located at
the rear of the lower drum. The design of the boiler shall provide jet induced circulation which shall mix the return water and the
hot water within the boiler.
2.3.1.9 A dip tube shall be included as an integral part of the hot water outlet. An air vent tapping shall be located on the top cen-
terline of the boiler for connection to an expansion tank.
2.3.1.10 A _____" drain connection shall be located in the lower drum.
2.3.2 Refractory
2.3.2.1 Refractory shall be limited to the furnace floor to insulate the lower drum, and to the burner throat tile.
2.3.2.2 High temperature insulation shall be installed on the front wall of the furnace.
2.3.3 Insulation and Casing
2.3.3.1 The boiler insulation shall be a minimum of 2" fiberglass, and shall cover the entire pressure vessel.
2.3.3.2 The insulation shall be covered with a corrugated metal lagging.
2.3.3.3 The metal lagging and insulation shall be arranged for easy removal and installation if required.
2.3.3.4 The front head (windbox) shall be attached with a davit arm, gasket sealed, and bolted. The front head shall swing open to
provide full access to the furnace chamber and burner throat tile.
2.3.3.5 Observation ports shall be provided at each end of the boiler for visual inspection of the pilot and main flame conditions.
2.3.3.6 Two lifting eyes shall be located on top of the boiler.
2.3.3.7 The exhaust gases shall vent at the rear of the boiler, on the top centerline.
2.3.4 Trim
2.3.4.1 The water column shall be the probe type and shall be located on the top centerline of the boiler. It shall be wired into the
burner control circuit preventing burner operation if the boiler water level falls below the designated safe level.
2.3.4.2 A pressure gauge and a temperature gauge shall be located at the front end of the boiler.
2.3.4.3 Water relief valves shall be provided of a size and type to comply with ASME Code requirements. The relief valve set pres-
sure shall be ______ psig.
2.3.4.4 A high limit temperature control shall be provided. It shall be a manual reset type and shall be wired to prevent burner oper-
ation and lockout if excessive water temperature occurs. The sensing element shall be located adjacent to the outlet connection.
B2-24
04-02
2.3.4.5 An operating limit control shall be provided. It shall be wired to provided on off control of the burner at operating set
points. The sensing element shall be located adjacent to the outlet connection.
2.3.4.6 A firing rate control shall be provided. It shall control the firing rate of the burner based on the boiler load. The sensing ele-
ment shall be located adjacent to the outlet connection.
2.3.4.7 A hot water circulating pump shall be mounted between the supply and return connections (standard on ASME Section IV
heating boilers only). This pump will blend the supply and the system return water. It will ensure a minimum continuous circula-
tion at all times to a level of ten boiler water changes per hour.
2.3.4.8 A stack thermometer shall be shipped loose for field installation.
2.3.5 Soot Cleaning
2.3.5.1 Soot washer lances shall be provided in the convection area of the boiler measuring the full length of the pressure vessel.
2.3.5.2 Each lance shall be provided with a shutoff valve and the assembly shall be capable of rotating 360 degrees. This shall
ensure complete washing of the convection zone while the boiler is operating in the low fire mode.
2.3.5.3 Soot washer troughs shall be provided at the bottom of the boiler. These shall be furnished for each convection side and
shall measure the full length of the boiler.
2.3.5.4 The soot washer troughs shall be provided with 2" drain connections at the rear of the boiler, and shall have inspection/
cleanout openings at the front of the boiler.
2.3.6 Burner Design General
2.3.6.1 The burner shall be integral to the front head (windbox).
2.3.6.2 All air for combustion shall be supplied by a forced draft blower mounted in the front head (windbox), above the burner, to
minimize noise and vibration level.
2.3.6.3 The blower motor shall be an open drip proof type with a minimum service factor of 1.15.
2.3.6.4 The impeller shall be an enclosed centrifugal fan type, properly balanced, and directly connected to the blower motor shaft.
2.3.6.5 The combustion air damper shall be integral to the front head (windbox) and shall be operated by a single damper motor.
2.3.6.6 The burner shall remain in the low fire position during ignition and until main flame has been established.
2.3.7 Burner Design Gas
2.3.7.1 The burner shall be the high radiant multiport type approved for operation with natural gas.
2.3.7.2 The burner shall operate on the _______________ (lowhighlow or full modulation) principle and must return to the low
fire position prior to ignition.
2.3.7.4 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.
2.3.8 Burner Design No. 2 Oil
2.3.8.1 The burner shall be the pressure atomizing type approved for operation with commercial grade No. 2 oil.
2.3.8.3 The burner shall remain in the low fire position during 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.
2.3.8.4 Automatic electric ignition of the low fire oil supply shall be provided with a minimum 10,000 volt transformer and heavy
duty electrodes.
B2-25
04-02
NOTICE
Optional insurance compliance may require a premix gas pilot in lieu of direct spark ignition.
2.3.8.5 [Optional] Automatic electric ignition of the premix gas pilot shall be furnished. An electric scanner, of the UV principle,
shall confirm the pilot prior to the delivery of the low fire oil supply.
2.3.8.6 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.
2.3.9 Burner Design Gas and No. 2 Oil
2.3.9.1 The burner shall be the high radiant multiport type for gas and shall be the pressure atomizing for oil. The burner must be
approved for operation with either natural gas or commercial grade No. 2 oil.
2.3.9.3 The burner shall remain in the low fire position during ignition and until main flame has been proven.
2.3.9.5 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.
2.3.10 Natural Gas Main Train
2.3.10.1 The gas burner piping shall include a primary gas shutoff valve. It shall be controlled by the programming relay to start or
stop the burner and to close automatically in the event of power failure, flame failure, or a low water condition.
2.3.10.2 A manual shutoff valve shall be located ahead of the primary gas valve.
2.3.10.3 A plugged leakage test connection and a second manual shutoff valve shall be provided as a means for a tightness check of
the primary shutoff valve.
2.3.10.4 A gas pressure regulator shall be factory mounted and piped for pressure regulation to the burner.
2.3.10.5 Gas Train Components Standard (UL)
2.3.10.5.1 [Sizes 15002500] The primary gas shutoff valve shall be motorized with a proof of closure switch.
2.3.10.6 Gas Train Components Factory Mutual Insurance (FM)
2.3.10.7 Gas Train Components Industrial Risk Insurers (IRI)
2.3.10.7.1 [ Size 15005000] The gas train piping shall include both primary and secondary motorized gas safety shutoff valves
and a second plugged leakage test cock. A vent valve shall be located between the primary and secondary gas shutoff valves. High
and low gas pressure switches shall be provided.
2.3.10.7.2 [Size 6000] The primary gas shutoff valve shall be motorized with a proof of closure switch. A second gas motorized
shutoff valve and an additional plugged leakage test cock shall be provided. A vent valve shall be located between the primary and
secondary gas shutoff valves. High and low gas pressure switches shall be provided.
B2-26
04-02
2.3.11 Natural Gas Pilot Train

2.3.11.1 A pilot gas pressure regulator shall be factory mounted and piped for pressure regulation of the pilot gas to the burner.
2.3.11.2 The pilot gas train shall include a safety shutoff valve. It shall be controlled by the programming relay to start the burner.
2.3.11.3 A manual shutoff valve shall be located ahead of the pilot gas pressure regulator.
2.3.12 Oil System
2.3.12.1 An oil pump shall be provided. The oil pump, integral with the burner, shall include a builtin relief valve and selfclean-
ing strainer.
2.3.12.2 The oil pump shall be belt driven from the blower motor.
2.3.12.3 The fuel oil system shall include supply and return tubing to a terminal block, an oil pressure gauge, shutoff cock, and four
solenoid oil shutoff valves. These items shall be factory mounted and piped on the front head (windbox).
2.4 Burner Management System
2.4.1 Control Panels
2.4.1.1 The control panel shall be a NEMA 1 rated panel and have a key lock.
2.4.1.2 The control panel shall be mounted on the front head of the boiler and shall be conveniently located for the boiler operator.
2.4.1.3 The panel shall contain the blower motor starter, control circuit fuses, control circuit transformer, and control switches. A
damper selector switch shall be provided to permit selection of automatic or manual selection of low or high firing.
2.4.1.4 A terminal board shall be provided to which all wires entering or leaving the panel shall be connected.
2.4.1.5 The panel shall include four indicating lights to show operating conditions of: red = low water; red = flame failure; white =
load demand; and white = fuel valve open. The lights and switches shall be located on the panel switch ledge.
2.4.1.6 The panel shall include a low fire hold timer wired to hold the boiler in a low firing mode, for a minimum of ten minutes,
each time the boiler cycles on. This low fire hold timer ensures gradual boiler warmup.
2.4.1.7 All electrical service connections shall be made to an electrical entrance box to be mounted on the right hand side of the
boiler.
2.4.1.8 All electrical wiring shall be oil, heat, and moisture resistant and shall be number coded.
2.4.2 Combustion Safeguard Control
2.4.2.1 A combustion safeguard control (program relay) shall be provided to control ignition, starting, and stopping of the burner.
It shall provide precombustion and postcombustion purge periods and shall stop burner operation in the event of ignition, pilot, or
main flame failure. Trial for ignition shall be limited to 10 seconds.
2.4.2.2 The boiler shall be provided with a combustion safeguard controller that provides technology and functions equal to the
Cleaver Brooks Model CB100.
2.4.2.3 The combustion safeguard control shall be microprocessor based, with self diagnostics, nonvolatile memory, and a mes-
sage center with a vocabulary of 42 different messages. Messages shall scroll across an alphanumeric display and provide
sequence status and flame failure mode information.
2.4.2.4 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.
2.4.2.5 The controller shall be the nonrecycle type for maximum safety that will shut down the burner and indicate as a minimum
the following trip functions: pilot failure, main 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).
2.4.2.6 The controller shall have a test/run switch. It will allow interruptions to sequence just after prepurge, during pilot ignition
trial, and during run cycles, for adjustments to firing rate motor, damper linkages, and pilot flame for turndown tests.
2.4.2.7 The controller shall also have the following functions: display history of operating hours and totals of completed onoff
cycles; provide a constant flame signal strength readout; and have provisions for remote display capability.
B2-27
04-02
3.0 Execution
3.1 Shop Tests
3.1.1 The pressure vessel shall be hydrostatically tested in accordance with ASME requirements.
3.1.2 The boiler will be test fired by the manufactured, prior to shipment, to verify proper and safe operation.
3.2 Shipment
3.2.1 Painting
3.2.1.1 The entire boiler, base frame, and other components shall be factory painted, before shipment, using a hard finish enamel.
3.2.1.2 The boiler surface shall be cleaned/prepared for painting using manufacturer's specifications and standard industrial paint-
ing practices.
3.2.2 Preparation
3.2.2.1 All boiler openings shall be plugged/covered prior to shipment.
3.2.2.2 The boiler shall be skid mounted and protected with a weather resistant covering.
3.2.2.3 All shipped loose components shall wrapped in protective material and packaged in a separate container(s).
3.3 Installation
3.4 StartUp
3.4.1 The boiler startup shall be performed by a factory trained representative and will be done in accordance with the manufac-
turer's recommended procedures.
3.4.2 The boiler startup shall include boiler operator training and shall cover boiler operation, water treatment, and maintenance of
the unit.
3.5 Operation and Maintenance Manuals
3.5.1 The manufacturer shall supply _____ copies of the Operating & Maintenance Manual.
B2-28
04-02
Section B3
MODEL 5 BOILERS
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-3
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-4
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-4
Special Insurance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-5
Added Equipment for IRI Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-5
Added Equipment for FM Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-5
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-12
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-12
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-12
Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-12
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-12
Steam Boiler Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-16
Hot Water Boiler Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3-21
B3-1
10-02
ILLUSTRATIONS
Figure B3-1. Model 5 Standard Gas Trains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-7
Figure B3-2. Model 5 Steam Boiler Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-8
Figure B3-3. Model 5 Hot Water Boiler Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-10
Figure B3-4. Model 5 Over Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-15
TABLES
Table B3-1. Model 5 Boiler Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3- 3
Table B3-2. Model 5 Hot Water Boiler Ratings (N/A to LWV Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6
Table B3-3. Model 5 Emission Data, Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6
Table B3-4. Model 5 Emission Data, No. 2 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-12
Table B3-5. Model 5 Oil Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-12
Table B3-6. Model 5 Gas Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-12
Table B3-7. Model 5 Boiler Reference Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-13
Table B3-8. Model 5 Hot Water Boiler Circulating Rates and Temperature Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-13
Table B3-9. Model 5 Boiler Recommended Steam Nozzle Size at Reduced Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-14
Table B3-10. Model 5 Hot Water Boiler Circulating Rates and Temperature Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-14
Table B3-11. Model 5 Boiler Recommended Steam Nozzle Size at Reduced Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . B3-14
Table B3-12. Model 5 Boiler Sound Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-15
The Model 5 Commercial Watertube Boiler product line is used for low and high pressure steam and hot water applications. Sizes range
from 1.5 to 8 MMBtu/hr. The Model 5 Boiler is an excellent choice where high outputs and space limitations exist. The model number
designation is 1500 through 8000, representing Btu/hr input (1,500,000 to 8,000,000 Btu/hr).
Fuel series designation is as follows:
Series 100: No. 2 oil 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
M5HW-700-2500-140 boiler designates a gas-fired, 2,500,000 Btu/hr, 140 psig, hot water boiler.
B3-2
10-02
FEATURES AND BENEFITS Low Water Volume Design (optional):

Meets various provincial operating engineer codes and
The following features and benefits apply to the Model 5 regulations.
Boiler product line.
Reduced operating costs.
33" Cased Width: High and low pressure steam.

Boiler fits through most standard doorways.
Steam Design Pressures to 500 psig:
Reduced installation costs.
High performance in a compact design.
Direct Driven, Vibration-Free Centrifugal Impeller: Proven vessel design for high design pressure applications.
Quiet operation.
PRODUCT OFFERING
Sound levels below 80 dbA.
Information in this section applies to Cleaver-Brooks Model 5
Ideal for noise critical areas such as hospitals, churches, etc. watertube boilers in sizes ranging from 1.5 to 8 MMBtu/hr
input, as shown in Table B3-1. Model numbers represent input
Minimum Refractory: (1,000 Btu/hr).
Membrane waterwalls reduce the need for refractory by The Model 5 Boiler is a compact, packaged, all-steel mem-
95%. braned waterwall watertube boiler. It is a three-pass boiler with
Reduced maintenance costs and refractory repair watertubes and membranes formed to direct the flow of com-
requirements. bustion gases through the boiler. The pressure vessel is con-
structed to conform with Sections I or IV of the ASME Codes
for hot water, low-pressure steam, and high-pressure steam
Membrane Waterwalls:
boilers.
Enhanced heat transfer area in compact design.
The vessel consists of formed membrane tubes and downcom-
Sealed combustion chamber improves heat transfer for high ers, connected to the upper and lower drums. The boiler vessel
efficiency. is gas tight, insulated on the outside, and covered by casing
constructed of removable, formed steel panels. The standard
Small Boiler Footprint: boiler/burner package is CSA approved in hot water, low- pres-
sure steam, and high-pressure steam (150 psig design) when
Savings of up to 50% in floor space.
fueled by No. 2 oil and/or natural gas. The Model 5 Boiler is
available with higher pressure designs.
Weighs up to 40% less than Comparable Boilers:
Lower freight and rigging costs.
Reduced structural requirements. Table B3-1. Model 5 Boiler Sizes
HEAT STEAM SHIPPING
Standard Built-in Soot Washers: MODEL INPUT
OUTPUT
EQUIV
OUTPUT WEIGHT
NO. MBH HP
Boiler cleaning without shutdown. MBH LB/HR LBS
1500 1500 1200 35 1237 3100
Maintains peak boiler performance.
2000 2000 1600 47 1649 3100
2500 2500 2000 59 2062 3700
Packaged Forced Draft Burner:
3000 3000 2400 71 2474 3700
High pressure drop design. 3500 3500 2800 83 2887 4100
Optimum fuel and air mixing. 4000 4000 3200 95 3299 4100
4500 4500 3600 107 3711 4700
Improved combustion efficiency. 5000 5000 4000 119 4124 4700
6000 6000 4800 143 4949 5400
8000 LWV 8000 6320 194 65
NOTE: Steam output from and at 212 F.
LWV = Low Water Volume.

B3-3
10-02
Standard Equipment G. Combustion air proving switch.

Equipment described below is for standard boiler offerings. 4. Steam Boiler Control Standard Equipment (15 to 150 psig)
The Cleaver-Brooks Model 5 boiler is a packaged watertube A. ASME safety relief valve(s).
steel boiler consisting of pressure vessel, oil and/or gas burner, B. Steam pressure gauge.
burner controls, forced draft fan and integral air damper con-
trol assembly. C. Pressure controls:
1. Boiler High limit control-manual reset.
A. Designed, constructed, and hydrostatically tested in Operating limit control.
accordance with the ASME Boiler and Pressure Vessel High-low fire control (full modulation for gas firing).
Code.
D. Low water cutoff with pump control.
B. Refractories for the boiler and burner are installed.
E. Water column gauge glass set and fittings.
C. Fully insulated under a preformed, sectional sheet metal
jacket. F. Auxiliary low water cut-off.
D. Mounted on an integral steel heavy base frame. G. Combustion air proving switch.
E. Factory painted using a hard-finish enamel. 5. Electrical Control Panel
2. Forced Draft Burner A. Mounted at eye level on the front head of the boiler.
A. Integral with front head of boiler (factory mounted and B. NEMA rating 1A with gasket dust seal.
tested). (Model 8000 LWV uses ProFire.) C. Contains electronic program relay and switches.
B. Combustion air fan and motor are integral with front 6. Miscellaneous
head of boiler. (N/A to Model 8000 LWV.)
A. The boiler is Canadian Standards Association (CSA)
C. Pressure atomizing type for No. 2 oil burner includes oil approved and bears the CSA label.
pump.
D. High radiant multi-port type burner for gas includes gas Optional Equipment
train and gas pressure regulator.
For more detailed information on optional equipment, contact
E. Gas burner operates on the full modulation principle. your local Cleaver-Brooks authorized representative. In sum-
F. Oil burner operation uses low-high-low principle. mary, options include the following:
(Model 8000 LWV is modulated.) A. Boiler Options
G. Ultra-violet type flame scanner. Hot water pressure gauge.
3. Hot Water Boiler Control Standard Equipment (140 psig) Drain valves.
A. ASME safety relief valve(s). Additional screwed tappings.
B. Temperature and pressure gauges. Surface blow-off valve.
C. Temperature controls: High altitude design.
High limit control-manual reset. Valves for soot lance.
Operating limit control. Feedwater control valves.
High-low fire rate control (full modulation for gas B. Burner/Control Options
firing).
Optional flame safeguard controller.
D. Low water cutoff-float type McDonnell-Miller or
approved equal. Lead/Lag system.
E. Boiler hot water circulating pump. Light package.
F. Low fire hold time delay. Day-night controls.
B3-4
10-02
Alarm bell/silence switch. A. Alarm bell mounted for non-recycling shutdowns.

Special motor requirements (TEFC, High efficiency). B. High and Low Gas Pressure Switches.
Remote contacts. C. Second Motorized Gas Valve (Size 6000).
Additional relay points and indicator lights.
Main disconnect (fusible/circuit breaker).
Dimension and rating information for Model 5 boilers, is
Elapsed time meter.
shown in Table B3-2 and Table B3-3, and Figures B3-1
Voltmeter/micro-ammeter. through B3-3.
Optional NEMA enclosure.
PERFORMANCE DATA
High stack temperature control.
C. Fuel Options Efficiency
Special water column.* Efficiency data provided is based on hot water or low pressure
Guarded plant status equipment. Insulation of upper steam operation. Nominal boiler efficiency is:
drum from furnace combustibles. Gas - 80 percent.
* Note: Not required for low pressure steam applications. Oil - 83 percent.
For high pressure steam applications, contact your local
Special Insurance Requirements Cleaver-Brooks authorized representative for expected effi-
ciency data.
Added Equipment for IRI Compliance
1. All fuels
A. Alarm bell mounted for non-recycling shutdowns.
2. Oil Fired
A. Low oil pressure switch.
B. Gas pilot.
3. Gas fired
A. Two motorized main gas valves with vent valve.
B. Proof of closure switch (on gas valve).
C. High and Low Gas Pressure Switches.
Added Equipment for FM Compliance

1. Oil Fired
B. Alarm bell mounted for non-recycling shutdowns.
2. Combination Oil and Gas Fired
B. Alarm bell mounted for non-recycling shutdowns.
C. High and Low Gas Pressure Switches.
D. Second Motorized Gas Valve (Size 6000)
3. Gas Fired
B3-5
10-02
Table B3-2. Model 5 Hot Water Boiler Ratings (N/A to LWV Models)
MODEL NO. 1500 2000 2500 3000 3500 4000 4500 5000 6000
Rated Capacity Btu Output (1,000 Btu/hr) 1200 1600 2,000 2400 2800 3200 3600 4000 4,800
EDR Water Gross, Sq-ft. 8000 10667 13333 16000 18667 21333 24000 26667 32000
Blower Motor Gas Only (hp) 2 2 2 2 2 3 3 3 5
Blower Motor Oil or Combination (hp) 2 2 2 2 5 5 5 5 5
Control Circuit Transformer kVA 1 1 1 1 1 1 1 1 1
Flooded Water Weight 794 794 1085 1085 1353 1353 1660 1660 1940
NOTE: Ratings are sea level to1000 ft.
Table B3-3. Model 5 Emission Data, Natural Gas
MODEL NO. 1500 2000 2500 3000 3500 4000 4500 5000 6000 8000 LWV
Rated Capacity in Lbs Steam/hr (212 F) 1237 1649 2062 2474 2887 3299 3711 4124 4949 6516
BTU Output (1,000 Btu/hr) 1200 1600 2000 2400 2800 3200 3600 4000 4800 6320
Boiler Horsepower 35 47 59 71 83 95 107 119 143 194
EDR Steam Gross, Sq-ft 5000 6667 8333 10000 11667 13333 15000 16667 20000 26667
Blower Motor Gas Only (hp) 3/4 1 1-1/2 2 2 3 3 3 5 10
Blower Motor Oil or Combination (hp) 2 2 2 2 3 5 5 5 5 10
Control Circuit Transformer kVA 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2
Oil Pump Belt Driven From Blower Motor Direct Drive

From Motor
Operating Water Weight 543 543 745 745 940 940 1158 1158 1353 720
NOTES:
1. Ratings are at sea level to 1000 ft.
2. Output rating for high pressure steam will be reduced based on operating conditions.
B3-6
10-02
ITEM PART SIZE (IN.)
SIZE 1500 - 3000

1 Gas Inlet 1-1/2
2 Shutoff Cock 1/2
3 Pilot Regulator 1/2
4 Solenoid Valve 1/2
5 Lub Shutoff Cock 1-1/2
6 Main Regulator 1-1/2
8 Motorized Gas Valve 1-1/2
9 Plugged Test Port 1/4
SIZES 3500 TO 5000
1 Gas Inlet 2
2 Shutoff Cock 1/2
5 Lub Shutoff Cock 2
6 Main Regulator 2
8 Motorized Gas Valve 2
11 Butterfly Valve 2
SIZE 6000
1 Gas Inlet 2
2 Shutoff Cock 1/2
5 Lub Shutoff Cock 2
6 Main Regulator 2-1/2
8 Motorized Gas Valve (2 reqd) 2
11 Butterfly Valve 2
Figure B3-1. Model 5 Standard Gas Trains
B3-7
10-02
FRONT VIEW
5
REAR VIEW
K
T
OO1
Figure B3-2. Model 5 Steam Boiler Dimensions - Sheet 1 of 2
B3-8
10-02
MODEL NO. 1500 2000 2500 3000 3500 4000 4500 5000 6000 8000LWV
A - Overall 69-11/16 69-11/16 85-13/16 85-13/16 104-7/16 104-7/16 121-1/16 121-1/16 136-11/16
B - Pressure Vessel with Casing 51-1/4 51-1/4 67-3/8 67-3/8 83 83 99-5/8 99-5/8 115-1/4
C - Base Frame 45-1/2 45-1/2 61-1/8 61-1/8 76-3/4 76-3/4 92-3/8 92-3/8 108
C1 - Base to Front Head 8 8 8 8 8 8 8 8 8
C2 - Base Frame Anchor Holes 43 43 58-1/2 58-1/2 74-1/2 74-1/2 90 90 105-1/2
D - Front Head Extension 13 13 13 13 16 16 16 16 16
DD - Front Casing to Steam Nozzle CL 16-3/8 16-3/8 24-3/8 24-3/8 30-1/8 30-1/8 36-3/4 36-3/4 44-5/8
HH - Steam Nozzle to Safety Valve 15# 7 7 12 12 11-1/2 11-1/2 13 13 17

II - Steam Nozzle to Safety Valve 150 # 8 8 12 12 17 17 17 17 17
E - Overall 57-1/2 57-1/2 57-1/2 57-1/2 57-1/2 57-1/2 57-1/2 57-1/2 57-1/2
F - Center to Water Column 33 33 33 33 33 33 33 33 33
G - Center to Aux. Water Control 23-1/2 23-1/2 23-1/2 23-1/2 23-1/2 23-1/2 23-1/2 23-1/2 23-1/2
H - Center to Outside Casing 16-1/2 16-1/2 16-1/2 16-1/2 16-1/2 16-1/2 16-1/2 16-1/2 16-1/2
I - Base Frame Inside 20 20 20 20 20 20 20 20 20
J - Base Outside 28 28 28 28 28 28 28 28 28
K - Soot Washer Centers 21-1/2 21-1/2 21-1/2 21-1/2 21-1/2 21-1/2 21-1/2 21-1/2 21-1/2
L - Center to Soot Washer 10-3/4 10-3/4 10-3/4 10-3/4 10-3/4 10-3/4 10-3/4 10-3/4 10-3/4
M - CL Base Rail to Center 12 12 12 12 12 12 12 12 12
N - Center to Soot Drain 3-1/2 3-1/2 3-1/2 3-1/2 3-1/2 3-1/2 3-1/2 3-1/2 3-1/2
OO - Overall (Base to Vent Outlet) 78-1/4 78-1/4 78-1/4 78-1/4 78-1/4 78-1/4 78-1/4 78-1/4 78-1/4
OO1 - Base to Top of Control Panel 84-1/2 84-1/2 84-1/2 84-1/2 84-1/2 84-1/2 84-1/2 84-1/2 84-1/2
O - Base to Steam Nozzle 15# 73-1/2 73-1/2 73-1/2 73-1/2 76-3/4 76-3/4 76-3/4 76-3/4 76-3/4
O1 - Base to Steam Nozzle 150# 73-1/4 73-1/4 73-1/4 73-1/4 73-1/4 73-1/4 76-1/2 76-1/2 76-1/2
P - Base to Drum CL 61-3/4 61-3/4 61-3/4 61-3/4 61-3/4 61-3/4 61-3/4 61-3/4 61-3/4
Q - Base to Feedwater Inlet 55-3/4 55-3/4 55-3/4 55-3/4 55-3/4 55-3/4 55-3/4 55-3/4 55-3/4
R - Base to Soot Washer 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 Conn. 26-5/8 26-5/8 26-5/8 26-5/8 26-5/8 26-5/8 26-5/8 26-5/8 26-5/8
OR - Base to Oil Return Conn. 24-5/8 24-5/8 24-5/8 24-5/8 24-5/8 24-5/8 24-5/8 24-5/8 24-5/8
T - Bottom Drum Blow Down 15 # (one) 1-1/4 1-1/4 1-1/4 1-1/4 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2
T1 - Bottom Drum Blow Down 150 # (one) 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 - Steam Nozzle 15 # 4A 4A 4A 4A 6B 6B 6B 6B 6B
V - Steam Nozzle 150 # 2-1/2 A
2-1/2 A
3A
3A
3 A
3 A
4 B
4 B
4B
W - Soot Washer Drains (Two) 2 2 2 2 2 2 2 2 2
X - Surface Blow Off (One) 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4
Y - Feedwater Inlet (One) 1 1 1 1 1 1 1 1 1
Z - Soot Washers (Two) 1/4 1/4 1/4 1/4 1/4 1/4 1/4 1/4 1/4
GG - Oil Supply & Return 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2
JJ - Relief Valve Outlet 15# 1-1/2 2 2 2 2-1/2 2-1/2 2-1/2 2-1/2 3
JJ - Relief Valve Outlet 150 # 3/4 1 1 1 1-1/4 1-1/4 1-1/4 1-1/4 1-1/2
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
RF - Allowance for Front Door Swing and 30" Rear 133 133 149 149 167 167 184 184 200
Aisle Space
Front Door Swing
NOTES:
1. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by
certified prints. For 200 psig design pressure or higher, contact factory for certified prints.
2. Allow sufficient space for soot washer lance removal at rear of boiler.
3. Furnace access opening, 15 x 20 located inside rear head.
4. Control panel may be larger due to additional electrical devices accounting for an additional 4 inches in overall height.
5. Subtract 3-1/2 for gas-fired only units.
A. Female pipe thread.
B. Flg 150 psig FF.
Figure B3-2. Model 5 Steam Boiler Dimensions - Sheet 2 of 2
B3-9
10-02
FRONT VIEW
6
REAR VIEW
Z
B3-10
10-02
MODEL NO. 1500 2000 2500 3000 3500 4000 4500 5000 6000
A - Overall 80 80 96-5/8 96-5/8 115-1/4 115-1/4 132-7/8 132-7/8 148-11/16
B - Pressure Vessel with Casing 51-1/4 51-1/4 67-3/8 67-3/8 83 83 99-5/8 99-5/8 115-1/4
C - Base Frame 45-1/2 45-1/2 61-1/8 61-1/8 76-3/4 76-3/4 92-3/8 92-3/8 108
C1 - Base to Front Head 8 8 8 8 8 8 8 8 8
C2 - Base Frame Anchor Holes 43 43 58-5/8 58-5/8 74-1/4 74-1/4 89-7/8 89-7/8 105-1/2
E - Front Casing to Outlet 16-1/2 16-1/2 24-1/2 24-1/2 30 30 36-3/4 36-3/4 44-1/2
F - Outlet to Relief Valve 7 7 12 12 10-3/4 10-3/4 13 13 14
G - Rear Drum to Center Line Return 4-1/8 4-18 4-5/8 4-5/8 4-5/8 4-5/8 5-5/8 5-5/8 5-5/8
H - Rear Casing to Air Vent 5-3/8 5-3/8 5-3/8 5-3/8 5-3/8 5-3/8 5-3/8 5-3/8 5-3/8
I - Overall 46 46 46 46 46 46 46 46 46
J - Outside Casing to Blend Pump 39 39 39 39 39 39 39 39 39
K - Center to Outside Casing 16-9/16 16-9/16 16-9/16 16-9/16 16-9/16 16-9/16 16-9/16 16-9/16 16-9/16
L - Base, Inside 20 20 20 20 20 20 20 20 20
M - Base, Outside 28 28 28 28 28 28 28 28 28
N - Center to Soot Washer Drain 3-1/2 3-1/2 3-1/2 3-1/2 3-1/2 3-1/2 3-1/2 3-1/2 3-1/2
O - Center to Base Center 12 12 12 12 12 12 12 12 12
P - Center to Soot Washer 10-3/4 10-3/4 10-3/4 10-3/4 10-3/4 10-3/4 10-3/4 10-3/4 10-3/4
QQ - Overall (Base to Vent Outlet) 78-1/4 78-1/4 78-1/4 78-1/4 78-1/4 78-1/4 78-1/4 78-1/4 78-1/4
Q - Base to Outlet 79-7/8 79-7/8 79-7/8 79-7/8 80-5/8 80-5/8 80-5/8 80-5/8 80-5/8
R - Base to Soot Washer 54 54 54 54 54 54 54 54 54
S - Height of Base 4 4 4 4 4 4 4 4 4
T - Base to Return 8-1/4 8-1/4 8-1/4 8-1/4 8-1/4 8-1/4 8-1/4 8-1/4 8-1/4
U - Base to Soot Washer Drain 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8
OR - Base to Oil Return 24-3/4 24-3/4 24-3/4 24-3/4 24-3/4 24-3/4 24-3/4 24-3/4 24-3/4
V - Drain Valve, Low Water Control 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4
W - Soot Washers (Two) 1/4 1/4 1/4 1/4 1/4 1/4 1/4 1/4 1/4
X - Soot Washer Drains (Two) 2 2 2 2 2 2 2 2 2
Y - Bottom Drain (One) 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
Z - Base to Top of Control Box 84-1/2 84-1/2 84-1/2 84-1/2 84-1/2 84-1/2 84-1/2 84-1/2 84-1/2
HS - Water Outlet (Male Pipe Thread) 3 3 3 3 4 4 4 4 4
HR - Water Return (Female Pipe Thread) 3 3 3 3 4 4 4 4 4
FF - Air Vent 1 1 1 1 1 1 1 1 1
GG - Oil Supply and Return 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2
HH - Relief Valve Outlet 125 # Setting 3/4 3/4 3/4 1 1 1-1/2 1-1/2 1-1/2 1-1/2
DD - Front Door Swing 33 33 33 33 33 33 33 33 33
EE - Tube Removal Each Side 30 30 30 30 30 30 30 30 30
RF - Allowance for Front Door Swing and 30" Rear 133 133 149 149 167 167 184 184 200
Aisle Space
Front Door Swing
NOTES:
1. Accompanying dimensions, while sufficiently accurate for layout purposes, must be confirmed for construction by certified prints.
2. Allow sufficient clearance at rear of boiler for soot washer lance removal. (oil or oil/gas fired units only)
3. Furnace access opening, 15 x 20 located inside rear head.
4. Control panel may be larger due to additional electrical devices accounting for an additional 4 inches in overall height.
5. All Connections are threaded.
6. Subtract 3-1/2 for gas-only fired unit.
B3-11
10-02
Emissions ENGINEERING DATA

The emission data included in this section consist of uncon- Engineering data for Model 5 Boilers are shown in Tables B3-
trolled levels of nitrogen oxides (NOx) and carbon monoxide 7 through Table B3-12.
(CO) for Cleaver-Brooks Model 5 Boilers. The following
tables include typical emission levels and a range of actual Table B3-7 shows fuel, combustion air, and flue gas flow rates
emissions. Emission data is presented in Table B3-3 for natu- at rated boiler capacity.
ral gas, and for No. 2 oil in Table B3-4. Hot water boiler flow rates and pressure drops are shown in
Table B3-8. This table can be utilized to determine the boiler
pressure drop in relation to the full boiler output and system
NOTICE temperature drop.
The data in these tables represents typical emission Table B3-10 can be used to determine the maximum water cir-
levels only. Please contact your local Cleaver-Brooks culating rate in a hot water boiler in relation to the full boiler
authorized representative if an emission guarantee is output and system temperature drop. The maximum circulat-
required, or for emission level information not shown ing rate can be determined from the boiler size and expected
in these tables. system temperature drop.
See Figure B3-4 for minimum operating pressure, based on
Fuels the maximum temperature in a Model 5 hot water boiler.
Fuel requirements for the Model 5 Boiler are shown in Tables For more information, refer to Section 12, Hot Water Systems.
B3-5 and B3-6. Table B3-11 shows recommended steam nozzle sizes at vari-
Table B3-4. Model 5 Emission Data, No. 2 Oil ous operating pressures.
POLLUTANT UNCONTROLLED Table B3-12 shows maximum sound levels when firing oil or
ppmA 200 natural gas.
CO
lb/MMBtu 0.15
ppmA 100
NOx
lb/MMBtu 0.12
ppmA 1
SOx
lb/MMBtu 0.001
ppmA 40
HC/VOCs
lb/MMBtu 0.016
ppmA
PM
lb/MMBtu 0.01
A. ppm levels corrected to 3% O2 dry basis.
Table B3-5. Model 5 Oil Fuel Requirements

POLLUTANT UNCONTROLLEDB
ppmA 90
CO
lb/MMBtu 0.07
ppmA 187
NOx
lb/MMBtu 0.248
ppmA 278 Table B3-6. Model 5 Gas Fuel Requirements
SOx
lb/MMBtu 0.515
BOILER
ppmA 50 1500 2000 2500 3000 3500 4000 4500 5000 6000 8000 LWV
HC/VOCs MODEL
lb/MMBtu 0.025
OIL
ppmA
PM
lb/MMBtu 0.025 USAGEA 10.7 14.3 17.9 21.4 25.0 28.6 32.7 35.7 42.8
(GPH)
NOTES:
A. ppm levels corrected to 3% O2 dry basis. NOTES:
B. Based on the following fuel oil constituents. 1.Oil supply lines to be sized for 125 gph pumping rates.
Fuel-bound nitrogen = 0.05% (max) by weight. 2.Oil pump suction pressure -10 Hg to 3 psig.
Sulfur = 0.5% (max) by weight.
A.Usage Based on #2 Fuel @ 140,000 Btu/gal.
Ash = 0.01% (max) by weight.
B3-12
10-02
Table B3-7. Model 5 Boiler Reference Data

NATURAL GAS PROPANE VAPOR
MINIMUM REQUIRED PRESSURES MINIMUM REQUIRED PRESSURES

BOILER SIZE TRAIN SIZE USAGE (SCFH)
(INCHES OF WC) USAGE (SCFH) (INCHES OF WC)
STANDARD & FM IRI STANDARD & FM IRI

A
1500 1.5 4.3 5.3 1500 6.4 7.1 600
2.0 1.8 2.5 5.4 6.0
2000 1.5A 8.4 10.2 2000 9.8 11.2 800
2.0 3.8 5.0 8.0 9.0
2500 1.5A 11.3 14.9 2500 11.7 14.1 1000
2.0 4.9 6.9 9.1 11.0
2.5 4.1 6.0 8.8 10.6
3000 1.5A 14.9 20.0 3000 14.8 18.2 1200
2.0 6.8 9.7 11.6 14.1
2.5 4.5 7.3 10.7 13.1
3.0 3.7 6.3 10.4 12.7
3500 2.0A 10.0 12.1 3500 12.9 14.6 1400
2.5 8.3 10.3 12.2 13.9
3.0 5.8 7.6 11.2 12.8
4000 2.0A 11.9 14.7 4000 14.7 17.0 1600
2.5 10.0 12.6 14.0 16.1
3.0 6.8 9.0 12.7 14.7
4500 2.0A 11.5 13.6 4500 14.1 15.3 1800
2.5 9.1 10.8 13.1 14.2
3.0 4.9 6.2 11.5 12.4
5000 2.0A 16.0 18.4 5000 15.6 17.1 2000
2.5 12.1 14.1 14.0 15.3
3.0 6.3 7.8 11.7 12.8
4.0 4.8 6.0 11.1 12.1
6000 2.0A 20.4 24.0 6000 18.4 20.5 2400
2.5 16.3 19.3 16.8 18.7
3.0 8.8 11.1 13.8 15.4
4.0 6.7 8.4 13.0 14.3
8000 LWV 2.5A - 19.9 8000
3.0 - 17 N/A N/A N/A
4.0 - 13
NOTES:
1. Natural gas pressure based on 1000 Btu/cu-ft @ 0.65 specific gravity.
2. Propane pressures based on 2500 Btu/cu-ft @ 1.6 specific gravity.
3. All pressures given for regulator inlet.
A.Standard Gas Train Size.
Table B3-8. Model 5 Hot Water Boiler Circulating Rates and Temperature Drop
SIZE & INPUT 1500 2000 2500 3000 3500 4000 4500 5000 6000 8000 LWV
Gas (cfh) 1500 2000 2500 3000 3500 4000 4500 5000 6000 8000
Fuel Consumption
Oil (gph) 10.72 14.29 17.86 21.43 25.0 28.57 32.14 35.71 42.85 57.14
Hot Water Output 1000 Btu/hr 1200 1600 2000 2400 2800 3200 3600 4000 4800 N/A
Steam Rated Cap. (psig) Stm/h 1237 1649 2062 2474 2887 3299 3711 4124 4949 6516
(212)
Gas (scfh) 15480 20640 25800 30960 36120 41280 46440 51600 61920 82560
(lb/hr) 1207 1609 2012 2414 2817 3219 3621 4024 4828 6437
Combustion Air
Oil (scfh) 17049 22733 28414 34098 39782 45463 51147 56831 68196 90816
(lb/hr) 1269 1692 2115 2538 2961 3384 3808 4231 5077 7081
Gas (scfh) 17520 23360 29200 35040 40880 46720 52560 58400 70080 93438
(lb/hr) 1278 1704 2130 2556 2983 3409 3835 4261 5113 6817
Flue Gas
Oil (scfh) 17914 23886 29855 35827 41799 47769 53741 59713 71655 102782
lb/hr) 1357 1809 2261 2714 3166 3618 4070 4523 5427 5970
B3-13
10-02
T = 20 T = 30 T = 40 T = 50
BOILER OUTLET OUTLET OUTLET OUTLET

P P P P
SIZE VELOCITY FLOW VELOCITY FLOW VELOCITY FLOW VELOCITY FLOW
PSI FT/S GPM PSI FT/S GPM PSI FT/S GPM PSI FT/S GPM
1500 0.54 5.38 123.8 0.24 3.58 82.6 0.14 2.69 61.9 0.09 2.16 49.8
2000 0.96 7.17 165.2 0.43 4.79 110.4 0.24 3.58 82.6 0.16 2.88 66.4
2500 1.49 8.96 206.5 0.67 5.98 137.8 0.38 4.48 103.2 0.24 3.60 83.0
3000 2.13 10.75 247.6 0.95 7.17 165.2 0.54 5.38 123.9 0.343 4.30 99.2
3500 1.32 7.28 289.0 0.59 4.86 193.0 0.34 3.65 145.0 0.22 2.92 115.8
4000 1.72 8.34 330.8 0.77 5.55 220.4 0.44 4.17 165.6 0.28 3.34 132.4
4500 2.18 9.38 372.1 0.97 6.26 248.2 0.55 4.69 186.3 0.35 3.76 149.0
5000 2.68 10.42 413.4 1.20 6.95 275.6 0.68 5.21 206.9 0.43 4.17 165.6
6000 3.86 12.50 496.0 1.72 8.34 330.8 0.97 6.26 248.2 0.63 5.01 198.8
NOTE: Based on 200F outlet temperature
Table B3-10. Model 5 Hot Water Boiler Circulating Rates and Temperature Drop
BOILER SYSTEM TEMPERATURE DROP
SIZE
(BHP) 10 20 30 40 50 60 70 80 90 100
1500 (35) 247 123 83 62 50 41 35 31 28 25
2000 (47) 330 165 110 83 66 55 47 41 37 33
2500 (59) 413 206 138 103 83 69 59 52 46 41
3000 (71) 494 248 165 124 99 83 71 62 55 50
3500 (83) 578 289 193 145 116 97 83 72 64 58
4000 (95) 661 331 220 166 132 110 95 83 74 66
4500 (107) 740 372 248 186 149 124 106 93 83 74
5000 (119) 826 413 275 207 165 138 118 103 92 83
6000 (143) 992 496 330 248 198 166 142 124 110 99
OPERATING BOILER SIZE
PRESSURE
(PSI) 1500 2000 2500 3000 3500 4000 4500 5000 6000 8000
LWV
15A 4 4 4 4 6 6 6 6 6 8
20 3 4 4 4 6 6 6 6 6 8
40 2-1/2 3 3 4 4 4 6 6 6 8
65 2-1/2 2-1/2 3 3 3 4 4 4 4 6
75 2-1/2 2-1/2 3 3 3 4 4 4 4 6
95-125 B 2-1/2 2-1/2 3 3 3 3 4 4 4 6
NOTE: All dimensions are in inches.
A. Standard Nozzle Size for 15 psig DP Units.

B. Same Nozzle Size as 150 psig DP Units.
B3-14
10-02
Table B3-12. Model 5 Boiler Sound Levels
BOILER SIZE (BHP)

SOUND LEVEL /
FIRING RATE 1500 2000 2500 3000 3500 4000 4500 5000 6000
(35) (47) (59) (71) (83) (95) (107) (119) (143)
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.
Figure B3-4. Model 5 Over Pressure Requirements
B3-15
10-02
Steam Boiler Specifications

2.0 Boiler Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-16
3.0 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-18
Hot Water Specifications

2.0 Boiler Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-21
3.0 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-22
Steam Boiler Specification
1.0 Boiler Capacity

The steam boiler shall be Cleaver-Brooks Model 5, Series ______ (100, 200, 700), _______lbs/hr or ________ bhp, designed for
_______ psig (15, 150, 250, 350, or 500 psig) steam. The maximum operating pressure will be ________ psig.
(Series 100 - No. 2 oil; 200 - No. 2 oil and gas; 700 - gas.)
The boiler shall have a maximum output of _______ Btu/hr, or ____ horsepower, when fired with No.2 oil and/or natural gas
______ Btu/cu-ft. The boiler shall develop _______ lbs/hr when operating at _______ psig with feedwater temperature at ______
F. Safety relief valves shall be set at ________ psig.
Electrical power available will be _______ volts, _______ phase, _______ Hz. All electrical service connections shall be made to
an electrical entrance box mounted on the right hand side of the boiler.
2.0 Boiler Description

The boiler shall be an all steel membrane wall watertube boiler with 3-pass gas travel. It shall be mounted on a heavy duty steel
frame with integral forced draft burner and burner controls. The complete packaged boiler-burner unit shall be approved by Cana-
dian Standards Association and shall have the CSA label affixed to the front head. The boiler shall be completely assembled and
fire tested at the factory.
The boiler shell must be constructed and hydrostatically tested in accordance with the ASME Boiler and Pressure Vessel Code Sec-
tion I or IV. It must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the
purchaser.
Two lifting eyes shall be located on top of the boiler.
Two downcomers shall be located at the rear of the boiler and totally insulated from the generating tubes. The generating tubes
shall be 2" OD SA-178 Grade A with .095" wall thickness. The downcomers shall be 2-1/2" OD for 35 and 47 hp; 3" OD for 59 to
83 hp and 4" for 95 to 143 hp. Material shall be SA-178-A and the 2-1/2" and 3" downcomers shall have a 0.105" wall. The 4"
downcomers shall have a 0.135" wall.
The upper drum shall be 20" OD Schedule 20, SA-53-B seamless pipe with .375" wall. The lower drum shall be 6" nominal pipe
size, SA-53-B seamless pipe with .312" wall (up through 150 psig).
Refractory shall be limited to the furnace 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.
Observation ports shall be provided at each end of the boiler for visual inspection of the pilot and main flame conditions.
The exhaust gas vent shall be located at the rear of the boiler on the top centerline. A stack thermometer shall be shipped loose for
field installation.
B3-16
10-02
Inspection openings shall be provided in the convection area.

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.
2.1 Soot Cleaning
Soot washer lances shall be provided in the convection area of the boiler measuring full length of the pressure vessel. Each lance
assembly shall be capable of rotating 360 degrees. This shall ensure complete washing of the convection zone while the boiler is
operating in the low fire mode.
Soot washer troughs shall be provided at the bottom of the boiler. These shall be furnished for each convection side running the full
length of the boiler with 2" drain connections at the boiler rear. Inspection/cleanout openings for each trough shall be located at the
front of the boiler.
2.2 Boiler Connections
A feedwater tapping and an integral feedwater distribution pipe shall be located in the upper drum. This distribution pipe shall
blend the feedwater with the boiler water.
A 3/4" surface blowoff connection shall be located in the rear head of the upper drum.
Handholes shall be provided at each end of the lower drum and in the rear of the upper drum for inspection of the water side sur-
faces.
2.3 Boiler Trim
The water column shall be located on the left side of the boiler. It shall be piped with union connections for easy removal. A gauge
glass set, and gauge glass water column blowdown valves shall be provided.
The boiler feedwater pump control switch shall be included as an integral item of the water column. It shall provide automatic actu-
ation of a motor driven feedwater pump to maintain the boiler water level within normal limits.
The low water cutoff switch shall be an integral part of the water column. It shall be wired into the burner control circuit preventing
burner operation if the boiler water falls below the designated safe level.
An auxiliary low water cut-off shall be located on the right hand side of the boiler and shall be wired into the control circuit so as to
prevent burner operation in the event the primary cut-off fails and shall include a drain valve.
A minimum of three controls shall be provided: one auto reset type for burner on-off control, one for burner firing rate, and one
manual reset type for burner cutout on excessive steam pressure.
A steam pressure gauge shall be located at the front end of the boiler and shall include a cock and test connection.
Safety relief valves shall be provided of a type and size to comply with ASME Code requirements.
2.3.1 Low Water Volume Design, 150 psig
The water level control and water level cut-offs shall be installed at a level that limits the water content in the boiler to 75 gallons or
less at full operating capacity.
The water column shall be a McDonnell-Miller 193-7 or approved equal, located on the left side of the boiler. It shall be piped with
union connections for easy removal. A gauge glass set and gauge glass water column blowdown valves shall be provided.
Feedwater shall be controlled by means of a electric proportional feedwater valve, Worchester or approved equal, complete with
stop valve, check valve, and 3-valve by-pass.
Controls shall be provided to comply with Guarded Plant status requirements.
Provisions (insulation/wetpack) shall be made to ensure no combustibles within the boiler furnace, come in direct contact with the
upper or lower drum.
B3-17
10-02
2.3.2 Low Water Volume Design, 15 psig

Controls shall be provided to comply with Guarded Plant status requirements.
Provisions (Insulation/Wetpack) shall be made to ensure no combustibles within the boiler furnace come in direct contact with the
upper or lower drum.
3.0 Burner
All air for combustion shall be supplied by a forced draft blower mounted in the front head (windbox), above the burner, to mini-
mize vibration and noise level.
The impeller shall be an enclosed centrifugal fan type, properly balanced and directly connected to the blower motor shaft.
The maximum sound level shall not exceed 80 dBA measured 3 feet in front of the boiler.
The oil burner shall operate on the low-high-low principle and must return to the low fire position prior to ignition.
The gas burner shall operate on the full modulation system and must return to the low fire position prior to ignition.
The burner shall remain in the low fire position during ignition and until main flame has been proven.
3.2 Gas Fired Burner
3.2.1 General
The burner shall be integral with the front head of the boiler and shall be the high radiant multi-port type approved for operation
with natural gas.
Automatic electric ignition of the premix gas pilot shall be furnished. A UV flame detector shall monitor the pilot, preventing the
primary fuel valve from opening until the pilot flame has been established.
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.
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.
A plugged leakage test connection and a lubricated plug cock are provided as a means for a tightness check of the primary shutoff
valve.
A gas pressure regulator shall be factory mounted and piped for proper pressure regulation to the burner.
3.2.2 Gas Train Components
The primary shutoff valve shall be a motorized type. High and low gas pressure switches shall be provided.
3.3 No. 2 Oil Fired Burner
3.3.1 General
The burner shall be integral with the front head of the boiler. It shall be the pressure atomizing type approved for operation with
commercial grade No. 2 oil.
The burner shall operate on the low-high-low principle, and must return to the low-fire position prior to ignition.
The burner shall remain in the low-fire position during ignition and until low fire and main flames have been proven.
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.
B3-18
10-02
NOTICE
Optional insurance compliance may require a premix gas pilot in lieu of electric ignition.
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 pressure control.
3.3.2 Oil System:
An oil pump shall be provided. The oil pump, integral with the burner, shall include a built-in relief valve and self- cleaning
strainer. The pump shall be belt driven from the blower motor.
The fuel oil system shall include supply and return tubing to a terminal block, oil pressure gauge, shutoff cock, and four solenoid
oil shutoff valves. These items shall be factory mounted on the front head.
3.4 No.2 Oil and Gas Burner
3.4.1 General
The burner shall be integral with the front head of the boiler. It shall be the pressure atomizing type for oil and high radiant multi-
port type for gas. The burner must be approved for operation with either commercial grade No.2 oil or natural gas.
The oil burner shall operate on the low-high-low principle, the gas burner shall operate on the full modulation principle, and must
return to the low-fire position prior to ignition.
The burner shall remain in the low-fire position during ignition and until main flame has been proven.
Automatic electric ignition of the premix gas pilot shall be provided. A UV flame detector shall monitor the pilot to prevent the pri-
mary fuel valve from opening until the pilot flame has been established.
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 pressure control.
3.4.2 Oil System
An oil pump shall be included. The oil pump, integral with the burner, shall include a built-in relief valve and self-cleaning strainer.
The pump shall be belt-driven from the blower motor.
3.4.3 Gas System
shutoff.
valve.
A gas pressure regulator shall be factory-mounted and piped for proper pressure regulation to the burner.
3.5 Burner and Flame Failure Controller
A combustion safeguard control shall be provided to control ignition, starting and stopping the burner and provide precombustion
and postcombustion purge periods. It shall stop burner operation in the event of ignition, pilot or main flame failure. Trial for igni-
tion shall be limited to 10 seconds.
B3-19
10-02
3.6 Control Panel

The control panel shall be mounted on the front head of the boiler and shall be conveniently located for the operator. It shall be a
NEMA 1A rated enclosure and have a key lock.
Each boiler shall be factory-equipped with a flame safeguard controller that provides technology and functions equal to the
Cleaver-Brooks Model CB 100.
Flame safeguard controller shall be microprocessor based, with self-diagnostics, non-volatile memory, and a message center with a
vocabulary of 42 different messages. Messages shall scroll across an alpha-numeric display and provide sequence status and failure
mode information. The controller shall have a 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.
Controller shall be the non-recycle type for maximum safety that will shutdown the burner and indicate as a minimum the follow-
and fuel valve open.
The controller shall have a run/test switch. It will allow interruptions to sequence just after pre-purge, during pilot ignition trial, and
during run cycles for adjustments to firing rate motor, damper linkages, and pilot flame for turndown tests.
In addition to the above functions, the controller shall:
Display history of operating hours and totals of completed on-off cycles.
Provide a constant flame signal strength read-out.
Have provisions for a remote display capability.
The panel shall contain the blower motor starter, control circuit fuses, control circuit transformer, and control switches. A damper
positioning switch shall be provided to permit selection of automatic firing or manual selection of low or high fire.
A terminal board shall be provided to which all wires entering or leaving the panel shall be connected.
All electrical equipment shall be in conformity with the Canadian Standards Association requirements. Oil, heat and moisture resis-
tant wire shall be used and shall be number coded.
B3-20
10-02
Hot Water Boiler Specification
1.0 Boiler Capacity

The hot water boiler shall be Cleaver-Brooks Model 5, Series ______ (100, 200, 700), _______ bhp, designed for 140 psig hot
water. The maximum supply temperature will be ______ F, and the minimum return water temperature will be _______ F. The
minimum operating temperature of the boiler shall be 170 F. (Series 100 - No. 2 oil; 200 - No. 2 oil and gas; 700 - gas.)
The boiler shall have a maximum output of ______ Btu/hr, or _____ hp, when fired with No.2 oil and/or natural gas _______ Btu/
cu-ft. Safety relief valves shall be set at _______ psig.
Electrical power available will be ______ volts, _______ phase, _______ Hz. All electrical service connections shall be made to an
electrical entrance box mounted on the right hand side of the boiler.
2.0 Boiler Description

The boiler shall be an all steel membrane wall watertube boiler with 3-pass gas travel. It shall be mounted on a heavy duty steel
frame with integral forced draft burner and burner controls. The complete packaged boiler-burner unit shall be approved by Cana-
dian 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.
The boiler shell must be constructed and hydrostatically tested in accordance with the ASME Boiler and Pressure Vessel Code. It
must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser.
Two lifting eyes shall be located on top of the boiler.
Two downcomers shall be located at the rear of the boiler and totally insulated from the generating tubes. The generating tubes
shall be 2" OD SA-178 Grade A with .095" wall thickness. The downcomers shall be 2-1/2" OD for 35 and 47 hp; 3" OD for 59 to
83 hp and 4" OD for 95 to 143 hp. Material shall be SA-178-A and the 2-1/2" and 3" downcomers shall have a 0.105" wall. The 4"
downcomers shall have a 0.135" wall.
The upper drum shall be 20" OD schedule 20, SA-53-B seamless pipe with .375" wall. The lower drum shall be 6" nominal pipe
size, SA-53-B seamless pipe with .312" wall.
Refractory shall be limited to the furnace 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.
Observation ports shall be provided at each end of the boiler for visual inspection of the pilot and main flame conditions.
The exhaust gas vent shall be located at the rear of the boiler on the top centerline. A stack thermometer shall be shipped loose for
field installation.
Inspection openings shall be provided in the convection area.
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.
2.1 Soot Cleaning
Soot washer lances shall be provided in the convection area of the boiler measuring full length of the pressure vessel. Each lance
shall be provided with a shutoff valve and the assembly shall be capable of rotating 360 F. This shall ensure complete washing of
the convection zone while the boiler is operating in the low fire mode.
Soot washer troughs shall be provided at the bottom of the boiler. These shall be furnished for each convection side running the full
length of the boiler with 2" drain connections at the boiler rear. Inspection/cleanout openings for each trough shall be located at the
front of the boiler.
2.2 Boiler Connections
The hot water outlet connection shall be located on the top centerline of the boiler and the return connection shall be located at the
rear of the lower drum. The design of the boiler shall provide jet induced circulation, which shall mix the return water with the hot
water within the boiler.
B3-21
10-02
A dip tube shall be included as an integral part of the hot water outlet. An air vent tapping shall be located on the top centerline of
the boiler for connection to an expansion tank.
Handholes shall be provided at the end of the lower drum and in the rear of the upper drum for inspection of the water side surfaces.
2.3 Boiler Trim
The low water cutoff switch shall be a probe type, mounted in the top center-line of the boiler. It shall be wired into the burner con-
trol circuit to prevent burner operation if the boiler water falls below a proper level.
A minimum of three controls shall be provided: one auto reset type for burner on-off control, one for burner 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.
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 circula-
tion at all times to a level of 10 boiler water changes per hour.
A combination pressure-temperature gauge shall be located on the boiler.
Water relief valves shall be provided of a type and size to comply with ASME Code requirements.
3.0 Burner
All air for combustion shall be supplied by a forced draft blower mounted in the front head (windbox), above the burner, to mini-
mize vibration and noise level.
The impeller shall be an enclosed centrifugal fan type, properly balanced and directly connected to the blower motor shaft.
The maximum sound level shall not exceed 80 dBA measured 3 feet in front of the boiler.
The oil burner shall operate on the low-high-low principle and must return to the low fire position prior to ignition.
The burner shall remain in the low fire position during ignition and until main flame has been proven.
3.2 Gas Fired Burner
3.2.1 General
The burner shall be integral with the front head of the boiler and shall be the high radiant multi-port type approved for operation
with natural, manufactured, or mixed gas.
Automatic electric ignition of the premix gas pilot shall be furnished. A UV flame detector shall monitor the pilot, preventing the
primary fuel valve from opening until the pilot flame has been established.
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.
shutoff.
valve.
A gas pressure regulator shall be factory mounted and piped for proper pressure regulation to the burner.
B3-22
10-02
3.3 No. 2 Oil Fired Burner

3.3.1 General
The burner shall be integral with the front head of the boiler. It shall be the pressure atomizing type approved for operation with
commercial grade No.2 oil.
The burner shall operate on the low-high-low principle, and must return to the low-fire position prior to ignition.
The burner shall remain in the low-fire position during ignition, and until low fire and main flames have been proven.
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.
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.
3.3.2 Oil System
An oil pump shall be provided. The oil pump, integral with the burner, shall include a built-in relief valve and self- cleaning
strainer. The pump shall be belt driven from the blower motor.
3.4 No.2 Oil and Gas Burner
3.4.1 General:
The burner shall be integral with the front head of the boiler. It shall be the pressure atomizing type for oil and high radiant multi-
port type for gas. The burner must be approved for operation with either commercial grade No.2 oil or natural gas.
The oil burner shall operate on the low-high-low principle, and must return to the low-fire position prior to ignition.
The burner shall remain in the low-fire position during ignition and until main flame has been proven.
Automatic electric ignition of the premix gas pilot shall be provided. A UV flame detector shall monitor the pilot to prevent the pri-
mary fuel valve from opening until the pilot flame has been established.
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/pres-
sure control.
3.4.2. Oil System
An oil pump shall be included. The oil pump, integral with the burner, shall include a built-in relief valve and self-cleaning strainer.
The pump shall be belt-driven from the blower motor.
3.4.3 Gas System
shutoff.
valve.
B3-23
10-02
A gas pressure regulator shall be factory-mounted and piped for proper pressure regulation to the burner.
3.5 Burner and Flame Failure Controller
A combustion safeguard control shall be provided to control ignition, starting and stopping the burner and provide precombustion
and postcombustion purge periods. It shall stop burner operation in the event of ignition, pilot or main flame failure. Trial for igni-
tion shall be limited to 10 seconds.
3.6 Control Panel
The control panel shall be mounted on the front head of the boiler and shall be conveniently located for the operator. It shall be a
NEMA 1A rated enclosure and have a Yale key lock.
Each boiler shall be factory-equipped with a flame safeguard controller that provides technology and functions equal to the
Cleaver-Brooks Model CB100.
Flame safeguard controller shall be microprocessor based, with self-diagnostics, non-volatile memory, and a message center with a
vocabulary of 42 different messages. Messages shall scroll across an alpha-numeric display and provide sequence status and failure
mode information. The controller shall have a 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.
Controller shall be the non-recycle type for maximum safety that will shutdown the burner and indicate as a minimum the follow-
and fuel valve open.
The controller shall have a run/test switch. It will allow interruptions to sequence just after pre-purge, during pilot ignition trial, and
during run cycles for adjustments to firing rate motor, damper linkages and pilot flame for turndown tests.
In addition to the above functions, the controller shall:
Display history of operating hours and totals of completed on-off cycles.
Provide a constant flame signal strength read-out.
Have provisions for a remote display capability.
The panel shall contain the blower motor starter, control circuit fuses, control circuit transformer, and control switches. A damper
positioning switch shall be provided to permit selection of automatic firing or manual selection of low or high fire.
A terminal board shall be provided to which all wires entering or leaving the panel shall be connected.
All electrical equipment shall be in conformity with the Canadian Standard Association requirements. Oil, heat and moisture resis-
tant wire shall be used and shall be number coded.
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.
B3-24
10-02
Section B4
ELECTRIC BOILERS
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-3
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-4
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-5
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-5
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-5
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-5
ILLUSTRATIONS
Figure B4-1. Models HW and CWB Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-7
Figure B4-2. Model S Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-8
Figure B4-3. Model CR Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-9
Figure B4-4. Model CSB Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-10
Figure B4-5. Models TWH and TWV Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-11
Figure B4-6. Model IWH Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-12
B4-1
04-02
Electric Boilers Commercial Boilers
TABLES
Table B4-1. Cleaver-Brooks Electric Boilers Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-3
Table B4-2. Power Supply Wire Lug Sizing Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6
Table B4-3. Model HW Ratings - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-13
Table B4-4. Model CWB Ratings - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-15
Table B4-5. Model S/CR Ratings - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-18
Table B4-6. Model CSB Ratings - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-20
Table B4-7. Model TWH/TWV Vessel Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-22
Table B4-8. Model TWH/TWV Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-23
Table B4-9. Model IWH Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-24
Power Supply Wire Lug Sizing Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-24
This section contains information on the complete line of Cleaver-Brooks electric boilers with kilowatt output ratings from 9 to
3,375 kW. Electric boilers are typically utilized for applications where stringent environmental regulations and boiler space
requirements are critical.
B4-2
04-02
Commercial Boilers Electric Boilers
FEATURES AND BENEFITS High Turndown/Input Control:
In applications where electric power is more economically By individually controlling the heating elements with solid
available than fossil fuels, or where fossil fuel combustion and state digital step controllers, a high degree of input control is
the handling of combustion by-products are unacceptable, achievable.
electric boilers offer a viable alternative. Virtually unlimited input control is available with optional
solid state SCR power controllers.
Reduced Maintenance:
The absence of high maintenance combustion equipment Quiet Operation:
and the use of solid state control devices reduce the Elimination of combustion noise and minimal moving parts
complexity and number of moving parts. results in extremely quiet operation.
Electric elements are easily accessible and replaceable either
individually or in flange mounted groups. Low Return Water Temperatures:
Pressure vessel components are not subjected to thermal Electric boilers are able to withstand virtually any return
stresses induced by high temperature differentials and water temperature. With combustion by-products and high
cycling encountered with fossil fuel combustion. temperature differentials eliminated, condensation and
thermal shock do not limit return water temperatures.
Compact Size:
Electric boilers are typically one-quarter to one-half the size PRODUCT OFFERING
of fossil fuel boilers with similar Btu output. Information in this section applies directly to Cleaver-Brooks
Electric Boilers.
No Emissions:
See Table B4-1 for description of the various models in the
Because there is no combustion, electric boilers are 100% electric boiler line.
emission free. This may be beneficial in meeting total plant
emission requirements. Hot Water Boilers
Hot water boilers are available in heating or process applica-
No Stack Requirements:
tions with flow rates of 10 to 1840 gpm.
With no products of combustion to contend with, installation
costs are reduced by the elimination of stack requirements. Steam Boilers
Table B4-1. Cleaver-Brooks Electric Boilers Product Offering
PRODUCT OUTPUT ELEMENT WATER DESIGNB

MODEL DENSITY CONTENT PRESSURE NOTES
TYPE (KW) (W/SQ-IN.) (GALLONS) (PSIG)
Hot Water Boilers HW 9-2520 50 16-500 150 1
CWB 12-3360 75 16-500 150 1
Steam Boilers S 12-1944 67 16-595 15/50/125 2
CR 12-480 67 16-115 15/50/125 2,3
CSB 540-3375 75 180-790 15/50/125 2
Hot Water Storage Heaters TWV 30-360 75 150-1500 125/150 2
TWH 30-360 500-2500 125/150 2
75
Instantaneous Water IWH 15-360 50/75 13-360 A 150 1, 2
Heaters
Notes: 1. Heating elements are of copper construction.
2. Heating elements are of Incoloy construction.
3. CR identical to Model S but has integral condensate return tank and pump.
A. Water content not applicable. Flow rate in GPM is listed.
B. Some boiler combinations that have vessel sizes above 42, or above 600 gallons, will have additional design
pressure limitations. Contact your local Cleaver-Brooks authorized representative for final design pressure and
model selection.
B4-3
04-02
Steam boilers are available for use in steam heating or process 2 Step: One 2-stage temperature switch.
applications requiring 42 to 10,080 pounds of steam per hour.
3 Step: One 3-stage time delay sequencer.
Hot Water Storage Heaters 4 Step: One 4-stage time delay sequencer.
Hot water storage heaters are typically used for domestic hot 5 Step and above: Solid state proportional linear sequence
water heating or high surge volume applications. Model TWV step control with adjustable span and interstage time delay.
uses vertical storage tanks. Model TWH uses horizontal stor- All Steam Boilers:
age tanks.
Manual reset high pressure cut-off.
Instantaneous Hot Water Heaters Auxiliary auto-reset high pressure cut-off.
Instantaneous hot water heaters are typically used in standby Combination low-water cut-off and pump control.
or on-demand hot water applications where hot water storage
is not acceptable. High delta T and high flow applications can Pilot light to indicate high pressure alarm.
be achieved by linking multiple units in series or in parallel Bottom and water column blowdown valves.
respectively.
Feedwater stop and check valves.
Standard Equipment Pressure gauge.
The equipment described below applies to standard boilers. Sight gauge with drain and guards
All Boilers: Inspection opening.
ASME Code carbon steel vessel with glass fiber Pressure controls as follows:
insulation.
1 Step: One On-Off pressure switch.
UL listing.
2 Step: Two On-Off pressure switches.
Heavy gauge steel enclosure.
3 Step and above: Solid state proportional linear sequence
Electrical lugs for primary power supply. step control with adjustable span and interstage time delay.
200,000 amp interrupting capacity fusing. Models TWV and TWH:
Contactors rated for 500,000 cycles. Magnesium anode.
120 V control transformer with primary fusing and Lined tank.
power switch with integral breaker.
Model IWH:
Pilot lights to indicate control power on and low water
Flow switch.
alarm (except model IWH).
ASME relief/safety valves. Optional Equipment
All Hot Water Boilers and Heaters: All Boilers:
Manual reset high-temperature cut-off. This is a partial list of boiler options and accessories. Contact
Auxiliary auto-reset high temperature cut-off. your local Cleaver-Brooks authorized representative for a com-
plete list of all available options and accessories.
Auto-reset probe, low-water cut-off (except model IWH
which includes flow switch). Output step enable/disable toggle switches.
High temperature alarm with pilot light. Additional pilot lights.
Drain valve. Alarm relays and terminal strips.
Pressure and temperature gauges. Audible alarm.
Inspection opening. Alarm silencer.
Temperature controls as follows: Safety door interlock.
1 Step: On-off temperature switch. Time clock.
B4-4
04-02
Ammeter. PERFORMANCE DATA

Voltmeter.
Kilowatt hour meter. Efficiency
Ground fault detector. All Cleaver-Brooks Electric Boilers are virtually 100% effi-
cient, excluding radiant losses. These losses are minimized due
Outdoor reset control. to insulation supplied as standard.
Progressive sequence step controls.
Emissions
Auxiliary low-water cut-off.
Since electric boilers have no combustion, there are no emis-
Flow switch. sions. This eliminates the need for stacks, pollution controls,
Preheat switch. and emission permits.
Unfused manual disconnect.
ENGINEERING DATA
Fused manual disconnect.
Calculations:
Molded case disconnect.
The following formula can be used to correctly size a hot water
Molded case circuit breaker. boiler:
Shunt trip for molded case disconnect/circuit breaker. kW = gph x delta T (in F)/410, or
Main-power door interlock (standard with disconnects 600 kW = 1 gph x delta T (in C)/862
amps and below).
Where:
DIMENSIONS AND RATINGS kW is the boiler output rating.
This section contains all of the dimensions and ratings for the gph is the hot water flow rate.
electric boiler product line. The figures are arranged by boiler delta T is the temperature rise of water.
models.
For conversion of pounds of steam to kW, the following can be
Dimensions for electric boilers are shown in Figures B4-1 used:
through B4-6.
10 kW = 34 lbs steam/hr = 1.02 BHP
Finally, the following formula can be used to determine amper-
NOTICE age of three phase power to size power line feeds to the boiler:
Ratings information for Model TWV and Model TWH Amps (3 ph) = Watts/(Volts x 1.73)
is split into two tables. Since this model is used for Power Supply:
hot water storage as well as heating, the boiler vessel
capacity in gallons and the heating rate must be se- The information in Table B4-2 can be used to correctly size
lected to meet specific application needs. Table B4-6 power lugs when designing power supply lines for the boilers.
gives the vessel capacity and boiler base models. Ta- Ground Fault Detection:
ble B4-7 gives the heating or kilowatt rating of the
units. For example, if a large storage capacity is Available on all boilers, this equipment monitors the supply
needed, from Table B4-6 and the base model TWV- circuit for ground current in the boiler. In the event of a ground
100, which gives a 1000 gallon capacity, from Table fault, a signal opens the control circuit or trips the supply cir-
B4-7 the suffix of - 90, which would add a 90 KW heat- cuit breaker.
er, the full model number would be TWV-100-90. This equipment can prevent excessive boiler damage from arc-
Ratings for electric boilers are shown in tables B4-3 though ing faults to ground when used with a supply circuit breaker
B4-9. with shunt trip. Per NEC, ground fault interruption (GFI) is
required on all wye power supplies rated 1000 amps or more.
B4-5
04-02
Table B4-2. Power Supply Wire Lug Sizing Guide

Disconnect:
A manual disconnect (safety switch), a non-auto circuit SUPPLY WIRE GROUND
breaker, or an automatic circuit breaker can be installed inte- MAX KW LUG LUG
gral with the boiler. If specified, the devices can also include QTY/PH/SIZE SIZE
such features as a mechanical door interlock and, for circuit 208V, 240V/3-PH/60 HZ
breakers, an automatic trip coil. The capacity of fused or auto- 18 1 @ SLU70 SLU35
matic disconnects must not be less than 125 percent of the 90 1 @ SLU350 SLU70
maximum rated amp draw of the boiler; manual disconnects 105 1 @ SLU500 SLU70
may be rated at 100% of the maximum boiler draw. 180 2 @ TA500 SLU125
420 4 @ TA500 SLU225
540 6 @ TA500 SLU300
480V/3-PH/60 HZ
36 1 @ SLU70 SLU35
180 1 @ SLU350 SLU70
105 1 @ SLU500 SLU70
360 2 @ TA500 SLU125
1000 4 @ TA500 SLU225
1480 6 @ TA500 SLU300
NOTE: Contact your local Cleaver-Brooks authorized
representative for information on 600 volt supply lugs.
B4-6
04-02
MINIMUM
CONNECTION APPROXIMATE
DIMENSIONS (IN.) RECOMMENDED
SIZES WEIGHTS (LBS.)
MODEL CLEARANCES (IN.)
NO.
INLET & DRAIN WIDTH DEPTH HEIGHT INLET TOP SIDE REAR SHIPPING OPERATE
OUTLET (NPT) A B C D E F G
HW-120 2 3/4 28 28 39 8 12 15 12 450 580
HW-121 3 3/4 28 28 39 8 12 15 12 550 680
HW-201 4FB 1-1/4 36 36 66 14 18 18 18 800 1410
HW-202 4F 1-1/4 36 36 66 14 18 18 18 1050 1660

HW-203 4F 1-1/4 46 36 66 14 18 18 18 1350 1990
HW-204 4F 1-1/4 46 36 66 14 18 18 18 1550 2190
HW-241 6F 1-1/2 50 42 72 18 18 21 18 2450 3450
HW-242 6F 1-1/2 50 42 80 19 18 21 18 2850 4020
HW-361 6F 1-1/2 62 54 72 20 24 24 24 3300 5230
HW-362 8F 1-1/2 62 54 88 23 24 24 24 3700 6280
HW-363 8F 2 62 54 100 23 24 24 24 4200 7230
HW-421A 10F 2 68 72 86 24 24 30 24 6100 9600
HW-422A 10F 2 68 72 100 24 24 30 24 6700 10800
CWB-120 2 3/4 28 28 39 8 12 15 12 450 580

CWB-121 3 3/4 28 28 39 8 12 15 12 500 630
CWB-122 3 3/4 28 28 54 8 12 15 12 800 1005
CWB-201 4F B 1-1/4 46 36 66 14 18 18 18 1400 2040
CWB-202 4F 1-1/4 46 36 66 14 18 18 18 1500 2140

CWB-241 6F 1-1/2 50 42 72 18 18 21 18 2200 3200
CWB-242 6F 1-1/2 50 42 72 18 18 21 18 2400 3400
CWB-243 6F 1-1/2 50 42 80 18 18 21 18 2800 3980
CWB-361 6F 1-1/2 62 54 72 20 24 24 24 3300 5260
CWB-362 8F 1-1/2 62 54 88 23 24 24 24 3600 6220
CWB-363 8F 2 62 54 100 23 24 24 24 4200 7280
CWB-421A 10F 2 68 72 86 24 24 30 36 5800 9300
CWB-422A 10F 2 68 72 100 24 24 30 36 6500 10500
NOTE: Heights are for boiler only. Control panel size varies based on the number of steps.
A. Normally supplied with 2 control cabinets for 2 power supplies.
B. Flanged connection (150 psig ANSI).
Figure B4-1. Models HW and CWB Dimensions

B4-7
04-02
MODELS S-120 THRU S-200 MODELS S-241 THRU S-480
DIMENSIONS (IN.) CLEARANCES
SIZE (NPT) WEIGHTS (LBS)
MODEL NO.
BLOWDOWN STEAM OUTLET WIDTH DEPTH HEIGHT LWCO TOP SIDES
FW SHIPPING OPERATE
A B C D E F
15 PSIG 125 PSIG 15 PSIG 125 PSIG
S-120 1/2 3/4 3/4 1 3/4 28 28 38 20 12 18 600 675

S-161 1/2 3/4 3/4 1-1/2 1 32 32 54 34 12 18 750 880
S-162 1/2 3/4 3/4 2 1 32 32 54 34 12 18 800 930
S-200 3/4 1 1 2-1/2 1-1/4 36 36 66 41 12 18 1150 1480
S-241 3/4 1-1/4 1 3 1-1/2 50 42 72 41 12 18 1400 1900
S-242 3/4 1-1/4 1 3 1-1/2 50 42 72 41 12 18 1600 2000
S-301 3/4 1-1/2 1 4FA 2 56 48 72 40 15 21 2100 3000
S-302 3/4 1-1/2 1 4FA 2-1/2 56 48 88 50 15 21 2200 3300
S-361 3/4 1-1/2 1 4FA 2-1/2 62 54 72 42 18 24 2900 4000
S-362 3/4 1-1/2 1 6FA 3FA 62 54 86 52 18 24 3200 4800
S-421 1 1-1/2 1 6FA 3FA 68 60 72 41 18 27 4150 5800
S-480 1 2 1-1/4 8FA 4FA 74 66 92 53 18 27 5450 8000
NOTE: Heights are for boiler only. Control panel size will vary based on the number of steps
A. Flanged connection (150 psig ANSI)
Figure B4-2. Model S Dimensions
B4-8
04-02
DIMENSIONS (IN.)
SIZE (NPT) WEIGHTS (LBS.)
MODEL NO.
BLOWDOWN STEAM OUTLET WIDTH DEPTH HEIGHT LWCO
COND. OVER- SHIPPING OPERATE
RETURN FLOW
15 PSIG 125 PSIG 15 PSIG 125 PSIG A B C D
CR-120 3/4 3/4 1 3/4 3/4 3/4 28 38 38 20 850 950
CR-161 3/4 3/4 1-1/2 1 1 1 32 42 54 28 1050 1200
CR-162 3/4 3/4 2 1 1 1 32 42 54 34 1150 1280
CR-200 1 1 2-1/2 1-1/4 1-1/4 1-1/4 36 48 66 41 1650 2030
CR-241 1-1/4 1 3 1-1/2 1-1/2 1-1/2 50 52 72 41 2000 2600
CR-242 1-1/4 1 3 1-1/2 1-1/2 1-1/2 50 52 72 41 2200 2700
NOTE: Heights are for boiler only. Control panel size will vary based on the number of steps.
Figure B4-3. Model CR Dimensions
B4-9
04-02
DIMENSIONS (IN.) CLEARANCES
MODEL NO.
BLOWDOWN STEAM OUTLET
WIDTH DEPTH HEIGHT LWCO TOP SIDES
FW SHIPPING OPERATE
A B C D E F
15 PSIG 125 PSIG 15 PSIG 125 PSIG
CSB-301 3/4 1-1/2 1 4FA 2 56 48 72 40 15 21 2400 3200
CSB-302 3/4 1-1/2 1 4FA 2-1/2 56 48 88 50 15 21 2650 3700
CSB-361 3/4 1-1/2 1 4FA 2-1/2 62 54 72 42 18 24 2900 4000
CSB-362 3/4 1-1/2 1 6FA 3FA 62 54 88 52 18 24 3300 4800
CSB-421 1 1-1/2 1 6FA 3F A 68 60 72 41 18 27 4250 5800
CSB-422 1 1-1/2 1 6FA 3FA 68 60 88 51 18 27 4600 6700
CSB-423 1 2 1-1/2 8FA 4FA 130 68 62 34 24 36 5700 8000
CSB-424 1 2 1-1/2 8FA 4FA 140 68 62 34 24 36 6400 9300
CSB-425 1 2 1-1/2 8FA 4FA 150 68 62 34 24 36 7100 10600
NOTE: Heights are for boiler only. Control panel size will vary based on the number of steps
A. Flanged connection (150 psig ANSI)
Figure B4-4. Model CSB Dimensions
B4-10
04-02
DIMENSIONS (IN.)
SIZE (NPT) WEIGHTS (LBS.)
MODEL NO.
INLET & WIDTH DEPTH HEIGHT SHIPPING OPERATE
OUTLET DRAIN A B C
TWV-015 1 1 34 44 64 1250 2500
TWV-020 1 1 34 44 80 1400 3050
TWV-025 1-1/4 1 40 50 72 1525 3600
TWV-030 1-1/4 1 40 50 84 1700 4200
TWV-035 1-1/4 1 40 50 96 1900 4800
TWV-040 1-1/2 1-1/2 46 56 84 2100 5400
TWV-050 1-1/2 1-1/2 46 56 100 2500 6700
TWV-060 1-1/2 1-1/2 52 62 92 3000 8000
TWV-075 1-1/2 1-1/2 52 62 110 3800 10000
TWV-100 2 1-1/2 64 72 100 4600 12900
TWV-125 2 1-1/2 64 72 120 5300 15700
TWV-150 2 1-1/2 64 72 140 6000 18500
TWH-050 1-1/2 1-1/2 94 46 52 2700 6800
TWH-060 1-1/2 1-1/2 110 46 52 3100 8100
TWH-075 2 1-1/2 108 52 58 4000 10200
TWH-100 2 1-1/2 140 52 58 4900 13200
TWH-125 2 1-1/2 172 52 58 5800 16200
TWH-150 2 2 164 58 66 6700 19200
TWH-175 2 2 194 58 66 7500 22000
TWH-200 3 2 178 64 72 7700 24300
TWH-225 3 2 198 64 72 8500 27200
TWH-250 3 2 220 64 72 9300 30000
NOTE: Heights are for boiler only. Control panel size will vary based on the number of steps.
Figure B4-5. Models TWH and TWV Dimensions
B4-11
04-02
INLET REIEF VALVE OUTLET
12 MIN B RL A RR
E D
TYP
3
C
DRAIN
1-1/2 B + 1-1/2
END FRONT
* MINIMUM CLEARANCE FOR MAINTENANCE OR ELEMENT REMOVAL

** C-C OF 5/8 MOUNTING HOLES
MINIMUM
DIMENSIONS (INCHES) RECOMMENDED
MODEL CLEARANCES (IN.)
NO.
INLET & WIDTH DEPTH HEIGHT INLET INLET LEFT RIGHT
DRAIN FRONT SHIPPING OPERATE
OUTLET A B C D E RL RR
IWH-611 2 3/4 30 20 18 8-1/2 6 20 12 36 250 295
IWH-612 2 3/4 50 20 18 8-1/2 6 20 20 36 400 440
IWH-621 2 3/4 50 20 18 8-1/2 6 36 12 36 300 340
IWH-622 2 3/4 82 20 18 8-1/2 6 36 36 36 450 525
IWH-812 3 3/4 50 22 22 9-1/2 8 20 20 36 450 252
IWH-821 3 3/4 50 22 22 9-1/2 8 36 12 36 350 425
IWH-822 3 3/4 82 22 22 9-1/2 8 36 36 36 500 630
IWH-022 3A 3/4 82 26 30 10 9 36 36 36 600 810
NOTE: Heights are for Boiler only. Control panel size will vary based on the number of steps.
A. For flow rates above 240 gpm, specify 4" flanged connections.
Figure B4-6. Model IWH Dimensions
B4-12
04-02
Table B4-3. Model HW Ratings - Sheet 1 of 2

MODEL VES MAX ELEMENTS NO. OF CONT NO. AND KW OF STEPS 3- PHASE AMPS VS VOLTAGE
RATED
CAP FLOW MBTU/HR
NO. KW QTY KW <250V >250V 208-240V 480-600V 208 240 480 600
GAL. GPM
HW-120 16 80 9 31 3 3 1 1 1@9 1@9 26 23 12 10
12 41 3 4 1 1 1@12 1@12 34 30 15 13
18 61 6 3 1 1 1@18 1@18 51 44 23 18
24 82 6 4 2 1 2@12 1@24 68 59 30 24
27 92 9 3 2 1 1@18,1@9 1@27 76 66 33 27
36 123 9 4 2 1 2@18 1@36 101 88 44 36
48 164 12 4 4 2 2@24 2@24 134 116 59 47
HW-121 16 80 60 205 15 4 5 2 2@24,1@12 1@36,1@24 168 145 73 59
72 246 18 4 6 2 3@24 2@36 201 174 88 70
84 287 21 4 7 3 3@24,1@12 1@36,2@24 234 203 102 82
96 328 24 4 8 3 4@24 2@36,1@24 267 232 116 93
HW-201 74 230 90 307 18 5 6 3 3@30 3@30 251 218 109 88
105 358 21 5 7 4 3@30,1@15 3@30,1@15 292 254 127 102
120 409 24 5 8 4 4@30 4@30 334 290 145 116
HW-202 74 230 135 461 27 5 9 5 4@30,1@15 4@30,1@15 376 326 163 131
150 512 30 5 10 5 5@30 5@30 417 362 181 145
165 563 33 5 11 6 5@30,1@15 5@30,1@15 459 398 199 160
180 614 36 5 12 6 6@30 6@30 501 434 218 174
195 665 39 5 13 7 6@30,1@15 6@30,1@15 542 470 236 189
210 717 42 5 14 7 7@30 7@30 584 506 254 203
225 768 45 5 15 8 7@30,1@15 7@30,1@15 626 542 272 218
240 819 48 5 16 8 8@30 8@30 667 578 290 232
HW-203 78 300 270 921 54 5 18 9 6@45 4@60,1@30 750 651 326 261
300 1024 60 5 20 10 4@45,4@30 5@60 834 723 362 290
330 1126 66 5 22 11 6@45,2@30 5@60,1@30 917 795 398 319
360 1228 72 5 24 12 8@45 6@60 1000 867 434 347
HW-204 78 300 390 1331 78 5 13 6@60,1@30 470 376
420 1433 84 5 14 7@60 506 405
450 1535 90 5 15 7@60,1@30 542 434
480 1638 96 5 16 8@60 578 463
HW-241 122 670 468 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
HW-242 142 670 612 2088 102 6 17 7@72,3@36 737 590
648 2211 108 6 18 8@72,2@36 780 625
684 2334 114 6 19 9@72,1@36 824 659
720 2457 120 6 20 10@72 867 694
HW-361 235 900 750 2559 75 10 25 5@90,5@60 903 723
780 2661 78 10 26 6@90,4@60 939 752
810 2764 81 10 27 7@90,3@60 975 780
840 2866 84 10 28 8@90,2@60 1011 809
870 2968 87 10 29 9@90,1@60 1047 838
900 3071 90 10 30 10@90 1084 867
930 3173 93 10 31 7@90,5@60 1120 896
960 3276 96 10 32 8@90,4@60 1156 925
B4-13
04-02
Table B4-3. Model HW Ratings - Sheet 2 of 2
MODEL VES MAX ELEMENTS NO. OF CONT NO. AND KW OF STEPS 3- PHASE AMPS VS VOLTAGE
RATED
CAP FLOW MBTU/HR
NO. KW QTY KW <250V >250V 208-240V 480-600V 208 240 480 600
GAL. GPM
990 3378 99 10 33 9@90,3@60 1192 954
1020 3480 102 10 34 10@90,2@60 1228 982
1050 3583 105 10 35 11@90 1264 1011
1080 3685 108 10 36 12@90 1300 1040
HW-362 315 900 1110 3787 111 10 37 9@90,5@60 1336 1069
1140 3890 114 10 38 10@90,4@60 1372 1098
1170 3992 117 10 39 11@90,3@60 1408 1127
1200 4094 120 10 40 12@90,2@60 1444 1156
1230 4197 123 10 41 13@90,1@60 1480 1185
1260 4299 126 10 42 14@90 1517 1213
1290 4401 129 10 43 10@90,6@60 1553 1242
1320 4504 132 10 44 12@90,4@60 1589 1271
1350 4606 135 10 45 13@90,3@60 1625 1300
1380 4709 138 10 46 14@90,2@60 1661 1329
1410 4811 141 10 47 15@90,1@60 1697 1358
1440 4913 144 10 48 16@90 1733 1387
HW-363 370 1170 1470 5016 147 10 49 13@90,5@60 1769 1416
1500 5118 150 10 50 14@90,4@60 1805 1444
1530 5220 153 10 51 15@90,3@60 1841 1473
1560 5323 156 10 52 16@90,2@60 1877 1502
1590 5425 159 10 53 17@90,1@60 1913 1531
1620 5527 162 10 54 18@90 1950 1560
1650 5630 165 10 55 15@90,5@60 1986 1589
1680 5732 168 10 56 16@90,4@60 2022 1618
1710 5835 171 10 57 17@90,3@60 2058 1646
1740 5937 174 10 58 18@90,2@60 2094 1675
1770 6039 177 10 59 19@90,1@60 2130 1704
1800 6142 180 10 60 20@90 2166 1733
HW-421 425 1560 1830 6244 183 10 61 1@120,19@90 2202 1762
1860 6346 186 10 62 2@120,18@90 2238 1791
1890 6449 189 10 63 3@120,17@90 2274 1820
1920 6551 192 10 64 4@120,16@90 2310 1849
1950 6653 195 10 65 5@120,15@90 2346 1877
1980 6756 198 10 66 6@120,14@90 2383 1906
HW-422 500 1840 2101 6858 201 10 67 7@120,13@90 2528 2023
2040 6960 204 10 68 8@120,12@90 2455 1964
2070 7063 207 10 69 9@120,11@90 2491 1993
2100 7165 210 10 70 10@120,10@90 2527 2022
2130 7268 213 10 71 11@120,9@90 2563 2051
2160 7370 216 10 72 12@120,8@90 2599 2079
2190 7472 219 10 73 13@120,7@90 2635 2108
2220 7575 222 10 74 14@120,6@90 2671 2137
2250 7677 225 10 75 15@120,5@90 2707 2166
2280 7779 228 10 76 16@120,4@90 2743 2195
2310 7882 231 10 77 17@120,3@90 2779 2224
2340 7984 234 10 78 18@120,2@90 2816 2253
2370 8086 237 10 79 19@120,1@90 2852 2282
2400 8189 240 10 80 20@120 2888 2310
2520 8598 252 10 84 4@150,16@120 3032 2426
B4-14
04-02
Table B4-4. Model CWB Ratings - Sheet 1 of 3

ELEMENTS NO. OF CONT. NO. AND KW OF STEPS 3-PHASE AMPS VS VOLTAGE
MODEL VES MAX RATED
CAP. FLOW MBTU/HR
NO. KW 208- 480-
GAL. GPM QTY KW 208-240V 480-600V 208 240 480 600
240V 600V
CWB-120 16 80 12 41 3 4 1 1 1@12 1@12 34 30 15 13
18 61 3 6 1 1 1@18 1@18 51 44 23 18
24 82 6 4 2 1 1@24 1@24 68 59 30 24
30 102 6 5 2 1 1@30 1@30 84 73 37 30
36 123 6 6 2 1 1@36 1@36 101 88 44 36
45 154 9 5 3 2 1@30,1@15 1@45 126 109 55 44
54 184 9 6 3 2 1@36,1@18 1@54 151 131 66 53
60 205 12 5 4 2 2@30 2@30 168 145 73 59
72 246 12 6 4 2 2@36 2@36 201 174 88 70
CWB-121 16 160 90 307 15 6 5 3 2@36,1@18 2@36,1@18 251 218 109 88
108 368 18 6 6 3 3@36 3@36 301 261 131 105
126 430 21 6 7 4 3@36,1@18 3@36,1@18 351 304 153 122
144 491 24 6 8 4 4@36 4@36 401 347 174 140
CWB-122 25 160 162 553 27 6 9 5 4@36,1@18 3@36,1@54 451 391 196 157
180 614 30 6 10 5 5@36 5@36 501 434 218 174
198 676 33 6 11 6 5@36,1@18 5@36,1@18 551 477 239 192
216 737 36 6 12 6 6@36 6@36 601 521 261 209
234 798 39 6 13 7 6@36,1@18 6@36,1@18 651 564 282 226
252 860 42 6 14 7 7@36 7@36 700 607 304 243
270 921 45 6 15 8 7@36,1@18 7@36,1@18 750 651 326 261
288 983 48 6 16 8 8@36 8@36 800 694 347 278
CWB-201 78 300 324 1105 54 6 18 9 6@54 3@72,3@36 900 780 391 313
360 1228 60 6 20 10 4@54,4@36 2@72,6@36 1000 867 434 347
396 1350 66 6 22 11 6@54,2@36 3@72,5@36 1100 954 477 382
432 1474 72 6 24 12 8@54 4@72,4@36 1200 1040 521 417
CWB-202 78 300 468 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-241 122 670 600 2047 60 10 20 10@60 723 578
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@60 867 694
CWB-242 122 670 750 2559 75 10 25 5@90,5@60 903 723
780 2661 78 10 26 6@90,4@60 939 752
810 2764 81 10 27 7@90,3@60 975 780
840 2866 84 10 28 8@90,2@60 1011 809
870 2968 87 10 29 9@90,1@60 1047 838
900 3071 90 10 30 10@90 1084 867
930 3173 93 10 31 7@90,5@60 1120 896
960 3276 96 10 32 8@90,4@60 1156 925
CWB-243 142 670 990 3378 99 10 33 9@90,3@60 1192 954
1020 3481 102 10 34 10@90,2@60 1228 982
B4-15
04-02
VES MAX ELEMENTS NO. OF CONT. NO. AND KW OF STEPS 3-PHASE AMPS VS VOLTAGE
MODEL RATED
CAP. FLOW MBTU/HR 208- 480-
NO. KW QTY KW 208-240V 480-600V 208 240 480 600
GAL. GPM 600V
240V
1080 3685 108 10 36 12@90 1300 1040
1110 3787 111 10 37 9@90,5@60 1336 1069
1140 3890 114 10 38 10@90,4@60 1372 1098
1170 3992 117 10 39 11@90,3@60 1408 1127
1200 4094 120 10 40 12@90,2@60 1444 1156
CWB-361 235 900 1224 4176 102 12 34 10@108,2@72 1473 1179
1260 4299 105 12 35 11@108,1@72 1517 1213
1296 4422 108 12 36 12@108 1560 1248
CWB-362 315 1170 1332 4545 111 12 37 9@108,5@72 1603 1283
1368 4668 114 12 38 10@108,4@72 1646 1317
1404 4790 117 12 39 11@108,3@72 1690 1352
1440 4913 120 12 40 12@108,2@72 1733 1387
1476 5036 123 12 41 13@108,1@72 1776 1421
1512 5159 126 12 42 14@108 1820 1456
1548 5282 129 12 43 11@108,5@72 1863 1491
1584 5405 132 12 44 12@108,4@72 1906 1525
1620 5527 135 12 45 13@108,3@72 1950 1560
1656 5650 138 12 46 14@108,2@72 1993 1594
1692 5773 141 12 47 15@108,1@72 2036 1629
1728 5896 144 12 48 16@108 2079 1664
CWB-363 370 1170 1764 6019 147 12 49 13@108,5@72 2123 1698
1800 6142 150 12 50 14@108,4@72 2166 1733
1836 6264 153 12 51 15@108,3@72 2209 1768
1872 6387 156 12 52 16@108,2@72 2253 1802
1908 6510 159 12 53 17@108,1@72 2296 1837
1944 6633 162 12 54 18@108 2339 1872
1980 6756 165 12 55 15@108,5@72 2383 1906
2016 6879 168 12 56 16@108,4@72 2426 1941
2052 7001 171 12 57 17@108,3@72 2469 1976
2088 7124 174 12 58 18@108,2@72 2512 2010
2124 7247 177 12 59 19@108,1@72 2556 2045
2160 7370 180 12 60 20@108 2599 2079
CWB-421 425 1840 2200 7506 165 13.3 55 15@120,5@80 2647 2118
2240 7643 168 13.3 56 16@120,4@80 2695 2156
2280 7779 171 13.3 57 17@120,3@80 2743 2195
2320 7916 174 13.3 58 18@120,2@80 2792 2233
2360 8052 177 13.3 59 19@120,1@80 2840 2272
2400 8189 180 13.3 60 20@120 2888 2310
2440 8325 183 13.3 61 1@160,19@120 2936 2349
2480 8462 186 13.3 62 2@160,18@120 2984 2387
2520 8598 189 13.3 63 3@160,17@120 3032 2426
2560 8735 192 13.3 64 4@160,16@120 3080 2464
2600 8871 195 13.3 65 5@160,15@120 3128 2503
2640 9008 198 13.3 66 6@160,14@120 3176 2541
B4-16
04-02

VES MAX ELEMENTS NO. OF CONT. NO. AND KW OF STEPS 3-PHASE AMPS VS VOLTAGE
MODEL RATED
CAP. FLOW MBTU/HR 208- 480-
NO. KW QTY KW 208-240V 480-600V 208 240 480 600
GAL. GPM 600V
240V
CWB-422 500 1840 2680 9144 201 13.3 67 7@160,13@120 3225 2580
2720 9281 204 13.3 68 8@160,12@120 3273 2618
2760 9417 207 13.3 69 9@160,11@120 3321 2657
2800 9554 210 13.3 70 10@160,10@120 3369 2695
2840 9690 213 13.3 71 11@160,9@120 3417 2734
2880 9827 216 13.3 72 12@160,8@120 3465 2772
2920 9963 219 13.3 73 13@160,7@120 3513 2811
2960 10100 222 13.3 74 14@160,6@120 3561 2849
3000 10236 225 13.3 75 15@160,5@120 3609 2888
3040 10372 228 13.3 76 16@160,4@120 3658 2926
3080 10509 231 13.3 77 17@160,3@120 3706 2965
3120 10645 234 13.3 78 18@160,2@120 3754 3003
3160 10782 237 13.3 79 19@160,1@120 3802 3042
3200 10918 240 13.3 80 20@160 3850 3080
3240 11055 243 13.3 81 9@160,15@120 3898 3119
3280 11191 246 13.3 82 10@160,14@120 3946 3157
3320 11328 249 13.3 83 11@160,13@120 3994 3196
3360 11464 252 13.3 84 12@160,12@120 4042 3234
B4-17
04-02
Table B4-5. Model S/CR Ratings - Sheet 1 of 2

ELEMENTS NO. OF CONT. NO. AND KW OF STEPS 3-PHASE AMPS
MODEL WATER STEAM ASME
RATED
VOL SPACE RATING 208-
NO. KW QTY KW 480V 208/240V 480V 208V 240V 480V
GAL GAL LBS STM 240V
S/CR-120 9 7 12 42 3 4 1 1 1@12 1@12 34 30 15
24 84 6 4 2 1 1@24 1@24 68 59 30
36 126 9 4 3 1 1@36 1@36 101 88 44
48 168 12 4 4 2 2@24 2@24 134 116 59
S/CR-161 23 16 60 210 9 6.7 3 2 1@40,1@20 1@40,1@20 168 145 73
80 280 12 6.7 4 2 2@40 2@40 223 193 97
S/CR-162 23 16 100 350 15 6.7 5 3 2@40,1@20 2@40,1@20 279 242 121
120 420 18 6.7 6 3 3@40 3@40 334 290 145
140 490 21 6.7 7 4 3@40,1@20 3@40,1@20 390 338 169
160 560 24 6.7 8 4 4@40 4@40 445 386 193
S/CR-200 48 26 160 560 24 6.7 8 4 4@40 4@40 445 386 193
180 630 27 6.7 9 5 4@40,1@20 4@40,1@20 501 434 218
200 700 30 6.7 10 5 5@40 5@40 556 482 242
220 770 33 6.7 11 6 5@40,1@20 5@40,1@20 612 530 266
240 840 36 6.7 12 6 6@40 6@40 667 578 290
S/CR-241 62 53 260 910 39 6.7 13 7 6@40,1@20 6@40,1@20 723 626 314
280 980 42 6.7 14 7 7@40 7@40 778 675 338
300 1050 45 6.7 15 8 7@40,1@20 7@40,1@20 834 723 362
320 1120 48 6.7 16 8 8@40 8@40 889 771 386
S/CR-242 62 53 340 1190 51 6.7 17 9 8@40,1@20 8@40,1@20 945 819 410
360 1260 54 6.7 18 9 2@60,6@40 1@80,7@40 1000 867 434
380 1330 57 6.7 19 10 3@60,5@40 1@80,6@40,1@60 1056 915 458
400 1400 60 6.7 20 10 4@60,4@40 2@80,6@40 1111 963 482
420 1470 63 6.7 10 2@80,5@40,1@60 506
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-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@60 602
520 1820 78 6.7 13 5@80,3@40 626
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@36 910
792 2772 66 12 22 10@72,2@36 954
828 2898 69 12 23 11@72,1@36 997
864 3024 72 12 24 12@72 1040
B4-18
04-02
Table B4-5. Model S/CR Ratings - Sheet 2 of 2

ELEMENTS NO. OF CONT. NO. AND KW OF STEPS 3-PHASE AMPS
MODEL WATER STEAM ASME
RATED
VOL SPACE RATING 208/
NO. KW QTY KW 480V 208/240V 480V 208V 240V 480V
GAL GAL LBS STM 240V
936 3276 78 12 26 13@72 1127
972 3402 81 12 27 13@72,1@36 1170
1008 3528 84 12 28 14@72 1213
1044 3654 87 12 29 14@72,1@36 1257
1080 3780 90 12 30 15@72 1300
S-421 210 140 1044 3654 87 12 29 15@72,1@36 1257
1080 3780 90 12 30 15@72 1300
1116 3906 93 12 31 15@72,1@36 1343
1152 4032 96 12 32 16@72 1387
1188 4158 99 12 33 16@72,1@36 1430
1224 4284 102 12 34 17@72 1473
1260 4410 105 12 35 17@72,1@36 1517
1296 4536 108 12 36 18@72 1560
S-422 270 180 1332 4662 111 12 37 18@72,1@36 1603
1368 4788 114 12 38 19@72 1646
1404 4914 117 12 39 19@72,1@36 1690
1440 5040 120 12 40 20@72 1733
1476 5166 123 12 41 1@108,19@72 1776
1512 5292 126 12 42 2@108,18@72 1820
S-480 360 235 1440 5040 120 12 40 20@72 1733
1476 5166 123 12 41 9@108,7@72 1776
1512 5290 126 12 42 10@108,6@72 1820
1548 5418 129 12 43 11@108,5@72 1863
1584 5540 132 12 44 12@108,4@72 1906
1620 5670 135 12 45 13@108,3@72 1950
1656 5790 138 12 46 14@108,2@72 1993
1692 5922 141 12 47 15@108,1@72 2036
1728 6050 144 12 48 16@108 2079
1764 6174 147 12 49 13@108,5@72 2123
1800 6300 150 12 50 14@108,4@72 2166
1836 6426 153 12 51 15@108,3@72 2209
1872 6550 156 12 52 16@108,2@72 2253
1908 6678 159 12 53 17@108,1@72 2296
1944 6800 162 12 54 18@108 2339
NOTE: Contact your local Cleaver-Brooks authorized representative for model availability at 600 Volts.
B4-19
04-02
Table B4-6. Model CSB Ratings - Sheet 1 of 2

WATER STEAM ASME ELEMENTS NO. OF NO. AND KW 3-PH
MODEL RATED
VOL SPACE RATING CONT. OF STEPS AMPS
NO. KW QTY KW
GAL GAL LBS STM 480V 480V 480V
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@90 867
CSB-302 140 90 750 2625 75 10 25 5@90,5@60 903
780 2730 78 10 26 6@90,4@60 939
810 2835 81 10 27 7@90,3@60 975
840 2940 84 10 28 8@90,2@60 1011
CSB-361 150 100 760 2660 57 13.3 19 9@80,1@40 915
800 2800 60 13.3 20 10@80 963
840 2940 63 13.3 21 9@80,3@40 1011
880 3080 66 13.3 22 10@80,2@40 1059
920 3220 69 13.3 23 11@80,1@40 1108
960 3360 72 13.3 24 12@80 1156
CSB-362 200 130 1000 3500 75 13.3 25 12@80,1@40 1204
1040 3640 78 13.3 26 13@80 1252
1080 3780 81 13.3 27 13@80,1@40 1300
1120 3920 84 13.3 28 14@80 1348
1160 4060 87 13.3 29 14@80,1@40 1396
1200 4200 90 13.3 30 15@80 1444
CSB-421 210 140 1120 3920 84 13.3 28 14@80 1348
1160 4060 87 13.3 29 14@80,1@40 1396
1200 4200 90 13.3 30 15@80 1444
1240 4340 93 13.3 31 15@80,1@40 1492
1280 4480 96 13.3 32 16@80 1541
1320 4620 99 13.3 33 1@120,15@80 1589
1360 4760 102 13.3 34 2@120,14@80 1637
1400 4900 105 13.3 35 3@120,13@80 1685
1440 5040 108 13.3 36 4@120,12@80 1733
CSB-422 270 180 1480 5180 111 13.3 37 5@120,11@80 1781
1520 5320 114 13.3 38 6@120,10@80 1829
1560 5460 117 13.3 39 7@120,9@80 1877
1600 5600 120 13.3 40 8@120,8@80 1926
1640 5740 123 13.3 41 9@120,7@80 1974
1680 5880 126 13.3 42 10@120,6@80 2022
CSB-423 300 200 1560 5460 117 13.3 39 7@120,9@80 1877
1600 5600 120 13.3 40 8@120,8@80 1926
1640 5740 123 13.3 40 9@120,7@80 1974
1680 5880 126 13.3 42 10@120,6@80 2022
1720 6020 129 13.3 43 11@120,5@80 2070
B4-20
04-02
Table B4-6. Model CSB Ratings - Sheet 2 of 2

MODEL WATER STEAM RATED ASME ELEMENTS NO. OF NO. AND KW 3-PH
NO. VOL SPACE KW RATING CONT. OF STEPS AMPS
GAL GAL LBS STM QTY KW 480V 480V 480V
1800 6300 135 13.3 45 13@120,3@80 2166

1840 6440 138 13.3 46 14@120,2@80 2214
1880 6580 141 13.3 47 15@120,1@80 2262
1920 6720 144 13.3 48 16@120 2310
CSB-424 385 260 1960 6860 147 13.3 49 1@160,15@120 2359
2000 7000 150 13.3 50 2@160,14@120 2407
2040 7140 153 13.3 51 3@160,13@120 2455
2080 7280 156 13.3 52 4@160,12@120 2503
2120 7420 159 13.3 53 5@160,11@120 2551
2160 7560 162 13.3 54 6@160,10@120 2599
2200 7700 165 13.3 55 7@160,9@120 2647
2240 7840 168 13.3 56 8@160,8@120 2695
2280 7980 171 13.3 57 9@160,7@120 2743
2320 8120 174 13.3 58 10@160,6@120 2792
2360 8260 177 13.3 59 11@160,5@120 2840
2400 8400 180 13.3 60 12@160,4@120 2888
CSB-425 470 320 2440 8540 183 13.3 61 13@160,3@120 2936
2480 8680 186 13.3 62 14@160,2@120 2984
2520 8820 189 13.3 63 15@160,1@120 3032
2560 8960 192 13.3 64 16@160 3080
2600 9100 195 13.3 65 11@160,7@120 3128
2640 9240 198 13.3 66 12@160,6@120 3176
2680 9380 201 13.3 67 13@160,5@120 3225
2720 9520 204 13.3 68 14@160,4@120 3273
2760 9660 207 13.3 69 15@160,3@120 3321
2800 9800 210 13.3 70 16@160,2@120 3369
2840 9940 213 13.3 71 17@160,1@120 3417
2880 10080 216 13.3 72 18@160 3465
NOTE: Contact your local Cleaver-Brooks authorized representative for model availability at 600 volts.
B4-21
04-02
Table B4-7. Model TWH/TWV Vessel Sizes
MODEL BASE VESSEL DIMENSIONS (INCHES)

TANK SIZE
(1) GAL. DIAMETER OVER ALL LENGTH
TWV-015 150 30 54
TWV-020 200 30 70
TWV-025 250 36 62
TWV-030 300 36 74
TWV-035 350 36 86
TWV-040 400 42 74
TWV-050 500 42 90
TWV-060 600 48 82
TWV-075 750 48 100
TWV-100 1000 60 90
TWV-125 1250 60 110
TWV-150 1500 60 130
TWH-050 500 42 90
TWH-060 600 42 106
TWH-075 750 48 104
TWH-100 1000 48 136
TWH-125 1250 48 168
TWH150 1500 54 160
TWH-175 1750 54 190
TWH-200 2000 60 174
TWH-225 2250 60 194
TWH-250 2500 60 216

NOTES:
1. Add recovery heater kw size to complete model number (see below) recovery heaters for TWV-015 cannot exceed 240 kW
2. Note: Use this table in conjunction with Table B4-7.
B4-22
04-02
Table B4-8. Model TWH/TWV Ratings
ELEMENTS
OUT- 3-PHASE AMPS
NO. OF CONT. NO. AND KW OF STEPS
.A GPH@ PUT VS VOLTAGE
MODEL NO RATED 208-240V 480-600V
100 F
SUFFIX KW RISE
208- 480-
MBH QTY KW QTY KW 208-240V 480V 208 240 480
240V 600V
TWV/TWH-030 30 123 61 6 5 3 10 2 1 1@30 1@30 84 73 37
-060 60 246 123 12 5 6 10 4 2 2@30 2@30 168 145 73
-090 90 369 205 18 5 9 10 6 2 3@30 3@30 251 218 109
-120 120 443 409 24 5 12 10 8 4 4@30 4@30 334 290 145
-150 150 615 512 15 10 5 2@60, 1@30 181
-180 180 738 614 18 10 6 3@60 218
-210 210 861 717 21 10 7 3@60, 1@30 254
-240 240 984 819 24 10 8 4@60 290
-270 270 1107 921 27 10 9 4@60, 1@30 326
-300 300 1230 1024 30 10 10 5@60 362
-330 330 1353 1126 33 10 11 5@60, 1@30 398
-360 360 1476 1228 36 10 12 6@60 434
A. Storage tank must be specified with a properly sized recovery heater to complete the model number (e.g., TWV-030-120 is a 300 gallon vertical
storage tank with a 120 kW recovery heater).
NOTICE
Ratings information for Model TWV and Model
TWH is split into two tables. Since this model of
electric boiler is used for hot water storage as well
as heating, the boiler vessel capacity in gallons
and the heating rate must be selected to meet spe-
cific application needs. Table B4-6 gives the ves-
sel capacity and boiler base models. Table B4-7
gives the heating or kilowatt rating of the units.
For example, if a large storage capacity is needed,
for instance, 1000 gal with a vertical tank, from Ta-
ble B4-6, the base model is TWV-100, and if 90 kW
recovery is required, from Table B4-7 the suffix is
-90, which would add a 90 KW heater, the full mod-
el number would be TWV-100-90.
B4-23
04-02
Table B4-9. Model IWH Ratings
MAX ELEMENTS NO. OF CONT NO. AND KW OF STEPS 3- PHASE AMPS VS VOLTAGE
MODEL FLOW RATED MBTU
NO. KW /HR
GPMA QTY KW <250V >250V 208-240 480-600 208 240 480 600
IWH-611 135 15 51 3 5 1 1 1@15 1@15 43 37 19 15
30 102 6 5 2 1 1@30 1@30 84 73 37 30
IWH-612 135 45 154 9 5 3 2 1@45 1@45 126 109 55 44
60 205 12 5 4 2 2@30 1@60 168 145 73 59
IWH-621 135 30 102 3 10 1 1@30 37 30
60 205 6 10 2 1@60 73 59
IWH-622 135 90 307 9 10 3 1@ 30,1@ 60 109 88
120 409 12 10 4 2@ 60 145 116
IWH-812 240 75 256 15 5 5 3 1@30,1@45 1@30,1@45 209 181 91 73
90 307 18 5 6 3 2@45 3@30 251 218 109 88
105 358 21 5 7 4 1@45,2@30 1@45, 2@30 292 254 127 102
120 409 24 5 8 4 4@30 4@ 30 334 290 145 116
IWH-821 240 90 307 9 10 3 3 @ 30 109 88
120 409 12 10 4 4 @ 30 145 116
IWH-822 240 150 512 15 10 5 3@30,1@60 181 145
180 614 18 10 6 2@30,2@60 218 174
210 717 21 10 7 1@30,3@60 254 203
240 819 24 10 8 4@60 290 232
IWH-022 360 210 717 21 10 7 1@30,3@60 254 203
240 819 24 10 8 4@60 290 232
270 921 27 10 9 3@30,3@60 326 261
300 1024 30 10 10 2@30,4@60 362 290
330 1126 33 10 11 1@30,5@60 398 319
360 1228 36 10 12 6@60 434 347
A. Maximum flow rate is based on a maximum velocity of 1.5 fps through the heater; Minimum flow rate should not be less than 10% of
the maximum flow rate listed.
B4-24
04-02
The following sample specifications are provided by Cleaver-Brooks to assist you in meeting your customers specific needs and
application.
1.0 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-25

2.0 Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-25
3.0 Heating Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-25
4.0 Trim and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-26
5.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-26
1.0 Capacities
1.1 Boiler Capacity - Hot Water
The ____ gallon _____ capacity hot water boiler shall be Cleaver-Brooks Model ___________ rated ____ kW at ____ V, ____ ph,
60 Hz, ____ MBtu/hr. Unit shall be suitable to operate under the following conditions: system flow rate ____ gpm; outlet water
temperature ____ F; return water temperature ____F; system operating pressure ____ psig.
Boiler Capacity - Steam
The _____ gallon ______ capacity steam boiler shall be Cleaver-Brooks Model ______________ rated _____ kW at ____ V,
_____ ph, 60 Hz. Unit shall produce ______ lbs steam/hr (from and at 212 F) at a nominal pressure of ____ psig.
Water Heater Capacity - Instantaneous
The horizontal circulation water heater shall be Cleaver-Brooks Model IWH ___________ rated _____ kW at ____ V, ____ ph,
60 Hz.
1.2 Storage Tank Heater Capacity
The _____ gallon capacity (horizontal or vertical) shall be Cleaver-Brooks Model ___________ rated kW at _____ V, _____ ph,
60 Hz, and shall recover ____ gpm at 100 F rise.
2.0 Boiler
The vessel shall be constructed in accordance with ASME Boiler Code.
The vessel shall be designed for ____ psig.
The relief valve shall be per ASME Code, set at ____ psig.
The vessel shall be insulated with a double wrap of 2-inch fiber blanket insulation having 1-1/2 PCF density.
The boiler shall be UL listed, and bear the Underwriters Laboratories label.
The boiler shall be of the packaged type, factory assembled, wired, and tested.
The boiler shall be mounted on a full size structural steel base.
The boiler enclosure shall be 16-gauge steel.
The entire enclosure shall be finished in light blue enamel paint.
The overall dimensions of the boiler shall be _____ inches long, ______ inches wide, and _____ inches high.
For CR Models, the boiler shall include built-in condensate receiver and feed pump, with make-up valve mounted on
common base with boiler, factory wired and piped, and enclosed in boiler casing.
For TWV and TWH models, the vessel interior shall be lined with Epoxy, cement or sprayed copper or nickel and have
magnesium anode protection.
3.0 Heating Elements

The heating elements shall be individually mounted, rod type, and field replaceable with standard tools.
B4-25
04-02
The heating watt density shall not exceed _______ (50 or 75) W/sq-in.
The heating elements shall be _________ (copper or Incoloy) sheathed.
4.0 Trim and Controls

The units shall be complete with the following:
Main lugs for supply circuits.
Supplemental internal branch circuit fuses, current limiting, rated at 200,000 amps interrupting capacity.
Fused 120 V control circuit transformer.
Magnetic contactors rated at 500,000 cycles.
Integral high temperature limit (hot water boilers).
High pressure limit (steam boilers).
Low water cutoff (float-type with gauge glass for steam) on all models except IWH which is supplied with a flow switch.
Pressure-temperature gauge (hot water boilers).
Pressure gauge (steam boilers)).
Pilot switch.
Pilot lights for power on, low water, high temperature or pressure.
Relief valve.
Drain valve (hot water boilers).
Bottom and water column blowdown valves (steam boilers).
Feedwater stop and check valves (steam boilers).
All models (except IWH, TWV, and TWH) shall be supplied with modulating step controls to gradually apply the load in
____ steps.
All models (except IWH, TWV, and TWH) shall be supplied with proportioning temperature (hot water units) or pressure
(steam units) control to balance power input to match system demand.
NOTICE
Temperature control on IWH, TWV, and TWH is one of the following methods (select A or B or C).
A. Thermostats - The heating elements shall be staged by control thermostats. (Standard for one and two step heaters).
B. Sequencer - The heating elements shall be staged by a time delay sequencer, to energize heating elements in ____ stages
with an adjustable 1 to 15 second time delay between stages. (Standard for 3 or 4 step heaters.)
C Modulating Step Control - (Standard for heaters above 4 steps).
5.0 Warranty
1. The Cleaver-Brooks unit shall be warranted against defective workmanship and materials for a period of one year from the date
of start- up or 18 months from shipment.
2. The TWH and TWV models shall include a 5 year warranty against vessel leakage.
B4-26
04-02
Section B5
TRUEFIRE BOILERS
Table of Contents
TrueFire Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-2
Three-Pass Wetback Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-2
Optimal Boiler Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-2
High Boiler Fuel-to-water Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-2
Advanced Insulated Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-2
Quality Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-2
Hinged Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-2
Designed for Heating Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-2
TrueFire Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-3
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-3
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-3
Boiler Room Combustion Air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5-3
Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-4
System Operating Parameters: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-4
B5-1
02-03
TrueFire Boilers Commercial Boilers
LIST OF FIGURES
Figure B5-1. Model MTF Hot Water Boiler Dimensions (Page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-6
Figure B5-2.Model MTF Minimum Room Clearance Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-8
LIST OF TABLES
Table B5-1. Model MTF Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-5
Table B5-2. Model MTF Minimum Over Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-9
Table B5-3. Model MTF Circulation & Temperature Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-9
Table B5-4. Model MTF Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-10
Table B5-5. Model MTF Minimum Required Gas Pressure Altitude Conversion . . . . . . . . . . . . . . . . . . . B5-10
Table B5-6. Model MTF Boilers Minimum and Maximum Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . B5-11
Table B5-7. TrueFire Furnace Dimensions and Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-11
TrueFire Features and Benefits Quality Construction

ASME construction ensures high quality design, safety,
Three-Pass Wetback Design and reliability.
Three-pass wetback design provides excellent boiler effi- ISO 9001 certified manufacturing process ensures the
ciency with minimal refractory. highest degree of manufacturing standards are always fol-
Dimpled tubes on the third pass provide high flue-gas lowed.
velocities and exceptional heat transfer.
Hinged Front Door
Unique wetback design provides access to boiler tubes,
tube sheet, and furnace for ease of maintenance. Provides access to all tubes and the furnace section for
easy inspection and maintenance.
Optimal Boiler Sizing No crane or hoist is required to access the burner and com-
Ten boiler sizes with capacity range of 300,000 Btu/hr ponents for inspection.
through 3,000,000 Btu/hr provides the flexibility for opti-
mal boiler sizing on every heating application under 60 Designed for Heating Applications
PSI. Pressure vessel is warranted for 20 years against thermal
shock.
High Boiler Fuel-to-Water Efficiency
Corrosion risk is minimized due to the tube arrangement at
The advanced boiler design guarantees an efficiency of up the hottest point of the boiler, which guarantees an even
to 84% on gas operation and up to 88% on oil operation. gas flow and heat distribution through the boiler.
Advanced Insulated Construction

All non-heat transfer pressure vessel surfaces are com-
pletely insulated to reduce the radiation losses and
increase efficiency.
B5-2
02-03
Commercial Boilers TrueFire Boilers
TrueFire Product Offering 6 dial pressure gauge (New York code).
Information in this section applies to hot water boiler sizes IRI gas train and FM gas train.
ranging from 300,000 Btu input to 3,000,000 Btu input. Lead/lag systems for up to 6 boilers.
The TrueFire boiler is a three-pass wetback firetube boiler. The
boiler/burner package is UL/cUL approved. The pressure ves- Gas-Fired Burners
sel conforms to Section IV of the ASME Code. The pressure Table B5-5 shows correction factors for gas pressure at eleva-
vessel is wrapped in blanket insulation and contained inside a tions over 700 ft above sea level.
casing that is composed of removable steel panels.
Table B5-6 shows minimum and maximum gas pressure
requirements for Standard, FM and IRI Boiler gas trains
Standard Equipment
upstream of the gas pressure regulator.
Equipment described below is for the standard boiler offering.
For oversized or undersized gas trains or altitude above 2,000
feet, contact your local Cleaver-Brooks Authorized Represen-
1. Boiler: tative.
A. All boilers are designed and constructed in accordance
with the ASME Code. Fuel Connections - Gas
B. Boiler is mounted on a base, insulated, and cased. The local gas company should be consulted for requirements
2. Forced draft burner: piping. Installation of gas supply piping and venting must be in
accordance with all applicable engineering guidelines and reg-
A. Burner is mounted on the hinged front door. Door can
ulatory codes. All connections made to the boiler should be
be hinged from either side.
B. The burner has UL/cUL approval. tion, cleaning and maintenance.
C. Burner Controls: A drip leg should be installed in the supply piping before the
connection to the gas pressure regulator. The drip leg should
Natural Gas: Series 700
be at least as large as the inlet fitting supplied with the boiler.
Light Oil: Series 100 Consideration must be given to both volume and pressure
Combination: Series 200
MTF-300, On-Off burner. the particular installation. Connections to the burner gas train
MTF-500 through MTF-750, Low-High-Off burner.
MTF-1000 through MTF-3000, full modulation burner. vice. Upon completion of the gas piping installation, the sys-
3. Water Controls: valves.
A. Pressure and temperature gauges.
B. Operating and limit controls.
C. Low water cutoff probe control. room, air flow, and velocity of air must be reviewed as follows:
Optional Equipment room.
Options include the following: A. Two (2) permanent air supply openings in the outer
30# safety relief valve. walls of the boiler room are recommended. Locate one
Drain valve.
height of 7 feet. This allows air to sweep the length of
Probe type auxiliary low water cutoff. the boiler.
B5-3
02-03
B. Air supply openings can be louvered for weather System Operating Parameters:
System over-pressure requirements are shown on Table B5-2.
qualities and is subject to clogging by dust or dirt. Minimum return water temperature = 130 F.
C. A vent fan in the boiler room is not recommended, as it Minimum supply water temperature (boiler outlet)= 150 F.
Maximum design temperature = 250 F.
This can result in unsatisfactory burner performance. Maximum operating temperature = 240 F.
Area (sq-ft) = cfm/fpm
Area Required: Area = cfm/fpm = 3000/250 = 12 sq-ft total.
NOTICE
quirements.

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.
B5-4
02-03
Table B5-1: Model MTF Boiler Ratings
MTF- MTF- MTF- MTF- MTF- MTF- MTF- MTF- MTF- MTF-
MODEL NO.
300 500 750 1000 1250 1500 1750 2000 2500 3000
Btu Input (1000 Btu/hr) 300 500 750 1000 1250 1500 1750 2000 2500 3000
Light Oil gph (140,000 Btu/gal) 2.1 3.6 5.4 7.1 8.9 10.7 12.5 14.3 17.9 21.4
Natural Gas CFH (1000 Btu/cu-ft) 300 500 750 1000 1250 1500 1750 2000 2500 3000
Gas (Therm/hr) 3.0 5.0 7.5 10.0 12.5 15.0 17.5 20.0 25.0 30.0
Blower Motor hp 3/4 3/4 1/2 1/2 3/4 3/4 1 1 1-1/2 1-1/2
BOILER DATA
Note:
Pressure atomized burners.
Integral oil pump.
For altitude above 2000 ft contact your local Cleaver-Brooks Authorized Representative.
B5-5
02-03
I
FF B GG
S
S F
X E
D
R U L O
J
K
G
Z
P W
Q
T
H C
N
A
M
MTF- MTF- MTF- MTF- MTF- MTF- MTF-

MODEL NO. DIM MTF-300 MTF-500 MTF-750 1000 1250 1500 1750 2000 2500 3000
LENGTHS
Gas
Overall Length A 75 88 93 112 112 120-1/2 130-1/2 130-1/2 130-1/2 140
Oil/Comb.
Shell Length B 39-3/4 52-3/4 57-1/2 61-1/2 61-1/2 70 74-1/2 74-1/2 74-1/2 84
Base Frame Length C 35-1/4 48 52-3/4 56-3/4 56-3/4 65-1/2 69-3/4 69-3/4 69-3/4 80-1/2
Front Head Extension E 9 9 9-1/4 10 10 10 11-3/4 11-3/4 11-3/4 11-3/4
Front Flange To Water Supply F 10 12 15-3/4 15-3/4 15-3/4 15-3/4 18-1/3 18-1/4 18-1/4 17-3/4
Rear Lag. To Return G 1-3/4 1-3/4 1-3/4 1-3/4 1-3/4 1-3/4 2-1/4 2-1/4 2-1/4 2-1/4
Base Frame To Rear Head H 8-1/4 8-1/4 8 9-1/4 9-1/4 9 9 9 9 7-1/2
Rear Lag. To Vent X 3-1/2 3-1/2 3-1/2 4-1/2 4-1/2 4-1/2 4-1/4 4-1/4 4-1/4 4-1/4
Rear Lag. To Drain Z 1-3/4 1-3/4 1-3/4 1-3/4 1-3/4 1-3/4 2-1/4 2-1/4 2-1/4 2-1/4
WIDTHS
Overall Width I 31-1/4 33-1/2 34-1/4 38-1/4 38-1/4 38-1/4 47 47 47 51-3/4
Base Outside M 28 29-1/4 31-1/4 33-1/2 33-1/2 33-1/2 41-3/4 41-3/4 41-3/4 46-1/2
Base Inside N 23-3/4 25 27 29-1/4 29-1/4 29-1/4 37-1/2 37-1/2 37-1/2 42-1/2
Figure B5-1. Model MTF Hot Water Boiler Dimensions (Page 1 of 2)
B5-6
02-03
MTF- MTF- MTF- MTF- MTF- MTF- MTF-

MODEL NO. DIM MTF-300 MTF-500 MTF-750 1000 1250 1500 1750 2000 2500 3000
HEIGHTS
O.A. Height D 49-1/2 50-1/2 54 57-1/4 57-1/4 57-1/4 75-1/4 76-1/4 76-1/4 83-1/4
Base To Top Of Lagging J 34-3/4 35 37-3/4 41-1/2 41-1/2 41-1/2 48-1/2 48-1/2 48-1/2 53-1/4
Base To Vent Outlet K 27-3/4 27-3/4 28-3/4 31-1/2 31-1/2 31-1/2 37-1/2 37-1/2 37-1/2 41-1/2
Base To Controls L 41-1/4 41-3/4 44-1/4 48 48 48 55 55 55 59-3/4
Base To Supply Port O 40-3/4 41-1/4 44-1/4 47-3/4 47-3/4 47-3/4 60-3/4 60-3/4 60-3/4 66-3/4
Base To Return Port P 13-1/2 13-1/2 12-1/4 16-1/2 16-1/2 16-1/2 14 14 14 21-3/4
Base Frame Q 4-3/4 4-3/4 4-3/4 4-3/4 4-3/4 4-3/4 4-3/4 4-3/4 4-3/4 4-3/4
Base To Lifting Lug R 39 39-1/4 42 45-1/4 45-1/4 45-1/4 53 53 53 57-1/2
Base To Drain T 7 6-1/2 6 7 7 7 7 7 7 6-3/4
CONNECTIONS
Supply S 1-1/2 2 2-1/2 2-1/2 2-1/2 2-1/2 4 4 4 5
Return U 1-1/2 2 2-1/2 2-1/2 2-1/2 2-1/2 4 4 4 5
Drain W 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2
Vent Outlet Y 6 6 8 10 10 10 12 12 12 14
MISCELLANEOUS
Tube Removal Rear FF 28-1/4 40-1/4 45-3/46 49-3/4 49-3/4 58 62-1/2 62-1/2 62-1/2 74-3/4
Front Clearance Burner Aisle* GG 47-1/4 47-1/4 47-1/4 63-1/2 63-1/2 63-1/2 67 67 67 67
WEIGHTS
Normal Water Weight (Lbs) - 304 463 619 802 771 926 1217 1146 1146 2067
Shipping Weight - 1095 1384 1657 1964 2188 2299 2786 2992 3107 4801
* Dimensions given exceed front tube removal requirements.
Figure B5-1. Model MTF Hot Water Boiler Dimensions ( Page 2 of 2)
B5-7
02-03
A A
Distance
Between
Burner Hinged
Boilers
Side
(Hinged
Side) B
B C
D
E
Stack & Smokebox Removal
Distance Between Boilers
(Hinged Side)
MODEL NO. DIM MTF-300 MTF-500 MTF-750 MTF-1000 MTF-1250 MTF-1500 MTF-1750 MTF-2000 MTF-2500 MTF-3000
LENGTHS (in)
Door, Aisle A 47-1/4 47-1/4 47-1/4 63-1/2 63-1/2 63-1/2 67 67 67 67
Hinged Side B 25 25 25 41-1/2 41-1/2 41-1/2 45-1/2 45-1/2 45-1/2 43
Between Boilers (Hinged Side) C 56 56 56 89 89 89 97 97 97 92
Stack, Smokebox D 36 36 40 44 44 44 48 48 48 52
Between Boilers (Non-Hinged Side) E 6 6 6 6 6 6 6 6 6 6
Door Swing (LH or RH) is Interchangable

Customer to apply B & C Dimensions Appropriately
Figure B5-2. Model MTF Minimum Room Clearance Dimensions
B5-8
02-03
Table B5-2: Model MTF Minimum Over Pressure Requirements
MAXIMUM OUTLET MINIMUM SYSTEM

TEMPERATURE (F) PRESSURE (PSI)
180 12
190 15
200 18
210 21
220 24
230 27
240 30
Table B5-3: Model MTF Circulation & Temperature Drop
SYSTEM TEMPERATURE DROP (DEGREES F)
MODEL
10 20 30 40 50 60 70 80 90 100 110
NO.
Circulation Rate (GPM)
MTF-300 51.5 25.8 17.2 12.9 10.3 8.6 7.4 6.4 5.7 5.2 4.7
MTF-500 86.5 43.3 28.8 21.6 17.3 14.4 12.4 10.8 9.6 8.7 7.9
MTF-750 131.3 65.7 43.8 32.8 26.3 21.9 18.8 16.4 14.6 13.1 11.9
MTF-1000 176.1 88.0 58.7 44.0 35.2 29.3 25.2 22.0 19.6 17.6 16.0
MTF-1250 217.6 108.8 72.5 54.4 43.5 36.3 31.1 27.2 24.2 21.8 19.8
MTF-1500 259.6 129.8 86.5 64.9 51.9 43.3 37.1 32.5 28.8 26.0 23.6
MTF-1750 304.6 152.3 101.5 76.2 60.9 50.8 43.5 38.1 33.8 30.5 27.7
MTF-2000 350.1 175.1 116.7 87.5 70.0 58.4 50.0 43.8 38.9 35.0 31.8
MTF-2500 435.2 217.6 145.1 108.8 87.0 72.5 62.2 54.4 48.4 43.5 39.6
MTF-3000 531.2 265.6 177.1 132.8 106.2 88.5 75.9 66.4 59.0 53.1 48.3
B5-9
02-03
Table B5-4: Model MTF Boiler Safety Valve Openings
VALVE
60 psig
SETTING
NO. OF VALVES OUTLET SIZE

MODEL NO.
REQD (IN)
MTF-300 1 1
MTF-500 1 1
MTF-750 1 1
MTF-1000 1 1
MTF-1250 1 1
MTF-1500 1 1
MTF-1750 1 1
MTF-2000 1 1 1/4
MTF-2500 1 1 1/4
MTF-3000 1 1 1/4
Note: Valve manufacturer is Kunkle, #537
Table B5-5: Model MTF Minimum Required Gas Pressure Altitude Conversion
CORRECTION CORRECTION
ALTITUDE (FT) ALTITUDE (FT)
FACTOR 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 gas pressure at altitudes above

700 feet, multiply the pressure by the listed factors:
Inches WC x0.577 = oz/sq.in.
oz/sq.in x 1.732 = Inches WC
Inches WC x 0.0361 = psig
psig x 27.71 = Inches WC
psig x 16.0 =oz/sq-in.
B5-10
02-03
Table B5-6: Model MTF Boilers Minimum and Maximum Gas Pressure
STD PIPE MINIMUM BURNER MAXIMUM BURNER

MODEL NO.
SIZE (IN) PRESSURE (W.C.) PRESSURE (W.C.)
UL IRI/FM MAX. PRESS.
MTF-300 1 1.8 1.8 14
MTF-500 1 4.2 4.0 14
MTF-750 1 4.1 3.7 14
MTF-1000 1-1/2 9.6 9.8 14
MTF-1250 1-1/2 10.8 11.1 14
MTF-1500 1-1/2 6.8 7.3 14
MTF-1750 1-1/2 7.0 7.6 14
MTF-2000 1-1/2 9.5 10.4 14
MTF-2500 2 11.7 11.5 14
MTF-3000 2 8.9 8.9 14
Minimum and maximum gas pressure at the entrance to UL and IRI gas trains (upstream of gas
pressure regulator
Table B5-7: TrueFire Furnace Dimensions and Pressures
FURNACE
FURNACE FURNACE LENGTH
MODEL NO. PRESSURE
INNER DIA. (IN.) (IN.) (IN. WC)
MTF-300 15-1/4 29-1/2 0.3
MTF-500 15-1/4 42-1/2 0.5
MTF-750 17-1/4 48 0.7
MTF-1000 19-1/4 51 0.9
MTF-1250 19-1/4 51 1.2
MTF-1500 19-1/4 59-3/4 1.9
MTF-1750 23-3/4 64 2.0
MTF-2000 23-3/4 64 2.1
MTF-2500 23-3/4 64 2.1
MTF-3000 27 74-1/2 2.3
B5-11
02-03
Notes
B5-12
02-03
CLEAVER-BROOKS TRUEFIRE FIRETUBE BOILER

SUGGESTED SPECIFICATION
1.0 BOILER CAPACITY

1.1 The hot water boiler shall be Cleaver-Brooks Model MTF designed for 60 psig (hot water). Maximum water temperature shall
be _______ F, and maximum system temperature drop shall be _______ F.
1.2 The boiler shall have a maximum output of ____________ Btu/hr when fired with No. 2 oil, and/or ________________ Btu/cu-
ft when fired with natural gas. Available electrical power will be _____ Volt, _____ phase, ____ Hz.
2.0 GENERAL BOILER DESIGN
2.1 Boiler shall be a compact firetube type, three pass, wet back, updraft design with high efficiency heat transfer technology and
efficiency herein listed. The boiler shall be designed for natural gas firing (and/or No. 2 oil firing). Gas supply pressure to the
boiler gas pressure regulating valve shall be ____ psig minimum and ___ psig maximum. Boilers shall attain full rating at an ele-
vation of ___ feet. The burner shall be forced draft multiport type for gas (and pressure atomizing type for oil). The boiler and
burner must be supplied or approved by the boiler manufacturer to assure compatibility and single source responsibility for the
package's performance. The boilers shall be constructed in accordance with ASME Section IV Code. The complete packaged
boiler/burner unit shall be listed by Underwriters Laboratories, and shall have the UL/cUL label affixed to the unit.
2.2 Front door shall be hinged and be easily converted to allow door swing to either side for easy access. Front tube sheet along
with all three flue gas passes must be fully accessible for inspection and cleaning when the door is swung open without the need for
a confined entry space permit. Rear tube sheet shall be accessed through inspection access panel.
2.3 Other factory furnished and installed items for each boiler shall include:
2.3.1 Two lifting eyes on top center line of boiler.
2.3.2 Two (2) inch fiberglass blanket insulation and readily removable steel jacket.
2.3.3 Burner observation port.
2.3.4 Automatic to manual firing switch for manual control of the firing rate plus all operating controls (Models MTF 500 -
MTF 3000).
2.3.5 Factory painting using a hard finish enamel.
2.3.6 Dial type hot water temperature gauge.
2.3.7 Hot water pressure gauge.
2.3.8 ASME Code relief valve(s) with side outlet set for 60 psig.
2.3.9 A probe-type, low water cut-off control.
2.4 Each boiler shall be rated at ___ MBH output (___BHP) for 60 psig hot water design pressure. Controls shall include High-
Low temperature control on larger units, operating limit temperature control and high limit temperature control of the manual reset
type. Controls shall be adjusted for ___oF operating temperature.
3.0 BOILER CONNECTIONS
3.1 Hot water Boiler(s) shall be specifically designed for bottom inlet and top outlet with necessary internal baffling. Inlet connec-
tion shall be ___". Outlet connection shall be ___".
4.0 BURNER AND CONTROLS
4.1 The boiler shall be provided with a UL/cUL approved fuel burning system in full accordance with the requirements of state,
provincial and local codes, the local gas utility, and other applicable regulatory bodies. The burner shall be a Cleaver-Brooks Pro-
Fire burner or approved equal.
B5-13
02-03
4.2 Option (specify A or B, as required)

A. The complete fuel burning system shall be in full accordance with Factory Mutual (FM) requirements.
B. The complete fuel burning system shall be in full accordance with Industrial Risk Insurers (IRI) requirements.
A. The boiler shall include a gas burner having rated capacity to burn ________ MMBtu/hr of ______ Btu/cu-ft of
__________ gas at a pressure of _______ (lbs/sq-in.) (inches of water column) at the inlet of the burner gas control train.
B. The boiler shall include an oil burner having rated capacity to burn ______ gph of No. 2 fuel oil.
C. The boiler shall include a combination gas-oil burner having rated capacity to burn _______ MMBtu/hr of Btu/cu-ft ______
gas at a pressure of _________ (lbs/sq-in.) (inches of water column) at the inlet to the burner gas control train or _______ gph
of No. 2 fuel.
4.3.2 The burner shall be forced draft type with (specify A, B, or C) firing rate. All combustion air shall be furnished by the burner
fan, which shall be an integral part of the burner. Each burner motor shall not be larger than ______ hp, ____ phase.
A. On-Off for Model MTF-300.
B. Low-High-Off for Models MTF-500 and MTF-750.
C. Full modulation for Models MTF-1000 through MTF-3000.
than 15% excess air and less than 40 ppm (corrected to 3% O2) CO in the products of combustion.
maximum of No. 1 smoke spot, as measured on the Bacharach Scale when burning oil.
4.3.5 The burner shall be equipped with an aluminium reverse curve fan for lower fan motor hp requirements and self-cleaning
characteristics.
burner controls are to be for use on 120 volts, 1 phase, 60 Hz.
4.4.1 A separate pilot gas cock, gas pressure regulator, and pilot safety shutoff gas valve, shall be provided for the ignition gas
supply.
4.5 Oil Burner
4.5.3 Two approved automatically operated safety shutoff valve(s) shall be provided in the oil supply line to the burner valves to be
B5-14
02-03
with local codes.
NOTICE
4.6.4 Provide one ________ inch, automatically operated motorized safety gas valve. One safety shutoff valve shall be proven
closed during pre- ignition by proof of valve closure interlock switch on valve.
valve.
valves.
shutdown in the event of either high or low gas pressure (optional on Models MTF-300 through MTF-2000).
4.7 Burner Controls
4.7.1 An additional high limit safety temperature control of the manual reset type shall be provided to control the burner.
4.7.2 Pre- and post- operation of the burner fan shall be provided per current UL/cUL requirements.
4.7.3 The burner shall utilize a Cleaver-Brooks flame safeguard programmer, incorporating 7 LED indicator lights to annunciate
the current operating status of the burner.
4.7.6 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.
guard control, programming timer, burner motor starter, fuses, control circuit transformer, control switches, indicating lamps, and
relays as required.
4.7.9 The changing from one fuel to the other shall be manual by means of a fuel selector switch. No burner adjustments shall be
B5-15
02-03
4.7.13 Full modulation of fuel input shall be provided on Models MTF-1000 through MTF-3000. A modulating temperature con-
trol shall be supplied to modulate a burner mounted damper motor, controlling both fuel and air supply by means of direct mechan-
ical linkage.
5.0 EFFICIENCY
5.1 The boiler(s) will have a guaranteed efficiency of up to 84% on gas and up to 88% on #2 oil at 100% of rating.
6.0 OPERATING TESTS, START-UP AND ON-SITE SERVICES
6.1 The boiler system and accessories shall be furnished by a single vendor to assure proper installation and service design inter-
face, and to provide in-warranty and post-warranty unified responsibility for the owner and consulting engineer.
6.2 Boiler/burner vendor's service organization shall employ service technicians having experience in all aspects of troubleshoot-
ing, corrective service, and preventive maintenance O&M reporting. Service personnel shall be full-time employees of the vendor's
organization, and shall be available 24 hrs/day, 365 days per year.
6.3 Boiler/burner vendor shall be covered by a general liability insurance policy in the minimum amount of $________. Boiler/
burner vendor shall provide the owner with a certificate of insurance specifying amounts and types of coverage. All personnel
involved in start-up, service, adjustment, or testing of the equipment must be covered by this insurance.
6.4 Boiler/burner vendor shall provide a factory trained service engineer for periodic supervision during installation, field start-up
service to supervise starting, adjusting and testing of the boiler, training of operating personnel in the proper operation and mainte-
nance.
7.0 WARRANTY
up or 18 months from date of shipment, whichever comes first. The warranty shall include parts only to repair or replace all defec-
tive parts and material. In addition the pressure vessel shall have a seven (7) year warranty against failure caused by low water flow
or burner flame impingement on any heating surface. The boiler will be additionally warranted for 20 years against thermal shock.
The warranty will not include damage caused by corrosion, operation at low water level, accumulation of scale, sludge or dirt or
other improper service, operation, or neglect.
B5-16
02-03
Section B6
CLEARFIRE BOILERS
Table of Contents
Clearfire Features and Benefits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-2
Compact Firetube Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-2
High Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-2
Advanced Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-2
Ease of Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-2
Quality Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-2
Full Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-2
Premix Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-2
Designed For Heating Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-2
Clearfire Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-3
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-3
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-3
Gas-Fired Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-3
Fuel Connections - Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-3
Boiler Room Combustion and Ventilation Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-3
Indoor Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-3
Direct Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-4
Conventional Combustion Air Supply (For U.S. Installation only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-4
Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-4
System Operating Parameters: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-4
SUGGESTED SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-13
B6-1
04-8-03
Clearfire Boilers Commercial Boilers
List of Figures
AluFer Firetubes for Extended Heat Transfer Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-2
Ratio of Return Water Temperature to Efficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-5
Comparison of Return Water Temperature to Heat exchanger
Temperature and Fluegas Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-5
Model MCF Hot Water Boiler Dimensions (Page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-7
Model MCF Minimum Room Clearance Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-9
List of Tables
Table B6-1. Model MCF Boiler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-5
Table B6-2. Model MCF Minimum Over Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-9
Table B6-3. Model MCF Circulation & Temperature Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-9
Table B6-4. Model MCF Boiler Safety Valve Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-10
Table B6-5. Model MCF Minimum Required Gas Pressure Altitude Conversion . . . . . . . . . . . . . . . . . B6-10
Table B6-6. Model MCF Boilers Minimum and Maximum Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . B6-11
Table B6-7. Clearfire Furnace Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-11
Clearfire Features and Benefits Ease of Maintenance

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

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

interface.
Clearfire Product Offering 4. Condensate treatment tank assembly.
Information in this section applies to hot water boiler sizes 5. Outside air intake for sealed combustion.
ranging from 750,000 Btu input through 1,800,000 Btu input.
Gas-Fired Burners
Standard Equipment
Table 6-5 shows correction factors for gas pressure at eleva-
Equipment described below is for the standard boiler offering: tions over 700 feet above sea level.
1. Boiler Table 6-6 shows minimum and maximum gas pressure
A. All boilers are designed for 60 psig and constructed in requirements for standard gas trains upstream of gas pressure
accordance with ASME Code. regulator.
B. Boiler is mounted on a base, insulated, and casing pro- For oversize or undersize gas trains or altitudes above 2,000
vided. feet, contact your local authorized Cleaver-Brooks Represen-
tative.
2. Forced Draft Burner
A. Burner shall be a unitized Venturi, gas valve, blower, Fuel Connections - Gas
and burner head design. The local gas company should be consulted for requirements
B. Burner shall incorporate a variable speed DC combus- and authorization for installation and inspection of gas supply
tion air fan capable of modulating 5:1. piping. Installation of gas supply piping and venting must be
C. Burner head shall be constructed of a Fecralloy-metal regulatory codes. All connections made to the boiler should be
fiber for solid body radiation of the burner flame. arranged so that all components remain accessible for inspec-
D. The whisper quiet burner shall produce no more than tion, cleaning and maintenance.
70-dBA sound power reading at full firing rate. A drip leg should be installed in the supply piping before the
E. Burner design shall have provision for induction of out- connection to the gas pressure regulator. The drip leg should
side combustion air for sealed combustion. be at least as large as the inlet fitting supplied with the boiler.
3. Control requirements when choosing gas supply piping size. Refer to
Boiler/burner controls shall be an integrated, digital mod- the boiler dimension diagram provided by Cleaver-Brooks for
ulating controller that controls the following functions: the particular installation. Connections to the burner gas train
Heating loops. the burner may be easily disconnected for inspection or ser-
Burner sequencing with safe start check, pre-purge, vice. Upon completion of the gas piping installation, the sys-
direct spark ignition and post purge. tem should be checked for gas leakage and tight shutoff of all
valves.
Electronic ignition.
Flame supervision. Boiler Room Combustion and Ventilation Air
Safety shutdown with display of error. Indoor Units
Modulating combustion fan. The boiler must be supplied with sufficient quantities of non-
contaminated air to support proper combustion and equipment
Circulating pump.
ventilation. Combustion air can be supplied via conventional
Low gas pressure, air proving, high limit, and frost venting, where combustion air is drawn from the area immedi-
protection. ately surrounding the boiler, or via direct vent, where combus-
tion air is drawn directly from outside. All installations must
Optional Equipment comply with the requirements of NFGC for U.S., CAN\CGA
B 149.1 and.2 for Canada, and all local codes.
1. Controller options for multiple boiler sequencing.
2. Outside temperature reset.
B6-3
04-8-03
2. The openings must communicate either directly or by ducts

with the outdoors.
3. Each opening must have a minimum free area of one(1)
square inch per 4,000 Btu/Hr of total input rating of all
equipment in the room when the opening is communicating
directly with the outdoors or through vertical ducts. The
Direct Combustion Air minimum free area required for horizontal ducts is one (1)
square inch per 2,000 Btu/Hr of total input rating to all the
If outside air is drawn through a vent pipe directly to the unit equipment in the room.
for combustion:
4. Refer to NFGC, Part 5, for additional information.
1. Install combustion air direct vent in accordance with
manufacturer s instructions
2. Provide for adequate ventilation. NOTICE
3. In cold climates, and to mitigate potential freeze-up, it is Consult local codes, which may supersede these re-
highly recommended that a motorized sealed damper be quirements.
used to prevent the circulation of cold air through the
boiler during non-operating hours. Stack/Breeching Size Criteria
Conventional Combustion Air Supply The design of the stack and breeching must provide the
(For U.S. Installation only) required draft at each boiler flue gas outlet. Proper draft is crit-
All air from Inside the Building. If all combustion air is
drawn from inside the building (the mechanical equipment Although constant pressure at the flue gas outlet is not
room does not receive air from outside): required, it is necessary to size the stack/breeching to limit flue
gas pressure variation. The allowable pressure range is 0.25
1. The mechanical equipment room must be provided with (-60Pa) W.C. to +0.5 W.C. (120 Pa)
two permanent openings communicating directly with
additional room(s) of sufficient volume so that the System Operating Parameters:
combined volume of all spaces meet the criteria for an
unconfined space. (An unconfined space is defined as a System over pressure requirements are shown on Table B6-2.
space whose volume is more that 50 cubic feet per 1,000
Btu/H of aggregate input rating of all appliances installed
No minimum return water
in that space.) temperature.
2. Each opening must have a minimum free area of one (1)
square inch per 1,000 Btu/Hr of the total input rating of all
No minimum supply water
gas utilization equipment in the mechanical equipment temperature (boiler outlet).
room.
3. One opening must commence within twelve (12) inches of
Maximum design temperature:
the top, and one opening must commence within twelve 210 F (99C).
(12) inches of the bottom of the room
4. Refer to NFGC, Part 5, for additional information.
Maximum operating temperature:
All Air from Outdoors. If all combustion air is received from
195 F (90C).
the air outside the building, (the mechanical equipment room
directly communicates with the outdoors), the following
method can be used:
1. The mechanical equipment room must be provided with
two permanent openings, one commencing within twelve
(12) inches of the top, and one opening commencing
within twelve (12) inches of the bottom of the room.
B6-4
04-8-03
50% Firing Rate
100% Firing Rate
Figure B6-2. Ratio of Return Water Temperature to Efficiency
100% Load
50% Load
25% Load
Figure B6-3. Comparison of Return Water Temperature to Heat Exchanger

Temperature and Fluegas Temperature
B6-5
04-8-03
Table B6-1: Model MCF Boiler Ratings
MODEL NO. MCF-750 MCF-1000 MCF-1500 MCF-1800

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

LENGTHS
Top Clearance A 12 12 12 12
Side Clearance B 20 20 20 20
Backway C 8 8 8 8
Front D 36 36 36 36
Between Boilers E 3 3 3 3
Figure B6-5. Model MCF Minimum Room Clearance Dimensions
B6-9
04-8-03
Table B6-2: Model MCF Minimum Over Pressure Requirements

MAXIMUM OUTLET MINIMUM SYSTEM
TEMPERATURE (F) PRESSURE (PSI)
180 12
190 15
195 18
Table B6-3: Model MCF Circulation & Temperature Drop
SYSTEM TEMPERATURE DROP (DEGREES F)
MODEL
10 20 30 40 50 60 70 80 90 100 110
NO.
CIRCULATION RATE (GPM)
MCTF-750 131.1 65.6 43.7 32.8 26.2 21.9 18.7 16.4 14.6 13.1 11.9
MCF-1000 175.7 87.8 58.6 43.9 35.1 29.3 25.1 22.0 19.5 17.6 16.0
MCF-1500 260.3 130.2 86.8 65.1 52.1 43.4 37.2 32.5 28.9 26.0 23.7
MCF-1800 351.0 175.5 117.1 87.8 70.2 58.5 50.1 43.9 39.0 35.1 31.9
B6-10
04-8-03
Table B6-4: Model MCF Boiler Safety Valve Openings
Safety Valve
VALVE SETTING 60 psig MBH
Opening (in)
Minimum
NO. OF VALVES OUTLET SIZE
MODEL NO. Release Valve
REQ D (IN.)
Capacity
MCF-750 1 3/4 750
1-1/2 MCF-1000 1 3/4 1000
1-1/2 MCF-1500 1 3/4 1500
MCF-1800 1 3/4 1800
Table B6-5: Model MCF Minimum Required Gas Pressure Altitude Conversion
CORRECTION CORRECTION
ALTITUDE (FT) ALTITUDE (FT)
FACTOR 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 gas pressure at altitudes above

700 feet, multiply the pressure by the listed factors:
Inches WC x0.577 = oz/sq.in.
oz/sq.in x 1.732 = Inches WC
Inches WC x 0.0361 = psig
psig x 27.71 = Inches WC
psig x 16.0 =oz/sq-in.
B6-11
04-8-03
Table B6-6: Model MCF Boilers Minimum and Maximum Gas Pressure
STD PIPE GAS BURNER

MODEL NO. MAX.
SIZE (IN) MIN. PRESSURE
UL IRI PRESS.
MCF-750 1 4.1 4.6 14
MCF-1000 1 5 6.3 14
MCF-1500 1-1/4 5.3 6.4 14
MCF-1800 1-1/4 7.2 8.5 14
Minimum and maximum gas pressure at the entrance to UL and IRI
Gas Trains (Upstream of Gas Pressure Regulator).
Table B6-7: Clearfire Furnace Dimensions
FURNACE
MODEL NO. FURNACE LENGTH (IN.)
INNER DIA. (IN.)
MCF-750 28.6 15.86
MCF-1000 28.6 15.86
MCF-1500 34.17 16.06
MCF-1800 34.17 16.06
B6-12
04-8-03
CLEAVER-BROOKS CLEARFIRE FIRETUBE BOILER
SUGGESTED SPECIFICATION
1.0 BOILER CAPACITY

1.1 Furnish and install in accordance with plans and specifications including manufacturers recommendations, state and local code
_____ hot water boiler(s). The hot water boiler(s) shall be Cleaver-Brooks Model MCF Clearfire rated at 60 psig design pressure
and capacity as scheduled on the drawing and specifications.
2.0 BOILER DESIGN
2.1 Boiler shall be a compact Firetube type, single pass, and down-fired design with ultra low emission and high efficiency con-
densing technology herein listed. The boiler shall be designed for natural gas firing. Gas supply pressure to the boiler gas pressure-
regulating valve shall be ____psig minimum and ____psig maximum. Boiler shall attain full rating at an elevation of ____feet. The
burner shall be a forced draft design with gas and combustion air premixed prior to the burner head. The boiler, and burner, shall be
supplied by the same manufacturer to assure compatibility and single source responsibility for the package performance. The boil-
ers shall be constructed in accordance with ASME Section IV Code. Boiler to be manufactured within an ISO 9001 certified facil-
ity.
2.2 The boiler shall be constructed with a minimum of 10 square-feet of fireside heating surface per 33,475 Btu s of input.
2.3 The pressure vessel shall be constructed with titanium stabilized stainless steel boiler tubes with aluminum extended internal
heating surface (AluFer). Firetube internal surface shall be a minimum of 4 times the external waterside surface area. The pressure
vessel shall be of a counter flow design with no minimum return water temperature requirements and no minimum flow require-
ments.
2.4. Other
2" fiberglass blanket insulation and easily removable casing.
Burner observation port.
Factory paint with durable powder coat paint finish for corrosion protection.
ASME Code relief valves with side outlet set for 60 psig.
3.0 BOILER CONNECTIONS
3.1 Hot Water Boiler(s) shall be specifically designed for top water outlet and bottom water inlet.
Inlet connections shall be _____. Outlet connections shall be_____.
4.0 COMPUTERIZED BURNER CONTROL
4.1 Boiler Burner controls shall be an integrated, digital modulating controller.
4.2 Controller shall provide the following functions:
2 Heating loops.
Burner sequencing with safe start check, pre-purge, direct spark ignition and post purge.
Electronic ignition.
Flame supervision.
Safety shutdown with display of error.
Modulating combustion fan.
Circulating pump operation.
Low gas pressure, air proving, high limit, and frost protection.
4.3 Controller shall have an option for multiple boiler sequencing. (Up to five boilers.)
B6-13
04-8-03
4.4 Controller shall have an option for communication device to computer interface.
5.0 BURNER DESIGN
5.1 Burner shall be a unitized Venturi, gas valve, blower, and burner head design.
5.2 Burner shall incorporate a variable speed DC combustion air fan capable of modulating the burner at a 5:1 ratio from high fire
to low fire.
5.3 Burner head shall be constructed of a Fecralloy-metal fiber for solid body radiation of the burner flame.
5.4 Burner shall produce less than 70-dBA sound reading at full firing rate.
5.5 Burner design shall have provision for induction of outside combustion air for sealed combustion.
6.0 ELECTRICAL REQUIREMENTS
6.1 Power available will be 220-1-60 phase with option for 115-1-60.
6.2 All wiring shall be in compliance with National Electrical Code.
7.0 EFFICIENCY
7.1 The boiler(s) will have a guaranteed efficiency of up to 98% based on return water temperatures of 80 degrees Fahrenheit at full
firing rate.
8.0 EMISSIONS
8.1 Burner Boiler design shall produce NOx emission levels of no more than 20 PPM at full firing rate.
9.0 OPERATING TESTS, STARTUP AND ON SITE SERVICES
9.1 A single vendor to assure proper installation and service design interface, and to provide in-warranty and post-warranty unified
responsibility for the owner and consulting engineer, as well as shall furnish the boiler system and accessories.
9.2 Boiler vendor s service organization shall employ service technicians having experience in all aspects of troubleshooting, cor-
rective service, and preventative maintenance O&M reporting. Service personnel shall be full-time employees of the vendors orga-
nization and shall be available 24 hours per day and 365 days per year.
9.3 Boiler vendor shall be covered by a general liability insurance policy in the minimum amount of $__________. Boiler vendor
shall provide the owner with a certificate of insurance specifying amounts and types of coverage. All personnel involved in start-up
service, adjustment, or testing of the equipment must be covered by this insurance.
9.4 Boiler vendor shall provide a factory trained service engineer for periodic supervision during installation, field start-up service
to supervise starting, adjusting and testing of the boiler, training of the operating personnel in the proper operations and mainte-
nance.
10.0 MANUFACTURER S WARRANTY
10.1 All equipment shall be guaranteed against defects in materials and or workmanship for a period of 12 months from the date of
startup, or 18 months from the date of shipment, whichever comes first. The warranty shall include parts only to repair or replace
all defective parts and material.
10.2 The pressure vessel shall be warranted for 20 years against thermal shock.
B6-14
04-8-03
Section C
INDUSTRIAL WATERTUBE BOILERS
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4
Boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-5
Flue Gas Recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-5
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6
Optional Equipment (Partial Listing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-7
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-7
EMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-32
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-34
Steam Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-34
Lower Drum (Mud Drum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-34
Drum Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-35
Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-35
Convection Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-37
Casing and Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-39
Structural Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-41
Burner/Controls Information (A, BR, CN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-41
Flame Safeguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-41
Burner/Controls Information (CT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-44
Flame Safeguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-45
Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-46
Breeching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-47
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-55
ILLUSTRATIONS
Figure C-1. Model D Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-16
Figure C-2. Models DL and DLD Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-18
Figure C-3. Model DLDH Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-20
Figure C-4. Model DFE Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-22
Figure C-5. Model DW Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-24
Figure C-6. Model DLW Dimensions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-26
Figure C-7. General A Burner Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-28
C-1
02-02
Industrial Watertube Boilers
Figure C-8. General BR Burner Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-29
Figure C-9. General CN Burner Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-30
Figure C-10 General CT Burner Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-31
Figure C-11. Drum Internals and Steam Purifiers for 1, 3, and 7 ppm Solids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-36
Figure C-12. Drum Internals and Separator for 99.5% Dry Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-36
Figure C-13. D Series Boiler Tube Cut-Away . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-37
Figure C-14. Convection Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-38
Figure C-15. D Series Boiler Enclosure Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-39
Figure C-16. Series Skid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-40
Figure C-17. Support Drum in Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-40
Figure C-18. Forced FGR System, Industrial Watertube Boiler (A, BR, CB Burners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-44
Figure C-19. Induced FGR System, Industrial Watertube Boiler (CT Burner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-47
Figure C-20. Recommended Pier Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-48
Figure C-21. Right Hand Boiler Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-48
Figure C-22. Left Hand Boiler Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-48
Figure C-23. RH and LH Boiler Arrangement With Separate Stacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-49
Figure C-24. LH and RH Boiler Arrangement With Common Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-49
Figure C-25. Two-Boiler Arrangement With Separate Stacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-50
Figure C-26. Breeching,; Top Outlet Transition Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-51
Figure C-27. Breeching; Gas Outlet Transition (Direct-to-Stack) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-52
Figure C-28. Breeching, Gas Outlet Transition (Connection to horizontal breeching) . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-53
TABLES
Table C-1. Industrial Watertube Steam Boiler Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C- 6
Table C-2. Standard Trim (Model D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8
Table C-3. Standard Trim (Models DL and DLD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9
Table C-4. Standard Trim (Model DLDH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10
Table C-5. Standard Trim (Model DFE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-11
Table C-6. 300 psig Steel Trim (Model D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12
Table C-7. 300 psig Steel Trim (Models DL and DLD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13
Table C-8. 300 psig Steel Trim (Model DLDH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-14
Table C-9. 300 psig Steel Trim (Model DFE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-15
Table C-10. Industrial Watertube Emission Data - Natural Gas (A, B, CN Burners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-32
Table C-11. Industrial Watertube Emission Data - No. 2 Oil (A, BR, CN Burner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-32
Table C-12. Industrial Watertube Emission Data - Heavy Oils (A, BR, CN Burners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-32
Table C-13. Industrial Watertube Emission Data - Natural Gas (CT Burner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-33
Table C-14. Industrial Watertube Emission Data - No. 2 Oil (CT Burner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-33
Table C-15. Industrial Watertube Emission Data - Heavy Oils (CT Burner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-33
Table C-16. Heating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-34
Table C-17. Maximum Heat Output (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-35
Table C-18. Maximum Heat Output (Steam). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-35
Table C-19. Burner Data (Model A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-42
Table C-20. Burner Data (Model BR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-42
Table C-21. Burner Data (Model CN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-42
Table C-22. Standard Offering (A, BR, and CN Burners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-43
Table C-23. Burner Data (Model CT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-45
Table C-24. Standard Offering (Model CT Burner). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-46
Table C-25. Industrial Watertube Boiler Stack Size Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-54
C-2
02-02
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 designa-
tions for the high temperature hot water boilers are DW and DLW.
C-3
02-02
FEATURES AND BENEFITS 10 Gauge Double Casing:
The following features and benefits apply to Cleaver-Brooks Provides static zone to prevent flue gas entrapment and acid-
Industrial Watertube Boiler Products. corroding of the casing.
Allows higher furnace pressures required to minimize NOx
Boilers formations when utilizing flue gas recirculation
technologies.
Six Furnace Wall Cooling: Rugged and suitable for outdoor installation.
Ensures minimal refractory maintenance and extends boiler
life. Heavy Base Frame:
Ensures proper circulation with tiles to protect furnace floor Permits easy lifting, jacking, or skidding during initial
tubes to. installation.
Allows placement of piers, facilitating visual underside
Tangent Tube Design, 2" Tubes on 2" Centers inspections and simplifying general housekeeping.
Provides greater uniform heat transfer. Provides maximum support for boiler vessel.
Minimizes thermal stress with non-welded water-cooled,
heating surfaces. Burners
Provides cooler furnace temperature minimizing the
formation of thermally-produced NOx emissions. High Turndown Capability:
Reduces burner cycling.
Membrane Inner Furnace Wall, 2" Tubes on 4" Centers:
Eliminates by-pass of furnace gases into the convection
section. Reduces fuel costs.
Minimizes both CO and NOx emissions. Is available for gas, oil or combination.
Rear Furnace Wall: Integral Forced Draft Fan:
Maximizes heat transfer area and minimizes refractory Eliminates need for special ducting or breeching.
maintenance with 80% wall coverage with tubes m. Creates smaller overall package and an integral part of the
Allows stressless pressure vessel/tube expansion because of burner windbox.
floating rear wall with positive end wall seals. Reduces motor horsepower requirements.
Assures proper sizing for combustion air requirements.
Convection Section Design:
Enables easy tube removal with wide and narrow spacing Steam or Air Atomazation:
between rows of tubes.
Provides clean, efficient firing of oil fuels.
Eliminates abrasion of tubes from sootblower action by
locating sootblower nozzle within the wide space area of Provides low steam consumption.
tubes. Provides packaged air compressor with air atomized burners.
Maximizes heat transfer with even distribution of flue gases
through the utilization of vertical baffles. Patented Fuel Oil Controller:
Consolidates function of four valves.
Patented Drum Internals:
Eliminates need for up to 35 separate pipe fittings.
Eliminates, in many applications, the need for expensive
two-or-three-element feedwater control systems through use Provides ease of maintenance and operation.
of Cleaver-Brooks patented system of baffles to ensure Furnished completely piped and assembled.
stable water levels under dynamic load conditions.
C-4
02-02
Low NOx Capability: Assures high fuel-to-steam efficiency (no loss in efficiency
over standard package).
Guaranteed NOx levels to 10 ppm available.
Offers synchronized FGR operation with boiler modulation.
Provides ease of operation and installation.
Ensurer simplified control and safe and reliable operation
Meets or exceeds EPA air quality regulations.
with single-point-positioning of fuel, air and FGR.
Controls Is engineered specifically for CB Boilers.

Assures reliable, trouble-free operation with integrated
Microprocessor-Based Flame Safeguard System: safety controls.
Provides diagnostic capability with alpha-numeric display.
Patented Dual Canister Burner Housing Design (Model A
Is UL, FM, IRI, and CSA approved. Burner) - Extended Burner Drawer (Model BR & Model CN
Retains last fault/lockout condition with non-volatile Burners):
memory (refer to Boiler Controls, Section 8 for more Guarantees NOx emission control on natural gas and #2 oil-
information on optional flame safeguard systems). utilizing forced FGR system configuration.
Improves CO performance.
Full Modulation Combustion Controls System:
Features single-point positioning for safety, simplicity, Maintains flame stability and combustion control.
reliability, and ease of start-up. Assure complete mixing of flame and recirculating flue gases
Maintains pressure or temperature setpoint automatically. for excellent NOx and CO control.
Features built-in low-fire hold. Proven Venturi-Type Burner Design

Enables single switch quick changeover from gas firing to CT Burner venturi design allows for low NOx emissions
oil firing. through utilization of induced FGR.
Cleaver-Brooks Water Column: Mechanical Linkage Assembly

Comes with five probes for high and low water alarm Minimizes complex controls.
conditions (audio-visual alarm provided in boiler control
panel) and dual redundant low water cutoffs. Allows for single-point-positioning to synchronize fuel, air
and FGR flow rates.
Complete Controls Package Includes:
Manual Shutoff Valve:
All controls piped and wired.
Allows for isolation of FGR system during maintenance
Custom control systems (optional). periods while allowing boiler to operate and maintain load.
All wiring conforms to NEC and industry standards.
PRODUCT OFFERING
Atomizing Air Compressor (Optional):
Cleaver-Brooks Industrial Watertube Boilers range from
Pre-piped (A and BR Burner) or mounted in a convenient 10,000 to 150,000 lbs/hr steam. Design pressure to 1000 psig.
console (CN Burner). Super heat temperature to 750 F.
Automatically-controlled and interlocked through flame High temperature hot water boilers range from 13.4 to 62.5
safeguard system. MMBtu/hr output.
Flue Gas Recirculation
Integrated Boiler/Burner/FGR Control Package

Satisfies FM/IRI requirements.
C-5
02-02
Table C-1. Industrial Watertube Steam Boiler Models
materials and equipment:
MAX OUTA
MODEL NO. LBS/HR
(STEAM) Inner and outer 10-gauge casing.
26 16 Packaged burner assembly.
34 21.4 Electric single-point positioning full modulating combustion
42 26.8 controls.
52 37.41 Forced draft fan and motor drive.
D 60 43.92
Sootblowers for heavy oil firing.
68 50.22
240 psig trim package.
76 57.17
86 65.12
Membrane inner furnace wall.
94 72.62 IRI requirements.
52 45.47 2. Each burner is furnished with a standard Cleaver-Brooks
60 53.31 electric positioning combustion control system designed to
68 61.47
operate in conjunction with the burner and fuel control valves
DL provided.
76 70.3
86 79.91
The system includes the following major components:
94 87.41 Master pressure control.
68 60.15 Limiting pressure control.
76 68.87
DLD Electric drive motor.
86 78.14
Control shaft and linkages.
94 85.54
60 63.4
Gas control valve (for gas or combination burners).
68 76.3 Fuel oil controller (for oil or combination burners).
76 85.6 Forced draft fan control.
86 97
DLDH The combustion control system is mounted on the unit at the
94 106.2 plant and is shipped as a completely integrated system.
102 115.6
3. The boiler is built in accordance with the following require-
110 124.9 ments:
118 134.1
American Society of Mechanical Engineers (ASME) Boiler
85 81.3 and Pressure Vessel Code, Section I, Power Boilers.
98 101.5
American Boiler Manufacturers Association (ABMA)
DFE 110 111.5 Manual of Industry Standards.
121 121.6
National Fire Protection Association (NFPA), 8501
132 151.7 Prevention of Furnace Explosions in Fuel Oil and Natural
A. DLDH with Economizer. Gas-Fired Single Burner Boiler Furnaces.
Steel Structures Painting Council (SSPC), Surface
Preparation SP-l.
Table C-1 shows Models D, DL, DLD, DLDH and DFE steam
National Electric Code (NEC)
boilers and the associated outputs.
National Electrical Manufacturers Association (NEMA).
An FGR system can be purchased with a new boiler or retro-
fit. Insurance Requirements: Safety equipment and combustion
controls described above, which are Cleaver-Brooks standard,
Standard Equipment can be modified to meet Factory Mutual, Military, or other
1. Included with each standard packaged unit are the following
C-6
02-02
requirements. Fuel Options

Industrial Risk Insurers: Equipment is furnished in compliance Low fire fuel change-over.
with published requirements of the Industrial Risk Insurers as Special gas train sizes.
given in the latest IRI information Single Burner Boiler Fur-
naces. Gas strainer.
Tables (C-2, C-3, C-4 and C-5) show boiler trim packages Special fuel shut-off values.
included with standard design pressure of 260 psig. Special oil pump sets.
Tables (C-6, C7, C-8 and C-9) show boiler trim installed at Alternate fuel firing.
300 psig design pressure.
For information on the following options please refer to the ref-
Optional Equipment (Partial Listing) erenced section:
The following options are available: Economizers (selected for specific job site conditions),
Section G.
Boiler Options Optional Controls, Section D.
Design pressure up to 1000 psig.
Superheaters.
The following illustrations (Figures C-1 thru C-8) show dimen-
Hinged manway covers in steam drum.
sions for the Industrial Watertube Product offering.
Clean out ports in front and rear convection wall.
Figure C-1. Model D Dimensions
Multiple 12" x 24" convection side access doors.
Figure C-2. Model DL and DLD Dimensions
Warm up coil in lower drum.
Figure C-3. Model DLDH Dimensions
Platforms and ladders.
Figure C-4. Model DFE Dimensions
Various steam quality drum internals.
Figure C-5. Model DW Dimensions
Special blowdown valves.
Figure C-6. Model DLW Dimensions
Weatherproofing.
Figure C-7. General A Burner Dimensions
Wash drains.
Figure C-8. General BR Burner Dimensions
Rear furnace access door.
Figure C-9. General CN Burner Dimensions
Burner/Control Options Figure C-10. General CT Burner Dimensions

Special motors (TEFC, high efficiency, etc.). FGR sytems for Industrial Watertube boiler applications are
custom engineered to meet specific application requirements.
NEMA enclosures. Specific information regarding dimensions, ratings, and perfor-
Special combustion control systems: Single-point, parallel mance data will be provided on a job-by-job basis. Contact
positioning, full metering, cross-limited systems. your local Cleaver-Brooks authorized representative for assis-
tance.
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.
C-7
02-02
Table C-2. Standard Trim (Model D)
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.
C-8
02-02
Table C-3. Standard Trim (Models DL and DLD)
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 - - - - - -
C-9
02-02
Table C-4. Standard Trim (Model DLDH)
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 - - - - - - - -
C-10
02-02
Table C-5. Standard Trim (Model DFE)
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
C-11
02-02
Table C-6. 300 psig Steel Trim (Model D)
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
C-12
02-02
Table C-7. 300 psig Steel Trim (Models DL and DLD)
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 - - - - - -
C-13
02-02
Table C-8. 300 psig Steel Trim (Model DLDH)
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 - - - - - - - -
C-14
02-02
Table C-9. 300 psig Steel Trim (Model DFE)
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
C-15
02-02
Figure C-1. Model D Dimensions - Sheet 1 of 2
C-16
02-02
MODEL D
26 34 42 52 60 68 76 86 94
DIMENSIONS (IN.)
A. Length, Over Casing 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 LevelB 41900 49350 56470 65610 72970 83280 91310 100990 108550
Weight, FloodedB 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
C-17
02-02
Figure C-2. Models DL and DLD Dimensions - Sheet 1 of 2
C-18
02-02
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 84 84 84 84 84 84 84 84 84 84
FlangeA
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 (2) 94 (2) 108 (3) 82 (3) 92 (3) 104 (3) 114 (3)82 (3) 92 (3) 104 (3) 114
spacing
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
Weight, Filled to Oper LevelB 78700 86200 96990 105220 115600 131300 98700 107000 117700 133700
Weight, FloodedB 83430 91610 103090 111830 122900 137200 107500 117800 129700 144200
(1) Main Steam OutletC 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 ValvesC 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
Sootblower (if applicable)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.
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
C-19
02-02
Figure C-3. Model DLDH Dimensions - Sheet 1 of 2
C-20
02-02
MODEL DLDH
60 68 76 86 94 102 110 118
DIMENSIONS (IN.)
A. Length, Over Casing 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
G. Skid to CL of Sootblower FlangeA 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, DryB 83500 93503 101247 108106 111666 119611 127596 135581
Weight, Filled to Oper LevelB 105400 118027 127801 138079 144330 154966 178337 176318
Weight, FloodedB 112100 125997 135925 147813 155051 166674 165642 190000
(1) Main Steam OutletC 8 8 10 10 10 10 12 12
(1) Feedwater Inlet 3 3 3 3 3 3 3 3
(2) Safety ValvesC (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
Sootblower (if applicable)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
local Cleaver-Brooks authorized representative.
Figure C-3. Model DLDH Dimensions - Sheet 2 of 2
C-21
02-02
Figure C-4. Model DFE Dimensions - Sheet 1 of 2
C-22
02-02
MODEL DFE
85 98 110 121 132
DIMENSIONS (IN.)
A. Length, Over Casing 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
G. Skid to CL of Sootblower FlangeA 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, DryB 117,250 130,750 143,350 154,750 166,350
Weight, Filled to Oper LevelB 154,300 170,400 188,050 204,100 220,450
Weight, FloodedB 163,450 184,400 203,800 221,400 239,350
(1) Main Steam OutletC 10 10 10 12 12
(1) Feedwater Inlet 3 3 3 4 4
(2) Safety ValvesC Code Code Code Code Code
(1) Blowdown (Surface) 1.5 1.5 1.5 1.5 1.5
Sootblower (if applicable)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-
Figure C-4. Model DFE Dimensions - Sheet 2 of2
C-23
02-02
Figure C-5. Model DW Dimensions - Sheet 1 of 2
C-24
02-02
MODEL DW
26 34 42 52 60 68 76 86 94
DIMENSIONS (IN.)
A. Length, Over Casing 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
G. Skid to CL of Sootblower FlangeA 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, DryB 35200 40700 45870 52580 57970 66330 72490 79640 85250
Weight, FloodedB 44400 52540 60340 70340 78380 89380 98200 108630 116865

- - - - - - - - -
(1) Water Inlet/OutletC
(2) Safety/ Relief ValvesC Code Code Code Code Code Code Code Code Code
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
(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
C-25
02-02
Figure C-6. Model DLW Dimensions - Sheet 1 of 2
C-26
02-02
MODEL DLW
52 60 68 76 86 94
DIMENSIONS (IN.)
A. Length, Over Casing 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
G. Skid to CL of Sootblower FlangeA 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, DryB 62700 68200 77550 83600 91300 96800
Weight, FloodedB 83430 91610 103090 111830 122900 13720

- - - - - -
(1) Water Inlet/OutletC
(2) Safety/ Relief ValvesC Code Code Code Code Code Code
Sootblower (if applicable)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
C-27
02-02
BURNER STANDARD
MODEL 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
NOTES:
1. Fuel train shipped loose and not included in above weights.
2. Weight includes forced draft fan and drive.
sion prints.
Figure C-7. General A Burner Dimensions
C-28
02-02
BURNER STANDARD
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
NOTES:
sion prints.
Figure C-8. General BR Burner Dimensions
C-29
02-02
STANDARD
BURNER
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
NOTES:
3. Approx CN console weight: 1200 lbs (oil and gas unit) (not shown).
Approx CN console weight 500 lbs (gas unit only) (not shown).
Figure C-9. General CN Burner Dimensions
C-30
02-02
BURNER
A B C D E F G H
MODEL
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
C-31
02-02
Cleaver-Brooks Industrial Watertube Boilers are available

EMISSIONS with a standard burner package or optional flue gas recircula-
The emission data included in this section consists of uncon- tion (FGR) package.
trolled and controlled levels of nitrogen oxides (NOX) and car-
The Cleaver-Brooks FGR packages are integrated boiler/
bon monoxide (CO) for Cleaver-Brooks D, DL, DLD, DLDH
burner/control packages designed specifically for Cleaver-
and DFE Industrial Watertube Boilers equipped with Cleaver-
Brooks boilers.
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 perfor-
mance for your application. Emission data for natural gas,
No. 2 oil, and No. 6 oil are presented in Tables C-9 through C-
14.
Table C-10. Industrial Watertube Emission Data - Natural Gas (A, BR, CN Burners)
TYPICAL UNCONTROLLED EMISSIONS TYPICAL EMISSIONS CONTROLLED W/FGR
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% O2.
Table C-11. Industrial Watertube Emission Data - No. 2 Oil (A, BR, CN Burner)
POLLUTANT
< 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% O2.
Table C-12. Industrial Watertube Emission Data - Heavy Oils (A, BR, CN Burners)
TYPICAL UNCONTROLLED EMISSIONS
POLLUTANT
< 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% O2.
C-32
02-02
Table C-13. Industrial Watertube Emission Data - Natural Gas (CT Burner)

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% O2.
Table C-14. Industrial Watertube Emission Data - No. 2 Oil (CT Burner)
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.
Table C-15. Industrial Watertube Emission Data - Heavy Oils (CT Burner)
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.
C-33
02-02
Table C-16. Heating Surface

ENGINEERING DATA
The following engineering data will assist in selecting and FURNACE
CONV TOTAL
HEATING FURNACE
HEATING HEATING
specifying Cleaver-Brooks Industrial Watertube Boilers. MODEL NO. SURFACE SURFACE SURFACE VOLUME
(PROJ) (CU-FT)
(SQ-FT) (SQ-FT)
(SQ-FT)
Table C-16 shows heating surfaces for the IWT Boilers. Tables
C-17 and C-18 show temperature and pressure information for 26 1120 241 1361 317
selection of high temperature hot water boilers. 34 1517 302 1819 425
42 1911 369 2280 527

Steam Drum
52 2407 449 2856 654
Model D and DL boilers have 36" ID steam drums, con-
D 60 2806 511 3317 754
structed of SA-515 Grade-70 steel plate. Models DLD and
DLDH boilers have 42" ID steam drums; the DFE has a 48 68 3206 580 3786 855
Drum constructed of SA- 515 Grade-70 steel plate. All drums 76 3595 634 4229 951
are of welded construction in strict conformance with the
86 4087 726 4313 1081
ASME Power Boiler Code. All drums are stress-relieved, and
welded seams are radiographed and hydrostatically tested at 94 4470 793 5263 1184
1-1/2 times design pressure. The drum incorporates elliptical 52 2912 518 3430 903
heads with 12" x 16" manholes on each end, and is wholly
60 3393 593 3986 1048
supported by the tubes, so no extra supporting steel is
required. All tubes are expanded into the drums. 68 3870 676 4546 1194
DL
76 4346 751 5097 1328
The steam drum has the following external connections:
86 4947 848 5795 1510
One main steam outlet, flanged.
94 5418 923 6341 1654
Two 12" x 16" manways.
68 3774 673 4447 1188
One feedwater inlet.
76 4248 747 4995 1321
DLD
Two or three safety valve flanged connections (as required). 86 4825 842 5667 1502
One blowdown connection, screwed. 94 5284 919 6203 1645
One soot blower connection, screwed. 60 4000 650 4650 1111
Two water column connections, screwed. 68 4564 737 5301 1261
76 5126 818 5944 1411

Two feedwater regulator connections, screwed.
86 5806 923 6729 1599
One chemical feed connection, screwed. DLDH
94 6368 1004 7372 1750
Two lifting Lugs.
102 6930 1089 8019 1900
The steam drum is fitted with an internal feed pipe, chemical
110 7495 1172 8667 2050
feed pipe, and blowdown piping. Water level control baffling is
installed to ensure that all steam released from the generating 118 8056 1253 9309 2200
tubes is released behind the baffles and not through the water 85 5707 923 6663 1750
level. Standard patented drum internals consist of steam sepa-
98 6622 1063 7685 2024
rators or dryers that are installed to ensure the steam leaving
the drum will contain not more than 1/2 of 1 percent moisture DFE 110 7461 1187 8648 2274
when boiler water concentrations are maintained in accor- 121 8223 1305 9528 2501
dance with ABMA recommendations. Special drum internals
132 9000 1416 10416 2733
for more stringent moisture content are available. See Figures
C-11 and C-12 for illustration of drum internals.
Lower Drum (Mud Drum)

The lower drum is 24" OD of SA-53 Grade-B seamless pipe,
and is of fusion-welded construction, or 30" OD of SA-515,
C-34
02-02
Table C-17. Maximum Heat Output
(Hot Water) Table C-18. Maximum Heat Output (Steam)
HOT WATER GENERATORS MAX OUT STEAM BOILER MAX OUTA

MODEL NO. MM MODEL NO. MMBTU/HR
BTU/HR (STEAM)
26 13.4 26 16
34 17.9 34 21.4
42 22.5 42 26.8
52 28.2 52 37.41
DW 60 32.7 D 60 43.92
68 37.5 68 50.22
76 41.7 76 57.17
86 47.5 86 65.12
94 51.9 94 72.62
52 33.8 52 45.47
60 39.3 60 53.31
68 44.8 68 61.47
DLW DL
76 50.3 76 70.3
86 57.1 86 79.91
94 62.5 94 87.41
68 60.15
Grade-70, welded plate (DLDH and DFE boiler). The lower
76 68.87
drum is stress relieved, seams are radiographed, and hydrostat- DLD
ically tested at 1-1/2 times design pressure. The drum incorpo- 86 78.14
rates two 12" x 16" manways - one at each end - and required 94 85.54
blow-drum connections.
60 63.4
Internally, the drum has a blowdown guide baffle to ensure 68 76.3
effective blowdown of the lower drum without disturbing
76 85.6
water circulation in the unit. The drum is supported by the
structural steel frame (skid) and has welded guide lugs that fit 86 97
DLDH
into the base frame, permitting expansion of the drum within 94 106.2
the skid, thereby eliminating potential expansion stresses.
102 115.6
Drum Enclosure 110 124.9
118 134.1
The steam drum is shop-insulated with mineral wool block
and enclosed in a welded 10-gauge steel casing. All drum 85 81.3
heads are shop-insulated and enclosed in a 10-gauge steel cas- 98 101.5
ing. No further insulation is required in the field.
DFE 110 111.5
121 121.6
Furnace
132 151.7
The furnace (combustion chamber) employs 2" OD, SA-178A
A. DLDH with economizer.
electric resistance welded tubes, arranged for maximum cover-
age 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 spac-
ing arrangement to provide as much water-cooled surface as
possible. With the exception of the inner furnace wall, which is
C-35
02-02
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
C-36
02-02
MEMBRANE
Figure C-13. D Series Boiler Tube Cut-Away
membrane construction, extended metallic surfaces are not jected to an air pressure test of 8" WC. It is considered tight if
used. See Figure C-13. air pressure drop does not exceed 2" WC in 5 minutes.
All tubes in the furnace are accessible for mechanical tube Flue Gas Outlet: One flanged rectangular flue gas outlet, sized
cleaners. No headers are employed in the boiler, and all tubes for desired flue gas velocity and arranged for field welding,
terminate in the upper and lower drums. Both floor and roof will be provided. Top gas outlet is also available on the D, DL
tubes are designed with adequate pitch to ensure drainage and and DLD models
proper circulation without swedging ends of tubes.
The six-wall furnace cooling is arranged as follows: Convection Tubes
Front wall - Tubes closely spaced around burner.
Definition
Tangent outer side wall - 2" tubes spaced on 2" centers. The convection section, or boiler section, of a D type boiler
Membrane sealed inner wall - 2" tubes spaced on 4" centers. are those tubes to which heat is transmitted mainly by convec-
tion from the products of combustion.
Tangent floor - 2" tubes spaced on 2" centers.
Tangent roof - 2" tubes spaced on 2" centers. Tubes
Rear wall - Triple row of tubes. The convection section consists of 2" OD, wall tubes. The
tubes are SA-178 electric resistance-welded construction in
Furnace exit - Double row of screen tubes.
accordance with ASME standards.
Access: Access to furnace is through burner opening in front
wall or optional rear access door. Tube Arrangement
Observation: Two air-cooled observation ports, with Pyrex eye The tubes are arranged with longitudinal rows of tubes in alter-
shields, provided in rear wall. nate wide and narrow spacing to ensure proper and effective
arrangement of soot-blowing equipment. This arrangement
Air Pressure Test: Inner seal-welded 10-gauge casing, sub-
C-37
02-02
also allows removal of any tube without the necessity of Soot blower bearings are of the welded-type, which eliminates
removing adjacent tubes. All tubes in the boiler section are problems of misalignment associated with bolted bearings. The
expanded into the upper and lower drums. No swaged or soot blower is a valve-in-head type and arranged for manual
finned tubes are used in the convection section, thereby allow- operation by means of a chain. Purging air is piped to the soot
ing heating surface to be reported based on actual tube surface, blower from the burner windbox to provide continuous clean-
not extended metal surfaces or fins. ing of the inside of the element, and to prevent combustion
gases from leaking back to the valve mechanism in the soot
Baffling blower head. On boilers without sootblowers, wall boxes and
bearing are provided.
The convection bank is designed to eliminate the need for lon-
gitudinal baffles. A vertical steel deflector baffle is placed
Internal Cleaning
immediately in front of the flue gas outlet connection in order
to prevent any short-circuiting of flue gas at the outlet. The The internal surfaces of all tubes, both convection and furnace
boiler incorporates vertical baffles located to maintain gas types, can be mechanically cleaned using either electric or
velocities and transfer rates.(Figure C-14). pneumatic driven tube cleaners. Acid cleaning procedures are
also available.
Soot Blowers
Tube Removal
On heavy oil fired units, soot blowers are installed to provide
the operator with a means of cleaning the boiler while it is in The use of the alternate wide-and-narrow spacing of boiler
operation. The soot blower element is installed on the outside tube rows makes it possible to remove and replace individual
row of tubes, and blows an approximate 180 arc using steam tubes in the convection section without the necessity of cutting
piped from the steam drum. Where the length of the convec- and removing adjacent tubes. In other staggered convection
tion bank requires a blower in excess of 20 feet, two soot bank designs, it is often necessary to remove many good tubes
blowers are provided - one entering from the rear of the unit in order to provide physical clearance to remove a damaged
and one from the front. tube.
Inner furnace wall
Outer furnace and

convection wall
with membrane
design.
Membrane Design
The inner furnace wall separating the furnace from the convec-
tion section incorporates welded extended surfaces on each
side of the tube. After the tubes are installed the adjacent sur-
face 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.
Figure C-14. Tubes with Membrane design for Inner furnace.
C-38
02-02
MEMBRANE
2-1/2 BLOCK (LOW DENSITY)
Figure C-15. D Series Boiler Enclosure Construction
Casing and Insulation 2-1/2 low density block insulation.

1/4 burner front plate.
Design
2. Rear Wall:
The unit is enclosed by a double panel casing, with that por-
tion of the casing exposed to the products of combustion com- 3", 4-way interlocking tile.
pletely seal-welded to form an air and gas tight enclosure. The 4" Hi-temperature block insulation.
outer casing panels are skip-welded and are suitable for indoor
installation (seal-welded for outdoor optional). 10-gauge inner seal welded casing.
The casing is supported off the structural steel frame and is not 2-1/2 low density block insulation,
welded or attached to tubing, thereby ensuring free expansion 1/4 outer casing.
of pressure parts within the casing enclosure.
3. Convection Section and Furnace Side Wall and Roof:
Casing and Wall Design 10-gauge inner seal welded casing.
Construction of the boiler enclosure is as follows (Figure C- 4-3/8 low-density mineral wool block.
15):
10-gauge outer steel casing.
1. Front Wall - Furnace Area:
4. Casing Finish:
3", 4-way interlocking tile.
Painted with high-temperature enamel paint prior to
4" Hi-temperature block insulation. shipment.
10-gauge inner seal welded casing.
C-39
02-02
Figure C-16. Series Skid Assembly
Figure C-17. Support Drum in Skid
C-40
02-02
Furnace Floor positioning controls. A switch is provided to permit

changeover from automatic, fully-modulated firing, to continu-
Furnace floor tubes are covered with 1-1/2 square edge tile.
ous firing at any desired rate between minimum and maximum.
Control safeguards assure that the burner always returns to the
Structural Frame minimum firing position for ignition.
Models D, DL, DLD, DLDH and DFE boilers (see Figure C- For air-atomized oil-fired boilers (air atomazation is optional),
16 and C-17) are supported by a heavy structural steel frame filtered primary air for atomizing the fuel oil is provided inde-
skid assembly. The skid assembly consists of two 14" wide pendent of the combustion air by a motor-driven air compres-
flange beams running parallel to the drum. The beams are sor. The fuel oil pump may be mounted near the boiler, or at a
attached by means of heavy steel plates that form the saddle remote location.
and support for the lower drum. The skid assembly also incor-
porates 10 ga. floor plate of the boiler beneath the furnace area For burning heavy oil, the burner is equipped with a combina-
and convection section. The skid assembly is fabricated as a tion steam-electric heater, each controlled by a thermostat.
complete structure prior to assembly of the unit. This method Both heaters are installed in a single compact shell, and are
of support, using saddle plates and guide lugs, permits the mounted, piped, and wired on the burner.
lower drum to ride in the saddle plates, thus permitting expan- The thermostatic controls are set to cut out the electric heater
sion of the pressure parts in the structural frame and casing when steam is available. A metering valve permits circulation
enclosure of the boiler. Stops are provided during assembly to of hot oil to the burner at all times. An automatic purge pump
limit movement of the drum within the expected expansion system back-purges the burner drawer oil piping and nozzle
limits. upon shut-down and returns any unburned oil to the storage
To facilitate lifting and handling of the boiler, lifting lugs are tank.
welded to the upper drum. In addition, the main beams of the The FGR system used with the A, BR and CN burner and con-
skid are coped and reinforced to provide space beneath the end trols, is shown in Figure C-18.
of the beam for jacking of the unit as required during installa-
tion. Holes are provided in the main beams for use by riggers
to drag or lift the unit by its base frame. Flame Safeguard
The boiler is equipped with a fully automatic flame safeguard
Burner/Controls Information (Models A, BR, system to ensure pre-purge, proper light-off, shutdown upon
CN) flame failure, and post purge on shutdown. The system is
designed to meet Factory Mutual or Industrial Risk Insurers
Each application requires burner selection based on boiler and requirements.
overall project requirements. Tables C-19, C-20, and C-21
show the standard Cleaver-Brooks burners and associated The control system includes safety interlocks to shut down the
inputs and fuel requirements. Once the boiler has been unit in the event of any of the following, as required for the fuel
selected, the burner is matched based on the input require- or fuels being fired:
ments for the boiler. Table C-22 shows the standard offering Flame failure.
for each burner package.
High steam pressure.
The burner assembly is attached to the front wall of the boiler
with all components readily accessible for inspection and Low drum water level.
maintenance. Low atomizing pressure (oil or combination burners).
The oil burner is either low pressure air or steam atomized Low fuel oil pressure (oil or combination burners).
ignited by gas pilot. The main gas burner is also ignited by a
gas pilot. Low fuel oil temperature (oil or combination burners).
The gas burner is designed for a 8:1 turndown when supplied High fuel oil temperature (oil or combination burners - IRI
with 10 psig gas pressure, turndown on oil is 6:1 when sup- only).
plied with 125 psig oil pressure. Low fuel gas pressure (gas or combination burners).
The burner operates with full modulation through single point High fuel gas pressure (gas or combination burners).
Forced draft fan failure.
C-41
02-02
Table C-19. Burner Data (Model A)

GAS PRESSURE (INCHES H2O)
4 GAS LINE 4 GAS LINE OIL

W/4 GC VALVES W/4 MAXON VALVES PRESSURE
(PSIG)
MAX HP HP
BURNER FM IRI FM IRI
INPUT
MODEL (MBTU) (OIL)A (GAS)
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-20. Burner Data (Model BR)

GAS PRESSURE (INCHES H2O)
OIL
4 GAS LINE W/4 4 GAS LINE W/4 6 GAS LINE W/4 PRESSURE
MAX HP
BURNER HP GC VALVES MAXON VALVES MAXON VALVES (PSIG)
INPUT
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-21. Burner Data (Model CN)

GAS PRESSURE IN INCHES H2O
4 GAS LINE W/4 6 GAS LINE W/4 OIL
MAXON VALVES MAXON VALVES PRESSURE
MAXIMUM (PSIG)
BURNER HP HP
INPUT 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.
C-42
02-02
Table C-22. Standard Offering (A, BR, and CN Burners)

BURNER MODEL
AND SIZE
STANDARD EQUIPMENT
A BR CN
1-8 1-4 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 Type of damper:
X 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 Type of air compressor drive (if air-atomized):
X 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
C-43
02-02
FGR INLET PIPING

AND SUPPORT STEEL
(BY OTHERS)
Figure C-18. Forced FGR System, Industrial Watertube Boiler (A, BR, CB Burners)
Burner/Controls Information (Model CT) plete with structural framing, support legs, access door, and
splitter vanes and baffles for equalizing air flow distribution to
Each application requires burner selection based on boiler and the burner.
overall project requirements. Table C-23 shows the Model CT
burner selections and the associated inputs and fuel require- A forced draft fan of centrifugal-type construction, arrange-
ments. Burner selection is based upon input requirements for ment four, with downblast discharge provides combustion air
the boiler. Table C-24 shows standard non FGR offerings for for the burner system. The fan is mounted directly on top of the
the Model CT burner equipment package. windbox for applications up to 80,000 pph of steam (may be
less than 80,000 lbs/hr with certain FGR conditions). In appli-
The burner assembly is seal-welded to the front wall of the cations exceeding 80,000 pph of steam, the forced draft fan is
boiler, with all components readily accessible for inspection mounted remote from the windbox. The combustion air fan is
and maintenance. The windbox is non-insulated for ambient supplied with a variable inlet vane-type damper, inlet screen,
combustion air, and is fabricated of ASTM A-36 plate, com- and silencer to reduce fan noise to 85 dBA at a distance of
C-44
02-02
Table C-23. Burner Data (Model CT)
NOMINAL LOAD NATURAL GAS FIRING NO. 2 FUEL OIL FIRING

FD FAN MOTOR HEAT INPUT HEAT INPUT
BURNER MODEL REFERENCE
HP
LB/HR 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.
three (3) feet from the fan. The combustion air fan utilizes a ignition system.
240V or 480V, 3-phase, 60 Hz, electric motor drive. Special
The burner operates with full modulation through single-point-
voltages and frequencies are available.
positioning controls. A switch is provided to permit
The gas burner is of multi-spud injector-type design, utilizing changeover from automatic, fully modulated firing, to continu-
fuel staging within the flame envelope for reduction in thermal ous firing at any desired rate between minimum and maxi-
NOx formation. The burner is designed to provide 10:1 turn- mum. Control safeguards assure that the burner always returns
down on natural gas when supplied with constant 15 psig gas to the minimum firing position for ignition.
pressure at the inlet to the gas pressure regulator.
The oil burner is of the low-pressure, steam-atomizing type, Flame Safeguard
and is designed to provide 8:1 turndown when supplied with The burner is equipped with a fully automatic flame safeguard
constant 175 psig oil pressure at the inlet to the fuel oil train. system to ensure pre-purge, proper light-off, shutdown on
Both the gas and oil burners utilize a spark-ignited, gas-pilot flame failure, and post-purge on shutdown. The system is
designed to meet FM, IRI, and CSA requirements.
C-45
02-02
Table C-24. Standard Offering (Model CT Burner).
BURNER MODEL AND SIZE
CT CT STANDARD EQUIPMENT ON CT BURNER

1-20 21-27
FORCED DRAFT FAN
1 X X Fan driven by open drip proof motor.
2 X X Damper at FD fan inlet.
3 FD Fan Location:
X a. On windbox.
X 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 Pressure
Control and Modulating Pressure Control) and 8-1/2 steam gauge all on a common manifold assembly,
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.
The control system includes safety interlocks to shut down the Low fuel oil temperature (oil or combination gas/oil
system in the event of any of the following, as required for the burners).
fuel or fuels being fired:
High fuel oil temperature (oil or combination gas/oil burners,
Flame failure. IRI only).
High steam pressure. Low or high fuel gas pressure.
Low drum water level. Forced draft fan failure.
Low atomizing steam pressure (oil or combination gas/oil In forced FGR applications, the FGR fan can be mounted on
burners). the boiler as shown in Figure C-19, mounted on a separate ped-
estal, or mounted on the floor.
Low fuel oil pressure (oil or combination gas/oil burners).
C-46
02-02
Boiler Room Information Breeching

Figure C-20 shows the recommended pier arrangement for If more than one boiler is connected to a common stack or
industrial watertube boilers. Figures C-21, C-22, C-23, C-24, breeching, an outlet damper and damper regulator is required
and C-25 show different boiler and stack arrangements for unless otherwise noted.
industrial watertube boilers.
Refer to Figure C-26 through C-28 for breeching transition
dimensions, and to Table C-25 for stack size selection.
FGR DUCT (BY OTHERS)
(by others)
Figure C-19. Induced FGR System, Industrial Watertube Boiler (CT Burner)
C-47
02-02
Figure C-20. Pier Arrangement
Figure C-21. Right Hand Boiler Arrangement Figure C-22. Left Hand Boiler Arrangement
C-48
02-02
Figure C-23. RH and LH Boiler Arrangement With Separate Stacks
Figure C-24. LH and RH Boiler Arrangement With Common Stack
C-49
02-02
Figure C-25. Two-Boiler Arrangement With Separate Stacks
C-50
02-02
DIMENSIONS IN INCHES
BOILER MODEL
A B C
26 15 36 86-3/4
34 18 36 86-3/4
42 27 36 86-3/4
52 30 36 86-3/4
D 60 30 39 98-3/4
68 33 39 98-3/4
76 36 39 98-3/4
86 36 39 98-3/4
94 42 42 107-3/4
52 30 39 86-3/4
60 33 39 98-3/4
68 36 39 98-3/4
DL
76 42 39 107-3/4
86 42 42 107-3/4
94 42 42 116-3/4
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-26. Breeching,; Top Outlet Transition Piece
C-51
02-02
BOILER MODEL
A B C
26 54 15 36
34 54 18 36
42 54 27 36
52 54 30 36
D 60 66 30 36
68 66 33 36
76 66 36 36
86 66 36 36
94 75 42 36
68 66 36 36
76 75 42 36
DL
86 75 42 36
94 84 42 36
NOTES
1. Dimensions vary per stack size and velocities.
Figure C-27. Breeching; Gas Outlet Transition (Direct-to-Stack)
C-52
02-02
BOILER MODEL
A B C D E
26 54 15 36 35 24
34 54 18 36 35-1/2 24
42 54 27 36 35-1/2 24
52 54 30 36 35-1/2 24
D 60 66 30 39 41-1/2 25-1/2
68 66 33 39 41-1/2 25-1/2
76 66 36 39 41-1/2 25-1/2
86 66 36 39 41-1/2 25-1/2
94 75 42 42 46 27
52 66 30 39 41-1/2 25-1/2
60 66 33 39 41-1/2 25-1/2
68 66 36 39 41-1/2 25-1/2
DL
76 75 42 39 46 25-1/2
86 75 42 42 46 27
94 84 42 42 50-1/2 27
NOTES:
1. Dimensions vary per stack size and velocity.
Figure C-28. Breeching; Gas Outlet Transition (Connection to horizontal breeching)
C-53
02-02
Table C-25. Industrial Watertube Boiler Stack Size Selection Chart
FLUE GAS FLOW TO FLUE GAS VELOCITY

STACK STACK FPM AT 560 F
FREE AREA ELEVATION MULTIPLICATION
LBS/HR DIAMETER GAS TEMP
SQ-FT FT FACTOR
IN.*
MINIMUM MAXIMUM MINIMUM MAXIMUM
12,910 15,500 24 3.012 1840 2200 0- 500 1.0
15,510 21,200 28 4.125 1620 2200 501-1000 1.025
21,210 24,400 30 4.747 1920 2200 1001-1500 1.05
24,410 32,000 34 6.121 1710 2240 1501-2000 1.07
32,010 36,000 36 6.874 1995 2245 2001-2500 1.085
36,010 43,000 39 8.296 1860 2220 2501-3000 1.105
43,010 50,000 42 9.621 1920 2225 3001-3500 1.12
50,010 57,000 45 11.045 1940 2220 3501-4000 1.15
57,010 66,000 48 12.566 1945 2250 4501-4500 1.17
66,010 75,000 51 14.186 1990 2260 4501-5000 1.19
75,010 84,000 54 15.904 2020 2260 5001-5500 1.22
84,010 94,000 57 17.720 2030 2270 5501-6000 1.24
94,010 104,000 60 19.635 2050 2270 6001-6500 1.26
104,010 115,000 63 21.647 2060 2270 6501-7000 1.28
115,010 126,000 66 23.758 2080 2270
126,010 137,500 69 25.967 2085 2270
137,510 150,000 72 28.274 2090 2270
150,010 162,500 75 30.680 2100 2270
162,510 178,000 78 33.183 2100 2300
178,010 192,000 81 35.785 2130 2300
192,010 206,000 84 38.484 2140 2300
206,010 221,000 87 41.282 2145 2300
221,010 237,000 90 44.179 2150 2310
237,010 255,000 93 47.173 2155 2310
255,010 271,000 96 50.265 2170 2310
271,010 287,000 99 53.456 2180 2310
* 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 corresponds 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.
WEIGHT (LBS) WEIGHT (LBS)

STACK DIAMETER STACK DIAMETER
IN. 3/16 1/4 IN. 3/16 1/4
PLATE PLATE PLATE PLATE
24 1305 1749 45 2439 3267
27 1460 1956 48 2593 3474
30 1632 2187 51 2765 3705
33 1787 2394 54 2940 3910
36 1959 2623 57 3080 4140
39 2113 2830 60 3220 4350
42 2268 3037 63 3400 4570
The stack weights shown include the base ring, clean-out door, and connection for breeching.
C-54
02-02
application. A separate specification is provided for steam boiler packages and high temperature hot water packages.
Steam Boiler
1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-51
2.0 Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-53
3.0 Economizer (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-57
4.0 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-57
5.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-59
Hot Water Generator

1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-61
2.0 Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-62
3.0 Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-66
4.0 Instrumentation and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-66
5.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-67
FGR System (A, BR and CN Burners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-69
FGR System (CT Burner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-70
Steam Boiler
1.0 General
1.1 Shop-Assembled Steam Boiler
This specification shall govern the construction features, materials, fabrication, inspection, and preparation for shipment of pack-
aged-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
1.2.1 Proposal
Complete description, drawings, and material specifications and performance shall accompany each proposal.
1.2.2 Guarantee
Steam will contain not more than 1/2 of 1% moisture when boiler water concentrations are maintained in accordance with ABMA
recommendations.
The boiler manufacturer shall guarantee the steam generating capacity and thermal efficiency as stated herein, while the unit is
being fired with the primary fuel at the specified operating conditions.
Performance and efficiency tests shall be conducted immediately after completion of start-up. The manufacturer must have a repre-
sentative in attendance at the time the test is conducted.
All equipment is to be guaranteed against defective design, workmanship, or material for one year from the date of initial opera-
tion, not to exceed eighteen (18) months from shipment.
1.2.3 Standards and Codes
The following regulatory codes and standards, publication issue in effect at date of invitation for bids, form a part of this specifica-
tion. All applicable components shall be designed and constructed in accordance with these codes with additions or modifications
as required by this specification.
American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section I, Power Boilers.
American Boiler Manufacturers Association (ABMA) Manual of Industry Standards.
C-55
02-02
Underwriters Laboratories (UL), UL 795 Commercial-Industrial Gas-Fired Heating Equipment.

National Fire Protection Association (NFPA), 8501 Prevention of Furnace Explosions in Fuel Oil and Natural Gas-Fired Single
Burner Boiler Furnaces.
Steel Structures Painting Council (SSPC), Surface Preparation SP-l.
All equipment shall comply with the state, provincial or municipal laws and regulations governing the location where the equip-
ment is to be installed.
1.2.4 Documentation Requirements
Dimension drawing with dry and flooded weights, major component identification, and service connection location and size.
Electrical drawings including elementary ladder logic and field component interconnection diagram. Fuel train schematics.
Two (2) copies of certified ASME Manufacturers Data Reports on the pressure vessel.
Operating and maintenance manuals.
Recommended spare parts list.
1.2.5 Design Requirements
Design continuous capacity: _____ lb/hr.
Design pressure: _____ psig.
Operating pressure: _____ psig.
Final steam temperature: _____ F.
Steam quality (solids): _____ ppm.
Feedwater temperature: _____ F.
Elevation above sea level: _____ ft.
Electrical characteristics: _____ Volts, _____ phase, ____ Hz.
Primary fuel: _____, Supply pressure ______.
Standby fuel _____, Supply pressure ______.
Insurance requirements _____.
1.2.6 Manufacturer
Subject to compliance with requirements, provide watertube boiler manufactured by Cleaver-Brooks, Division of Aqua-Chem, Inc.
1.2.7 Efficiency Guarantee
Fuel-to-steam efficiency at above capacity is ____% when firing oil and ____% when firing gas.
1.2.8 Heating Surface
The unit will have the following heating surface:
Boiler heating surface: _____ sq-ft.
Water wall projected surface: _____ sq-ft.
Total heating surface: _____ sq-ft.
Furnace volume: _____ cu-ft.
C-56
02-02
2.0 Product
2.1 Packaged Watertube Boiler(s)
Boilers shall be factory-assembled, packaged, and mounted on heavy steel base frame, complete with integral forced draft burner,
burner controls, boiler trim, and refractory. Boilers shall be assembled and wired so that only water, steam, fuel, blowdown, electri-
cal, 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 pro-
vincial boiler inspection department.
2.3 Drums
The boiler shall have one upper steam drum and one lower mud drum extending the full length of the boiler setting. Each drum
head shall have a 12" x 16" manhole opening with cover, yoke, and gasket. Furnish one operating set of gaskets and two complete
spare sets. Drums shall be X-rayed and stress relieved as required, and under the inspection of the Hartford Steam Boiler Inspection
and Insurance Company.
A. Steam Drum - The unit shall incorporate a steam drum of SA-515 grade 70 steel plate (70,000 psig tensile strength) welded
construction in strict conformance with the ASME Power Boiler Code. The drum will be stress-relieved, seams radiographed,
and hydrostatically tested at 1-1/2 times the design pressure.
The steam drum shall be fitted with an internal feed pipe, chemical feed pipe, and the blowdown pipe. Water level control baf-
fling 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.
B. Lower Drum - The lower drum shall be of fusion-welded construction and will be stress-relieved, seams radiographed, and
hydrostatically tested at 1-1/2 times the design pressure. The lower drum shall be fitted with an internal blowdown guide baffle
to ensure effective blowdown of the lower drum disturbance to the water circulation in the unit.
2.3.1 Drum Connections
Provide the following openings in the drums for piping connections, all flanges shall be raised face and drilled 300 psig ANSI.
Steam outlet: _____ One (1) flanged.
Safety valves: _____ as required by ASME.
Sootblower: _____ One (1) 2" screwed.
Water Column: _____ Two (2) 1" screwed.
Feedwater Regulator: _____ Two (2) 1" screwed.
Top Vent: _____ One (1) 1" screwed.
Continuous Blowdown: _____ One (1) 1" screwed.
Chemical Feed: _____ One (1) 1/2 screwed.
Feedwater: _____ One (1) 2" screwed.
Blowdown: _____ One (1) 1-1/4 screwed.
All openings shall be properly protected from damage and weather during shipment.
C-57
02-02
2.4.Boiler and Furnace
2.4.1. Furnace
The furnace shall employ six-wall cooling with the following:
Front wall tubes closely spaced around the burner.
Tangent floor, roof, and outer furnace wall.
Triple row of rear wall tubes.
Double row of screen tubes at furnace exit.
All tubes shall terminate in the upper and lower drums. No headers are to be used, and all heating surface in the furnace is based on
actual projected tube surface and membrane surface. All tubes shall be cleanable by mechanical tube cleaners. All tubes to be
expanded into upper and lower drums.
2.4.2 Boiler Section
The boiler convection section shall consist of 2" OD tubes SA 178A Grade A arranged in line with longitudinal rows of tubes
arranged on wide and narrow spacing to ensure proper and effective arrangement of sootblowing equipment. This arrangement
shall also permit removal of any tube without the necessity of removing adjacent tubes.
2.4.3 Tube Material
All tubes in the unit for boiler and furnace shall be 2" OD, of SA-178, Grade A, electric resistance welded construction in accor-
dance with ASME Code.
2.4.4 Superheater (Optional)
A bare tube, completely drainable superheater shall be furnished as an integral part of the boiler. All superheater elements and
headers shall be of suitable carbon and alloy steel material of a thickness required for temperature and pressure prevailing under
maximum load conditions. The superheater shall be equipped with a weld end superheater outlet connection and safety valve noz-
zle, 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). Super-
heater outlet header is equipped with a connection for the customers automatic start-up and shut-down vent valve size. Piping con-
tractor or others shall furnish and install an automatic controlled vent valve when superheater is subjected to low load conditions.
All super heater tube material subject to radiant furnace heat shall be constructed of alloy steel suitable for the temperatures
involved.
2.5 Boiler Enclosure
2.5.1 Casing
The boiler shall be enclosed with Cleaver-Brooks standard double panel casing with the portion of the casing exposed to the prod-
ucts of combustion completely seal welded to form an air and gas tight enclosure. The outer casing panels shall also be welded.
The casing is to be supported off the structural steel frame and shall not be welded or attached to tubing, thereby ensuring free
expansion of pressure parts within the casing enclosure.
2.5.2 Arrangement of Casing
Construction of the boiler casing enclosure shall be as follows
2.5.2.1 Front Wall - Furnace Area
4" high-temperature block insulation.
2-1/2 low density block insulation.
C-58
02-02
2.5.2.2 Rear Wall - Furnace Area

2-1/2 low-density block insulation.
2.5.2.3 Convection Section - Furnace
4-3/8 low-density mineral wool block.
2.5.3 Furnace Floor
Furnace floor tubes shall be covered with 1-1/2 square edge tile.
2.5.4 Drum Enclosure
The steam drum shall be shop-insulated with mineral wool block and enclosed in a welded 10-gauge casing. All drum heads will
be shop-insulated and enclosed in a 10-gauge casing. No further insulation in the field shall be required.
2.5.5 Access
Access to the furnace shall be through the burner opening in the front wall, and through a separate refractory lined door on the rear
wall.
2.5.6 Observation
Two (2) air-cooled observation ports, with Pyrex eye shields, shall be provided in the rear wall.
2.5.7 Air Pressure Test
The inner seal welded 10-gauge casing shall be subject to an air pressure test of 8" WC, and shall be considered satisfactorily tight
if the air pressure drop does not exceed 2" WC in five (5) minutes.
2.5.8 Baffling
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.
2.5.9 Insulation
The setting and insulation shall be so designed to ensure that a maximum average casing surface temperature of 130F is not
exceeded under full load 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.
2.5.10 Pressure Connection
Provide a sensing location in furnace, free of turbulence from flame, for draft control sample connection.
2.5.11 Painting
The surfaces shall be prepared per SSPC SP-l specifications and finished with rust resistant primer and a high-quality, high-temper-
ature finish coat of enamel paint.
2.6 Sootblower
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:
Sootblowers shall be steam operated, valve-in-head type, and shall be furnished complete with wall sleeves, clamps, hangers,
supports, operating chains, and other appurtenances required for a complete installation.
C-59
02-02
Blower elements shall be so arranged that all parts of the heating surfaces shall be cleaned of any soot deposits when rotated by
manual or automatic means.
Elements shall be of such length, diameter, and total nozzle area that, for the operating pressure involved, there will be no
significant difference in the cleaning effect between the nozzle nearest the inlet and those farthest from the inlet of the element.
Sootblower piping shall include a valve, chain-operated from the floor, in addition to an auxiliary steam-stop valve, and drain
connection.
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
Each unit shall be provided with the following trim (and quantity), which shall be designed for a minimum of 240 psig.
Steam Pressure Gauge (1).
Safety Valves, Consolidated/Kunkle (ASME Code).
Feedwater Regulator, Fisher 2500 (1).
Feedwater Regulator By-Pass, Velan S254B (1).
Feedwater Regulator Shutoff, Velan S274B (2).
Water Column, Cleaver-Brooks (1).
Water Gauge, Reliance 404-RS (1).
Feedwater Regulator Drain, Velan S274B (1).
Gauge Cocks, Reliance No. GC-451 (3).
Column Drain, Velan S274B (1).
Gauge Drain, Velan S274B (1).
Hi-Low Alarm, Warrick Probe (1).
Low Water Cutoff, Warrick Probe (2).
Feed Stop, Velan S254B (1).
Feed Check, Lunkenheimer 624 (1).
Drum Blowdown Valve, Edwards No. 848-849 (1 Set).
Air Vent, Velan S274B (1).
Continuous Blowdown, Velan/Vogt S2054B (1).
Chemical Feed Stop, Edwards No. 848 (1).
Chemical Feed Check, Edwards No. 838 (1).
Auxiliary Low-Water Cutoff, Float Magnetrol #249 (1).
Sootblower Shutoff, Velan S254B (1 when required).
Sootblower Drain, Velan S274B (1 when required).
All above items, including required piping and supports, shall be assembled in the shop to assure proper fit. Drain piping shall be
extended for installation of valves at hand height.
2.8 Burner
Provide the unit with a forced-draft, register-type burner, arranged to burn natural gas complete with gas electric ignition and obser-
vation port. The burner shall be of a type that can be readily converted to oil in the future. The windbox shall be ruggedly con-
C-60
02-02
structed and of a proven design which will assure an even supply of air to all quadrants of the burner register. The burner shall be a
standard product of the boiler manufacturer specifically designed for the boiler.
2.8.1 Forced Draft Fan
The assembly shall be attached to the windbox in such a way that will allow easy access for maintenance. An inlet screen shall be
provided, and the air volume shall be regulated by inlet vanes. The fan shall develop sufficient static pressure to ensure proper dis-
tribution of air over the entire turndown range of the burner.
2.8.2 Operating and Safety Controls
The unit shall be provided with a full complement of operating and safety controls, consisting of not less than the following items
and features, which shall be shop assembled:
Automatic gas-electric ignition system for gas operation.
Underwriters Laboratories listed and Factory Mutual approved microprocessor burner programming and safety controller to
automatically provide proper cycling for pre-combustion purge, ignition, start, stop, post-combustion purge and safety shutdown,
for use on gas firing and oil firing. This controller shall be a standard product of the boiler manufacturer.
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.
Separate high-pressure safety cutoff for steam and low-fire hold pressure control.
Separate auxiliary low-water safety cutoff for water level with momentary bypass pushbutton for blowdown function.
Blower damper to automatically proportion combustion air to firing rate.
Air flow safety switch.
The following gas valve trains shall be mounted on the burner windbox. All electrical devices shall be prewired to terminals within
a burner mounted box. The gas train will be made from Schedule 40 pipe. Sizes 4" and above shall be with butt-weld fittings.
The pilot gas train shall conform to NFPA-8501 and be of the interruptible type consisting of two (2) pilot gas solenoid valves,
one (1) pilot vent valve, one (1) manual shutoff valve, and a gas pressure regulator.
The main gas train shall conform to NFPA-8501 and consist of two (2) main gas valves with one valve having an overtravel
protection interlock, a 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.
2.8.3 The oil burner shall be of the steam-atomizing type for fully-automatic operation. Low pressure air-atomazation is available
as an option. Air-atomizing burners shall be supplied with a self-lubricating air compressor. The entire module, a motor driven air
compressor and lubricating system, is to be mounted either on the front of the boiler or in a console that can be set adjacent to the
boiler. The burner design shall assure proper fuel-air mixture for smoke-free operation at all loads. When 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.
2.8.4 The fuel train shall be constructed with Schedule 40 piping, and shall conform to NFPA-8501 requirements consisting of the
appropriate pressure and temperature limits (if heavy oil is used), and one (1) fuel valve with valve seal overtravel interlock. If No.
2 oil is used, a second valve is required. All electrical devices shall be prewired to terminate within a burner mounted box.
2.8.5 All controls for the boiler shall be enclosed in a suitable cabinet, with hinged door and lock, containing all necessary relays,
magnetic starters, contactors, terminal blocks, fuse blocks, fuses, transformers, switches, rheostats, and colored indicating lights.
All instruments on the panel front shall be 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.
Electronic continuity tests shall be provided on all circuits to ensure minimal start-up time.
3.0 Economizer (Optional)
NOTICE
Refer to Economizer, Section G, for specification.
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02-02
4.0 Controls
4.1 Feedwater Control Valve
Provide a single element pneumatic system consisting of a steam drum water level sensing device that controls a diaphragm-oper-
ated control valve. The control valve shall be a tight shut-off with air-to-open type. Provide means to control set point and propor-
tional band.
4.2 Feedwater - Two-Element Control (Optional)
The feedwater system shall be of the two-element control type. Drum level shall be maintained by integrating both steam 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.
4.3 Feedwater - Three-Element Control (Optional)
The feedwater system shall be of the three-element control type. Drum level shall be maintained by integrating steam 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.
4.4 Combustion Control - Single-Point
Provide a full modulating single-point electronic combustion control package consisting of the following:
Master controller shall maintain steam pressure at boiler outlet within 3% of set point.
The control shall be capable of handling load swings from a steady state condition to an increase or decrease in load equal to 20%
of the maximum rated capacity of the boiler.
Provide a single jackshaft to regulate the 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.
4.5 Combustion Control - Parallel Positioning (Optional)
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.
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.
4.6 Combustion control - Full Metering (Optional)
Provide a single-fuel-fired combustion control system that uses the concept of parallel metering of fuel(s) and air with cross-limit-
ing. For multiple boiler applications, include a plant master single-loop controller in addition to a boiler-master, fuel flow control-
ler(s), and an air flow controller.
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.
Steam header pressure shall be controlled to within one percent of set point without excessive hunting or overshooting.
4.7 Monitoring and Recording (Optional)
4.7.1. The following items shall be recorded. Measuring devices such as orifice plate and transmitters shall also be included:
Steam flow.
Water flow.
Steam pressure.
Stack temperature.
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02-02
Economizer outlet stack temperature.
Feedwater temperature at economizer inlet.
Fuel water temperature at economizer outlet.
Fuel Flow.
Drum Level.
Percent Oxygen.
4.7.2 Multi-point indicator shall be provided for:
Furnace pressure.
Windbox pressure.
Boiler outlet.
4.7.3 A multi-point annunciator shall be provided for the following as applicable:
Flame failure.
High-low gas pressure.
High-low oil pressure.
High-low oil temperature.
Low atomizing media.
Combustion air.
Main and pilot failure.
Drum level, High-low.
High steam pressure.
4.7.4. The annunciator shall include alarm horn, silence and test switch.
4.8 Forced Flue Gas Recirculation - (Optional)
4.9 Induced Flue Gas Recirculation (Optional)
NOTICE
Refer to FGR specifications.
5.0 Execution
5.1 Testing
A shop hydrostatic test shall be performed at 1-1/2 times the design pressure under the inspection of the Hartford Steam Boiler
Inspection and Insurance Company.
The boiler casing shall be subjected to a shop internal air test at a minimum pressure of 8" WC, and held for five minutes without
dropping 2" WC to ensure that no leaks are present. Any detected leaks shall be corrected.
Provide electronic continuity tests on all circuits to ensure minimal start-up time.
5.2 Examination
Examine and verify size, location, and condition of concrete pads upon which boilers are to be installed. Do not proceed with
installation until unsatisfactory conditions have been corrected.
5.3 Installation
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5.3.1 General
Install boilers in accordance with manufacturers installation instructions, requirements of state, provincial and local code, and
requirements of the local utility company. Maintain manufacturers recommended clearances around and over boilers.
5.3.2 Support
Install boilers on 15" high concrete pads. Pads to be located under each boiler drum saddle.
5.3.3 Erection
Assemble boiler trim shipped loose or unassembled for shipment purposes. Follow manufacturers installation instructions.
5.3.4 Gas Piping
Connect gas piping to boiler, full size of boiler gas train inlet, and provide union with sufficient clearance for burner removal and
service.
5.3.5 Oil Piping
Connect oil piping to boiler, full size of inlet to burner, and provide shutoff valve and union with sufficient clearance for burner
removal and service.
5.3.6 Steam and Condensate Piping
Connect supply, return, and blowdown boiler tappings as indicated, with shutoff valve and union, or flange, at each connection.
5.3.7 Breeching
Connect breeching to boiler outlet, full size of outlet.
5.4 Cleaning
Flush and clean boilers, upon completion of installation, in accordance with manufacturers instructions.
5.5 Field Quality Control
5.5.1 Hydrostatically test assembled boiler and piping in accordance with applicable sections of ASME Boiler and Pressure Vessel
Code.
5.5.2 A representative of the National Board of Boiler and Pressure Vessel Inspectors (or Provincial Boiler Inspection Agency in
Canada) shall inspect boiler installation, piping connections, and observe hydrostatic testing and for certification of completed
boiler units.
5.6 Demonstrations
5.6.1 Services
After testing and inspection is complete, provide the services of an authorized factory service representative to perform start-up and
operation demonstration services.
5.6.2 Start-Up
Perform services in accordance with manufacturers written start-up instructions. Test controls and demonstrate compliance with
requirements. Replace or repair damaged or malfunctioning controls and equipment.
5.6.3 Maintenance and Operation Training
As part of the maintenance and operating instructions, review data in operating and maintenance manual, including preventative
maintenance schedule and procedures, and procedures for obtaining repair parts and technical assistance. Demonstrate all phases of
operation including start-up and shut-down. Schedule training with Owner, and provide at least 7-day notice to Architect/Engineer.
5.6.4 Factory-trained authorized service and parts representative shall be located within 4 hours of boiler plant.
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Hot Water Generator
1.0 General
1.1 Shop-Assembled Watertube Hot Water Generator
This specification shall govern the construction features, materials, fabrication, inspection, and preparation for shipment of pack-
aged-type, shop-assembled, watertube hot water generating equipment with burner assembly, all necessary appurtenances, con-
trols, and auxiliary equipment mounted to the maximum practical extent, as an integral unit on a steel base so as to make a
complete self-contained assembly.
1.2 General Requirements
1.2.1 Proposal
Complete description, drawings, and material specifications and performance shall accompany each proposal.
1.2.2 Guarantee
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.
Performance and efficiency tests shall be conducted immediately after completion of start-up. The manufacturer must have a repre-
sentative in attendance at the time the test is conducted.
All equipment is to be guaranteed against defective design, workmanship, or material for one year from the date of initial opera-
tion, not to exceed eighteen (18) months from shipment.
1.2.3 Standards and Codes
The following regulatory codes and standards, publication issue in effect at date of invitation for bids form a part of this specifica-
tion. All applicable components shall be designed and constructed in accordance with these codes with additions or modifications
as required by this specification.
American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section I, Power Boilers.
American Boiler Manufacturers Association (ABMA) Manual of Industry Standards.
Underwriters Laboratories, Inc. (UL), UL 795, Commercial-Industrial Gas-Fired Heating Equipment.
National Fire Protection Association (NFPA), 85A, Prevention of Furnace Explosions in Fuel Oil and Natural Gas-Fired Single
Burner Boiler Furnaces.
Steel Structures Painting Council (SSPC), Surface Preparation SP-1.
National Electric Code (NEC).
All equipment shall comply with the state, provincial or municipal laws and regulations governing the location where the
equipment is to be installed.
1.2.4 Documentation Requirements
Dimension drawing with dry and flooded weights, major component identification, and service connection location and size.
Electrical drawings including elementary ladder logic and field component interconnection diagram.
Fuel train schematics.
Two (2) copies of certified ASME Manufacturers Data Reports on the pressure vessel.
Operating and maintenance manuals.
Recommended spare parts list.
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1.2.5 Design Requirements

Design continuous capacity: _____ Btu/hr.
Design supply temperature: _____ F.
Design return temperature: _____ F.
Operating pressure: _____ psig.
Flow rate:_____ gph.
Elevation above sea level: _____ ft.
Electrical characteristics: _____ Volts, _____ phase, _____ Hz.
Primary fuel: _____, Supply pressure _____.
Standby fuel: _____, Supply pressure _____.
Insurance Requirements _____.
1.2.6 Manufacturer
Subject to compliance with requirements, provide watertube generator manufactured by Cleaver-Brooks; Division of Aqua-Chem,
Inc.
1.2.7 Efficiency Guarantee
Fuel-to-water efficiency at above capacity is ____% when firing oil and ____% when firing gas.
1.2.8 Heating Surface
The unit will have the following heating surface:
Boiler heating surface: _____ sq-ft.
Water wall projected surface: _____ sq-ft.
Total heating surface: _____ sq-ft.
Furnace volume: _____ cu-ft.
2.0 Product
2.1 Packaged Watertube Generator(s)
Generator shall be factory-assembled, packaged, mounted on heavy steel base frame, complete with integral forced draft burner,
burner controls, generator trim, and refractory. Factory-assemble and wire generators so that only water, steam, fuel, blowdown,
electrical, and vent connections are required.
2.2 Design Pressure
The pressure vessel shall have a design pressure of 260 psig in accordance with ASME Power Boiler Construction Code Section 1,
and the laws of the state or province in which the equipment is to be installed. The generator shall be registered with the National
Board of Boiler and Pressure Vessel Inspectors (or Provincial Boiler Inspection Agency in Canada), and with the 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 opening with plate, yoke, and gasket. Furnish one operating set of gas-
kets and two complete spare sets. Drums shall be X-rayed and stress-relieved, as required, and under the inspection of the Hartford
Steam Boiler Inspection and Insurance Company.
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2.3.1 Drum Connections

Provide the following openings in the drums for all accessories and piping connections. All flanges shall be raised faced and drilled
300 psig ANSI.
Supply: one (1) flanged.
Return: one (1) flanged.
Safety relief valves: (as required by ASME) flanged.
Water column: two (2) 1" screwed.
Top vent: one (1) 1" screwed.
Chemical feed: one (1) 1/2 screwed.
Blowdown: one (1) 1-1/4 screwed.
All openings shall be properly protected from damage and weather during shipment.
2.4 Boiler and Furnace
2.4.1 Furnace
The furnace shall employ six-wall cooling with the following:
Front wall tubes closely spaced around the burner.
Tangent floor, roof, and outer furnace wall.
Triple row of rear wall tubes.
Double row of screen tubes at furnace exit.
All tubes shall terminate in the upper and lower drums. No headers are to be used, and all heating surfaces in the furnace are based
on actual projected tube surface and membrane surface. All tubes shall be cleanable by mechanical tube cleaners. All tubes to be
expanded into upper and lower drums.
2.4.2 Boiler Section
The boiler convection section shall consist of 2" OD tubes arranged in line with longitudinal rows of tubes arranged on wide and
narrow spacing to ensure proper and effective arrangement of sootblowing equipment. This arrangement shall also permit removal
of any tube without the necessity of removing adjacent tubes.
2.4.3 Tube Material
All tubes in the unit for boiler and furnace shall be 2" OD, SA-178, Grade A, electric resistance-welded construction in accordance
with ASME Code.
2.5 Boiler Enclosure
2.5.1 Casing
The boiler shall be enclosed with Cleaver-Brooks standard double-panel casing with the portion of the casing exposed to the prod-
ucts of combustion completely seal-welded to form an air and gas-tight enclosure. The outer casing panels shall also be welded.
The casing is to be supported off the structural steel frame and shall not be welded or attached to tubing, thereby ensuring free
expansion of pressure parts within the casing enclosure.
2.5.2 Arrangement of Casing
Construction of the boiler enclosure shall be as follows:
2.5.2.1 Front Wall - Furnace Area
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2-1/2 low density block insulation.
2.5.2.2 Rear Wall - Furnace Area
2-1/2 low-density block insulation.
2.5.2.3 Convection Section - Furnace
4-3/8 low-density mineral wool block.
2.5.3 Furnace Floor
Furnace floor tubes shall be covered with 1-1/2 square edge tile.
2.5.4 Drum Enclosure
The steam drum shall be shop-insulated with mineral wool block and enclosed in a welded 10-gauge casing. All drum heads will be
shop-insulated and enclosed in a 10-gauge casing. No further insulation in the field shall be required.
2.5.5 Access
Access to the furnace shall be through the burner opening in the front wall, and through a separate (optional) refractory lined door
on the rear wall.
2.5.6 Observation
Two (2) air-cooled observation ports, with Pyrex eye shields, shall be provided in the rear wall.
2.5.7 Air Pressure Test
The inner seal welded 10-gauge casing shall be subject to an air pressure test of 8" WC, and shall be considered satisfactorily tight
if the air pressure drop does not exceed 2" WC in five (5) minutes.
2.5.8 Baffling
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.
2.5.9 Insulation
The setting and insulation shall be so designed to ensure that a maximum casing surface temperature of 130F is not exceeded
under full load 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.
2.5.10 Pressure Connection
Provide a sensing location in furnace, free of turbulence from flame, for draft control sample connection.
2.5.11 Painting
The surfaces shall be prepared per SSPC SP-l specifications and finished with rust resistant primer and a high-quality, high-temper-
ature finish coat of enamel paint.
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02-02
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 contractor is to supply an appropriately sized air compressor/receiver.
2.7 Generator and Trim Accessories
Each unit shall be provided with the following trim, designed for a minimum of 240 psig:
Drum pressure gauge (1).
Safety valves, Consolidated/Kunkle (ASME Code).
Water column, Cleaver-Brooks (1).
Water gauge, Reliance 404-RS (1).
Gauge cocks, Reliance no. GC-451 (3).
Column drain, Velan S274B (1).
Gauge drain, Velan S274B (1).
Low water cutoff, Warrick probe (2).
Drum blow-off valve, Edwards No. 848-849 (1 Set).
Air vent, Velan S274B (1).
Continuous blow-off, Velan/Vogt (1).
All above items, including required piping and supports, shall be assembled in the shop to assure proper fit. Drain piping shall be
extended for installation of valves at hand height.
2.8 Burner
Provide a forced-draft, register-type burner arranged to burn the 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.
2.8.1 Forced Draft Fan
Assembly shall be attached to the windbox in such a way that will allow easy access for maintenance. An inlet screen shall be pro-
vided, 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.
2.8.2 Operating and Safety Controls
The unit shall be provided with a full complement of operating and safety controls consisting of not less than the following items
and features which shall be shop assembled:
Automatic gas-electric ignition system for gas operation.
Underwriters Laboratories listed, and Factory Mutual approved microprocessor burner programming and safety controller to
automatically provide proper cycling for pre-combustion purge, ignition, start, stop, post-combustion purge, and safety shutdown
for the fuels as specified. This controller shall be a standard product of the generator manufacturer.
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.
Separate high-pressure safety cutoff and low fire hold pressure control.
A mounted 8-1/2 diameter pressure gauge for drum pressure.
Blower damper to automatically proportion combustion air to firing rate.
Air flow safety switch.
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2.8.3 If natural gas is specified, then the following is to be provided:

Main manual gas shutoff valve with square head and wrench handle.
Gas pressure regulators for both pilot and main gas.
Gas control valve to regulate gas flow.
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.
Two (2) pilot gas solenoid valves, pilot vent valve, and manual stop cock.
2.8.4 If oil is specified, provide the following:
Main shutoff valve (two required for light oil).
Integral fuel oil metering controller with pressure gauges and temperature gauges if heavy oil.
Components to be Factory Mutual and Underwriters Laboratories approved. The configuration, along with safety interlocks,
shall be in accordance with the specified site insurance requirements.
If heavy oil, a reverse oil-purge pump shall be supplied to evacuate the oil gun on burner shutdown.
2.8.5 All controls for the generator shall be enclosed in a suitable cabinet, with hinged door and lock, and containing all necessary
relays, magnetic starters (if provided), conductors, terminal blocks, fuse blocks, fuses, transformers, switches, rheostats and col-
ored 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 dia-
gram. All wiring shall be done in conformity with the National Electric Code.
2.8.6 Two (2) 6" diameter pressure gauges and two (2) 5" diameter thermometers to be field-installed into the supply and return
lines.
2.8.7 Provide an interlock to the burner operation for low water circulation. This shall include an orifice plate and differential pres-
sure transmitter to be field-installed. The contractor shall supply appropriate flanges. The generator manufacturer to supply a three-
valve manifold assembly for the transmitter.
3.0 Tests
A shop hydrostatic test shall be performed at 1-1/2 times the design pressure under the inspection of the Hartford Steam Boiler
Inspection and Insurance Company.
The generator casing shall be subjected to a shop internal air test at a minimum pressure of 8" WC and held for five minutes with-
out dropping 2" WC to insure that no leaks are present. Any detected leaks shall be corrected.
Provide electronic continuity tests on all circuits to ensure minimal start-up time.
4.0 Instrumentation and Control

4.1 System Instrumentation (Optional)
Provide a freestanding panel piped, pre-wired with a finish coat of paint complete with the following:
Four (4) pen recorder for water flow, water supply temperature, water return temperature, and stack temperature.
Draft gauges, illuminated vertical scales for windbox pressure, furnace pressure and boiler outlet pressure.
Temperature indicators, digital readouts for return water temperature, supply water temperature and stack temperature.
Annunciator, first-out indication, silence and reset buttons, per Instrument Society of America (ISA) standard F3M-3-14.
Canopy light.
4.2 Combustion Control - Single Point
Provide a full modulating single point electronic positioning combustion control consisting of the following:
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02-02
Master regulator to maintain temperature at generator outlet within 3% of control setpoint.

Control shall be capable of swings from a steady state condition to an increase or decrease in load equal to thirty (30)% of the
maximum rated capacity of the generator.
Single jackshaft to regulate the 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.
5.0 Execution
5.1 Examination
Examine and verify size, location, and condition of concrete pads upon which the generators are to be installed. Do not proceed
with installation until unsatisfactory conditions have been corrected.
5.2 Installation
5.2.1 General
Install generators in accordance with manufacturers installation instructions, requirements of state, provincial and local code, and
requirements of local utility company. Maintain manufacturers recommended clearances around and over generators.
5.2.2 Support
Install generators on 15" high concrete pads.
5.2.3 Erection
Assemble generators trim shipped loose or unassembled for shipment purposes. Follow the manufacturers installation instructions.
5.2.4 Gas Piping
Connect gas piping to the generators, full size of generator gas train inlet, provide union with sufficient clearance for burner
5.2.5 Oil Piping
Connect oil piping to the generators, full size of inlet to burner, provide shutoff valve and union with sufficient clearance for burner
5.2.6 Connect supply and return piping.
5.2.7 Breeching
Connect breeching to generator outlet, full size of outlet.
5.3 Cleaning
Flush and clean generators upon completion of installation, in accordance with manufacturers instructions.
5.4 Field Quality Control
Hydrostatically test-assembled generator and piping in accordance with applicable sections of ASME Boiler and Pressure Vessel
Code.
Arrange with National Board of Boiler and Pressure Vessel Inspectors (or Provincial Boiler Inspection Agency in Canada) for
inspection of generator installation, piping connections, observation of hydrostatic testing, and for certification of completed gener-
ator units.
5.5 Demonstrations
5.5.1 Services
After testing and inspection is complete, provide the services of an authorized factory service representative to perform start-up and
operation demonstration services.
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5.5.2 Start-Up
Perform services in accordance with manufacturers written start-up instructions. Test controls and demonstrate compliance with
requirements. Replace or repair damaged or malfunctioning controls and equipment.
5.5.3 Maintenance and Operation Training
As a part of the maintenance and operating instructions, review data in operating and maintenance manual, including preventative
maintenance schedule and procedures, and procedures for obtaining repair parts and technical assistance. Demonstrate all phases of
operation including start-up and shut-down.
Schedule training with the owner, and provide at least 7-day notice to the Architect/Engineer.
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02-02
Flue Gas Recirculation (A, BR, and CN Burners)

1.0 Each boiler shall be furnished with a Cleaver-Brooks Flue Gas Recirculation (FGR) system capable of reducing the boiler NOx
emissions to 40 ppm, corrected to 3% oxygen in the boiler flue gases when firing natural gas and 125 ppm corrected to 3% oxygen
when firing #2 oil and/or #6 oil with a maximum fuel bound nitrogen content of.01 percent.
2.0 In forced FGR systems, the Flue Gas Recirculation fan motor, and belt drive shall be mounted on a steel base. The motor shall
be a __________ hp, open drip proof (TEFC optional). The bearings shall be high temperature type capable of handling tempera-
tures up to 550 F. The fan shall be shipped loose. The motor starter and overloads shall be provided. (Optional placement of motor
starter.)
3.0 Flue Gas Recirculation control valve, __________ inch diameter, shall be of the butterfly type to provide proportional control
of fuel/air/FGR throughout the firing range of the boiler. The control valve is actuated through direct mechanical linkage by an
assembly attached to the jackshaft. (Pre-fit, shipped loose or mounted.)
4.0 Manual shutoff valve, *____________ inch diameter, shall be of the butterfly type to provide for isolation of the FGR system
during maintenance periods while allowing the boiler to operate. The valve shall include an open and closed limit switch to bypass
the interlocks and prevent the fan from energizing. (Pre-fit, shipped loose.)
5.0 Option (select A or B)
A. Single fuel boilers: The control valve mechanical linkage assembly shall consist of a variable cam to provide a proper flue
gas rate control throughout the firing range of the boiler. The mechanical linkage assembly on the fan housing, shall also
include a linkage to the jackshaft and a linkage arm that connects to the control valve.
B. Dual fuel boilers: The control valve mechanical linkage assembly shall consist of two variable cams, each providing inde-
pendent control of the recirculated flue gas. These cams provide for proper flue gas control, respective to the fuel being used,
throughout the firing range. A limit switch shall be used to distinguish the proper cam-to-fuel selection. The linkage assembly
shall also include a linkage to the jackshaft and have a linkage arm that connects to the control valve.
6.0 Dual canister burner housing, for Model A burner, shall be designed to allow for the mixing of the burner combustion air and
the recirculated flue gases. The dual canister housing shall consist of two separate housing chambers to provide for independent
introduction of gaseous fuel and recirculated flue gas to the combustion process. (Mounted.)
7.0 Extended burner drawer, for Model BR and Model CN Burners, shall be designed to allow for mixing of the combustion air,
recirculated flue gas and burner gases. Here the flue gas is introduced as a premix to cool the combustion temperature. (Mounted.)
8.0 Differential pressure interlock switch shall be installed across the Flue Gas Recirculation fan to ensure proper direction of flue
gas flow. The switch shall operate such that it will prevent the Flue Gas Recirculation system and boiler from operating upon open-
ing of the switch. (Shipped loose.)
9.0 Minimum flue gas temperature switch, located in boiler stack, shall prevent the boiler from modulating until the boiler has
reached operational temperature. (Shipped loose.)
10.0 Miscellaneous timers and relays shall be provided to allow automatic operation of the boiler and FGR system, including a
timer to keep the recirculation fan operational for a period of up to ten minutes after the boiler has been shutdown to allow for
proper cooling of recirculation fan. (Mounted.)
11.0 All of the above equipment shall be designed and furnished by the boiler/burner manufacturer. Shipped loose items are to be
field-erected by others under the supervision of the boiler/burner manufacturer.
12.0 The installing contractor shall furnish and install all required duct work, insulation, and supports as required by safety codes
or the customer unless specified otherwise.
13.0 After normal boiler start-up has been completed, the FGR system shall be placed into operation and calibrated for required
performance. Any testing of emissions shall follow, and the cost of these tests shall be borne by the owner.
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Notes
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Controls
Section D
CONTROLS
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
CB-HAWK ICS BOILER MANAGEMENT CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5
KEY FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-6
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-7
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-7
CB-HAWK ICS COMBUSTION AIR FAN VARIABLE SPEED DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-11
CB-HAWK ICS OXYGEN MONITORING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-12
APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-13
CB-HAWK ICS ETHERNET COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-14
CB-HAWK ICS PAGING and REMOTE DIAL-UP ACCESS with MODEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-15
CB-HAWK ICS INTERNET WEB SITE MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-16
CB-HAWK ICS LEAD/LAG FOR TWO BOILER SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-17
APPLICATION AND SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-17
CB-HAWK ICS LEAD/LAG for up to EIGHT BOILERS SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-18
APPLICATION AND SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-19
CB780 CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-20
SAMPLE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-21
D-1
12-02
Controls
CB100E CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-22

SAMPLE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-22
CB110 CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-23
LEAD/LAG SYSTEMS (TWO BOILER LEAD/LAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-24
APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-25
LEAD/LAG SYSTEMS (TWO THROUGH FOUR BOILER LEAD/LAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-26
APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-27
LOW FIRE HOLD CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-28
APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-28
MINIMUM TEMPERATURE LOW FIRE HOLD CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-29
APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-29
ASSURED LOW FIRE CUTOFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-30
APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-30
REMOTE MODULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-31
APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-31
AUTOMATIC FUEL CHANGEOVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-32
APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-32
OXYGEN TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-33
APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-35
D-2
12-02
Controls
CB-HAWK BOILER MANAGEMENT CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-36

FEATURES & BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-36
CB-LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-40
CB-HAWK ENHANCER BASE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-42
CB-HAWK ENHANCER EFFICIENCY MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-43
CB-HAWK ENHANCER LEAD/LAG CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-44
CB-HAWK TWO BOILER LEAD/LAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-45
TABLES
Table D-1. Flame Safeguard Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
D-3
12-02
Controls
GENERAL
Table D-1. Flame Safeguard Comparison
CB Hawk ICS CB Hawk ICS

CB 110 CB 100E CB 780 CB Hawk w/ CB780 w/ CB100E
DATA DISPLAY
Display Type Icons Backlit LCD VFD LCD Backlit LCD or Color Backlit LCD or Color
Active Matrix TFT Active Matrix TFT
Character Type NA Alpha-Numeric Alpha-Numeric Alpha-Numeric Graphical Graphical
No. of Characters NA 2 x 16 2 x 20 2 line x 40 NA NA
Alarm/Status LEDs 7 none 5 5 NA NA
No. of Keys/Buttons 1 3 5 12 Touchscreen Touchscreen
Fault Indication Binary Codes Message Code & Message Code & Message Code & Message Code & Message
No. of Faults 23 23 127 73 up to 275 up to 75
Fault History none last 6 last 6 last 6 last 100 last 100
Flame Signal no yes yes yes yes yes
Burner Hours/Cycles no yes yes yes yes yes
Door/Remote Mountable no Optional Optional Standard (Door) Standard (Door) Standard (Door)
Languages Available International Icons English & Spanish English & Spanish English English English
DIAGNOSTIC ANNUNCIATOR
Availability NA CB300 CB783 Not Required Optional Optional
LEDs NA none 26 NA NA NA
Additional Points NA 17 18 NA 16 16
Additional Messages NA 31 36 NA 16 16
FEATURES
Purge Time Fixed DIP Switches Interchangeable Card Adjustable Interchangeable Card DIP Switches
Fuel Pressure & Switches Switches Switches Solid State Sensor(s) Switches Switches
Temperature Sensing
Water Temp./Steam Switches Switches Switches Solid State Sensor Transmitter Transmitter
Press. Sensing
Firing Rate Control Separate Separate Separate Integral Integral (PID) Integral (PID)
Thermal Shock Protection Optional Optional Optional Built-in (indirectly Built-in (based on Built-in (based on
based on Water measured Water measured Water
Temperature) Temperature) Temperature)
Hot Stand-By Operation Optional Optional Optional Optional Built-in Built-in
Assured Low Fire Cutoff Optional Optional Optional Built-in Built-in Built-in
Setback Capability Optional Optional Optional Standard Standard Standard
Lead/Lag Capability, Remote Optional Optional Optional Optional Standard Standard
Modulation, Remote Setpoint
High Stack Temp. Optional Optional Optional Optional Standard Standard
Alarm & Shutdown
Efficiency Monitoring NA NA NA Optional Standard Standard
COMMUNICATION
Local/Remote PC E500 Comm E500 Comm Module CB-LINK Comm CB-LINK EtherNet I/P or EtherNet I/P or
Module Module Comm Module RAP Modem RAP Modem
Software Type Terminal Emulation Terminal Emulation Windows Windows Windows 2000/XP Windows 2000/XP
Building/EMS Interface E500 Comm E500 Comm Module GPI Interface GPI Interface RSLinx OPC Server RSLinx OPC Server
Module or Mod Bus
Email & Paging of Alarms NA NA NA NA Optional Optional
Printing Alarm History NA NA NA NA Standard Standard
Remote Access Internet NA NA NA NA EtherNet I/P EtherNet I/P
Remote Access Telephone NA NA CB-LINK CB-LINK RAP Modem RAP Modem
Comm Module Comm Module
OPTIONAL FEATURES
Parallel-Positioning Control Optional Optional Optional NA CB Fuel-Air CB Fuel-Air
Ratio Control Ratio Control
Variable Speed Fan Drive NA NA NA NA Yes Yes
O2 Trim Optional Optional Optional Yes Yes Yes
D-4
12-02
Controls
CB-HAWK ICS BOILER MANAGEMENT

CONTROL SYSTEM
The CB-HAWK ICS is a state-of-the-art boiler control system Assured low fire cut-off
that integrates the functions of a Programmable Controller and
Assured Start Permissive Safety Interlocking
Burner Management Controller, as well as other boiler
operating and ancillary controls. The CB-HAWK ICS system High Stack Temperature Alarm and Shutdown
incorporates a graphical Human Machine Interface (HMI),
Boiler Efficiency Calculations
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 Optional Features:
complete boiler firing rate controls for steam or hot water Color Graphical HMI
boilers. The CB-HAWK ICSs advanced technology features
utilize the latest communication methods, such as DeviceNet, E-Mail and Pager Alarm/Fault Forwarding
Ethernet, and the Internet. The CB-HAWK ICS also has the Fuel-Air Ratio Control
capability of interfacing with various Building/Plant
Automation Systems. Additional features include lead/lag Building/Plant Automation System Interface
capability; e-mailing and paging of alarms, remote monitoring, Remote Internet Monitoring and Diagnostics
and HMI alarm history printing.
O2 Monitoring and Trim
The CB-HAWK ICS Integrated Control System may be used
Internet Parts and Service Lookup
on most types of steam or hot water boilers, including firetube,
industrial watertube, and commercial watertube. It is designed Built-in two boiler lead/lag control
to operate with a gas, oil, or combination burner using a single-
Lead/Lag Capability for Multiple Boiler Systems
point modulating control or a parallel-positioning fuel-air ratio
control system. Variable Speed Drive on Combustion Air Fan
In addition to installation on new boilers, the CB-HAWK ICS Diagnostic Annunciator
can be added as a retrofit to existing boilers. Contact your local
authorized Cleaver-Brooks representative for details. Safety Provisions and Diagnostics:
A. Integrated Burner Management
KEY FEATURES AND BENEFITS
Utilizes the CB780 or CB100E Flame Safety Control
Advanced Technology
Communicates with the Programmable Controller via
Standard Features: DeviceNet
Integrates control function of burner sequencing and safety Burner Control Status, Faults, and Diagnostics displayed on
with firing rate, fuel-air ratio, and operating limit controls HMI
Incorporates a Programmable Controller B. Integrated Boiler Controls
Touch Screen Graphical Human Machine Interface (HMI) Operating and Modulating Controls
Monitors and Displays Connected Boiler Parameters Primary Low Water Cut-Off
Optimizes Boiler Firing Rate Control Variable Speed Drive fault shutdown communicates via
Alarm/Fault Indication and History DeviceNet (optional)
On-Screen Fault Diagnostics Password protection of Programmable Controller Logic
Night/Day Setback Control Password protection of Parallel Positioning Control
(optional)
Thermal Shock Protection
Remote Modulation
Remote Setpoint
D-5
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Controls
Powerful Display/Diagnostic Capabilities: PRODUCT OFFERING

Touch Screen Graphical Human Machine Interface (HMI).
Color (optional). Included in each CB-HAWK ICS system is the following:
HMI allows easy screen navigation to monitor various boiler Programmable Controller
parameters & diagnostics and to configure boiler controls.
Touch Screen HMI
Displays alarms/faults, burner status, and flame signal from
DeviceNet Communication Network
the Flame Safety Control.
Various Controller Input/Output Modules
Diagnostics in plain English and prioritized fault
annunciation simplify troubleshooting. Flame Safety Controller
Displays Boiler Steam Pressure, Water Temperature, Firing Various Temperature and Pressure Sensors
Rate, Stack Temperature, Boiler Efficiency, Combustion Air
Temperature (optional), Flue Gas O2 Concentration Optional Features and Equipment: (see individual specifica-
(optional), Combustion Air Fan Motor Speed and kW (VSD tions for these options)
option), Combustion Air Pressure (with VSD option), Water
Ethernet/IP Module to provide communication between the
Level (CB-Level Master option), Shell Water Temperature
Programmable Controller and other Ethernet compatible
(Steam Boilers), and other control points.
devices
Displays Boiler Operating Status (e.g. Warm Up, Auto/
Manual, Boiler On, fuel selection, etc.). OPC Server software for interface with Building/Plant
Automation System
Displays Boiler Firing Rate control parameters and settings.
Lead/Lag Control of Multiple Boilers
Provides Remote Monitoring and Diagnostic capabilities via
Fuel-Air Ratio Control System and Actuators
the Internet or Modem (optional).
Variable Speed Drive for Combustion Air Fan Motor
Provides E-mail Forwarding and Paging of Alarm/Fault
Codes (optional). O2 Analyzer and/or External O2 Trim System
Touch Screen controls simplify screen navigation and boiler Combustion Air Temperature Sensor
configuration
Economizer Stack Flue Gas Temperature, Feed Water
Reliable and accurate controls using microprocessor-based Temperature, Oil Temperature, and Gas & Oil Pressure
programming Sensors
Steam, Water, and Fuel Flow Monitoring
Simplified Servicing:
CB-Level Master primary safety water level control
Diagnostics and fault history, up to 100 faults, through touch
screen display simplifies troubleshooting procedures Internet Web Site Monitoring Package
E-Mail Forwarding and Paging of System Fault Codes when Paging and Remote Dial-Up Access with Modem
applicable (optional) communication
Connection to user Building Automation System when E-mailing with Ethernet/IP option
applicable (optional)
D-6
12-02
Controls
ENGINEERING DATA Thermal Shock Protection based on water temperature

and setpoint
Supply Voltage: 120 VAC (+10%/-15%) 50 or 60 Hz.
Various High and Low limit alarms and shutdowns
Maximum total connected load: 2000 VA
Touch Screen graphical operator interface and monitoring
Operating temperature limits: 32 to 130F
Manual control of the boiler-firing rate utilizing control
85% RH continuous, non-condensing, humidity screens on the HMI to increment and decrement the
0.5G continuous vibration firing rate
On screen indication of burner management controller
SAMPLE SPECIFICATIONS status and diagnostics
1.0 Each unit shall be factory equipped with a Boiler Control On screen real-time display of all connected process
System providing technology and functions equal to the parameters
CB-HAWK ICS Boiler Control system. On screen display of system alarms and faults
2.0 Each Boiler Control System shall be factory equipped with On screen history of alarms and faults
a pre-configured Programmable Controller and Human
Machine Interface (HMI). On screen recommendation for troubleshooting fault
conditions
3.0 Major system components shall include:
On screen water level indication (optional) and alarm(s)
Programmable Controller
Printing Alarm/Fault history
Touch Screen HMI
E-Mail or Paging of boiler alarms (with either Ethernet/IP or
DeviceNet Communication Network Modem Option)
Various Controller Input/Output Modules Building/Plant Automation System interface (with Ethernet/
One Burner Management Controller and Wiring Sub-Base IP Option)
One Flame Scanner: Infrared, Ultra-Violet, or UV Ethernet and Internet communications (with Ethernet/IP
Self-Check Option)
One Flame Amplifier, to correspond with the selected Flame Tamper resistant control logic and password protection.
Scanner Night/Day Setback control
Various Temperature and Pressure Sensors Stack Flue Gas, Combustion Air (optional), and Shell (water)
4.0 Major functions that the Boiler Control System shall temperatures
provide: Boiler Efficiency calculation
Automatic sequencing of the boiler through standby, Outdoor Reset for Hot Water Boilers
pre-purge, pilot flame establishing period, main flame
establishing period, run and post purge Remote Modulation or Firing Rate Setpoint control
Flame proving and lockout on flame failure during pilot Assured Low Fire Cut-Off (ALFCO)
flame proving, main flame proving, or run Assured Start Permissive Safety Interlocking
Low fire damper/valve position for flame ignition trials
Full modulating control of fuel and combustion air
Utilize solid state controls and sensors to provide various
control functions, such as:
On/Off, and Modulating Control
Modulating Control algorithm shall be Proportional-
Integral-Derivative (PID) type
D-7
12-02
Controls
5.0 The Boiler Control System shall provide the following English text description of the system fault and
safety provisions for: troubleshooting procedures
A. Integrated Burner Management Water Level indication and low water Shutdown Alarm
Examine all load terminals to assure it is capable of Dynamic Self Checking
recognizing the true status of the external controls, limits
7.0 The Boiler Control System shall be able to operate in these
and interlocks. If any input fails this test, the burner
environmental conditions.
management system should lockout on safety shutdown.
Supply Voltage: 120 VAC (+10%/-15%) 50 or 60 Hz
Closed-loop logic test verifies integrity of safety critical
loads (ignition, pilot, and main fuel valves) and must be Maximum total connected load: 2000 VA
able to lockout on safety.
Operating temperature limits: 32 to 130F
Pre-ignition interlocks (fuel valve proof of closure, etc.)
85% RH continuous, non-condensing, humidity
and flame signal checked during Standby and Pre-Purge.
0.5G continuous vibration
Dynamic checking of the flame signal amplifier. The
control flame signal amplifier must be able to recognize 8.0 All Boiler Control System wiring shall be in accordance
a no flame signal during this dynamic amplifier check. with the National Electrical Codes and local electrical codes.
Safe start check and expand check to include monitoring 9.0 Boiler Control System component functions shall be as
flame signal during standby. follows:
High and Low fire switches checked for proper Burner Management Controller: Provides boiler sequencing
sequencing. logic to meet FM/IRI/UL/cUL approval body requirements.
Tamper-proof Purge Timing and safety logic. Touch Screen Graphical Interface: Provides user interface to
the control system, boiler overview screen with connected
B. Integrated Boiler Controls
boiler parameter readouts, Burner Management Control
Operating and Modulating Control status screen, alarm banners, diagnostic screens for fault
troubleshooting, alarm history screen, system firing rate
Primary Low Water Cut-Off
screen and system configuration screens.
Variable Speed Drive (if used) fault shutdown
DeviceNet Communication Network: Provides
Password protection of Programmable Controller Logic communication between the Programmable Controller and
other peripheral devices.
Password protection of Parallel Positioning Control
(if used) Various Programmable Controller Input/Output modules:
Provides interface for discrete powered and/or isolated relay
6.0 The Boiler Control System shall provide annunciation and
signals, as well as for analog signals, from and/or to other
diagnostics:
input/output devices.
Active alarm annunciation
Stack Temperature Sensor: Measures and transmits a signal
Provide historical alarm information for on screen display to the Programmable Controller in relation to boiler exit flue
gas temperature. It is used for indication and in the
Detects and isolates an alarm, and reports internal circuit
calculation of boiler efficiency; it can also be used for high
faults
stack temperature alarm and shutdown.
Printer output capable for logging alarms
Steam Pressure Transmitter (Steam Boiler): Provides an
Capability of printing alarm history of date, time, cycle of analog signal to the Programmable Controller for indication
occurrence and date and time of acknowledgement up to the of boiler steam pressure; utilized for on/off and modulating
most recent 100 faults control of the burner.
D-8
12-02
Controls
Water Temperature Transmitter (Hot Water Boilers): O2 Analyzer and/or External O2 Trim System
Provides an analog signal to the Programmable Controller
Combustion Air Temperature Sensor: Measures and
for indication of boiler water temperature; utilized for
transmits a signal to the Programmable Controller in relation
thermal shock protection, on/off, and modulating control of
to the combustion inlet temperature for indication and for use
the burner.
in the calculation of boiler efficiency; also can be used for
Water (shell) Temperature Sensor: Measures and transmits a high combustion air temperature alarm and shutdown, based
signal to the Programmable Controller in relation to boiler on setpoint
water temperature; used for indication and thermal shock
Economizer Flue Gas Inlet and Outlet Temperatures, Feed
protection.
Water Temperature, Oil Temperature, and Gas & Oil Pressure
10.0 Optional Equipment (see individual data sheets for these Sensors
options)
Steam, Water & Fuel Flow Monitoring
Ethernet/IP Module: Provides communication between the
CB-Level Master primary safety water level control
Programmable Controller and other Ethernet Compatible
devices (e.g. Boiler Room Master Control, Building/Plant Internet Web Site Monitoring Package
Automation system, and the Internet) and E-mail
Paging and Remote Dial-Up Access with Modem
functionality
Lead/Lag Control for Multiple Boiler Systems
Fuel-Air Ratio Control System and Actuators
Variable Speed Drive for Combustion Air Fan Motor
D-9
12-02
Controls
CB-HAWK ICS COMBUSTION AIR FAN

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

Improved Boiler Efficiency:
Maintains consistent Wind Box Pressure throughout the
Modulating Firing Range of the Boiler
Energy Savings:
Reduces electrical energy consumption
Soft starting reduces electrical and mechanical stress on the
motor, extending the life of the motor
Provides Substantial Savings from Mid to Low Fire
modulation points ENGINEERING DATA
Average Payback in approximately 6 8 Months
Drive:
PI Control Logic: Ambient Operating Temperatures: 32 122F
Precise control. Altitude: 3300 Ft (1000 m) Max without derating
Monitors rate of change to anticipate needs of system, Shock: 15G peak for 11ms duration (1.0 ms)
increasing and decreasing the output speed (frequency) to the
Vibration: 0.152 mm (0.0006 in.) displacement, 1G peak
blower motor as needed
Voltage Tolerance: -10% of minimum, +10% of Maximum
Maintains Wind Box Pressure at the Setpoint
Frequency Tolerance: 47 63 Hz
Communication: Input Phases: Three-phase input provides full rating of all
Communicates with the Boiler Controller through drives, Single-phase operation provides 50% of rated current
DeviceNet Displacement Power Factor:
Provides Drive process information on the Boiler Control PF70 C & D Frames 0.92 lagging (entire speed range),
Panel Display PF70 A&B Frames 0.64 lagging,
PF700 TBD
Provides Drive faults and troubleshooting suggestions, in
Plain English, on Boiler Control Panel Display Output Voltage: 0 to rated motor voltage
Output Frequency Range: 0 400 Hz
PRODUCT OFFERING Frequency Accuracy: Digital Input Within 0.01% of set
Cleaver-Brooks shall supply the following equipment: output frequency, Analog Input Within 0.4% of maximum
output frequency
Adjustable Frequency Variable Speed Drive.
Intermittent Overload: 110% Overload capability for up to
Wind Box Pressure Transmitter.
1 minute, 150% Overload capability for up to 3 seconds
VSD Compatible Combustion Air Fan Motor.
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Current Limit Capability: Proactive Current Limit SAMPLE SPECIFICATIONS

programmable from 20 to 160% of rated output current;
Independently programmable proportional and integral gain The Boiler Manufacturer shall provide a Variable Speed Drive
controller for use on the burners Combustion Air Fan blower
Line Transients: Up to 6000 volts peak per IEEE motor for the purpose of providing Improved Boiler Efficiency
C62.41-1991 and Reduced Electrical Energy consumption.
Ground Fault Trip: Phase-to-ground on drive output The Drives voltage, frequency, and current ratings shall be
Short Circuit Trip: Phase-to-phase on drive output rated in accordance with the electrical requirements as dictated
by job site specifics, and for the properly rated motor
Drive Overcurrent Trip: Software 20 to 160% of rated horsepower.
current, Hardware 200% of rated current (typical),
Instantaneous 220 to 300% of rated current (dependent on The Variable Speed Drive must be capable of communicating
drive rating) over the DeviceNet protocol.
Electronic Motor Overload Protection: Class 10 protection A pressure transmitter shall be supplied to measure the Wind
with speed sensitive response. Investigated by U.L. to Box Pressure of the Burner and shall be capable of supplying a
comply with N.E.C. Article 430, UL File E59272 Volume 12 4 20mA process variable input signal to the VSD.
See Drive Manual for other, Model and Voltage Specific, A Motor suitable for variable speed drive service must be
specifications. supplied for use in conjunction with the Variable Speed Drive,
and sized to match the motor requirements of the Combustion
Pressure Transmitter: Air Fan Blower.
Pressure Range: 0 2 psig Variable Speed Drive shall be interlocked with boiler control to
ensure safe operation.
Output: 4 20mA DC
Connection: 1/4" NPT
Enclosure: NEMA 4
Accuracy: 0.25% FS
Compensated Range: -4 to +176F
Motor:
Motor suitable for variable speed drive service
Variable Torque, 3 phase
Other specifications based on Specific Horsepower, Voltage,
and Frequency requirements. Contact your local Authorized
Cleaver-Brooks Representative for further details.
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CB-HAWK ICS OXYGEN MONITORING SYSTEM
The CB-HAWK ICS Oxygen Monitoring System provides

indication and monitoring of the boilers exit flue gas O2
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 O2 Trim is desired see page D-33, Oxygen Trim, of the CB
Boiler Book.

Integrated Type In-Situ Zirconia Oxygen Analyzer:
Reduces wiring, piping and installation costs
Allows replacement of the zirconia cell on site
Built-in heater assembly of the probe can be replaced on site
Analyzer Probe is Direct Insertion, In-situ Zirconia Type
Can be configured on site without opening the cover using an Which Provides:
infrared sensor
High accuracy
O2 measurement circuitry built into probe head electronics
Fast Response
O2 Level percentages displayed on the Boiler Control Panel
Human Machine Interface (HMI) Proven Reliability
Provides accurate Boiler Efficiency Calculations with the

CB-HAWK ICS Programmable Controller
PRODUCT OFFERING
In-Situ Zirconia Probe and Analyzer
Separate analyzer/converter display panel not required
Process Variable % O2 Readout on Control Panel HMI
Combustion Air Temperature: Combustion Air Temperature measurement and indication
Provides temperature measurement of boilers combustion
Accurate Efficiency Calculations
air
Indication on HMI display Options:
Used in overall boiler efficiency calculations Separate O2 Converter/Display Panel
Replacement Zirconia Cell
Stack Flue Gas Temperature (included in standard offering):
Auto Calibration Pneumatics
Provides temperature measurement of boilers stack flue gas
Replacement Heater Assembly
Indication on HMI display
Remote Indicator/Alarm
Used in overall boiler efficiency calculations
Probe Stack Mounting Adapter
User Configurable Alarm Points Calibration Gas Kit
Low O2 Alarm
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ENGINEERING DATA 2.0 Combustion Air Temperature Probe
Ambient Temperature: -4 to 131F (-20 to +55C) Type J thermocouple
Sample Gas Temperature: 32 to 1292F (0 700C) 3.0 Analyzer
Sample Gas Pressure: -1.5 to 73.8 in Hg (-5 to +250 kPa) Shall be of the Integrated Type (in probe head)
Output Signal: 4 20mA DC, One Point, Maximum Load Provide 4 20mA DC Signal output in relation to process
Resistance 550 Ohms variable for remote display
Digital Output (HART): 250 500 Ohms 4.0 Monitoring System
Contact Output Signal: Two Points, 30 VDC 3A, 250 VAC 3A Indicate O2 Percentages
(one is fail safe normally open) Provide Low O2 Alarm Indication
Contact Input Signal: Two Points Perform Efficiency Calculations and display results using
Reference Air: Natural Convection, Instrument Air, pressure O2 percentages
compensated 5.0 Combustion Air Thermocouple to be Type J
Instrument Air: 200 kPa plus the pressure in the furnace 6.0 The system shall continuously monitor oxygen
Power Supply: 100 240 VAC, 50/60Hz concentration in the boilers exit flue gas and provide
indication of O2 percentages and alarm points on a Human
Power Consumption: Max 300 W, approx. 100 W for Machine Interface (HMI) type display.
ordinary use
Combustion Air Thermocouple: Type J APPLICATION
This system is applicable to modulating burners using the
SAMPLE SPECIFICATIONS CB-HAWK ICS Integrated Control System. This system shall
This specification covers the hardware and monitoring monitor and display O2 concentration in the boilers exit flue
functions of the CB-HAWK ICS Oxygen monitoring system. gas and provide overall boiler efficiency calculations.
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.
The system shall be completely configured from the factory
requiring only job specific data to be entered (or modified) in
the field.
O2 Sensor Requires calibration in the field!
Hardware:
Hardware shall consist of the following:
1.0 Oxygen Sensor
Integrated type Zirconia Oxygen Analyzer
Direct Insertion Type
Built-in Heater Assembly
4-20mA DC Process Variable Output
Heater to be of field replaceable construction
Cell to be of field replaceable construction
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CB-HAWK ICS ETHERNET COMMUNICATION
The CB-HAWK ICS Ethernet communication package ENGINEERING DATA

provides Ethernet communications between the CB-HAWK
ICS programmable controller and other Ethernet compatible Modular connection to CB-HAWK ICS Programmable
devices such as the Boiler Room Master Lead/Lag Control Controller unit
Panel, Building/Plant automation system, and the Internet. Ethernet Industrial Protocol (Allen-Bradley EPIC)
Follows Ethernet Rules and Practices
High Noise Rejection
Provides communication between the CB-HAWK ICS
programmable controller unit and other Ethernet Compatible Cabling: Category 5E rated twisted pair cable (solid core,
Devices PVC jacket with RJ45 connections).
Provides interface capability with many Building/Plant Meets Open Industrial Network Standards
automation systems when utilizing OPC server or protocol IEEE 802.3 Physical and Data Link Standard
bridge
Ethernet TCP/IP protocol suite industry standard
Provides interface with plants LAN/WAN
Control and Information Protocol (CIP) Compliant
Provides interface to the Internet (requires static IP address)
OPC (OLE Process Control) communication compatibility
E-mailing of boiler alarms/faults with RSLinx OPC Server software
Provides means of connection between various boiler room
control systems, such as the CB-HAWK ICS Master Panel SAMPLE SPECIFICATIONS
for lead/lag control
The Boiler Manufacturer shall furnish and install a control
Provides means of connection to a remote Personal module capable of Ethernet communications between the
Computer boilers programmable logic control system and other Ethernet
Ethernet Industrial Protocol compatible devices, as needed, and provide the following
minimum requirements:
IEEE 802.3 Physical and Data Link Standard
Interface with the Compact Logix Programmable Controller
Ethernet TCP/IP protocol suite industry standard Protocol
Control and Information Protocol (CIP) Compliant Ethernet Industrial Protocol (Allen-Bradley EPIC)
Follows Ethernet Rules and Practices
PRODUCT OFFERING
High Noise Rejection
Ethernet/IP Module
Open Industrial Network Standards
Optional Ethernet Communication Hub (necessary for stand-
alone boiler (no Master Panel) connection to LAN/WAN IEEE 802.3 Physical and Data Link Standard
and/or Paging Modem option) Ethernet TCP/IP protocol suite industry standard
E-mail functionality requires customer provided e-mail Control and Information Protocol (CIP) Compliant
service and address
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CB-HAWK ICS PAGING and REMOTE DIAL-UP

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

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

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

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

Master Slave
Controls Header Pressure and Temperature:
Maintains steam pressure or hot water supply temperature
based on system load demand. Running Idle
Available Unavailable
Lag Lag
Compensates for varying losses between boiler and header. ###.# % ###.# %
Sequences of Operation for Two Boilers:

Provides maximum system efficiency.
Boilers Start and Stop
Reduces cycling and boiler wear; thereby reducing
maintenance and downtime costs. Steam pressure, or hot water temperature, is compared with the
setpoint and controllers processor executes PID algorithm.
Optimizes fuel savings. 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/Lag Start with Lead/Lag Modulation: lead boiler reaches lag boiler start point. Lag boiler is
commanded to stop when a firing rate signal for the lag boiler
Lead boiler operates at full capacity prior to starting lag boiler.
reaches lag boiler stop point.
Lag boiler starts modulation when lead boiler reaches
maximum firing rate position. Lead/Lag Modulation
Ideal for steam boilers. Lag boiler starts modulation after lead boiler reaches
maximum firing rate.
Lead/Lag Start with Unison Modulation:
Lead boiler operates at full capacity prior to starting lag boiler. Unison Modulation
Firing rates for both boilers are equal.
Lag boiler operates at the same firing rate as a lead boiler.
Ideal for hot water boilers. Hot Standby
System shall have a provision for keeping lag boiler in hot
PRODUCT OFFERING standby. Standby routine shall be based on a water temperature
Cleaver-Brooks shall supply the following equipment: signal.
Boiler control for each boiler shall be CB-HAWK ICS.

APPLICATION AND SYSTEM
Pressure (steam) or temperature (hot water) transmitter
shipped loose for mounting in the common header.
REQUIREMENTS
This option is applicable to full modulation burners utilizing
SAMPLE SPECIFICATIONS the CB-HAWK ICS advanced boiler control system and
modulating controls.
Lead/Lag Start with either Lead/Lag or Unison Modulation.
All logic for Lead/Lag Control shall reside in the boiler
controller. No additional control panels shall be required.
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CB-HAWK ICS LEAD/LAG for up to

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

########## ########## ########## ##########
Controls Header Pressure and Temperature: A B C D
Maintains steam pressure or hot water supply temperature

Running Running Running Running
based on system load demand. Available Available Available Available
Working # # # #
Compensates for varying losses between boiler and header. Entered # # # #
Control ###.# ###.# ###.# ###.#
Auto Sequence Rotation in 0#h 0#m 0#s
Benefits:
Maximizes system efficiency.
Master Control Panel shipped loose for field mounting.
Reduces cycling and boiler wear, thereby reducing
maintenance and downtime costs. Requires Ethernet/IP Communication Option
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 either Lead/Lag or Unison Modulation.
Optimizes fuel savings.
Boilers Start and Stop
Lead/Lag Start with Lead/Lag Modulation: Steam pressure, or hot water temperature on hot water systems,
Lead boiler operates at full capacity prior to starting lag is compared with the setpoint and controllers processor
boiler #1. executes PID algorithm. Lead boiler is commanded to come
on-line first. Lag boiler #1 is commanded to come on-line
Lag boiler #1 starts when the lead boilers firing rate is close when a firing rate signal for the lead boiler reaches lag boiler
to the maximum. Operator can select this parameter via HMI. start point. Lag boiler #1 is commanded to stop when a firing
Lag boiler #1 starts modulation when the lead boiler reaches rate signal for the lead boiler reaches lag boiler stop point.
the maximum firing rate position.
Lag boiler #2 is commanded to come on-line when a firing rate
Subsequent lag boilers operate in the same fashion. 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
Ideal for steam boilers.
lag boiler #1 reaches lag boiler #2 stop point.
Lead/Lag Start with Unison Modulation: Subsequent boilers operate in a similar fashion.
Lead boiler operates at full capacity prior to starting the lag
boiler. Lead/Lag Modulation
All boilers operate at the same firing rate as the lead boiler. Lag boiler #1 starts modulation after lead boiler reaches
maximum firing rate (or firing rate selected by the operator).
Ideal for Hot Water boiler systems.
Lag boiler #2 starts modulation after lag boiler #1 reaches
maximum firing rate (or firing rate selected by the operator).
PRODUCT OFFERING
Subsequent boilers operate in a similar fashion.
Cleaver-Brooks shall supply the following equipment:
Boiler control for each boiler shall be the CB-HAWK ICS. Unison Modulation
Pressure (Steam) or temperature (Hot Water) transmitter Firing rates for all boilers are equal.
shipped loose for mounting in the common header.
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Hot Standby Selection

System shall have a provision for keeping lag boilers in hot Number of boilers
standby. Standby routine shall be based on a water temperature
Sequence of firing
signal.
Automatic or manual rotation
Firing Sequence Selection Individual boiler start and stop points with timers
Sequence in which boilers come on-line shall be selected via
Setpoint
HMI. Adequate check shall be provided that does not allow
improper sequence selection. Proportional, integral and derivative gains for control
algorithm
Automatic Rotation of the Boilers
System shall be provided with a sequence to automatically APPLICATION AND SYSTEM
rotate sequence in which the boilers are fired. Rotation shall be REQUIREMENTS
based on the elapsed time.
the CB-HAWK ICS advanced boiler control system and
HMI (HUMAN MACHINE INTERFACE)
modulating controls.
Master panel shall include HMI for display and selection of the
following parameters: Logic for Lead/Lag control shall reside in the Master Control
Panel. Communication between the Master Panel and the
Display individual Boiler Control Panels shall be via Ethernet
communication or hard wiring.
Available boilers
Number of boilers required
Selected sequence of firing
Control output to each boiler
Header steam pressure or water temperature on hot water
systems
Setpoint
Elapsed time from last rotation
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CB780 CONTROL
The CB 780 is a microprocessor-based, flame safeguard con-

trol 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 opera-
tion 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. 5 LEDs on base provide at-a-glance status of Power On,
Pilot, Flame, Main Valves, and Alarm conditions (Power
Closed-loop logic test verifies integrity of safety critical
LED blinks periodically to indicate proper control
loads (ignition, pilot, and main fuel valves) for proper
operation).
operation.
Diagnostic display capabilities are further enhanced by the
Pre-ignition interlocks (fuel valve proof-of-closure) and
optional CB783 Expanded Annunciator which provides 36
flame signal checked during Standby and Pre-Purge.
additional specific HOLD and Fault messages, as well as 26
High and Low fire switches checked for proper sequencing. LEDs to indicate current status or first-out alarm indication
(user-selectable).
Tamper-proof Purge Timer Card.
Communication capabilities to a local or remote Personal
Powerful Display/Diagnostic Capabilities: Computer, with optional CB-LINKcommunications module
2 line x 20 character Vacuum Fluorescent Display is easy to and Combustion System Manager software (runs under
read under all lighting conditions. Microsoft Windows).
Status and diagnostic messages displayed in English Application Flexibility:
Language with no scrolling necessary (Spanish also Purge Timing Cards available in 30, 60, 90 seconds or 2-1/2
available). minutes cover a wide range of applications, while
Displays flame signal in Volts dc, eliminating need for eliminating need for a separate purge timer.
separate meter. Separate output for ignition transformer simplifies
Displays burner hours and numbers of cycles. applications requiring early spark termination.
Diagnostic displays include on/off status of inputs and Selectable configuration jumpers allow application-specific
outputs, RUN/TEST switch status, selected purge time, configuration.
amplifier type and configuration data.
Simplified Servicing:
Fault history (retained in non-volatile memory) displays the
Diagnostic and fault history information available through
cycle, hours, code, description, and condition for the last six
display simplifies troubleshooting procedures.
fault occurrences.
Removable access covers for checking voltage at terminals.
Capability to mount display on front of Control Panel for
improved access, or remotely, in separate control room. 5-function RUN/TEST switch eases start-up procedure.
(Optional) Flame signal display facilitates pilot/light-off test
procedures.
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PRODUCT OFFERING ENGINEERING DATA

Included in each CB 780 system is the following: Supply voltage: 120 Vac (+10%/-15%) 50 or 60 Hz.
One CB780 chassis, including display module. Maximum total load: 2000 VA.
One Purge Timer Card. Load rating-fuel valve output: 65 VA pilot duty plus 1150 VA
inrush, 460 VA opening, 250 VA holding.
One wiring sub-base.
Operating temperature limits: -40 to 140 F.
One flame scanner, either Infrared, Ultra-Violet, or UV Self-
Check. Maximum ambient humidity: 85% non-condensing.
One flame amplifier, to correspond with the selected flame
scanner. SAMPLE SPECIFICATION
Flame safeguard shall be a Cleaver-Brooks Model CB 780
Included with the optional CB783 Expanded Annunciator is:
microprocessor-based control to monitor all critical boiler and
One CB783 Annunciator. burner interlocks, control and supervise burner light off
One wiring sub-base. sequence, and initiate an orderly safety procedure in the event
of interlock or flame failure. The system shall provide status,
All limits and interlocks are wired into wiring sub-base to pro- fault history, and diagnostic information by means of a two-
vide individual hold/fault indication on LEDs of Expanded line alpha-numeric display and alarm/status LEDs. The system
Annunciator, as well as on display module of CB 780 control. shall be approved by UL, FM, and CSA, and shall be accept-
able by IRI.
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CB100E CONTROL
The CB100E is a microprocessor-based, flame safeguard con-

PURGE 00:35
HIGH FIRE PURGE

FEATURES AND BENEFITS SCRL RESET MODE
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.
One flame scanner, either infrared, ultra-violet, or UV self-
Provides indication of burner cycles and run time. check.
Non-volatile memory retains last 6 fault/lockout conditions One flame amplifier to correspond with the selected flame
on power failure. scanner.
Display module can be mounted in cabinet door for external
Included with optional E300 Expansion Module is:
indication. (Optional)
One E300 expansion module.
Optional E300 expansion module provides additional 31
One wiring subbase.
messages pertaining to fault or hold status indication.
One interconnection cable to E100E.
Communication with local or remote PC by means of an
optional E500 communication module. All interlocks are wired into wiring sub base to provide indi-
vidual hold/fault indication on display of CB100E control.
Modular Design:
Interchangeable program modules in English or Spanish. ENGINEERING DATA
Purge time is selected via dip switches. Supply voltage: 120 Vac (+10%/-15%) 50/60 Hz.
Interchangeable amplifiers for infrared, ultra-violet, or UV Maximum total load: 2000 VA.
self-check flame scanners. Fuel valve output load rating: 1250 VA opening, 500 VA
holding.
Reduces part replacement costs.
Operating temperature limits:32 F to 125 F.
PRODUCT OFFERING Maximum ambient humidity: 85% non-condensing.
Included in each CB100E System is the following: SAMPLE SPECIFICATION

One chassis, including a dust cover.
Flame safeguard shall be a Cleaver-Brooks Model CB100E
One 2-line display module. microprocessor-based control to monitor all critical boiler and
burner interlocks, control and supervise burner light-off
One Programmer Module.
sequence, and initiate an orderly safety procedure in the event
One wiring sub-base. 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.
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CB110 CONTROL
The CB 110 is a micro-processor-based, flame safeguard con-


Self Diagnostics:
Seven LED display provided to indicate: Fan, High Fire, Low
Fire, Ignition, Flame detected, Auto and Alarm.
23 Fault indications.
Modular Design:
ENGINEERING DATA
Interchangeable amplifiers for infrared, ultra violet, or UV
self-check flame scanners. Supply voltage: 120Vac (+10%/-15%) 50/60 Hz.
Reduces part replacement costs. Maximum total load: 2000 VA.
Easily upgradeable to a CB 100E by replacing programmer Fuel valve output load rating: 1250 VA opening, 500 VA
and display modules. holding.
Operating temperature limits: -40 F to 125 F
PRODUCT OFFERING Maximum ambient humidity: 85% non-condensing.
Included in each CB 110 System is the following:

One CB 110 chassis, including dust cover.
Flame safeguard shall be a Cleaver-Brooks Model CB 110
One Programmer/Display Module. microprocessor-based control to monitor all critical boiler and
One wiring subbase. burner interlocks, control and supervise burner light-off
sequence, and initiate an orderly safety procedure in the event
One flame scanner, either infrared, ultra-violet, or UV self- of interlock or flame failure. The system shall provide status,
check. fault history, and diagnostic information by means of an LED
One flame amplifier to correspond with the selected flame display. The system shall be approved by UL, FM, and CSA,
scanner. and shall be acceptable by IRI.
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LEAD/LAG SYSTEMS (TWO BOILER LEAD/LAG)
This section contains information on Multiple Boiler Lead/Lag PRODUCT OFFERING

systems. For Lead/Lag systems used with boilers equipped
with the CB-HAWK Boiler Management System, refer to the Cleaver-Brooks shall supply the following equipment:
CB-HAWK Enhancer Lead/Lag Control and the CB-HAWK Lead/Lag selector switch mounted on one boiler.
Two Boiler Lead/Lag System.
On-off and firing rate controls shipped loose for mounting in
common header piping.
Minimum temperature low-fire-hold control steam
Controls Actual Header Pressure and Temperature: boilers.
Maintains steam or hot water supply to system load. Low-fire-hold control hot water boilers.
Compensates for varying losses between boiler and header. Components shall be Underwriters Laboratories approved
for intended service.
Sequences Operation of Two Boilers:
Maximum system efficiency.
Lead/Lag Start with either Lead/Lag Modulation or Lead/Lag
Reduces cycling and boiler wear reducing maintenance and
High-Low Fire.
downtime costs.
The boiler manufacturer shall supply a control system to lead
Optimizes fuel savings.
and lag two boilers. The system shall start, stop, and control the
firing rate of both boilers.
Lead/Lag Start with either Lead/Lag Modulation or Lead/Lag
High-Low Fire: Upon system demand, the lead boiler shall start and operate to
full capacity prior to starting the lag boiler. When both boilers
Lead boiler operates at full capacity prior to starting lag are on line, the lead shall always operate to full capacity and
boiler. the lag shall operate between minimum and maximum output
Ideal where load swings are infrequent and small such as to satisfy demand requirements.
heating applications. When system demand decreases, the lag boiler shall return to
the minimum firing rate position and shut off. A further
Lead/Lag Start with either Unison Modulation or Unison decrease shall cause the lead boiler to reduce its firing rate to
High-Low Fire: minimum and shut off.
Boilers operate in unison when both are on line. A switch shall be provided to rotate the lead position between
Ideal where load swings are frequent and large, such as both boilers.
process applications. For steam boilers, a means shall be provided to maintain mini-
mum boiler water temperature at low-fire when the boilers are
off line.
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For hot water boilers, a means shall be provided to keep the A switch shall be provided to rotate the lead position between
boilers at low-fire rate until a predetermined minimum temper- both boilers.
ature is reached. This releases the boiler to automatic operation
For steam boilers, means shall be provided to maintain mini-
from the firing rate control.
mum boiler water temperature at low-fire when boilers are off
All components shall be Underwriters Laboratories approved line.
For hot water boilers, means shall be provided to keep boilers
Lead/Lag Start with either Unison Modulation or Unison High- in a low-fire-hold mode until a predetermined minimum tem-
Low-Fire. perature is reached. This shall then release the boiler to auto-
matic operation from firing rate control.
and lag start of two boilers. The system shall start, stop, and All components shall be Underwriters Laboratories approved
control the firing rate of both boilers. for intended service.
Upon system demand, the lead boiler shall start and operate to The lead/lag system is a specialized digital control that
full capacity prior to starting the lag boiler. When both boilers sequences the starting, stopping, and controls modulation firing
are on line, they shall operate in unison between minimum and rate for two boilers. It can be used for either steam or hot water
maximum output to satisfy demand requirements. applications.
When system demand decreases, both boilers shall reduce their
firing rate, in unison, to minimum. The lag boiler shall shut off APPLICATION
and the lead boiler shall operate between minimum and maxi- This option is applicable to full modulation burners utilizing
mum until demand is satisfied, and then shut off. standard Cleaver-Brooks modulating controls.
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LEAD/LAG SYSTEMS (TWO THROUGH FOUR

BOILER LEAD/LAG)
The lead-lag system is a specialized digital control that ENGINEERING DATA
sequences the starting, stopping, and controls modulation firing
rate for two through four boilers. It can be used for either steam Voltage input: 115 V, 60 Hz
or hot water applications. 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).
PID Control Logic:
Precise control. Firing rate signal: 0 to 135 ohm resistive.
Monitors rate of change to anticipate needs of system, Sensor ranges:

turning boilers on or off as needed. Temperature: -30 F to 250 F accuracy plus or minimum
1F.
Lead/Lag Start and Modulation:
Pressure: 0-30 psig, 0-100 psig, 0-200 psig accuracy 1% full
Provides optimal control action for different applications. scale.
Lead boiler rotates automatically every 24 hours or manually Standby battery: Operates for 100 days minimum with overall
selected for fixed lead position. average life of 5 years.
Maximum ambient temperature: 120 F.
Boilers Controlled From Header Pressure or Temperature:
Maintain constant steam or hot water supply to system load. SAMPLE SPECIFICATIONS
Compensate for varying losses between boiler and header. 1.0 The boiler manufacturer shall furnish a microprocessor
based control system. The control shall be engineered and pro-
Sequences Optimal Number of Boilers on Line: grammed exclusively for the operation of multiple steam or hot
Maximum system efficiency. water full modulation boilers. It shall incorporate the following
integrated functions:
downtime costs. Manual or automatic lead stage rotation; boiler sequencing and
burner firing rate (modulation control). The control shall be of
Optimizes fuel savings. modular construction to facilitate field modification, upgrading
or repair. It shall include the following features.
PRODUCT OFFERING 2.0 The control shall have the capability of operating in a tem-
Cleaver-Brooks shall supply the following equipment: perature or pressure mode. Temperature sensors shall be of the
thermistor type, suitable for insertion into a 3/8 ID well. Stan-
Lead/lag sequencing control system for full modulating dard operating range shall be -30 F to +250 F. Pressure sen-
boilers (four boilers maximum). sors shall be of the 4-20 ma type. Standard operating range
Relays on control system panel for start-stop control of shall be 0-30, 0-100, 0-150 or 0-200 psig.
boilers. 3.0 The control shall provide an integral sensor set point
Pressure or temperature sensor and immersion well. 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
Assured low-fire cutoff upon boiler shut off (steam and hot
multi-turn knob. The setting value shall be stored in EEPROM
water boilers).
indefinitely.
Minimum temperature low-fire-hold control (steam boilers).
Low-fire-hold control (hot water boilers).
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4.0 The control shall provide a LED bar graph display of each 6.0 A lithium coin type battery shall be included to maintain
boilers approximate percent modulation. The control shall also the correct lead stage and lead stage rotation timer in the event
provide a digital LED display of actual temperature or pres- of power failure. Storage capacity shall be 100 days.
sure, set point temperature or pressure, gain adjustment and
7.0 A four position selector switch shall be provided to set the
each boilers exact percent modulation. In addition, the digital
operating mode of each stage. Positions include on, auto, off
display shall be used to indicate the following four control set-
and standby.
tings as they are being adjusted:
8.0 The control shall have the capability of operating up to four
Modulation start point shall be adjustable from 50 to 100%.
full modulation boilers. Each stage shall have the following
This setting determines the percent modulation a stage must
outputs:
achieve before the next stage is activated. There shall be
independent adjustment of this setting for each burner. A normally open contact to start/stop the burner.
Purge timer shall be adjustable from 0-9.9 minutes. This A 0-135 ohm output to independently control each burners
setting determines the delay time between a burner being firing rate.
started and the beginning of modulation.
9.0 The control shall be UL listed, tested per Standard 873.
Set back (additional set point) shall be adjustable from 0-75 Temperature Indicating and Regulating Equipment. It shall be
F/psig (0-7.5 psig on 0-30 psig units). This setting CSA listed, tested per Standard C22.2 Number 24-1987 Tem-
determines the F/psig drop from the primary set point perature Indicating and Regulating Equipment. It shall also be
whenever the setback mode is activated. An off setting approved for use in NYC by the City of New York; Department
shall also be included for complete burner shutdown. The set of Buildings, Bureau of Electrical Control and Department of
back mode shall be activated by an external switch closure. Environmental Protection, Bureau of Air Resources.
Standby timer shall be adjustable from 1-60 minutes. This 10.0 A surface mounted, locking steel, NEMA 1 type, mini-
setting determines the delay period which must elapse before mum 18 gauge enclosure shall be provided.
any designated standby boilers are activated. The timing
sequence shall begin when all active boilers reach 100% APPLICATION
firing rate.
5.0 LEDs shall be provided to indicate the lead stage and all standard Cleaver-Brooks modulating controls.
activated stages.
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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 con-
trol with sensor and immersion well. The control is Underwrit-
ers Laboratories approved for intended service and shall be
mounted and wired on the boiler.
The boiler manufacturer shall furnish and install a control to
sense boiler water temperature. The control shall maintain
burner in a low-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.
APPLICATION
This option is applicable to full modulation and high-low fire
burners.
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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.
refractory.
Operational mode-manual or automatic.
PRODUCT OFFERING
Cleaver-Brooks shall supply:
Boiler water temperature control and immersion well.
Interface relay.
Operation mode.
Manual selector switch.
Automatic activated by remote on-off boiler control
device.
Components Underwriters Laboratories approved for
intended service.
The boiler manufacturer shall furnish and install a control to
sense boiler water temperature. The control shall have an
adjustable set point to maintain a minimum temperature at a
pre-set level when the boiler is off line. This shall be accom-
plished at the burners minimum firing rate. The function can be
activated either manually or automatically. Components shall
be Underwriters Laboratories approved for intended service.
APPLICATION
burners.
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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.
refractory.
PRODUCT OFFERING
Cleaver-Brooks shall provide terminal connection points for
remote disable/enable signals, and internally wire additional
electrical components necessary to perform this function.
The boiler manufacturer shall make provisions to accept
remote enable/disable signal contact. Any disable signal shall
cause the burner to return to minimum low fire position prior to
shutting off the main fuel.
APPLICATION
burners.
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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.
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.
APPLICATION
standard Cleaver-Brooks modulating controls.
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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.
The boiler manufacturer shall furnish sequence to allow an
automatic changeover from primary to stand by fuel and
back. An automatic fuel changeover shall be initiated by gas
pressure, outdoor temperature or other dry contact.
APPLICATION
This option is applicable to dual-fuel (i.e., gas-oil fired) boilers
with exception of Model LE Boilers.
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OXYGEN TRIM
The C-B Model O2 Trim System is a complete package used to
maintain optimum fuel-to-air ratios and maximum fuel effi-
ciency.

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. High stack temperature alarm and/or boiler cutoff (when
Recorder output of oxygen values is operator selectable for used with optional stack temperature transmitter).
either 4-20 ma or 1-5 Vdc. Firing rate output is 1-5 Vdc. Analyzer malfunction.
Time delay may be incorporated into these contacts.
The Model C-B O2 Trim System Incorporates Dual Analyzer
Displays:
Analyzer Probe is Direct Insertion, In-Situ Type Which Pro-
A large LED display for oxygen levels. vides:
40 character, back-lit, LCD for display of configuration and High accuracy.
other data.
Fast response.
Display is used for friendly prompts during programming
calibration, service, and monitoring. Reliability.
The Controller Display is a Back-lit LCD Which Will Display PRODUCT OFFERING
the Following in Both Digital and Bar Graph Format: Oxygen trim system can be supplied for either fuel trim or air
Process variable (% O2). trim.
Set point. NEMA 12 Control Panel with the following:
Control Output. Oxygen analyzer.
Graphic trending of O2 or firing rate on controller display for Oxygen probe (15.75").
up to 24 hours. Graph timing is selectable. Oxygen controller.
Two Alarm Contacts Which Are User-Configurable for Any Fuel selection indicator lights.
of the Following Functions: Pneumatic control components and actuator.
Low O2 alarm. In-situ probe with zirconia cell.
Low O2 shutdown. Firing rate transducer.
50 ft cable for probe and firing rate transducer.
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Optional Equipment SAMPLE SPECIFICATIONS

Pneumatic actuator for switch over. This specification covers the hardware and control of the C-B
Stack temperature transmitter for display on analyzer. O2 Trim System. The system adjusts the fuel-to-air ratio in
order to maintain maximum efficiency and features reliable
Control panel stand. monitoring and control of oxygen concentrations.
Probe filter (stainless steel). 1.0 The system shall be completely configured from factory,
Probe stack mounting adaptor. requiring only job-specific data to be entered (or modified) in
the field. Controller/analyzer shall be shipped with default
27" probe. values and have a limit on the range of adjustments where
applicable.
ENGINEERING DATA Hardware:
Probe: Hardware shall consist of the following:
Sample Gas Temperature: 0 to 1100 F. 2.0 Oxygen Sensor:
Insertion length: 15.75", 27". The oxygen sensor shall be:
Ambient Temperature: 14 to 176 F. Zirconia cell with temperature held constant by a heater.
Material in contact with gas: Stainless Steel, Zirconia. Probe is in-situ type to provide fast response to changes
Installation: Flange mounting (equivalent to 2" 150 lbs FF. in O2 levels.
ANSI flange). 3.0 Analyzer:
Enclosure: NEMA 4. The analyzer shall be:
Weight: Insertion length 15.75" approximately 9 lbs. 4-20 ma O2 output signal with linearly proportional to a
Insertion length 27" approximately 12 lbs. 0-20%
Control Panel: Capable of single-point automatic calibration or dual
Power Supply: 110/120 Vac, 3 amps, 50/60 Hz. point manual calibration. Single point calibration is
programmable based on an internal time clock.
Dimensions: 20" H x 20" W x 13" D.
Able to provide a contact closure during calibration,
Weight: Approximately 70 lbs. which will be wired into controller to override trim
Ambient Temperature: 32 to 122 F. function during calibration.
Air Supply: 25-126 psig instrument air dry, oil free. Response 90% within five (5) seconds after gas is
introduced.
Outputs:
Capable of providing the following control and monitoring
Control: 3-15 psig. ability in the analyzer:
Recorder: O2 value 1-5 Vdc or 4-20 ma. Display interactive operation.
Firing Rate 1-5 Vdc. Analog bar display format on screen.
Contact: 250 Vac, 2 amps. Indicate average O2 computation.
Low O2 alarm. Maximum and minimum O2 levels.
Low O2 shutdown. Large LED display of O2 level.
40 character dot matrix back-lit LCD display of
configuration and other data.
Self testing for cell life.
Analog output range of 0-20% O2 computation.
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Efficiency calculations (with temperature transmitter 6.0 The system shall continuously monitor oxygen concentra-
option). tion in boiler flue gas and adjust fuel or air flow to maintain
oxygen level at set point. Set point shall be dependent on boiler
4.0 Controller:
firing rate and fuel selection inputs to controller. Controller
Controller shall: shall determine set point internally based on these inputs,
through separate curves (function generators) for each fuel.
Be microprocessor based.
The rate-of-change of the firing rate input shall be limited to
Have means for indicating the process variable (% allow for the response time of the gases traveling through the
oxygen) setpoint, and output: each of these in both boiler. Control to be direct acting. Proportional- plus-Integral
digital and bar graph format with range 0-20%. (PI) with integral-only response to set point changes. Gain
shall be varied based on firing rate, with faster response at high
Allow for switching between automatic and manual
firing rates and slower response at low firing rates. Control to
control, and for changing the setpoint and output.
incorporate anti-reset windup capabilities when output reaches
Accept 4-20 ma signal from the O2 analyzer, a its limit. Since trim output must be able to add or subtract from
calibration contact from the analyzer, and a firing rate fuel or air flow, the normal or no trim output shall be 50%.
signal from a boiler-mounted potentiometer.
Accept dry contact indication of fuel being fired. The APPLICATION
front panel display of the control shall be a bit mapped This system is applicable to modulating burners that utilize a
LCD type with a switch that allows operation and Cleaver-Brooks fuel oil controller (on oil firing) and/or specific
system adjustments to be performed from a menu. The gas pressure regulators (on gas firing). Contact your local
display panel shall also include trend and alarm features Cleaver-Brooks authorized representative for specific details.
for real-time, history, and allow viewing of related data
while making adjustments.
5.0 The control panel of the controller shall also have the fol-
lowing features:
Dedicated page key to be used for screen selection.
Programmed function key to define fuel type.
Mode key to determine auto or manual mode.
Failure light.
Alarm light.
8 character display description.
Oxygen level recorder output 4-20 ma or 1-5 Vdc.
Firing rate output 1-5 Vdc.
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CB-HAWK BOILER MANAGEMENT

CONTROL SYSTEM
The CB-HAWK is a complete boiler management control sys-
tem which combines the functions of a flame safeguard pro-
grammer with those of operating and firing rate controls. It
uses a solid state steam pressure or hot water temperature sen-
sor. The CB-HAWK also monitors the fuel pressure and tem-
perature (if required) with solid state sensors and provides a
built-in safety limit control of those functions.
The CB-HAWK may be used on most types of steam or hot
water boilers, including firetube, industrial watertube, and
commercial watertube. It is designed to operate a gas, oil or
combination burner using a single modulation motor and pro-
vides best results when used with a fully modulating burner.
In addition to installation on new boilers, the CB-HAWK can
be added as a retrofit to existing boilers. Contact your local
Cleaver-Brooks representative for details on retrofitting CB-
HAWK to any boiler.
FEATURES & BENEFITS

Complete Boiler Control System: Reduced Boiler Wear:
Combines control function of burner sequencing and safety Built in warm-up and shut down sequence to reduce thermal
with firing rate and operating limit control. shock.
Reduced modulation and cycling due to more accurate
Single boiler control with expansion capabilities for multiple
burner positioning.
boilers using Communication Interface, Enhancer, and
General Purpose Interface (GPI).
Greater Reliability and Safety with Solid State Design:
Keyboard/Display: Tamper resistant sensors prevent unsafe operation.
Provides single point for boiler monitoring and adjustments. Access code protection prevents unauthorized changes.
Complete dynamic self check of all circuits and sensors.
Digital set points and values for accurate information.
English messages, labels, and prompts for easy use. Complete Diagnostics Reduces Downtime:
Eliminates many screwdriver adjustments. 73 fault messages.
Fault History details: Cycles, hours of operation, boiler
Precise Control of Steam Pressure or Hot Water Tempera- status, firing rate, fault codes and messages for last six safety
ture: shutdowns.
Accurate measurement using solid state sensors. Diagnostics provide status and voltage of all inputs, without
the need for a test meter.
Advanced microprocessor control of firing rate is
characterized to specific boiler. Five function run test switch for improving set-up.
Special 400 position damper motor. Improved Energy Efficiency:

Customized pre-purge sequence limits purge losses.
Accurate firing rate control reduces excessive modulation.
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PRODUCT OFFERING Maximum Total Connected Load
Standard Equipment: Chassis and Program Module.
The CB-HAWK consists of the following components: 2000 VA.
Keyboard/display. Boiler Controller (Total System) Fuse:
Chassis module. 15A maximum, type FRN or equivalent.
Program module. Chassis Fuse:
Flame scanner and amplifier (IR or UV type). 10A, field replaceable.
Steam or hot water sensor.

400 Position damper motor.
1.0 Each unit shall be factory equipped with a boiler manage-
Fuel safety sensors. ment control system providing technology and functions equal
Optional Equipment: to the Cleaver-Brooks model CB-HAWK.
Details for the following optional equipment are found later in 2.0 Major functions of the boiler management system shall
this section. provide:
CB-LINK Communications Module. Automatic sequencing of the boiler system through standby,
pre-purge, pilot flame establishing period, main flame
CB-HAWK Enhancer Base Unit. establishing period, run and post-purge.
CB-HAWK Enhancer Efficiency Monitor. Flame proving and lockout on flame failure during pilot
CB-HAWK Enhancer Auxiliary Input Monitor. flame proving, main flame proving, or run.
CB-HAWK Time of Day Scheduling Control (Day/Night Low fire damper motor position for flame ignition trails.
Setback). Full modulating control of fuel and combustion air as well as
CB-HAWK Outdoor Reset Temperature Control. firing rate control.
CB-HAWK General Purpose Interface (GPI). Utilize solid state control and limit sensors providing the
following control functions:
CB-HAWK Enhancer Lead-Lag Control.
Steam (or hot water) on/off and proportioning control.
CB-HAWK Two Boiler Lead-Lag System.
Gas pressure high and low pressure limit. (if required).
ENGINEERING DATA Oil temperature high and low temperature limit (if
required).
Voltage and Frequency
Oil pressure high and low pressure limit (if required).
Chassis and Program Module.
Damper motor high and low fire damper motor position.
120 Vac (+10%/-15%) 50/60 Hz 10%.
Manual control of the damper motor utilizing slewing keys to
Keyboard and Display Module. increment and decrement the damper motor position.
24 Vac (+20%/-15%) 50/60 Hz. Status light emitting diodes (LEDs) indicating: 1) Green
Power Dissipation LED demand present, 2) Yellow LED main valve
energized, 3) Red LED (2) alarm, 4) Pulsing Green LED
Chassis and Program Module. proper programmer operation.
10 Watts maximum. Field replaceable 10 amp fuse in the valve and ignition
Keyboard and Display Module. control circuit for short circuit protection.
2 Watts maximum. NEMA 1 rated enclosure.
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Line voltage terminal inputs for lockout, pre-ignition, and 4.0 All boiler management control wiring shall be in accor-
recycle limits and interlocks. dance with the National Electrical Codes and local electrical
codes.
73 separate annunciation faults including damper motor
operation, gas pressure limit operation (if required), oil 5.0 The Boiler Management Control shall provide the follow-
pressure limit operation (if required), Oil temperature limit ing safety provisions:
(if required), and hot water (or steam) sensor control
Dynamic self-check safety circuit. The boiler management
operation.
controls microcomputer should continuously test itself and
Self test for proper operation. related hardware for proper circuit operation.
Monitor system circuits status. Examine all load terminals to assure it is capable of
recognizing the true status of external controls, limits and
Tamper resistant safety logic and timing.
interlocks. If any input fails this test, the Boiler Management
First out annunciation and diagnostics via a liquid crystal Control should lockout on safety shutdown.
display (LCD).
Closed-loop logic test of all safety critical loads (oil main
Thermal stress delayed release to modulation. valve, gas main valve, ignition transformer and pilot valve)
and must be able to lockout on safety shutdown if any safety
Non-volatile lockout and history files with last (6) lockouts
critical load is identified as operating improperly.
readable through integral LCD display.
Dynamic safety relay and contact. The control shall check
Dynamic Ampli-Check as standard flame amplification
the proper operation of the safety circuit, ability to open and
protection.
close relay contact. This will assure the boiler management
Characterization to the applied boiler for firing rate control, control is capable of de-energizing all safety critical
cycling control, and system prepurge. terminals (oil main valve, gas main valve, ignition
transformer and pilot valve).
A configurable rate linearization parameter which defines the
relationship between damper motor position and firing rate Dynamic amplifier check of the flame signal amplifier. The
and including drive to purge rate. control flame signal amplifier must be able to recognize a no
flame signal during this dynamic amplifier check.
Capability for remote or local communications to a personal
computer including the capability to change non-safety Safe start check and expand check to include monitoring
related parameters remotely. flame signal during standby.
Ability to be able to be installed in a continuous 0.5G Dynamic gas pressure sensor check. To assure the gas
environment. pressure limit sensor can signal zero gas pressure when gas
pressure is not present at the gas pressure limit sensing
3.0 Major system components shall include:
element.
1. Chassis.
Continuous monitoring of all applicable sensors, including
2. Program module. steam pressure, gas pressure, and oil pressure to ensure
signals are within operating range.
3. Keyboard and display module.
Monitoring the damper motor via a feedback circuit to assure
4. Flame amplifier, dynamic ampli-check infrared.
the damper motor is at the required position within 60
5. Damper motor: 90 degree stroke, 400 position. seconds, the damper motor is slewing properly, the damper
motor is within 0 to 90 degrees, and ensures proper amount
6. Flame sensor: infrared.
of prepurge air.
7. Control sensors: hot water temperature: 0 to 500 F range.
Automatically returns the burner to the low fire position
Steam pressure specify psi range.
before shutting off when power is interrupted.
8. Limit sensors:
Tamper resistant timing and safety logic.
A. Gas pressure limit specify psig range.
Require mandatory reprogramming when being installed on
B. Oil pressure limit specify psig range. another boiler.
C. Oil temperature limit specify temperature range.
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6.0 The Boiler Management Control System shall provide Infrared flame amplifier or UV amplifier: Provides flame
these annunciation and diagnostics: signal amplification. A dynamic ampli-check of the flame
signal amplifiers circuitry is conducted to assure the
First out annunciation plus time and cycle in sequences of
amplifier responds to loss of flame.
fault occurrence.
Gas pressure sensor: Provides a 1 to 6 Vdc signal to the
Indication of sequence failures at start-up or during normal
Boiler Management Control. Gas pressure sensors provides
sequence operation.
high and low gas pressure limits with gas pressure ranges of
Test itself for failure, detect and isolate an alarm, and report 0.1 to 15 psig.
internal circuit faults.
Steam pressure sensor: Provides a 1 to 6 Vdc signal to the
The ability of reading limit sensor voltages and resistance at Boiler Management Control indicating steam pressure in the
connector interface. boiler. Signal provides on/off and modulating control of the
burner, with ranges from .75 to 750 psig.
English text description of the system fault, while
maintaining the last six (6) faults in historical memory, which Oil pressure sensor: Provides a 1 to 6 Vdc signal to the Boiler
are readable through the LCD display. Management Control indicating oil pressure supplied to fuel
oil controller. Signal provides high and low oil pressure limit
7.0 The Boiler Management control shall be able to operate in
functions within range of 7.5 to 150 psig.
these environmental conditions:
Oil temperature sensor: Provides a resistance signal to Boiler
32 to 130 F temperature range; 85% RH continuous, non-
Management Control indicating oil temperature at the sensor
condensing, humidity; 0.5G continuous vibration; 120 Vac
well assembly. Signal provides high and low oil temperature
(+10/- 15%) 50/60 Hz voltage/frequency; maximum
limit functions within range of 0 to 300 F
connected load of 2000 VA.
Water temperature: Provides a resistance signal to the Boiler
8.0 Boiler Management Control System Component functions
Management Control indicating water temperature at the
shall be as follows:
sensor well assembly. Provides on/off and release to
Chassis module: Provides mounting means and line voltage modulation control of the burner. The sensors have ranges of
I/O for the boiler room control. 0 to 300 F and 0 to 500 F.
Program module: Provides boiler sequence logic to meet Damper motor: Drives firing rate valve and combustion air
FM/IRI approval body requirements. The Program module damper based on input from the Boiler Management Control
is the location of the system micro-computer which generates to purge the combustion chamber, provide fuel and air in
fault messages and descriptions and processes boiler proper proportion, and vary burner firing rate to meet the load
room I/O. demand on the boiler.
Keyboard and display: Provides user interface to the system
for sequence status fault history, and system configuration
interface, all via a 2 row by 40 character LCD.
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CB-LINK

Connects up to six boilers:
Allows single point monitoring and control of CB-HAWK.
Allows single point monitoring of CB780.
Allows multiple boiler control functions from Enhancer.
Allows multiple boiler communications from General
Purpose Interface (GPI).
Remote Annunciation of Boiler Faults:

Reduces response time of maintenance personnel.
Reduces response time of service company.
Allows unmanned facility to notify central office.
Remote Monitoring of Boiler Operation:

Monitor pressure, temperature, status, diagnostics. PRODUCT OFFERING
Reduce cost of maintenance and service calls. Base Unit includes the following:
Communications module with local RS232 serial port, and
Data Logging Using Personal Computer: six plug in module slots.
Reduces costs for recording information. One plug in module for each boiler.
Improved data accuracy. Combustion Systems Manager (CSM) software for operation
Improved planned maintenance by spotting trends. on an IBM AT compatible computer.
Help troubleshoot problems with historical data. NEMA 1 enclosure (Metal enclosure with hinged door and
removable sub-base is optional).
Fault History Log Using Personal Computer: Options:
Time and Date stamp all faults. One additional plug in module required for each additional
boiler.
Provides a permanent record of fault conditions.
Maximum six boiler connected, five if used with Enhancer,
Remote Setpoint Adjustments: five boilers if used with GPI card, and four boilers if used
with GPI with Enhancer.
Operator can take boilers on or off setback from remote
location.
Process engineers can adjust boiler settings affecting their
process.
Password Protection:
Prevents unauthorized personnel from accessing The Boiler
Management Control.
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ENGINEERING DATA 3.0 The communications module shall be able to activate a

remote pager as one of the three pre-programmed telephone
Power Required: numbers if desired.
Voltage and Frequency: 120 Vac (+10/-15%), 50/60 Hz ( 4.1 Either the local or remote personal computer software shall
10%). be provided on 3-1/2 floppy diskette that will operate on
Control Bus Communication: RS485. Microsoft Windows 3.1 or later. Data logging of boiler oper-
ating pressures and/or temperatures at predetermined times
Hayes Smart Modem compatible for remote communication shall be available. Access control password protection shall
with a personal computer. also be provided.
Environmental Ratings: The software shall be compatible with the following computer
Ambient Temperature: Operating 32 to 130 F, Storage -30 to hardware.
150 F. IBM AT Compatible Personal Computer with:
Humidity: Operating, 85% RH Continuous, Non- 8 MHz or faster clock speed.
condensing.
20 MB minimum hard disk drive.
Vibration: Continuous 0.5G.
5-1/4 or 3-1/2 floppy disk drive.
Enclosure: NEMA 1.
VGA graphics capability.
Weight: 4 lbs 10 oz (unpacked without Control Bus Module).
RS232 serial port (com 1 or 2).
SAMPLE SPECIFICATIONS Optional 1200 BAUD external modem.
1.0 A communications module shall be supplied providing 4.2 The HAWK LINK shall include communication protocol
technology and function equal to the Cleaver-Brooks model and device information to the building automation system inte-
CB-LINK communications module that shall allow for remote grator. Provide a General Purpose Interface module that occu-
programming control, monitoring and diagnostics up to 6 boil- pies one of the six slots on the LINK chassis. This module shall
ers equipped with CB-HAWK Boiler Management Control, support either ASCII or binary codes via RS-485 standards and
with an IBM AT compatible personal computer or a building connections. The system integrator can transfer select control
automation system. and monitoring information from any CB HAWK, CB-780 or
ENHANCER. Provide a disk to be used by the system integra-
2.0 The communications module shall provide for remote or tor that contains protocol specifications, device & point
local programming of non-safety functions such as boiler on, description files, instructions and ROM image file to convert
boiler off, operating setpoint, etc. It shall also provide for local any General Purpose Interface module into a Testcard device
and remote communication of individual boiler shutdowns and that implements all of the data types of all devices, a PC pro-
73 fault codes that are date and time stamped. Local communi- gram to test and demonstrate the General Purpose Interface
cations to an IBM AT compatible shall be via a RS232C module and its protocols (a RS-232 to RS-485 adapter will be
port. Remote communications to an IBM AT compatible required)
equipped with a modem shall be via a customer supplied exter-
nal modem (Hayes Smart Modem or equal) to the CB-LINK
communications module operating at 300 or 1200 BAUD.
Building automation system tie-in shall be via a General Pur-
pose Interface (GPI) device which provides a passive gateway.
On a fault shutdown condition, the communications module
shall report the shutdown to either a local computer or printer
and/or call out up to 3 pre-programmed telephone numbers via
an external modem.
D-41
12-02
Controls
CB-HAWK ENHANCER BASE UNIT

Keyboard and Display:
Single point monitor of multiple boilers.
Membrane-type keypad for reliability in boiler room
environments.
Large 1" LED Status Display:

Immediate annunciation of faults.
Continuous display of boiler status can be seen across room.
Base unit provides enclosure for Enhancer options. It must be
used in conjunction with one or more Enhancer options.
PRODUCT OFFERING
The CB-HAWK Enhancer is used in conjunction with one to
five boilers that are equipped with CB-HAWK Boiler Manage-
ment Control. The Enhancer and associated HAWK controls
must all be connected to a CB-LINK communication module. SAMPLE SPECIFICATIONS
Because of a conflict between control actions, Outdoor Reset
Control and Time of Day Schedule control can not be used The CB-HAWK Enhancer shall be provided complete in its
together. One or more Enhancer options must be used in con- own NEMA 12 enclosure, with the exception that the sensors
junction with the Enhancer base unit. are shipped loose for field installation. The keyboard/display
shall be mounted on the front door of the enclosure for access
Standard Equipment: to setpoints and display parameters. An LED annunciator shall
The Enhancer comes in a single 24" x 24" x 8" NEMA 12 also be mounted on the front door for annunciation of alarm
enclosure with keyboard/display, status display, 10-slot rack, conditions and lead/lag boiler status.
power supply, and required modules.
ENGINEERING DATA
Power required: 120 Vac, 50/60 Hz, 3 amps.
D-42
12-02
Controls
CB-HAWK ENHANCER EFFICIENCY MONITOR
FEATURES AND BENEFITS SAMPLE SPECIFICATIONS

1.0 The Enhancer shall include the Boiler Efficiency Monitor
Calculates Efficiency With or Without O2 Measurements: feature. It shall provide the user with basic information regard-
Uses separate O2 signal if available for increased accuracy. ing boiler operation. Up to five (5) boilers may be monitored
simultaneously. The following operating parameters shall be
Estimates efficiency without O2 for lower cost installation. displayed:
Calculations based on boiler efficiency and firing rate. Instantaneous boiler efficiency.
Calculate Fuel Usage: Average boiler efficiency.
Allows management to see where costs are. Total Btu input.

Total Btu output.
Easy to Understand Measurements:
Peak load.
No need to convert stack temperature measurements.
Quantity of fuel used (gallons of oil or therms of gas).
Instantaneous, 1 hour, 8 hours, 24 hours and 1 week
averages. Total fuel used.
Average cost to generate output ($/M Btu).
Indicates Conditions Requiring Attention:
The above parameters shall be calculated from known operat-
Assists the operator in maintaining optimal efficiency. ing characteristics and direct measurements based on the fol-
lowing formula:
Preventative maintenance may be performed before
expensive procedures are required. 2.0 Boiler Efficiency = 100% (stack losses + radiation &
convection losses).
High stack temperature alarm indicates problems.
The Boiler Efficiency Monitor shall not require mass flow
PRODUCT OFFERING meters for water, steam, or fuel.
The Enhancer Boiler Efficiency Monitor is an optional feature

of the CB-HAWK Enhancer and is used in conjunction with
the Enhancer Base Unit and CB-LINK Communication Mod-
ule. It may be used with up to five CB-HAWK Boiler Manage-
ment Control equipped boilers.
The efficiency calculation is not based on actual flow measure-
ments, but on data calculated from quantitative test results and
measurements of stack temperature, ambient temperature, oxy-
gen (measured or estimated) and boiler information from the
CB-HAWK Boiler Management Control.
Equipment provided with the Enhancer Boiler Efficiency Mon-
itor:
Stack temperature thermocouple for each boiler (shipped
loose).
Ambient air temperature thermocouple and bracket (shipped
loose).
Necessary input/output modules inside enclosure.
D-43
12-02
Controls
CB-HAWK ENHANCER LEAD/LAG CONTROL
FEATURES AND BENEFITS SAMPLE SPECIFICATIONS

The Enhancer Lead/Lag Control system provides lead/lag con-
Unison or Lead/Lag Modulation for up to Five Boilers: trol of the steam pressure (or water temperature) in the main
Provides optimal control action for different applications. header, fed by up to five (5) boilers. It shall provide the follow-
ing functions:
Controls Actual Header Pressure or Temperature: Control of header pressure (or water temperature) using solid
Maintains constant steam or hot water supply to load. state sensors for measurement.
Compensates for varying losses between boiler and header. Control shall not require a noticeable change in pressure (or
water temperature) to sequence a boiler on or off.
Sequences Optimal Number of Boilers on Line: Operator adjustable minimum-temperature control of lag
Maximum system efficiency. boilers.
Reduced cycling and boiler wear for lower maintenance and Boiler status and firing rate information of each boiler shall
downtime costs. be monitored and controlled by the lead/lag system via a
direct bi-directional digital communication link.
Boiler Sequencing Based on Boiler Firing Rate: Large 1" LED display to annunciate lead and lag boiler run
and alarm conditions.
Does not require a significant change in pressure or
temperature as in conventional systems. An alarm indicator annunciates conditions when the boiler
system capacity is insufficient to maintain system pressure
Starts new boiler as an immediate response to any boiler
(or water temperature) or if a system fault occurs.
taken off line for uninterrupted operation.
Keyboard entry of following parameters:
Minimum temperature control so lag boilers are always ready Lead Boiler.
to respond to load changes.
First through fourth lag boilers.
Alarm Annunciation: System set point.
Load Exceeds Capacity alarm warns of potential problems System on point and off point.
before a significant loss of pressure or temperature occurs.
Lag-on trigger and delay set points.
PRODUCT OFFERING Lag-off trigger and delay set points.
The Enhancer Lead/Lag Control is an optional feature of the Lead/lag system shall immediately start an additional lag
CB-HAWK Enhancer, and is used in conjunction with the boiler to compensate for lost capacity if an on-line boiler is
Enhancer Base Unit and the CB-LINK communication mod- turned off or if a fault causes a shut down.
ule. It may be used with up to five CB-HAWK Boiler Manage- The lead and lag boilers may be changed at any time without
ment Control equipped boilers. upsetting the system pressure (or water temperature)
Equipment provided with the Enhancer Lead/lag Control regardless of the number of boilers currently on line.
includes:
Header steam pressure or water temperature sensor (shipped
loose).
Minimum temperature controls for boilers (shipped loose).
Necessary input/output modules inside enclosure.
D-44
12-02
Controls
CB-HAWK TWO BOILER LEAD/LAG SYSTEM
FEATURES AND BENEFITS 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
Controls Actual Header Pressure or Temperature:
minimum and shut off.
Maintains steam or hot water supply to system load.
Provisions shall be made to transfer each boilers set point
Compensates for varying losses between boiler and header. between normal and setback, as a means for determining lead
and lag boiler.
Sequences Operation of Two Boilers: For steam boilers, a means shall be provided to maintain mini-
Maximum system efficiency. mum boiler water temperature at low-fire when the boilers are
not required to support the load. The boilers shall also be held
at low-fire until this temperature is reached.
downtime costs.
For hot water boilers, a means shall be provided to keep the
Optimized fuel savings.
boilers at low fire until predetermined minimum temperature is
reached. This then releases the boiler to automatic operation
Lead/Lag Start with Lead/Lag Modulation: from the firing rate control.
Lead boiler operates at full capacity prior to starting lag All components shall be Underwriters Laboratories approved
boiler. for intended use and bear the UL and CSA label.
Ideal where load swings are small and infrequent, such as
heating applications.
PRODUCT OFFERING
Cleaver-Brooks shall supply the following equipment:
Solid state sensors shipped loose for mounting in common
header.
Minimum temperature low fire hold control (steam boilers).
Low fire hold control (hot water boilers).
Provision for switching normal or setback set points for each
boiler, as a means for selecting lead and lag boiler.
Components shall be Underwriters Laboratories approved
Lead/Lag Start with Lead/Lag Modulation:
and lag two boilers. The system shall start, stop, and control fir-
ing rate of both boilers.
Upon system demand, the lead boiler shall start and operate to
full capacity prior to starting the lag boiler. When both boilers
are on line, the lead boiler shall always operate to full capacity
and the lag boiler shall operate between minimum and maxi-
mum output to satisfy demand requirements.
D-45
12-02
Controls
D-46
12-02
Section E
EMISSIONS
CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
POLLUTANTS AND CONTROL TECHNIQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3
NITROGEN COMPOUNDS (NOx). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
NOx CONTROL TECHNOLOGIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4
POST COMBUSTION CONTROL METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4
Selective Non-catalytic Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4
Selective Catalytic Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4
COMBUSTION CONTROL TECHNIQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4
Low Excess Air (LEA) Firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4
Low Nitrogen Fuel Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
Burner Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5
Water/Steam Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5
Flue Gas Recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5
CHOOSING THE BEST NOx TECHNOLOGY FOR THE JOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
Turndown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
Excess Air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7
Carbon Monoxide (CO) Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7
Total Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7
SULFUR COMPOUNDS (SOx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7
CARBON MONOXIDE (CO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8
PARTICULATE MATTER (PM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-8
VOLATILE ORGANIC COMPOUNDS (VOCs)/HYDROCARBONS (HC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-8
EMISSION LEVEL UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8
CORRECTING EMISSIONS TO 3% OXYGEN (15% EXCESS AIR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-9
CONVERTING EMISSIONS BETWEEN PPM AND LB/MMBTU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9
CALCULATION OF ANNUAL EMISSIONS FOR INDUSTRIAL BOILERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-11
NEW SOURCE PERFORMANCE STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-13
ILLUSTRATIONS
Figure E-1. Effects of Fuel-Bound Nitrogen on NOx Emissions for Fuel Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3
Figure E-2. Selective Non-Catalytic Reduction (SNCR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4
Figure E-3. Selective Catalytic Reduction (SCR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5
Figure E-4. Effects of Fuel Sulfur Content on SOx Emissions for Fuel Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7
Figure E-5. CO Emissions Conversion Curves, 3% Oxygen, (15% Excess Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-9
Figure E-6. NOx Emissions Conversion Curves, 3% Oxygen, (15% Excess Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-10
Figure E-7. SOx Emissions Conversion Curves, 3% Oxygen, (15% Excess Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-10
Figure E-8. Volatile Organic Compound Conversion Curves, 3% Oxygen, (15% Excess Air) . . . . . . . . . . . . . . . . . . . . . .E-11
Figure E-9. Annual NOx Emissions for 250-800 Horsepower Boilers, NOx = 110 ppm (Corrected to 3% O2) . . . . . . . . .E-12
Figure E-10. Annual NOx Emissions for 250-800 Horsepower Boilers, NOx = 20 ppm . . . . . . . . . . . . . . . . . . . . . . . . . . .E-12
Figure E-11. Annual NOx Emissions for 250-800 Horsepower Boilers, NOx =25 ppm
(Corrected to 3% O2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-12
E-1
02-02
Emissions
Figure E-12. Annual NOx Emissions for 250-800 Horsepower Boilers, NOx = 30 ppm
(Corrected to 3% O2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-13
(Corrected to 3% O2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-13
Figure E-14. Summary of Federal EPA Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-15
E-2
02-02
Emissions
INTRODUCTION industrial sources, including industrial boilers. In industrial

boilers, NOx is primarily formed in two ways; thermal NOx
This section of the Boiler Book contains background informa- and fuel NOx:
tion regarding boiler emissions.
Thermal NOx is formed when nitrogen and oxygen in the
This section does not include emission performance for indi- combustion air combine with one another at the high tem-
vidual Cleaver-Brooks boiler models. Emission information peratures in a flame. Thermal NOx makes up the majority
for each product is included in the specific section of the of NOx formed during the combustion of gases and light
Boiler Book for the product or you can contact your local oils.
Cleaver-Brooks authorized representative for the necessary
information. Fuel NOx is formed by the reaction of nitrogen in the fuel
with oxygen in the combustion air. It is rarely a problem
with gaseous fuels. But in oils containing significant
POLLUTANTS AND CONTROL amounts of fuel-bound nitrogen, fuel NOx can account for
TECHNIQUES up to 50% of the total NOx emissions.
Combustion of standard fossil fuels (natural gas and ASTM NOx emissions from boilers are influenced by many factors.
Grade Oil) in commercial and industrial boilers results in the The most significant factors are flame temperature and the
following nine emissions; carbon dioxide, nitrogen, oxygen, amount of nitrogen in the fuel. Other factors affecting NOx
water, carbon monoxide, nitrogen oxide, sulfur oxides, volatile formation are excess air level and combustion air temperature.
organic compounds, and particulate matter. The latter five
While flame temperature primarily affects thermal NOx forma-
products of combustion are considered pollutants and are
tion, the amount of nitrogen in the fuel determines the level of
known to, either directly or indirectly, cause harmful affects on
fuel NOx emissions. Fuel containing more nitrogen results in
humans and the environment.
higher levels of NOx emissions (see Figure E-1). Most NOx
The following section describes the formation and control of control technologies for industrial boilers, with inputs less than
each of the pollutants in commercial and industrial boilers: 100 MMBtu/hr, reduce thermal NOx and have little affect on
fuel NOx. Fuel NOx is most economically reduced in commer-
Carbon Monoxide
cial and industrial boilers by switching to cleaner fuels (fuels
Nitrogen Oxides containing less fuel-bound nitrogen), if available.
Sulfur Oxides
Volatile Organic Compounds/Hydrocarbons
Particulate Matter
NITROGEN COMPOUNDS (NOx)

NOx Emissions(ppm at 3% O2)
Although there is evidence proving NOx, in itself, is harmful

to humans, the main reason NOx is considered an environmen-
tal problem is because it initiates reactions that result in the
Increasing
production of ozone and acid rain. Ozone and acid rain can
damage fabric, cause rubber to crack, reduce visibility, dam-
age buildings, harm forests and lakes, and cause health prob-
lems. By controlling NOx levels, along with the other
pollutants, the levels of acid rain and ozone can be reduced.
The principal nitrogen pollutants generated by boilers are
nitric oxide (NO) and nitrogen dioxide (NO2), collectively
referred to as NOx.
0
The contribution from different NOx sources to the total NOx 0
levels varies among metropolitan areas. In general, the contri- Increasing
bution of mobile sources to the total NOx level ranges from 60 Fuel-Bound Nitrogen (% weight)
to 80 percent: For stationary sources, it ranges between 20 and
40 percent. A significant portion of the NOx from stationary Figure E-1. Effects of Fuel-Bound Nitrogen on NOx Emissions
sources can be attributed to residential, commercial, and for Fuel Oils
E-3
02-02
Emissions
NOx CONTROL TECHNOLOGIES However, the technology is extremely difficult to apply to

industrial boilers that modulate or cycle frequently. This is
NOx controls can be classified into two types: post combus- because the ammonia (or urea) must be injected in the flue
tion methods and combustion control techniques. Post com- gases at a specific flue gas temperature. And, in industrial boil-
bustion methods address NOx emissions after formation while ers that modulate or cycle frequently, the location of the
combustion control techniques prevent the formation of NOx exhaust gases at the specified temperature is constantly chang-
during the combustion process. Post combustion methods tend ing. Thus, it is not feasible to apply selective non-catalytic
to be more expensive than combustion control techniques and reduction to industrial boilers that have high turndown capabil-
generally are not used on boilers with inputs of less than 100 ities and modulate or cycle frequently.
MMBtu/hr. Following is a list of different NOx control meth-
ods.
Selective Catalytic Reduction
Post combustion control methods include:
Selective catalytic reduction involves the injection of ammonia
Selective Non-Catalytic Reduction in the boiler exhaust gases in the presence of a catalyst (see
Figure E-3). The catalyst allows the ammonia to reduce NOx
Selective Catalytic Reduction
levels at lower exhaust temperatures than selective non-cata-
Combustion control techniques include: lytic reduction. Unlike selective non-catalytic reduction, where
the exhaust gases must be approximately 1400-1600 F, selec-
Low Excess Air Firing
tive catalytic reduction can be utilized where exhaust gasses
Low Nitrogen Fuel Oil are between 500 F and 1200 F, depending on the catalyst
used. Selective catalytic reduction can result in NOx reductions
Burner Modifications
up to 90%. However, it is costly to use and can rarely be cost
Water/Steam Injection justified on boilers with inputs less than 100 MMBtu/hr.
Flue Gas Recirculation
COMBUSTION CONTROL
Each method results in a different degree of NOx control. For
example, when firing natural gas, low excess air firing typi- TECHNIQUES
cally reduces NOx by 10%, flue gas recirculation by 75%, and Combustion control techniques reduce the amount of NOx
selective catalytic reduction by 90%. emission by limiting the amount of NOx formation during the
combustion process. This is typically accomplished by lower-
POST COMBUSTION CONTROL ing flame temperatures. Combustion control techniques are
more economical than post combustion methods and are fre-
METHODS quently utilized on industrial boilers requiring NOx controls.
Selective Non-catalytic Reduction Low Excess Air (LEA) Firing

Selective non-catalytic reduction involves the injection of a As a safety factor to assure complete combustion, boilers are
NOx reducing agent, such as ammonia or urea, into the boiler fired with excess air. One of the factors influencing NOx for-
exhaust gases at a temperature of approximately 1400-1600 F mation in a boiler is the excess air levels. High excess air levels
(see Figure E-2). The ammonia or urea breaks down the NOx (>45%) may result in increased NOx formation because the
in the exhaust gases into water and atmospheric nitrogen. excess nitrogen and oxygen in the combustion air entering the
Selective non-catalytic reduction reduces NOx up to 70%.
AMMONIA (NH3) FLUE GAS TEMPERATURE

1400 - 1600 F
* NH3 H2O
FLUE GAS
NOx
** NOx
NH3 H2O
N2
CLEAN GAS
NOx
** NOx
NH3 H2O
N2
Figure E-2. Selective Non-Catalytic Reduction (SNCR)
E-4
02-02
Emissions
AMMONIA (NH3) CATALYST
* NH3 H2O
FLUE GAS
NOx
** NOx
NH3 H2O
N2
CLEAN GAS
NOx
** NOx
NH3 H2O
N2
Figure E-3. Selective Catalytic Reduction (SCR)
flame will combine to form thermal NOx. Low excess air fir- boiler performance when selecting NOx control technologies.
ing involves limiting the amount of excess air that is entering
the combustion process in order to limit the amount of extra Water/Steam Injection
nitrogen and oxygen that enters the flame. Limiting the
amount of excess air entering a flame is accomplished through Water or steam injection can be utilized to reduce NOx levels.
burner design and can be optimized through the use of oxygen By injecting water or steam into the flame, flame temperatures
trim controls. Low excess air firing can be used on most boil- are reduced, thereby lowering thermal NOx formation and
ers and generally results in overall NOx reductions of 5-10% overall NOx levels. Water or steam injection can reduce NOx
when firing natural gas. 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 the flame
Low Nitrogen Fuel Oil before condensation problems are experienced. Additionally,
When firing fuel oils, NOx formed by fuel-bound nitrogen can under normal operating conditions, water/steam injection can
account for 20-50% of the total NOx level. One method to result in a 3-10% boiler efficiency loss. Many times water or
reduce NOx levels from boilers firing distillate oils is through steam injection is used in conjunction with other NOx control
the use of low nitrogen fuel oil. Low nitrogen oils can contain methods such as burner modifications or flue gas recirculation.
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 Flue Gas Recirculation
is fired in firetube boilers utilizing flue gas recirculation, NOx
reductions of 60%-70% over NOx emissions from standard Flue gas recirculation, or FGR, is the most effective method of
No. 2 oils have been achieved. Low nitrogen oil is used most reducing NOx emission from industrial boilers with inputs
frequently in southern California. 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 for-
Burner Modifications mation. It is currently the most effective and popular low NOx
Burner modifications for NOx control involve changing the technology for firetube and watertube boilers. And, in many
design of a standard burner in order to create a larger flame. applications, it does not require any additional reduction
Enlarging the flame results in lower flame temperatures and equipment to comply with regulations.
lower thermal NOx formation which, in turn, results in lower
Flue gas recirculation technology can be classified into two
overall NOx emissions. The technology can be applied to most
types; external or induced.
boiler types and sizes. It is most effective when firing natural
gas and distillate fuel oil and has little affect on boilers firing External flue gas recirculation utilizes an external fan to
heavy oil. To comply with the more stringent regulations, recirculate the flue gases back into the flame. External
burner modifications must be used in conjunction with other piping routes the exhaust gases from the stack to the
NOx reduction methods, such as flue gas recirculation. If burner. A valve controls the recirculation rate, based on
burner modifications are utilized exclusively to achieve low boiler input.
NOx levels (30 ppm), adverse affects on boiler operating
Induced flue gas recirculation utilizes the combustion
parameters such as turndown, capacity, CO levels, and effi-
air fan to recirculate the flue gases back into the flame. A
ciency may result. It is important to address all aspects of
portion of the flue gases are routed by duct work or inter-
E-5
02-02
Emissions
nally to the combustion air fan, where they are premixed Every time the boiler cycles off, before it comes back on, it
with the combustion air and introduced into the flame must go through a specific start-up sequence for safety assur-
through the burner. New designs of induced FGR that uti- ance. It takes between one to two minutes to get the boiler back
lize an integral FGR design are becoming popular among on line. If there is a sudden load demand, the response cannot
boiler owners and operators because of their uncompli- be accelerated. Keeping the boiler on line assures a quick
cated design and reliability. response to load changes.
Theoretically, there is no limit to the amount of NOx reduction Frequent cycling also deteriorates the boiler components. The
with FGR; practically, there is a physical, feasible limit. The need for maintenance increases, the chance of component fail-
limit of NOx reduction varies for different fuels 80% for ure increases, and boiler downtime increases. So, when select-
natural gas and 20-25% for standard fuel oils. ing NOx control, always consider the burners turndown
capability.
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 spe- Capacity
cifically tailored to match the boiler's furnace design features, When selecting the best NOx control, capacity and turndown
such as shape, volume, and heat release. By designing the low should be considered together because some NOx control tech-
NOx technology as a package with the boiler, the adverse nologies require boiler derating in order to achieve guaranteed
effects of the low NOx technology on boiler operating parame- NOx reductions. For example, flame shaping (primarily enlarg-
ters (turndown, capacity, efficiency, and CO levels) can be ing the flame to produce a lower flame temperature thus
addressed and minimized. lower NOx levels) can require boiler derating, because the
shaped flame could impinge on the furnace walls at higher fir-
CHOOSING THE BEST NOx TECH- ing rates.
NOLOGY FOR THE JOB However, the boiler's capacity requirement is typically deter-
mined by the maximum load in the steam/hot water system.
What effect does NOx control technology ultimately have on a
Therefore, the boiler may be oversized for the typical load con-
boiler's performance? Certain NOx controls can worsen boiler
ditions that may occur. If the boiler is oversized, its ability to
performance while other controls can appreciably improve
handle minimum loads without cycling is limited. Therefore,
performance. Aspects of the boiler performance that could be
when selecting the most appropriate NOx control, capacity and
affected include turndown, capacity, efficiency, excess air, and
turndown should be considered together for proper boiler
CO emissions.
selection and to meet overall system load requirements.
Failure to take into account all of the boiler operating parame-
ters can lead to increased operating and maintenance costs, Efficiency
loss of efficiency, elevated CO levels, and shortening of the
boiler's life. Some low NOx controls reduce emissions by lowering flame
temperature, particularly in boilers with inputs less than 100
The following section discusses each of the operating parame- MMBtu/hr. Reducing the flame temperature decreases the radi-
ters of a boiler and how they are related to NOx control tech- ant heat transfer from the flame and could lower boiler effi-
nologies. ciency. The efficiency loss due to the lower flame temperatures
can be partially offset by utilizing external components, such
Turndown as an economizer. Or, the offset technique can be inherent in
the NOx design.
Choosing a low NOx technology that sacrifices turndown can
have many adverse effects on the boiler. When selecting NOx One technology that offsets the efficiency loss due to lower
controls, the boiler should have a turndown capability of at flame temperatures in a firetube boiler is flue gas recirculation.
least 4:1 or more, in order to reduce operating costs and the Although the loss of radiant heat transfer could result in an effi-
number of on/off cycles. A boiler utilizing a standard burner ciency loss, the recirculated flue gases increase the mass flow
with a 4:1 turndown can cycle as frequently as 12 times per through the boiler thus the convective heat transfer in the
hour or 288 times a day because the boiler must begin to cycle tube passes increases. The increase in convective heat transfer
at inputs below 25% capacity. compensates for losses in radiant heat transfer, with no net effi-
ciency loss. When considering NOx control technology,
With each cycle, pre- and post-purge air flow removes heat
remember, it is not necessary to sacrifice efficiency for NOx
from the boiler and sends it out the stack. The energy loss can
reductions.
be reduced by using a high turndown burner (10:1), which
keeps the boiler on even at low firing rates.
E-6
02-02
Emissions
Excess Air coals) results in pollutants occurring in the forms of SO2 (sul-
fur dioxide) and SO3 (sulfur trioxide), together referred to as
A boiler's excess air supply provides for safe operation above
SOx (sulfur oxides). The level of SOx emitted depends directly
stoichiometric conditions. A typical burner is usually set up
on the sulfur content of the fuel (see Figure E-4). The level of
with 10-20% excess air (2-4% O2). NOx controls that require
SOx emissions is not dependent on boiler size or burner
higher excess air levels can result in fuel being used to heat the
design. Typically, about 95% of the sulfur in the fuel will be
air rather than transferring it to usable energy. Thus, increased
emitted as SO2, 1-5% as SO3, and 1-3% as sulfate particulate.
stack losses and reduced boiler efficiency occur. NOx controls
Sulfate particulate is not considered part of the total SOx emis-
that require reduced excess air levels can result in an oxygen
sions.
deficient flame and increased levels of carbon monoxide or
unburned hydrocarbons. It is best to select a NOx control tech- Historically, SOx pollution has been controlled by either dis-
nology that has little effect on excess air. persion or reduction. Dispersion involves the utilization of a
tall stack, which enables the release of pollutants high above
Carbon Monoxide (CO) Emissions the ground and over any surrounding buildings, mountains, or
hills, in order to limit ground level SOx emissions. Today, dis-
High flame temperatures and intimate air/fuel mixing are persion alone is not enough to meet more stringent SOx emis-
essential for low CO emissions. Some NOx control technolo- sion requirements; reduction methods must also be employed.
gies used on industrial and commercial boilers reduce NOx
levels by lowering flame temperatures by modifying air/fuel Methods of SOx reduction include switching to low sulfur
mixing patterns. The lower flame temperature and decreased fuel, desulfurizing the fuel, and utilizing a flue gas desulfuriza-
mixing intensity can result in higher CO levels. tion (FGD) system. Fuel desulfurization, which primarily
applies to coal, involves removing sulfur from the fuel prior to
An induced flue gas recirculation package can lower NOx lev- burning. Flue gas desulfurization involves the utilization of
els by reducing flame temperature without increasing CO lev- scrubbers to remove SOx emissions from the flue gases.
els. CO levels remain constant or are lowered because the flue
gas is introduced into the flame in early stages of combustion Flue gas desulfurization systems are classified as either non-
and the air fuel mixing is intensified. Intensified mixing offsets regenerable or regenerable. Non-regenerable FGD systems, the
the decrease in flame temperature and results in CO levels that most common type, result in a waste product that requires
are lower than achieved without FGR. But, the level of CO proper disposal. Regenerable FGD converts the waste by-prod-
depends on the burner design. Not all flue gas recirculation uct into a marketable product, such as sulfur or sulfuric acid.
applications result in lower CO levels. 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
Total Performance technology cannot be cost justified on industrial boilers.
Selecting the best low NOx control package should be made
For users of industrial boilers, utilizing low sulfur fuels is the
with total boiler performance in mind. Consider the applica-
tion. Investigate all of the characteristics of the control tech-
nology and the effects of the technology on the boiler's 1200
performance. A NOx control technology that results in the
greatest NOx reduction is not necessarily the best for the 1000
application or the best for high turndown, adequate capacity,
SOx Emission Level*
high efficiency, sufficient excess air, or lower CO. The newer 800
(ppm at 3% O2)
low NOx technologies provide NOx reductions without affect-

ing total boiler performance. 600
400
SULFUR COMPOUNDS (SOx)
200
The primary reason sulfur compounds, or SOx, are classified
as a pollutant is because they react with water vapor (in the 0
flue gas and atmosphere) to form sulfuric acid mist. Airborne 0 .2 .4 .6 .8 1.0 1.2 1.4 1.6 1.8 2.0
sulfuric acid has been found in fog, smog, acid rain, and snow. Sulfur in Fuel (% weight)
Sulfuric acid has also been found in lakes, rivers, and soil. The
acid is extremely corrosive and harmful to the environment. *Based on EPA AP-42 Estimates
The combustion of fuels containing sulfur (primarily oils and Figure E-4. Effects of Fuel Sulfur Content on SOx Emissions
for Fuel Oils
E-7
02-02
Emissions
most cost effective method of SOx reduction. Because SOx four fuel constituents: sulfur, ash, carbon residue, and
emissions primarily depend on the sulfur content of the fuel, asphalenes. These constituents exist in fuel oils, particularly
burning fuels containing a minimal amount of sulfur (distillate residual oils, and have a major effect on particulate emissions.
oil) can achieve SOx reductions, without the need to install By knowing the fuel constituent levels, the particulate emis-
and maintain expensive equipment. sions for the oil can be estimated.
Methods of particulate control vary for different types and
CARBON MONOXIDE (CO) sizes of boilers. For utility boilers, electrostatic precipitators,
scrubbers, and baghouses are commonly utilized. For industrial
Carbon monoxide is a pollutant that is readily absorbed in the
and commercial boilers, the most effective method is to utilize
body and can impair the oxygen-carrying capacity of the
clean fuels. The emission levels of particulate matter can be
hemoglobin. Impairment of the body's hemoglobin results in
lowered by switching from a residual to a distillate oil or by
less oxygen to the brain, heart, and tissues. Even short-term
switching from a distillate oil to a natural gas. Additionally,
over exposure to carbon monoxide can be critical, or fatal, to
through proper burner set-up, adjustment and maintenance,
people with heart and lung diseases. It may also cause head-
particulate emissions can be minimized, but not to the extent
aches and dizziness in healthy people.
accomplished by switching fuels.
During combustion, carbon in the fuel oxidizes through a
series of reactions to form carbon dioxide (CO2). However,
100 percent conversion of carbon to CO2 is rarely achieved in
VOLATILE ORGANIC COMPOUNDS
practice and some carbon only oxidizes to the intermediate (VOCs)/HYDROCARBONS (HC)
step, carbon monoxide. Volatile organic compounds, or VOCs, are compounds contain-
Older boilers generally have higher levels of CO than new ing combinations of carbon, hydrogen, and sometimes oxygen.
equipment because CO has only recently become a concern VOCs vaporize easily once emitted into the air and are of con-
and older burners were not designed to achieve low CO levels. cern because of their role in ground level ozone formation. In
In today's equipment, high levels of carbon monoxide emis- reference to boiler performance, they are often referred to as
sions primarily result from incomplete combustion due to poor hydrocarbons and generally are divided into two categories
burner design or firing conditions (for example, an improper methane and non-methane.
air-to-fuel ratio) or possibly a leaky furnace. Through proper Formation of VOCs in commercial and industrial boilers pri-
burner maintenance, inspections, operation, or by upgrading marily result from poor or incomplete combustion due to
equipment or utilizing an oxygen control package, the forma- improper burner set-up and adjustment. To control VOC emis-
tion of carbon monoxide can be controlled at an acceptable sions from commercial and industrial boilers, no auxiliary
level. equipment is needed; properly maintaining the burner/boiler
package will keep VOC emissions at a minimum. Proper main-
PARTICULATE MATTER (PM) tenance includes keeping the air/fuel ratio at the manufacturer's
specified setting, having the proper air and fuel pressures at the
Emissions of particulate matter (PM) from combustion burner, and maintaining the atomizing air pressure on oil burn-
sources consist of many different types of compounds, includ- ers at the correct levels. An improperly maintained boiler/
ing nitrates, sulfates, carbons, oxides, and any uncombusted burner package can result in VOC levels over 100 times the
elements in the fuel. Particulate pollutants can be corrosive, normal levels.
toxic to plants and animals, and harmful to humans.
Particulate matter emissions generally are classified into two EMISSION LEVEL UNITS
categories, PM and PM10. PM10 is a particulate matter with a
diameter less than 10 microns. All particulate matter can pose This section describes the different units for emission levels.
a health problem. However, the greatest concern is with PM10, Emission levels can be provided in many different units
because of its ability to bypass the body's natural filtering sys- depending on whether the measurement is volume or mass
tem. based.
PM emissions are primarily dependent on the grade of fuel

fired in the boiler. Generally, PM levels from natural gas are CORRECTING EMISSIONS TO 3%
significantly lower than those of oils. Distillate oils result in OXYGEN (15% EXCESS AIR)
much lower particulate emissions than residual oils.
The following equation shows how to correct emission read-
When burning heavy oils, particulate levels mainly depend on ings to 3% oxygen (15% excess air). Because boilers don't
E-8
02-02
Emissions
Although emission levels can be given in many different units,

ppm Parts per Million Indicates emission levels on a the most common are ppm (corrected to 3% oxygen) and lb/
volume basis. Sometimes may be shown as ppmv. MMBtu. Conversion between these two types of units is very
Part per million must be referenced to some oxygen
level (excess air level) which, for industrial boilers, is
simple, however, it does depend on the fuel type and excess air
typically 3% oxygen (15% excess air). Actual mea- level.
surements recorded during boiler testing are usually
in ppm.
The following graphs and equations show the relationships and
conversions between ppm (corrected to 3% oxygen) and lb/
lb/MMBtu Pounds per Million Btu Indicates emission lev-
els on a mass basis. Emission levels are shown in MMBtu. If the conversion involves a ppm level referenced to
pounds of pollutant per million Btu input to the an oxygen level other than 3%, the ppm level must be cor-
boiler. This level is useful when hourly or annual rected to 3% oxygen (see previous section) before using the
emission levels must be determined. following graphs and equations (Figure E-5 through E-8).
lb/hr Pounds per Hour Indicates emission levels on a
mass basis. This unit represents the amount of pol-
lutant emitted on an hourly basis. CALCULATION OF ANNUAL
tpy Tons per Year Indicates emission levels on a EMISSIONS FOR INDUSTRIAL
mass basis. This unit corresponds to the annual pol-
lutant levels. Dry Analysis
0.18
lb/106 cu-ft Pounds per Million Cubic Feet Indicates emis-
sion levels on a mass basis. This unit is used for
gaseous fuels and indicates the emission level in
pounds per million cubic feet of fuel (gaseous fuel) 0.16 No. 6 Oil
input to the boiler. This is useful when the actual gas No. 2 Oil
usage of the boiler is known. Propane
lb/103 gal Pounds per Thousand Gallons Indicates emis- Natural
0.14 Gas
sion levels on a mass basis. This unit is used for liq-
uid (oil) fuels and indicates the emission level in
pounds per thousand gallons of oil fired. This is use-
ful when the actual oil usage of the boiler is known
0.12
CO Emissions (lb/MMBtu)
0.10
always operate at 3% oxygen, it is necessary to convert ppm 0.08

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 0.04
levels other than 3%, use the following equation.
CONVERTING EMISSIONS BETWEEN 0.02

PPM AND LB/MMBTU
0.00
0 20 40 60 80 100 120 140 160 180 200
ppm (@3%) = 21 3
x ppm (actual) CO Emissions (ppm)
21 O2 (actual)
Conversion Equations
No. 2 Oil: Natural Gas:
Example: What is the NOx level corrected to 3% oxygen ppm = (lb/MMBtu)*1290 ppm = (lb/MMBtu)*1370
for a measured level of 27 ppm at 7.1% oxygen? lb/MMBtu = (ppm)/1290 lb/MMBtu = (ppm)/1370
No. 6 Oil: Propane:
21 3 ppm = (lb/MMBtu)*1260 ppm = (lb/MMBtu)*1340
ppm (@3%) = x 27 = 35 ppm NOx lb/MMBtu = (ppm)/1260 lb/MMBtu = (ppm)/1340
21 7.1
Figure E-5. CO Emissions Conversion Curves, 3% Oxygen,

(15% Excess Air)
E-9
02-02
Emissions
Dry Analysis
0.28
No. 2 and No. 6 Oil
0.26
Propane
0.24
Natural Gas
0.22
0.20
NOx Emissions (lb/MMBtu)
0.18
0.16
0.14 No. 2 and No. 6 Oil:
ppm = (lb/MMBtu)*750
lb/MMBtu = (ppm)/750
0.12
Natural Gas:
0.10 ppm = (lb/MMBtu)*850
0.08 Propane:
0.06 lb/MMBtu = (ppm)/810
0.04
0.02
0.00
0 20 40 60 80 100 120 140 160 180 200
NOx Emissions (ppm)
Figure E-6. NOx Emissions Conversion Curves, 3% Oxygen, (15% Excess Air)
Dry Analysis
2.4
2.2 No. 2 and No. 6 Oil
2.0
1.8
SOx Emissions (lb/MMBtu)
1.6
No. 2 and No. 6 Oil:
1.4 ppm = (lb/MMBtu)*540
1.2
1.0
0.8
0.6
0.4
0.2
0.0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200
SOx Emissions (ppm)
Figure E-7. SOx Emissions Conversion Curves, 3% Oxygen, (15% Excess Air)
E-10
02-02
Emissions
Dry Analysis
0.060
0.055
0.050 No. 2 and No. 6 Oil
0.045
VOC Emissions (lb/MMBtu)

0.040
0.035 Natural Gas and Propane
0.030
0.025 Conversion Equations

No. 2 and No. 6 Oil:
0.020
0.015 lb/MMBtu = (ppm)/2000
0.010 Natural Gas and Propane

ppm = (Ib/MMBtu)*2500
0.005 lb/MMBtu = (ppm)/2500
0.000
0 10 20 30 40 50 60 70 80 90 100
VOC Emissions (ppm)
Figure E-8. Volatile Organic Compound Conversion Curves, 3% Oxygen, (15% Excess Air)
BOILERS year and having a NOx level of 110 ppm would be as follows.
Many provisions of the 1990 Clean Air Act Amendments Emission Factor = 0.13 lb/MMBtu (110 ppm = 0.13 lb/
assess the impact of pollution sources based on the potential MMBtu)
annual emissions (usually expressed as tons per year, or tpy). Boiler Input = 33.5 MMBtu/hr (Based on 80% Efficiency)
When addressing industrial boilers, the potential annual emis-
sions of NOx are of concern and frequently must be calcu- Annual Hours of Operation = 8760 hours/year (24 hours/
lated. Following is an example of how to calculate the day x 365 days/year)
potential annual NOx emissions for industrial boilers. Substituting this data into the previous equation yields the
To determine the annual NOx emissions for an industrial annual NOx emissions for this specific boiler, which is 19.1
boiler, three items must be known: tpy.
1. The NOx emission factor for the boiler. The following graphs (Figure E- 9 through E-13) indicate the
2. The maximum rated input for the boiler.

0.13 lb NOx x 33.5 MMBtu x 8760 hrs x 1 ton = 19.1 tpy NOx
3. The maximum allowable hours of operation for the MMBtu hr year 2000 lb
boiler.
annual NOx emissions for boiler sizes 250-800 horsepower fir-
Once the information above is obtained, the following equa-
ing natural gas at maximum input operating 24 hours/day, 365
tion can be used to determine annual emissions.
days/year. They are for NOx emission levels of 110, 60, 30, 25,
Emission Factor x Boiler Input x Annual Hours of Operation and 20 ppm.
= Total Annual Emissions
For example, the calculation of the total annual NOx emis-
sions for an 800 hp boiler operating 24 hours/day, 365 days/
E-11
02-02
Emissions
20 800 HP
700 HP
Annual NOx Emissions (tpy) 15 600 HP
500 HP
10 400 HP
350 HP
300 HP
250 HP
5
Efficiency = 80%
0
1000 2000 3000 4000 5000 6000 7000 8000 9000
Annual Hours of Operation
Figure E-9. Annual NOx Emissions for 250-800 Horsepower Boilers, NOx = 110 ppm (Corrected to 3% O2)
4
800 HP
Annual NOx Emissions (tpy)
3 700 HP
600 HP
500 HP
2
400 HP
350 HP
300 HP
1 250 HP
Efficiency = 80%
0
1000 2000 3000 4000 5000 6000 7000 8000 9000
Figure E-10. Annual NOx Emissions for 250-800 Horsepower Boilers, NOx = 20 ppm (Corrected to 3%
O2 )
5
800 HP
4 700 HP
600 HP
3 500 HP
400 HP
2 350 HP
300 HP
250 HP
1
Efficiency = 80%
0
1000 2000 3000 4000 5000 6000 7000 8000 9000
(Corrected to 3% O2)
E-12
02-02
Emissions
5
800 HP

4 700 HP
600 HP
3
500 HP
400 HP
2 350 HP
300 HP
250 HP
1
Efficiency = 80%
0
1000 2000 3000 4000 5000 6000 7000 8000 9000
12
800 HP
10
700 HP
8 600 HP
500 HP
6
400 HP
350 HP
4 300 HP
250 HP
2
Efficiency = 80%
0
1000 2000 3000 4000 5000 6000 7000 8000 9000
NEW SOURCE PERFORMANCE The Small Boiler NSPS apply to all new, modified, or recon-
structed boilers with inputs between 10-100 MMBtu/hr where
STANDARDS construction, modification, or reconstruction commenced after
The Federal EPA has established nationally uniform source- June 9, 1989. The Small Boiler NSPS set emission standards
specific regulations through the New Source Performance for SOx and particulate matter for boilers firing coal, distillate
Standards, or NSPS, for which all applicable sources must and residual oil, and wood. The Small Boiler NSPS also dic-
comply. The standards, which set minimal requirements for tate record keeping requirements regarding fuel usage for all
individual sources, address approximately 65 categories of fuels, including natural gas. Record keeping requirements and
new or modified stationary sources, including industrial boil- compliance standards for the different emissions depends on
ers. the type of fuel fired and on the boiler size. For a summary of
the Small Boiler NSPS, see Figure E-14.
The NSPS for industrial boilers regulate levels for NOx, SOx,
and particulate matter. The regulated pollutants and require- Be sure your boiler complies with the New Source Perfor-
ments vary for different fuels and boiler sizes. There are cur- mance Standards as non-compliance may result in fines and/or
rently three categories for the NSPS: forced boiler shutdown.
Boilers with inputs greater than 250 MMBtu/hr Contact your local Cleaver-Brooks authorized representative if
you have questions regarding the New Source Performance
Boilers with inputs between 100-250 MMBtu/hr Standards.
Boilers with inputs between 10-100 MMBtu/hr
E-13
02-02
Emissions
New Source Performance Standards for Boilers 10100 MMBtu/hr
Built or Modified After 6/9/1989
RULES FOR SULFUR DIOXIDE (SO2) EMISSIONS
1. Coal Firing
1.2 lb SO2/MMBtu Limit all 10-100 MMBtu.
90% SO2 reduction required if > 75 MMBtu and > 55% annual coal capacity.
Initial performance testing required within 180 days of start-up.
30 day rolling average used in calculations.
Continuous Emission Monitoring System (CEMS) required except:
Fuel analysis may be used (before cleanup equipment).
Units < 30 MMBtu may use supplier certificate for compliance.
2. Residual Oil Firing

Limit of 0.5 lb SO2/MMBtu or 0.5% sulfur in fuel.
CEMS required to meet SO2 limit except fuel analysis can be used as 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 emission
limits or testing. Required reports include:
Information on unit size, fuels, start-up dates and other equipment information.
Initial performance test results, CEMS performance evaluation.
Quarterly reports on SO2 and/or PM emission results, including variations from limits and corrective action taken.
For fuel supplies 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
E-14
02-02
Section F
STACKS
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3
Selection Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3
Special Stack Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5
Safety Specifications and Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5
Use of Noncombustible Enclosure or Chase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5
Clearance to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5
Connecting to the Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5
Expansion and Installation Concerns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7
Clearances For Noncombustible Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-11
Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-11
Stack Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-12
Typical Stack Arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-12
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-15
ILLUSTRATIONS
Figure F-1. System Extension Above Boiler Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7
Figure F-2. Thermal Expansion Between Two Fixed Points in Stack System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7
Figure F-3. Graphs for Calculating Thermal Expansion Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8
Figure F-4. Maximum Unsupported Distance Between Elbows, Tees, or Wyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8
Figure F-5. Maximum Support and Guide Assembly Spacing for Vertical, Horizontal, and Sloping Stack Runs . . . . . . . . F-10
F-1
02-02
Stacks
Figure F-6. Cable Guying Specifications for Roof Level Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-10
Figure F-7. Roof Framing and Curb Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-12
Figure F-8. Cable Guying Installation Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-12
Figure F-9. Model CBS-II Double Wall Stack Construction and Joint Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13
Figure F-10. Model CBS-III Triple Wall Stack Construction and Joint Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-13
Figure F-11. Model ICBS Fiber-Insulated Stack Construction and Joint Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-14
TABLES
Table F-1. Stack Product Offering and Application Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4
Table F-2. System Component Names and Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-6
Table F-3. Maximum Stack Height Supported Per Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-9
Table F-4. Roof Opening Size for Penetration of Roof Support Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-11
Table F-5. Stack System Clearances to Combustible Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13
Table F-6. Weight of Straight Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-14
This section contains information on the complete line of stacks. This line includes stack components in single, double, and triple
wall construction for discharging combustion gases and fumes from boilers, heaters, ovens and other sources generating exhaust
vapors at temperatures up to 1400 F.
F-2
02-02
Stacks
FEATURES AND BENEFITS Stack Sections and Fittings are Continuous Welded:
Prevents leakage from vented gases.
Custom Built to Customer Specifications Using CAD Meets stringent UL and ULC requirements.
Technology:
Assures proper system sizing and design. Patented Spacer Design:
Provides complete system drawing. Assures consistent product alignment and support.
Provides bill of material based on prefabricated CB-Stack Built to perform under the most demanding conditions.
components.
Built With Captive Nuts and Bolts:
System Designed to Use Standard Components:
Allows easy installation without the risk of losing hardware.
Reduces on-site construction costs.
Saves on installation time and cost.
Additions and modifications can be made easily and
economically.
PRODUCT OFFERING
All components are completely compatible.
Cleaver-Brooks manufactures a complete line of fully compat-
ible stack components as follows:
15 Year Factory Warranty:
Ameri-Vent type "B": gas vent.
Guaranteed to last.
Model CBS-I: single wall stainless steel.
Longest warranty in the business.
Model CBS-II: double wall air insulated.
Backed by Cleaver-Brooks.
Model CBS-III: triple wall air insulated.
Quick-Ship 10 Day Factory Delivery: Model ICBS: double wall - 1", 2", and 4" material insulated.
Provides the customer "What they want - when they want it". See Table F-1 for the product that best fits your specific appli-
Reduces downtime. cation.
Efficient job construction scheduling.

Selection Considerations
Lowest Clearance to Combustibles: The information in this section applies to product selection
which is governed by four major considerations:
Reduces needed clearances to combustibles and non-
combustibles. Type of heating equipment.
Increases usable floor space. Fuels to be burned and vapor or gases to be removed.
Saves on construction costs. Exhaust operating temperatures of the equipment.
Building use and type of construction materials used.
Shipped on Pallets and Shrink-Wrapped:
All CBS/ICBS chimney components will be custom fabricated
Simplified on-site handling. for your installation.
Protects materials until installation. Cleaver-Brooks application engineers design and size stack
Reduces freight damage. systems based on data provided by the engineer or contractor.
These data include information such as job-site elevation,
No Welding or On-Site Fabrication Required: equipment and fuel type, equipment input (Btu/hr), flue gas
temperature, as well as site dimensions and the need for offset,
Saves time and labor costs. drains, fittings, roof penetration, etc.
Components are light and easily assembled by one or two These data are used to generate a detailed installation drawing
people. and component parts list. Prior to fabricating the parts at our
No special equipment or supervision required. plant, the installation drawing and parts list are returned to the
engineer or contractor for verification. It is the engineers or
F-3
02-02
F-4
Table F-1. Stack Product Offering and Application Information
MODEL NO. AMERI-VENT CBS-I CBS-II CBS-III ICBS
Stacks
Description Type "B" Gas Vent Single Wall Stainless Steel Double Wall Air Insulated Triple Wall Air Insulated Double wall either 1", 2" or 4"
Material Insulated
Applications AGA Listed Gas Air/Product Boiler and Breeching Systems, Engine/Turbine Exhausts, Grease/Oven
Appliances Containment Exhausts, Air/Particle Containment
Breeching
Systems, Grease Duct
Fuel Types Natural or LP Gas LP; Natural Gas; #2, #4A, #5A or #6A Fuel Oil; Wood; CoalA; Grease Vapors;
Caustic Fumes; Particles
Exhaust Pressures Neutral or Negative Positive, Neutral or Negative
Exhaust Temp. 400F Plus Ambient Air Product Containment or 100 F Continuous, 1400 F Intermittent
Continuous/Intermittent 2000F for Grease Duct 1400 Continuous. 1800 F Intermittent
Grease Duct 500 F Continuous
Diameters 3" through 30" 6" through 48"
Materials Inner: Inner: Inner: Inner: Inner:

.012" Aluminum 3" to 6" Standard 304SS .035" All .035" 20-ga 304SS .035" 20-ga 304SS .035" 20-ga 304SS
.014" Aluminum 7" to 18" Diameters (Optional .035" Standard (Optional .035" Standard (Optional .035" Standard (Optional .035"
.018" Aluminum 20" to 30" 316SS Available) 20-ga 316SS Available) 20-ga 316SS Available) 20-ga 316SS Available)
Outer: Outer: Outer: Center: Insulation Material:

28-ga Galvanized N/A .025" 24-ga Aluminum .025" 24-ga Aluminum Eleven Pound Fiber
Steel 3" to 30" Coated Steel 6" to 24" Coated Steel 6" to 24" Insulation of 1", 2" or 4"
02-02
.034" 20-ga Aluminum .034" 20-ga Aluminum thickness
Coated Steel 26" to 48" Coated Steel 26" to 48"
Optional 304 or 316SS (Optional 304 or 316SS
Available) Available)
Outer: Outer:
.025" 24-ga Aluminum .025" 24-ga Aluminum
Coated Steel 6" to 24" CoatedSteel 6" to 24"
.034" 20-ga Aluminum .034" 20-ga Aluminum
Coated Steel 26" to 48" Coated Steel 26" to 48"
(Optional 304 or 316SS (Optional 304 or 316SS
Available) Available)
Insulation 1/4" Air 3" through 6" N/A 1" Air Innerwall to Center = 1" Air 1" Material
1/2 Air 7" through 30" Center to 2" Material or 4" Material
Outerwall = 1/2" Air
Application Ref. & Complies with one or more of the following: AGA; HUD; NBC; UBC; UMC; NMC; SMC; SBCCI; ICBO; BOCA;
Listings UL-103, 710, 411; ULC-S604; NFPA-85, A, B, D, 31, 34, 37, 54, 96, 211.
A. Recommended 316 Stainless Steel.
Stacks
contractors sole responsibility to field verify all dimensions, These stack systems must be installed as complete systems that
components, and layouts on the installation drawing. This ver- originate at the boiler and terminate outdoors.
ification must include an authorized signature and date before
Installing or using CBS or ICBS stack systems, or parts of sys-
the order will be fabricated and shipped.
tems, in ways other than those specified can be hazardous.
Special Stack Applications Always contact local building and/or fire officials concerning
application restrictions and installation inspection procedures.
Cleaver-Brooks can help in the design, layout and manufacture Obtain all required building permits.
of the following special stack applications:
Grease duct venting systems. Safety Specifications and Clearances
Engine/turbine venting systems. All CBS/ICBS stack systems should be sized in accordance
with the instructions provided by the manufacturer and perti-
Solid fuel venting systems.
nent job-site data.
Special stack applications may require unique design and
The stack system must never be jacketed, wrapped, or enclosed
product modifications. Contact your local Cleaver-Brooks
in combustible materials. Never place insulation in required
authorized representative for assistance.
clearance spaces or ventilation openings.
Standard Components, Table F-2, lists the names and part
numbers for the various components of all Cleaver-Brooks Use of Noncombustible Enclosure or Chase
model lines. Each model line has its own letter designation. N
is used to identify CBS-I single wall components. Double wall The following information on noncombustible chase and clear-
CBS-II uses the letter S, while CBS-III triple wall components ance to combustibles pertains to all applications, except grease
are designated with the letter V. Fiber-Insulated components duct systems:
use the letter A for 1" insulated, B for 2" insulated, and D for When the stack extends through any story above the one in
4" insulated. which the boiler is located, including drop ceilings and crawl
Every part shipped for your order has a label listing the com- spaces, it must be enclosed in a continuous enclosure made
ponent part number. The first two digits identify the stack of noncombustible materials. This enclosure or chase should
inner diameter. For example, a part labeled 16SEJ11 is a 16" extend from the first ceiling above the boiler to, or through,
ID, double wall, expansion joint. The last two digits of the part the roof of the building. Refer to Figure F-1. It must maintain
number are for manufacturing control. the integrity of the fire separations required for the
construction and occupancy classification of the building.
A part labeled 24BT9011 is a 24" ID, 90 tee that is fiber insu-
lated with 2" of insulation between its inner and outer walls. 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
ENGINEERING DATA allow boiler room air to mix with outside air. This means
Information in this section outlines typical installation require- there must be sufficient clearance between the walls of the
ments when installing a stack or breeching to a Cleaver- enclosure and the stack, its supports, and its guides.
Brooks boiler. Actual installation and arrangements will be
dictated by design, state, provincial or local codes, job-site Clearance to Combustibles
conditions and number of boilers installed.
Care must be taken when using combustible material around
This information, in addition to information listed in Table the stack. Refer to "Clearances for Non-Combustible Enclo-
F-1, will assist you in determining equipment required. sures" in this section for recommended clearances.
For special applications or additional information contact your
local Cleaver-Brooks authorized representative. Connecting to the Boiler
CBS/ICBS stack systems, in most applications, can be con-
Application nected directly to, and supported by the boiler. Refer to Table
Cleaver-Brooks CBS/ICBS stack systems comply with the F-6 for typical stack weights. For special applications contact
requirements of the approval bodies listed in Table F-1. These your local Cleaver-Brooks authorized representative.
stack systems are not for installation in one and two family
dwellings.
F-5
02-02
Stacks
Table F-2. System Component Names and Part Numbers
PART NAME PART NUMBERS
DESCRIPTION
MODEL NO. CBS-I CBS-II CBS-III ICBS-1" ICBS-2" ICBS-4"
N18 S18 V18 A18 B18 D18
A N30 S30 V30 A30 B30 D30
Straight pipe section
N42 S42 V42 A42 B42 D42
90 tee NT90 ST90 VT90 AT90 BT90 DT90
45 tee NT45 ST45 VT45 AT45 BT45 DT45
Wye NY SY VY AY BY DY
Drain wye NDY SDY VDY ADY BDY DDY
15 elbow NEB15 SEB15 VEB15 AEB15 BEB15 DEB15
Expansion joint NEJ SEJ VEJ AEJ BEJ DEJ
Bellows joint NBJ SBJ VBJ ABJ BBJ DBJ
Fixed adjustable length NFAL SFAL VFAL AFAL BFAL DFAL
Nozzle section NNS SNS VNS ANS BNS DNS
Drain section NDS SDS VDS ADS BDS DDS
Horizontal drain NHD SHD VHD AHD BHD DHD
Stack base drain NSBD SSBD VSBD ASBD BSBD DSBD
Drain plug NDP SDP VDP ADP BDP DDP
Inspection plug NIP SIP VIP AIP BIP DIP
Slip joint NSJ SSJ VSJ ASJ BSJ DSJ
Stepped increaser NSIR SSIR VSIR ASIR BSIR DSIR
Wall penetration assembly NWPA SWPA VWPA AWPA BWPA DWPA
Roof support assembly - SRSA VRSA ARSA BRSA DRSA
Penetration assembly - SPA VPA APA BPA DPA
Storm collar NSC SSC VSC ASC BSC DSC
Tall cone flashing NTCF STCF VTCF ATCF BTCF DTCF
Stack closure ring NSCR SSCR VSCR ASCR BSCR DSCR
Stack termination cap NSTC SSTC VSTC ASTC BSTC DSTC
Open termination NOT SOT VOT AOT BOT DOT
Stack exit cone NSEC SSEC VSEC ASEC BSEC DSEC
Containment band CB1 CB1 CB1 CB1 CB1 CB1
Closure bands - CB2 CB2 ACB2 BCB2 DCB2
CB3
Half closure bands - HCB2 HCB2 AHCB2 BHCB2 DHCB2
HCB3
Boiler adapters NBA SBA VBA ABA BBA DBA
Generator adapters NGA SGA VGA AGA BGA DGA
Stack support assembly NSSA SSSA VSSA ASSA BSSA DSSA
Split clamp flange NSCF SSCF VSCF ASCF BSCF DSCF
Half split angle ring NHSAF SHSAR VHSAR AHSAR BHSAR DHSAR
Split angle ring NSAR SSAR VSAR ASAR BSAR DSAR
Hanger bracket NHB SHB VHB AHB BHB DHB
Floor alignment guide NFAG SFAG VFAG AFAG BFAG DFAG
Wall guide assembly NWGA SWGA VWGA AWGA BWGA DWGA
Transition band - STB VTB ATB BTB DTB
Wall support assembly NWSA SWSA VWSA 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.
F-6
02-02
Stacks
Not load bearing. Therefore, these systems are usually

between support or guide assemblies.
Expansion Direction
To determine expansion direction, it is necessary to understand
how the expansion or bellows joint works. The expansion or
bellows joint itself does not expand. In fact, the opposite hap-
pens. 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-2.
Calculating Expansion
The amount of thermal expansion that will occur is calculated
by the following equation:
Expansion = 1" per 100 of stack per 100 F above ambient
temperature.
Figure F-1. System Extension Above Boiler Room
Expansion and Installation Concerns

When stack systems are exposed to the heating and cooling of
normal operation, the components will expand and contract.
The systems are designed to adjust to this movement, provided
the amount and direction of expansion is accurately calculated,
and the system is correctly installed.
The amount of thermal expansion that will occur depends on
the length of breeching, height of the stack, temperature of the
flue gas, and arrangement of the system. Therefore, the follow-
ing 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 Figure F-2. Thermal Expansion Between Two Fixed Points in Stack
components. System
F-7
02-02
Stacks
Expansion is calculated between fixed points in the system. If Stack support assembly (SSA).
more than 1/4" of expansion will occur between fixed points,
Wall support assembly (WSA).
an expansion or bellows joint must be installed within that run
of stack. Roof support assembly (RSA).
Thermal expansion can also be determined using the graphs Refer to Table F-3 for the maximum stack height supported per
shown in Figure F-3. assembly.
Support assemblies must also be located within 6 of elbows,
Support Assemblies tees, or wyes. It may be necessary to reduce this spacing if
CBS/ICBS support assemblies are load bearing items. They anticipated expansion is greater than 1/4" between fixed points.
are designed to carry the weight of the system and withstand Refer to Figure F-4 for the maximum unsupported distance
expansion forces. between elbows, tees, or wyes.
Support assemblies are connected to the inner wall flange of Refer to Figure F-5 for the maximum support and guide assem-
the stack. They must always be bolted or otherwise tied into bly spacing for vertical, horizontal and sloping stack runs.
rigid structural building supports. They must never be sus-
pended from lightweight rods or tubing.
Guide Assemblies
Three different types of support assemblies are used:
Guide assemblies are designed to provide lateral support and
guidance for the stack system. They must be rigidly mounted to
the building and plumb with the stack. Guide assemblies are
not tied into, or attached to, the stack in any way, but they do
bear part of the overall load in horizontal and sloped runs.
Three types of guide assemblies are used:
Split angle rings.
Wall guide assemblies.
Floor alignment guides.
The maximum spacing between any two guide assemblies, or
between a support assembly and a guide assembly, is 15 for
vertical runs and 12 for horizontal or sloping runs. Refer to
Figure F-5.
Figure F-3. Graphs for Calculating Thermal Expansion Figure F-4. Maximum Unsupported Distance Between Elbows,
Movement Tees, or Wyes
F-8
02-02
Stacks
Table F-3. Maximum Stack Height Supported Per Assembly

ICBS-2
WSA 6 210 78
MODEL ID (INCHES) SSA (FT) RSA (FT) 8 198 73
CBS-I 6-48 210 78A 10 165 61
CBS-II 6-16 210 78 12 141 52
18 203 77 14 123 45
20 192 75 16 109 40
22 189 73 18 103 39
24 178 70 20 98 38
26 175 68 22 95 37
28 169 65 24 93 36
30 162 63 26-28 83 33
32 155 61 30-32 82 32
34 148 58 34 81 32
36 142 56 36 81 31
42 121 49 42 70 28
48 100 42 48 61 24
CBS-III 6-16 136 50 ICBS-4 6 143 53
18 131 50 8 119 44
20 127 48 10 102 37
22 122 47 12 89 33
24 118 45 14 79 29
26 113 44 16 71 26
28 109 42 18 67 25
30 104 40 20 65 25
32 100 39 22 63 24
34 95 37 24 62 24
36 91 36 26-34 57 22
42 77 31 36 56 22
48 64 26 42 49 20
ICBS-1 6-10 210 78 48 43 17

12 188 70 NOTE:
1. A. Single wall VSI-I piping prohibits the use of penetration as-
14 163 61 semblies. A transition to double wall VSI-II pipe will be required
16 144 53 where the piping passes through a penetration assembly.
2. Numbers in table are in inches.
18 134 51 3. SSA = Stack Support Assembly.
20 128 49 4. WSA = Wall Support Assembly.
5. RSA = Roof SUpport Assembly.
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
F-9
02-02
Stacks
Figure F-5. Maximum Support and Guide Assembly Spacing for Vertical, Horizontal, and Sloping Stack Runs
The maximum height a vertical stack can extend above its

storm collar. This method may only be used if:
uppermost guide or guy cable location is 9. Refer to Figure F-
6. The roof deck and framing materials are noncombustible.
The stack does not pass through floors, drop ceiling or other
Load Bearing occupance zones on its way to the roof.
When designing or installing a CBS/ICBS stack, remember the The area above the boiler, to the roof level, is basically open,
inner stack wall is the load bearing member. All stack supports providing adequate air movement around the system.
must be connected to the inner wall flanges.
Outer or center walls (three wall stack) are not designed to bear Roof Opening Size, Framing and Curbing
loads. They act as jackets only. Never connect system supports
Opening size varies according to stack OD. In most cases the
or pierce these walls.
opening will be square and cut so it is basically flush with the
framing members. If the roof is made of noncombustible mate-
Roof Penetrations rials, the roof opening may be round.
Proper selection and use of various components at the location The opening must be level and provide attachment points for
the system penetrates the roof, are based on a number of fac- external brackets. The opening should be boxed in with struc-
tors, including roof material (combustible/noncombustible),
the use of noncombustible enclosures or chases, and the gen-
eral layout of the system.
When a stack system passes through a roof made of combusti-
ble materials, a penetration or roof assembly that consists of a
ventilated storm collar must be used. These assemblies are spe-
cifically designed to provide the proper clearances and ventila-
tion 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 enclo-
sure or chase. The enclosure must extend to, or above, the roof
deck and a penetration or roof assembly must be used regard-
less of the roof material.
Figure F-6. Cable Guying Specifications for Roof Level
A third roof penetration uses tall cone flashing along with a Guide
F-10
02-02
Stacks
tural steel or wood framing on all four sides. The framing must ture, tower, or wall. The structure must be capable of support-
be capable of supporting the load, or the penetration assembly, ing lateral wind load and maintain plumb alignment between
when the stack is exposed to wind loading and thermal expan- the guide assemblies and the stack.
sion forces.
On sloping roofs, a level curb must be constructed and tied Clearances For Noncombustible
into the openings framing so that the stack maintains its true Enclosures
vertical positions. Although consistent clearances are not critical, a minimum
Both framing and curbing can be constructed of combustible open area equivalent to a 1-1/2" clearance between the enclo-
materials if proper clearances are maintained. sure, its supports and guides, must exist at any plane within the
enclosure. Refer to Figure F-1.
Table F-4 list roof openings for all models in width of square,
or diameter of circle.
Clearances to Combustibles
Figure F-7 shows roof framing and curbing details for flat or
sloping roofs. When installed within the same room or zone as the boiler, the
stack must have a minimum air space clearance to combustible
Cable Guying Above the Roof - Guy cables are an acceptable construction, including building insulation and electrical wir-
method of providing lateral support to stack sections that ing as listed in Table F-5.
extend above the roof level. A stack should not use cable guy-
ing at locations higher than 15 above a roof, pier or super- These minimum clearances must never be altered in any way.
structure may be used for this type of application. The stack Lower than listed flue gas temperatures do not alter the clear-
may also extend 9 above guy cable connections. Refer to Fig- ances listed. For example, if the maximum flue gas tempera-
ures F-7 and F-8. ture 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.
Above the Roof Guiding
Stacks extending more than 24 above a roof, pier or wall When smaller clearances are desired, specify model CBS-III
should use a guide assembly rigidly mounted to a superstruc- or ICBS fiber insulated stacks.
Table F-4. Roof Opening Size for Penetration of Roof Support Assemblies
STACK ID WIDTH OF SQUARE OR DIAMETER OF CIRCLE

(INCHES)
CBS-II CBS-III ICBS-1" ICBS-2" ICBS-4"
6 17-1/2 18-1/2 17-1/2 19-1/2 23-1/2
8 19-1/2 20-1/2 19-1/2 21-1/2 25-1/2
10 21-1/2 22-1/2 21-1/2 23-1/2 27-1/2
12 23-1/2 24-1/2 23-1/2 25-1/2 29-1/2
14 25-1/2 26-1/2 25-1/2 27-1/2 31-1/2
16 27-1/2 28-1/2 27-1/2 29-1/2 33-1/2
18 29-1/2 30-1/2 29-1/2 31-1/2 35-1/2
20 31-1/2 32-1/2 31-1/2 33-1/2 37-1/2
22 33-1/2 34-1/2 33-1/2 35-1/2 39-1/2
24 35-1/2 36-1/2 35-1/2 37-1/2 41-1/2
26 37-1/2 38-1/2 37-1/2 39-1/2 43-1/2
28 39-1/2 40-1/2 39-1/2 41-1/2 45-1/2
30 41-1/2 42-1/2 41-1/2 43-1/2 47-1/2
32 43-1/2 44-1/2 43-1/2 45-1/2 49-1/2
34 45-1/2 46-1/2 45-1/2 47-1/2 51-1/2
36 47-1/2 48-1/2 47-1/2 49-1/2 53-1/2
42 53-1/2 54-1/2 53-1/2 55-1/2 59-1/2
48 59-1/2 60-1/2 59-1/2 61-1/2 65-1/2
F-11
02-02
Stacks
Figure F-7. Roof Framing and Curb Details
To assist with selection, the following figures will provide These weights include the stack sections and connecting hard-
basic construction details of the different types of stacks: ware.
Figure F-9 shows model CBS-II double wall stacks.
Typical Stack Arrangements
Figure F-10 shows model CBS-III triple wall stacks.
The purpose of a stack and breeching on a boiler is to conduct
Figure F-11 shows model ICBS fiber insulated stacks. the products of combustion to a point of safe discharge (atmo-
Each model includes: sphere).
Spacer bands that hold the sections together and maintain the The forced draft design of Cleaver-Brooks burner and boiler
proper air space between the walls. combinations, eliminates the need for a stack designed to cre-
ate a draft. A static pressure of 1/2" WC at the boiler flue gas
One air space is designed into model CBS-II and two spaces outlet will have no appreciable effect on burner operation.
are designed into model CBS-III. Refer to the individual product sections for allowable pressure
Model ICBS are available with 1", 2", or 4" of fiber variations.
insulation between the walls. If the stack height is over 150 or if an extremely large breech-
For information on single wall or type "B" gas vent stacks, ing and stack combination cause excessive draft, a simple baro-
contact your local Cleaver-Brooks authorized representative. metric damper can be located in the breeching - close to the
stack.
Stack Weight Automatic or special draft controls are not required and are not
recommended, except where dictated by state, provincial or
Table F-6 lists weights of all models in pounds per linear foot.
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 temper-
ature of the boiler, and the stack flue gas temperature.
Stack condensation is most likely to occur on boiler installa-
tions where light loads or intermittent firing causes a cool stack
condition, which results in condensation of the water vapor in
the flue gas.
Figure F-8. Cable Guying Installation Details The following items should be considered when planning to
keep stack condensation to a minimum:
F-12
02-02
Stacks
Table F-5. Stack System Clearances to Combustible Materials
MODEL 500F
1000F 1400 F
ID GREASE
NO. CHIMNEY CHIMNEY 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
CBS-III 6-16 4 6 4
18-20 4 9 5
22-24 4 12 6
26-28 4 14 7
30-32 4 17 8
34-36 4 20 9
42 18 20 10 Figure F-9. Model CBS-II Double Wall Stack Construction and

48 18 20 12 Joint Details
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 6-16 0.5 0.5 1.0

&
ICBS-4 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.

Figure F-10. Model CBS-III Triple Wall Stack Construction and
Joint Details
F-13
02-02
Stacks
The boiler should be sized as close as possible to the true

operating load. Oversized boilers should be avoided.
An off-set stack is recommended, with bottom clean-out and
drain connection, to prevent any condensed water from
draining back into the 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.
Figure F-11. Model ICBS Fiber-Insulated Stack Construction and

Joint Details
Table F-6. Weight of Straight Stack
STACK ID
WEIGHT IN POUNDS PER LINEAR FOOT
(INCHES)
CBS-I CBS-II CBS-III ICBS-1" ICBS-2" ICBS-4"
6 2.43 4.83 7.50 7.01 9.85 17.01
8 3.25 6.17 9.38 9.01 12.36 20.49
10 4.05 7.50 11.26 11.01 14.83 23.96
12 4.86 8.84 13.14 13.00 17.32 27.43
14 5.67 10.17 15.02 15.00 19.81 30.90
16 6.48 11.66 17.16 16.99 22.30 34.37
18 7.29 12.84 18.78 18.99 24.78 37.83
20 8.09 14.18 20.66 20.97 27.26 41.29
22 8.89 15.51 22.54 22.97 29.74 44.76
24 9.71 16.85 24.42 24.98 32.23 48.23
26 10.51 21.88 33.48 30.33 38.31 55.65
28 11.32 23.43 35.78 32.45 40.91 59.33
30 12.13 24.99 38.09 34.67 43.64 63.05
32 12.94 26.55 40.39 36.90 46.35 66.74
34 13.75 28.10 42.70 39.13 49.08 70.44
36 14.56 29.66 45.00 41.35 51.79 74.13
42 16.97 34.83 54.98 48.01 59.92 85.21
48 19.40 40.20 66.40 54.69 68.08 96.31
F-14
02-02
Stacks
The following sample specification is provided by Cleaver- Brooks to assist you in specifying your customers specific needs and
application.
1.0 Standard Component Specifications

Boiler stack and breeching components, supports and terminations shall be factory prefabricated.
All stack and breeching components shall be tested and listed by Underwriters Laboratories (UL and ULC), for use with building
heating equipment burning gas, liquid, or solid fuels, as described in NFPA 211, Chapter 2.
All stacks and breechings will have inner walls of 20-gauge Type 304 stainless steel for gas and No. 2 oil, or 20-gauge Type 316
stainless steel for coal, solid fuels, and No. 4 thru No. 6 oil.
Outer walls shall be 24-gauge aluminum-coated steel for sizes up to 24" ID and 20-gauge for sizes of 26" to 48" ID.
The stack and breeching shall be engineered, approved, and manufactured for the boiler equipment manufacturer.
The stack and breeching manufacturer must supply complete CAD system design drawings which include a complete component
bill of materials.
Stack and breeching systems must be designed to adjust to thermal expansion caused by the heating and cooling of normal boiler
operation.
All stack and breeching components must be warranted for a minimum of 15 years when installed according to the manufacturers
installation instructions.
The stack and breeching shall comply with national safety standards and all building codes where applicable.
The stack section joints shall be field sealed by use of containment bands with captive fasteners and high temperature joint sealant.
All stack and breeching components shall be shipped on pallets and shrink-wrapped to simplify on-site handling and protect mate-
rials until installation.
The system is to maintain air-tight integrity at pressures up to 72" WC at room temperature.
The system shall have a ______" minimum clearance to combustibles with 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 continu-
ous.
2.0 Specifications Specific to Double Wall Air Insulated Components

There shall be a minimum of 1" air space between the inner and outer wall.
3.0 Specification Specific to Triple Wall Air Insulated Components

There shall be a minimum of 1" air space between the inner and center wall, and a minimum of 1/2" air space between the center
and outer wall.
4.0 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.
F-15
02-02
Stacks
NOTES
F-16
02-02
Section G
ECONOMIZERS
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3
DIMENSIONS AND WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-12
G-1
04-02
Economizers
ILLUSTRATIONS
Figure G-1. Boilermate Cylindrical Economizer Mounting to Firetube Boiler (Model CB Boilers) . . . . . . . . . . . . . . . . . . G-7
Figure G-2. Economizer Above Industrial Watertube Boiler (Example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8
Figure G-3. Economizer on Side of Industrial Watertube Boiler (Example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8
Figure G-4. Typical Economizer Feedwater Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-9
Figure G-8. Typical Economizer Feedwater Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-11
TABLES
Table G-1. Firetube Boiler Cylindrical Economizers Dimensions and Weights (Model CB Boilers) . . . . . . . . . . . . . . . . . G-4
Table G-2. Industrial Watertube Boiler Rectangular Economizers, Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . G-4
Table G-3. Firetube Boiler Cylindrical Economizer, Performance Data (Model CB Boilers) . . . . . . . . . . . . . . . . . . . . . . . G-5
Table G-4. Industrial Watertube Boilers Rectangular Economizer Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6
Table G-5. Firetube Boiler Cylindrical Economizers, Efficiencies (Model CB Boilers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6
Table G-6. Industrial Watertube Boiler Rectangular Economizers, Efficiencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6
This section contains information on Economizers. An economizer recovers heat from flue gases and uses it to increase boiler feed-
water 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.
G-2
04-02
Economizers
FEATURES AND BENEFITS Prevents the forming of corrosive acids in the economizer.
Prevents stack corrosion.
Reduces Fuel Use and Cost:
Recovers heat from flue gases that would otherwise be Guaranteed Efficiency on Model CB Firetube Boilers:
wasted. $10,000 rebated for every full 1.0% efficiency point less than
Heat is used to raise boiler feedwater temperature prior to guaranteed.
entering the boiler.
PRODUCT OFFERING
Load Changes:
Cleaver-Brooks offers a line of custom-engineered economiz-
Rapid changes in load demands can be met faster due to ers for boiler sizes up to and including 150 MMBtu/hr input.
higher feedwater temperature. The model designation is Boilermate Fuel Economizers, and
they are available in either cylindrical or rectangular designs.
Emissions:
Reduced fuel-firing rates for any given steam output means Standard Equipment
reduced NOx emissions. Equipment described is for the standard Boilermate Fuel Econ-
omizer, as defined later in the specifications, and in the current
ASME Construction: literature.
Ensures high quality design and manufacturing standards. Standards for both cylindrical and rectangular Boilermate
Provides safety and reliability. Economizers include:
Designed and fabricated in accordance with the ASME
High Efficiency Heat Exchanger: Boiler and Pressure Vessel Code, Section I, Power Boilers.
Provides continuous, high-frequency resistance welding. Thermometer and safety valve connections at the feedwater
headers.
Provides uniform fin-to-tube contact for maximum heat
transfer. Incorporates self-draining design.
Fin tubing offers up to 12 times the heat exchange surface of Safety valve - standard with industrial watertube boilers
bare tubing of the same diameter. only. Valve is set at 490 psig.
Self-Draining Design: Optional Equipment

Suitable for outdoor installation. Vertical or horizontal flue gas flow patterns on rectangular
design.
Low Pressure Drop:
Utilization of waste gas.
Provides gas side pressure drops of 0.8" WC or less.
Soot blowers for oil firing.
Permits use of smaller forced draft fans.
Feedwater and sootblower piping from economizer to boiler.
Permits use of existing fans in almost all installations.
Feedwater preheating system.
Gas Tight Combustion Stack: Safety valve optional with firetube boilers. If supplied, valve
is set at 450 psig.
Provides inner casing of carbon steel.
Provides outer casing of weather resistant, corrugated,
galvanized carbon steel.
Compact dimensions provide for easy installation.
Feedwater Preheating System:

Controls cold end corrosion through all flow rates.
G-3
04-02
Economizers
Table G-1. Firetube Boiler Cylindrical Economizers

DIMENSIONS AND WEIGHTS Dimensions and Weights
(Model CB Boilers)
Information in this section outlines typical dimensions and
weights of an economizer, and typical ratings and efficiencies DIMENSIONS
(APPROX) DRY
when utilizing an economizer. BOILER ECONOMIZER UNIT
HP MODEL WEIGHT
Table G-1 lists dimensions and weights for a cylindrical Boil- NUMBER HEIGHT DIA (LBS)
ermate Economizer typically installed with a firetube boiler. (IN.) (IN.)
(Model CB Boilers). 100 hp EC-40821 61 34 1110
Table G-2 lists dimensions and weights for a rectangular Boil- 125 hp EC-41221 85 34 1496
ermate Economizer typically installed with an industrial 150 hp EC-41021 73 34 1285
watertube boiler.
200 hp EC-40820 61 34 1354
The selection of a cylindrical or rectangular economizer for a 250 hp EC-41120 85 34 1757
particular application will depend on type and capacity of the
boiler and job site conditions. 300 hp EC-40931 73 43 2166
350 hp EC-40831 61 43 1979
400 hp EC-40830 73 43 2272
500 hp EC-40831 61 43 1979
600 hp EC-30830 73 43 2121
700 hp EC-30842 73 52 2626
800 hp EC-30841 73 52 2938
NOTES:
2. Boiler firing natural gas.
3. Boiler operating pressure is 125 psig (acceptable tolerance is
5 psig).
4. Do not use this table for model CB-LE boilers. Contact your local
Cleaver-Brooks representative for sizing detail.
Table G-2. Industrial Watertube Boiler Rectangular Economizers, Dimensions and

Weights
ECONOMIZER APPROXIMATE DIMENSIONS DRY UNIT
BOILER GAS FLOW (INCHES) WEIGHT
MODEL DIRECTION (LBS)
(EXAMPLE) LENGTH WIDTH HEIGHT
D-34 VERTICAL 105 29 76 4400

D-52 HORIZONTAL 49 110 47 5800
D-76 VERTICAL 140 47 76 8800
D-94 VERTICAL 155 59 80 11600
NOTES:
2. Data indicated is for select applications. Each Economizer is designed on a job to job basis.
3. Boiler is firing natural gas.
4. Boiler operating pressure is 150 psig (acceptable tolerance is 5 psig).
5. Economizer gas flow direction can be either horizontal or vertical.
G-4
04-02
Economizers
PERFORMANCE DATA
Tables listed here contain performance data for:
Gas fired, 100 through 800 hp firetube boilers operating at
125 psig, and utilizing a cylindrical fuel economizer.
Gas fired, industrial watertube boilers operating at 150 psig
and utilizing a rectangular fuel economizer.
For additional operating pressures, load capacity or fuel selec-
tions, contact your local Cleaver-Brooks authorized represen-
tative.
Table G-3 lists typical water and gas side temperatures when
utilizing a cylindrical Boilermate Economizer with a firetube
boiler (Model CB Boilers).
NOTICE
Do not use on boilers equipped with flue gas recircu-
lation. Contact your local Cleaver-Brooks authorized
representative.
Table G-4 lists typical water and gas side temperatures when
utilizing a rectangular Boilermate Economizer with an indus-
trial watertube boiler.
Table G-5 lists typical increases in efficiency for a firetube
Table G-6 lists typical increases in efficiency for an industrial
watertube boiler.
Table G-3. Firetube Boiler Cylindrical Economizer, Performance Data (Model CB Boilers)
WATER SIDE GAS SIDE
BOILER HEAT HEATING
LOAD ECONOMIZER TEMPERATURE PRESS. TEMPERATURE PRESS. RECOVD SURFACE
HP % MODEL NO. FLOW FLOW
DROP DROP BTU/HR SQ-FT
PPH PPH
IN F OUTF PSIG IN F OUT F IN. WC
100 100 EC-40821 3450 220 253 0.6 3968 410 299 0.2 117213 240
125 100 EC-41221 4313 220 270 1.3 4959 465 295 0.5 223989 361
150 100 EC-41021 5175 220 255 1.6 5951 420 300 0.5 189303 301
200 100 EC-40820 6900 220 249 2.5 7935 395 296 0.3 209230 361
250 100 EC-41120 8625 220 266 1.1 9919 460 306 0.7 405328 496
300 100 EC-40931 10350 220 260 1.8 11903 435 302 0.4 420422 646
350 100 EC-40831 12075 220 252 2.1 13886 410 304 0.4 388523 574
400 100 EC-40830 13800 220 256 3.0 15870 425 304 0.4 508748 695
500 100 EC-40831 17250 220 244 4.3 19838 385 302 0.8 431393 574
600 100 EC-30830 20700 220 241 6.7 23805 370 299 0.7 447492 566
700 100 EC-30842 24150 220 239 10.6 27773 365 301 0.8 464527 589
800 100 EC-30841 27600 220 241 15.8 31740 370 298 0.6 589092 775
NOTES:
1. Feedwater temperature to economizer is at least 220 F (Deaerated).
2. Boiler operating pressure is 125 psig (acceptable tolerance 5 psig).
3. Gas side flow (pph) determined with 10% excess air (50 to 100% of capacity).
4. Continuous modulated feedwater flow must be provided.
5. Boiler firing natural gas
6. Do not use this table for model CB-LE boilers. Contact your local Cleaver-Brooks representative for sizing detail.
G-5
04-02
Economizers
Table G-4. Industrial Watertube Boilers Rectangular Economizer Performance Data

ECONOMIZER
WATER SIDE GAS SIDE

MODEL LOAD HEAT HEATING
NO. % TEMPERATURE TEMPERATURE PRESS- RECOVERED
PRESS. SURFACE
FLOW FLOW DROP
DROP BTU/HR SQ-FT
PPH PPH IN. WC
PSIG
IN F OUT F IN F OUT F (MAX)
D-34 100 15000 225 292 6.8 15884 532 318 0.75 1237000 786
D-52 100 31000 225 292 5.6 32582 532 318 0.75 2530000 1616
D-76 100 51500 225 280 8.1 53999 498 318 0.75 3424000 2370
D-94 100 63000 225 269 9.9 66018 459 318 0.75 3260000 2462
NOTES:
1. Feedwater temperature to Economizer is at least 220 F (Deaerated).
2. Boiler operating pressure is 150 psig (acceptable tolerance 5 psig).
3. Gas side flow (pph) determined with 10% excess air.
4. Continuous modulated feedwater must be provided.
5. Data indicated is for select application. Each Economizer is designed on a job to job basis.
6. Boiler is firing natural gas.
Table G-5. Firetube Boiler Cylindrical Economizers, Table G-6. Industrial Watertube Boiler Rectangular
Efficiencies (Model CB Boilers) Economizers, Efficiencies
BOILER LOAD ECONOMIZER EFF % FUEL EFF BOILER LOAD FLOW EFF % FUEL EFF
HP % MODEL NO. W/0 SAVED WITH MODEL % PPH W/O SAVED WITH
ECON ECON ECON ECON
100 hp 100 EC-40821 82.2 3.3 84.9 D-34 100 15000 77.47 6.3 82.72
125 hp 100 EC-41221 81.0 5.1 85.1 D-52 100 31000 78.07 6.3 83.34
150 hp 100 EC-41021 82.1 3.6 85.0 D-76 100 51500 79.17 5.2 83.54
200 hp 100 EC-40820 82.7 3.0 85.1 D-94 100 63000 80.15 4.1 83.59
250 hp 100 EC-41120 81.3 4.6 85.1 NOTES:

1. Feedwater temperature to Economizer is at least 220 F
300 hp 100 EC-40931 81.9 4.0 85.2 (Deaerated).
2. Savings depend on total design of the system.
350 hp 100 EC-40831 82.5 3.2 85.1 3. Data indicated is for select applications. Each Economizer is
designed on a job to job basis.
400 hp 100 EC-40830 82.2 3.6 85.2 4. Boiler is firing natural gas.
5. Boiler operating pressure is 150 psig (acceptable tolerance
500 hp 100 EC-40831 83.1 2.4 85.1 5 psig).
600 hp 100 EC-30830 83.5 2.1 85.2
700 hp 100 EC-30842 83.6 1.9 85.2
800 hp 100 EC-30841 83.5 2.1 85.2 Firetube Boilers (Model CB Boilers)
NOTES: Installation - economizer above boiler:
1. Feedwater temperature to Economizer is at least 220 F (Deaer-
ated). All standard firetube boilers (125 hp and above) can support
2. Selections are based on best Btu savings per dollar costs.
3. Boiler is firing natural gas. up to 2,000 lbs without additional reinforcement.
4. Boiler operating pressure is 125 psig (acceptable tolerance
5 psig). Firetube boilers up to 250 hp can be reinforced to support
4. Do not use this table for model CB-LE boilers. Contact your local 2,500 lbs, however, this must be specified.
Cleaver-Brooks representative for sizing detail.
Firetube boiler sizes 250 hp through 800 hp can be reinforced
ENGINEERING DATA to support 3,000 lbs, however, this must be specified.
Information in this section outlines typical installation. Actual All weights listed in Table G-1 are shipping weights. When
installation and piping arrangements will be dictated by installed, the water weight must be added to obtain total load
design, state, provincial or local codes, and job-site conditions. to be supported. Use an average add-on of 200 lbs.
G-6
04-02
Economizers
Add the weight of any stack (if unsupported) from the Feedwater Piping
economizer to the outside.
Piping arrangements are dictated by ASME Code, location of
Although the economizer can support additional weight, the the economizer in relation to the boiler, and feedwater regulat-
total weight of economizer and stack will very likely exceed ing system.
the allowable weight on the boiler. Be certain that either the
Figure G-4 outlines typical feedwater piping per ASME
economizer or the stack, or both, are supported external from
Code jurisdiction. If the economizer can be shut off from the
the boiler.
boiler by valve(s), the economizer must have a safety valve
If an expansion joint is used, the economizer and stack must and the boiler must have feed and check valves. Refer to
be supported to ensure all loading is removed from the Figure G-5.
expansion joint.
Figure G-5 outlines feedwater piping with the economizer
Refer to Figure G-1 for suggested mounting to a firetube mounted above the boiler.
Figure G-6 outlines feedwater piping with the economizer
For information on Model CB-LE Boilers, contact your mounted and the economizer outlet at or below water level in
local Cleaver-Brooks authorized representative. boiler drums.
Figures G-7, G-8, and G-9 outline different feedwater piping
Industrial Watertube Boilers arrangements with the economizer mounted above the boiler
Installation - economizer above boiler: and with gas and water isolation by-passes.
Maximum vertical loading of top mounted economizer and
stack at the boiler connection must not exceed 2,000 lbs. The
stack must be top-guided to prevent any overturning moment
at boiler connection.
The economizer and stack must be supported to ensure all
loading is removed from the expansion joint.
All weights listed in Table G-2 are shipping weights. When
installed, the water weight must be added to obtain total load
to be supported. Water weights will vary and can only be
obtained after economizer is selected.
Refer to Figure G-2 for suggested mounting above an
industrial watertube boiler.
Installation - economizer on side of boiler:
BOLT SPECIFICATIONS
Breeching must be supported to ensure all loading is Boiler hp 100 125-200 250-350 400-800
removed from expansion joints.
No. of Bolts 8 12 12 16
Concrete must be suitably reinforced. Piers and footings
Bolt Size 3/8 - 16 (threads per inch)
must be designed to meet soil conditions and local
ordinances at job site. Bolt Circle 13-7/8 17-7/8 21-7/8 25-7/8
The economizer support stand must be designed to support Vent Opening 12 16 20 24

(OD)
the economizer and water weight. All weights listed in Table
G- 2 are shipping weights. When installed, the water must be NOTES:
added to obtain total load to be supported. Water weights 2. For allowable weights on vent stub refer to dimensions and
will vary and can only be obtained after economizer is weights in this section.
3. For information on stacks refer to Section F.
selected.
Refer to Figure G-3 for suggested mounting on side of an
industrial watertube boiler. Figure G-1. Boilermate Cylindrical Economizer Mounting to
Firetube Boiler (Model CB Boilers)
G-7
04-02
Economizers
Figure G-2. Economizer Above Industrial Watertube Boiler (Example)
Figure G-3. Economizer on Side of Industrial Watertube Boiler (Example)
G-8
04-02
Economizers
Figure G-4. Typical Economizer Feedwater Piping
REFER TO PRODUCT OFFERING, PAGE G-3.
G-9
04-02
Economizers
G-10
04-02
Economizers
G-11
04-02
Economizers
The following sample specification is provided by Cleaver- Brooks to assist you in specifying your customers specific needs and
application.
1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-12

2.0 Common Construction Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-12
3.0 Specifications Specific To Cylindrical Economizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-12
4.0 Specifications Specific To Rectangular Economizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-12
5.0 Quality Control and Code Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-13
1.0 General
Specifications for Boilermate cylindrical and rectangular economizers shall include the furnishing of (___________) complete
packaged, extended surface boiler economizer(s), as furnished by Cleaver-Brooks.
2.0 Common Construction Specifications

Tube material is to be SA-178-A boiler tube.
Extended surface is to be of solid, continuous, high- frequency, resistance welded carbon steel fins. Serrated fins are not
acceptable.
Tube arrangement is to be square pitch only. Triangular or staggered tube pitch will not be acceptable.
Inner casing is to be a minimum of 10-gauge carbon steel.
Insulation type is to be mineral wool.
Outer casing is to be weather-proof with a minimum 27- gauge, corrugated, galvanized, carbon steel casing. All exposed
surfaces not enclosed by the outer casing are to be painted with high-temperature paint.
The economizer shall be completely drainable by gravity, after installation.
Safety valve to be supplied.
3.0 Specifications Specific To Cylindrical Economizers

The economizer shall be of the cylindrical design.
Fins are to be not less than .060" thick.
The economizer shall be equipped with a built-in sootblower and shall utilize lane blowing to provide maximum cleaning
capabilities. Longitudinal or mass blowing shall not be acceptable.
For economizers used on boilers which have an on/off type feedwater control system, a modulating feedwater system shall
be incorporated into the system to ensure proper economizer operation.
4.0 Specifications Specific To Rectangular Economizers

Tubes are to be commercially available 2" OD.
Fins are to be not less than .075" thick.
Tube sheets are to be of the open lattice design. Tube walls (pressure parts) shall not be in contact with tube sheets. The fins
shall rest on the tube sheet.
Sootblower wall boxes and distal bearings shall be included and are to be installed on the economizer by the vendor.
Sootblowers shall be installed (when specified) transversely to provide maximum cleaning capabilities. Longitudinal or
mass blowing shall not be acceptable.
An insulated access door of carbon steel construction, 16" square inside-to-inside, shall be included in the economizer design.
G-12
04-02
Economizers
5.0 Quality Control And Code Requirements

Economizer is to be designed and fabricated in accordance with the ASME Boiler and Pressure Vessel Code, Section I, Power
Boilers.
Minimum design temperature is to be 700 F.
Unit shall be hydrostatically tested at 1.5 times the design pressure in the presence of a Code Inspector.
Unit is to be ASME Code Stamped, and is to include nameplate and applicable code papers.
G-13
04-02
Economizers
NOTES
G-14
04-02
Section H
FEEDWATER SYSTEMS
Spraymaster Deaerators (Single Tank) H1
Spraymaster Deaerators (Duo Tank) H2
Boilermate Deaerators H3
Surge Tanks H4
Boiler Feed Systems H5
Chemical Feed Systems and Metering Pumps H6
Filters H7
Softeners H8
Dealkalizers H9
Blowdown Separators H10
Blowdown Heat Recovery Systems H11
Flash Tank Heat Exchangers H12
Sample Coolers H13
H-a
02-02
Feedwater Systems
H-b
Section H1
SPRAYMASTER DEAERATORS (Single Tank)
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-3
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-4
Deaerator Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-4
Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-4
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-5
RETURN ON INVESTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-8
Flash Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-8
Exhaust Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-8
Surface Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-8
Chemical Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-8
Makeup Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-8
Sewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-8
Intangibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-8
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-9
ILLUSTRATIONS
Figure H1-1. Spraymaster Tank Supports and Saddles, Details and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-5
Figure H1-2. Spraymaster Deaerator Dimensions and Ratings (Single Tank) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . H1-6
TABLES
Table H1-1. Spraymaster Deaerator Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-4
H1-1
02-02
Spraymaster Deaerators (Single Tank) Feedwater Systems
The Cleaver-Brooks designed deaerator assures high purity 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 princi-
pals of gas removal proven most effective and economical to every boiler owner. Contact your local Cleaver-
Brooks authorized representative for component sizing information.
H1-2
02-02
Feedwater Systems Spraymaster Deaerators (Single Tank)
FEATURES AND BENEFITS Exceeds ASME Recommendations for Oxygen Level:

Guaranteed to remove oxygen concentrations to 0.005 cc/
Low Profile Design: liter while operating between 5% and 100% capacity.
Low head allows installation in space restricted areas. Carbon dioxide concentrations are practically reduced to
zero.
Two-Stage Deaeration in a Common Vessel:
Capacity Not Affected by Mixed Inlet Temperature:
Recycle pumps are not required.
Consistent performance under variable conditions.
Packaged for easy maintenance.
Integral Level Control Automatically Introduces Cold Water

ASME Code Design (Section VIII):
Make-Up to Supplement Condensate Only When Necessary
Assures deaerator vessel quality in materials and fabrication to Meet Boiler Demand:
to meet safety requirements.
Saves Btus by accepting condensate before cold make-up
water. Maintains a minimal water level within the deaerator
Internal Stainless Steel Vent Condenser: vessel to prevent damage to the boiler feedpumps, and to
Protects deaerator vessel against corrosive gases while maintain system operation.
providing a means for removal of corrosive gases from boiler
feedwater. Variety of Tank Sizes to Handle Volume-Swings in Conden-
sate Return:
Self-Cleaning Water Spray Valve: Provides flexibility for selecting a tank for specific
Angles associated with the water spray valve assembly and applications, limiting the loss of hot condensate to drain.
actual water spray pattern, maintains deposit-free surfaces.
Packaged Units for Cost Effective Installation:
Reduces maintenance requirements.
Complete packages are pre-fabricated in the manufacturing
Internal Automatic Check Valves Prevent Back Flooding: facility to ensure piping alignment and control wiring
function. The unit is partially disassembled, and match
Both the water spray valve and steam atomizing valve are in marked for efficient field re-assembly.
the normally closed position under no flow conditions.
Prevents steam back-flow through the water spray valve and Available in Horizontal and Vertical Configuration:
water back flow through the steam atomizing valve.
Provides adaptability for installation in space restricted
areas.
Removable Water Spray Inlet Assembly:
Flanged assembly allows easy access for maintenance and/ Internal Pump Suction Vortex Breakers:
or inspections.
Eliminates the problems of loss in NPSHA and cavitation
associated with the creation of vortices within pump suction
Stainless Steel Deaeration Assembly: piping.
Ensures a longer life of wetted materials in intimate contact
with corrosive liquids and released corrosive gases. Vessel Corrosion Protection When Off-Line:
Optional epoxy lining
Pressurized Tank Reduces Flashing and Minimal Venting:
Recovery of exhaust and turbine steam. PRODUCT OFFERING
Saves Btus that would normally be exhausted to Information in this section applies directly to Cleaver- Brooks
atmosphere. Improves plant efficiency. packaged Spraymaster Deaerators ranging from 7,000 to
280,000 pounds/hour. For larger capacities contact your local
Auto Vent Valve Eliminates Dissolved Gases at Start-Up: Cleaver-Brooks authorized representative. The product offer-
Atmospheric contamination virtually eliminated for ing for Spraymaster Deaerators is shown in Table H1-1.
incoming water.
H1-3
02-02
Table H1-1. Spraymaster Deaerator Product Offering Piping

Pump and motor sets are mounted on individual bases before
STORAGE
MODEL NO.
RATING TANK
CAP. mounting on stand base.
(LBS/H) CAPACITY
(MIN)
Individual suction piping (including strainer, shutoff valve,
SM- 7 7000 230 16
flexible connector) are provided for all feed pumps.
SM-15 15000 300 10
SM- 30 30000 600 10 Standard Equipment
SM- 45 45000 900 10
SM -70 70000 1400 10 Spraymaster deaerator.
SM-100 100000 2000 10
SM-140 140000 2800 10 Deaerator storage tank.
SM-200 200000 4000 10
SM- 280 280000 5600 10 Deaerator water inlet atomizing valve.
NOTE: Model number designation (example, SM-7) is: SM =
Deaerator steam inlet atomizing valve.
Spraymaster Deaerator. 7 = 7,000 lbs/hr rating. Optional tank
sizes available, contact your local Cleaver-Brooks authorized Deaerator manual and automatic vent.
representative.
Gauge glass.
Steam pressure gauge.
The Spraymaster Deaerator is a pressurized low-headroom
system designed to remove dissolved oxygen in boiler feedwa- Feedwater thermometer.
ter to 0.005 cc per liter, or less, and eliminate carbon dioxide.
Required tappings.
A typical deaerator package includes the deaerator tank
mounted on a stand of appropriate height along with all oper- Optional Equipment
ating controls, feed pumps assembled and piped (typically
Steam pressure reducing valve.
knocked down for shipment and field assembly). The tank
conforms to section VIII of the ASME code. Three valve bypass and strainer (PRV).
The main deaerating portion is located internally and consists Water level controller with make-up valve.
of a water collector and steam atomizing valve. Built into a
Three valve bypass and strainer (MUV).
flange on top of the tank is a spring loaded water spray nozzle
which includes an automatic and manual vent valve. Steam relief valves.
Packaged Spraymaster systems offer substantial advantages High water alarm.
through, lower cost installation and simplified operation and
Low water alarm.
maintenance. Spraymaster Deaerators arrive on site ready for
hookup to your water, steam, and electric power connections. Low water pump cut off.
The deaerator stand comes with feed pump/motor set mounted High temperature condensate diffuser tube (over 227
on a solid base. The base is specially reinforced to prevent F).
vibration wear on vital system components. Rugged square
Boiler feed pump and motor sets.
structural tubing combines lasting strength with generous
working space for inspection or routine servicing. Recirculation orifice or relief valve
Suction shutoff valve.
Control Panel
Suction strainer.
The control panel, complete with starters, fuse protection,
switches, lights and pre-wired terminal blocks is mounted on Suction flexible fitting.
the stand assembly. Wiring to feed pump motor and all con- Discharge check valve.
trols is standard.
Discharge shutoff valve.
Deaerator Tank Discharge pressure gauge.
ASME construction - certified to 50 psig. All tanks provided Discharge manifold.
with manhole, individual pump suction tappings and other
openings as required. Saddles or legs standard on all sizes. Overflow drainer.
Select from sizes for 5 to 30 minutes of storage to overflow.
H1-4
02-02
Control panel. Packaging

Chemical feed quill. Fully packaged, factory piped and wired.
Vacuum breaker. Half packaged, suitable for field erection with
interconnecting piping and wiring by others.
Insulation and lagging.
Sentinel relief valve. DIMENSIONS AND RATINGS
Tank drain valve.
Dimensions and ratings for Spraymaster Deaerators are shown
Back pressure relief valve. in Figures H1-1 and H1-2.
Magnesium anode (not available with lined tanks).
Epoxy lining.
Stand.
TANK SUPPORT LEGS SADDLES
FRONT HEAD FRONT HEAD

"E" "A" "E" "A"
STANDARD ON 36"
48" & 54" TANKS
(4) 1.125" E HOLES
(4) .875" E HOLES FOR .75" E BOLTS
FOR .75" E BOLTS
"C" "D" "D" "C"
"H"
"F"
6
"B" "B"
"F" "G"/2
"G"
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
Figure H1-1. Spraymaster Tank Supports and Saddles, Details and Dimensions
H1-5
02-02
(NOTE 14)
"B" 4 3 5 1 1 1
(9" FOR SM15)

.5" NPT. AUTO VENT VALVE "C" 0 "D" "E" "F" "G" "J" "H" "K" "L"
12
"N" NPT. MANUAL VENT VALVE
4
2 DIA. HOLE
IN LIFTING LUGS 6
(NOTE 20)
12
20 2
13
"P"
"A"
TANK
DIA. "R"
21
8 9 10
14
"M"
(NOTE 1)
7 11 6
15 16 (NOTE 2)
18
17 (NOTE 3) STAND HEIGHT

VARIES PER
22 PROJECT
REQUIREMENTS
19 (NOTE 4)
"D4" "B2"
(4) "E5" E HOLES
"C3" FOR "F6" E BOLTS "A1"
FRONT VIEW SIDE VIEW
1. Mounted at dim. "H" (top of tank) on non-packaged units.

2. Tank mounted on non-packaged units.
3. Packaged units only. Mounted on front of stand.
4. Suction piping includes strainer, gate valve and flexible connector.
5. All couplings are 3000# F.S.
6. All flanges are 150# F.F. except as noted.
7. Two water and steam inlets used for SM200 and SM2800.
8. Customer to plug all fittings not being used.
9. Mount tank above pump at elevation necessary for static head including safe allowance for piping friction as approved by pump manufacturer.
10. Deaerator tank is built to ASME Code.
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 autho-
14. Dimension "B" will change depending on controls required - contact your local Cleaver-Brooks authorized representative.
15. No interconnecting piping or wiring furnished on non-packaged units unless specified, contact your local Cleaver-Brooks authorized representative for specific
piping or wiring furnished on packaged assemblies.
16. Weights shown are without controls or packaging - contact your local Cleaver-Brooks authorized representative for additions.
17. Capacities other than shown as standard available by proper selection of controls - contact your local Cleaver-Brooks authorized representative.
18. Optional tank sizes and ratings available - contact your local Cleaver-Brooks authorized representatives.
19. Lifting lugs are for lifting empty tank only.
20. Manway is standard. Manufacturing may require a larger manway for fabrication. See dimensional diagram for actual size.
RATINGS SM TANK
Capacity (Gal. to Overflow) 230 300 450 600 700 900 1000 1400 2000 2800 4000 5600
Tank Weight (Dry) (lb) 1100 1750 2200 2250 2500 2650 2850 4150 4950 5800 7400 9500
Tank Weight (Flooded) (lb) 3600 7850 10700 11750 13450 15500 17000 25450 33650 41550 52500 73600
Tank Size (Dia x Length) 36 x 71 48 x 96 48 x 134 54 x 118 54 x 136 60 x 129 60 x 142 66 x 176 72 x 199 84 x 183 96 x 177 108 x 197
TANK DIMENSIONS
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 13 14 16.5 18.5 20
D Water Inlet - SM 7 16.5 N/A N/A N/A
Water Inlet - SM 15 Thru 100 N/A 20 22 22
Water Inlet - SM140 N/A N/A N/A 18
E Steam Inlet 5.5 40 42 42
F Level Alarm 32 50 54 56
Figure H1-2. Spraymaster Deaerator Dimensions and Ratings (Single Tank) - Sheet 1 of 2
H1-6
02-02
RATINGS SM TANK
G High Temperature Return 27 55 62 63

H Level Control 44.5 60 79 90
J Relief Valve 38.5 66 70 100
K Relief Valve 50 N/A 86 111
L Relief Valve N/A N/A N/A 122
M Drain 10 30 98 84 98 93 103 135 153 135 127 114
P Overflow 5 10 10 14
R Overflow 10 N/A N/A 3.75 3.75 6.75 6.75 6.5 8 14.5 26.5 27.5
STAND DIMENSIONS
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 1 1 1.125 1.125 1.125 1.125 1.125 1.125 1.25
F6 Anchor Bolt Size 0.625 0.875 0.875 0.875 0.875 1 1 1 1 1 1 1.125
CONNECTIONS AND TRIM
1 Relief Valve Size Contact Your Local Cleaver-Brooks Authorized Representative
2 Overflow Size 1.5" NPT 3" NPT 3" NPT 3" NPT 3" NPT 3" NPT 3" NPT 4"-150 # FF 4"-150# 4"-150# 6"-150# 6"-150#
FF FF FF FF
3 Steam Inlet Size See Table Below
4 Water Inlet Size See Table Below
5 High Temperature Return Size 1.5" NPT 1.5" NPT 2" NPT 3" NPT
6 Drain Size 1.5" NPT 2" NPT 2" NPT 2" NPT
7 Suction Size 3" NPT 3" NPT 3" NPT 4"-1503 FF
8 Thermometer (.75" NPT)
9 Sample (.5" NPT)
10 Chemical Feed (1" NPT)
11 Recirculation (1" NPT)
12 Gauge Glass Assembly
13 Level Controller
14 Make-Up Valve
15 Pressure Gauge
16 Thermometer
17 Control Panel (Optional)
18 Feed Pump/Motor (Optional)
19 Suction Piping (Optional)
20 Manway, 12 x 16
21 Level Alarms (Optional)
22 Overflow Drainer (Optional)
RATINGS for
SPRAYMASTER MODEL TANK SIZES RATING (lb/hr) Conn 3 Steam Inlet Conn 4 Water Inlet
SM-7 230 7000 3"-150# FF Flg 1" NPT.
SM-15 300 Thru 700 15000 6"-150# FF Flg 1.5"-150# RF Fl.
SM-30 300 Thru 5600 30000 6"-150# FF Flg 2"-150# RF Flg
SM-70 300 Thru 5600 70000 6"-150# FF Flg 2.5"-150# RF Flg
SM-200 (NOTE 7) 2000 Thru 5600 200000 6"-150# F.F.Flg (2) 3"-150# RF Flg (2)
SM-280 (NOTE 7) 2000 Thru 5600 280000 8"-150# FF Flg (2) 4"-150# RF Flg (2)
Figure H1-2. Spraymaster Deaerator Dimensions and Ratings (Single Tank) - Sheet 2 of 2
H1-7
02-02
RETURN ON INVESTMENT Theoretically, it takes approximately 8 ppm of sodium sulfite

as Na2S03 to scavenge 1 ppm of dissolved O2
Payback for a pressurized deaerator verses an atmospheric
boiler feed system is based on an additional capital expendi-
ture required divided by the yearly operating cost savings. The
Makeup Water
differential in yearly operating costs are in the following areas: Increased make-up water is required because of lost flash
steam, lost exhaust steam, and additional surface blowdown.
Flash steam
This additional makeup water can be associated to a cost.
Exhaust steam Makeup water cost should be a combination of the utility
charge plus pretreatment equipment consumable costs.
Blowdown
Chemical treatment Sewer
Makeup water Utilities often base a sewer charge on make-up water usage. If
Sewer it is metered, the additional surface blowoff should only be
considered.
Intangibles
Intangibles
Flash Steam
It is difficult to calculate a cost savings for items such as
A percentage of the high-pressure condensate returns will reduced flue gas emission due to higher plant efficiencies of
flash to steam and be lost in an atmospheric vessel application. steam recovery and the prevention of boiler thermal shock.
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 relates to water temperature. Lowering the dissolved
oxygen content below what is naturally present, based on
mixed water temperature at atmospheric pressure, requires the
addition of a chemical treatment program. The most common
oxygen scavenger used is sodium sulfite. Sodium sulfite reacts
with dissolved oxygen as follows:
2Na2SO3 + O2 2Na2SO4
H1-8
02-02
application.
1.0 Deaerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H1-9

2.0 Make Up Valve and Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H1-10
3.0 Steam Pressure Reducing Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H1-11
4.0 Boiler Feedwater Pump and Motor Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H1-11
5.0 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H1-12
1.0 Deaerator
Provide one Cleaver-Brooks Model _________ spray type, pressurized, horizontal deaerator rated at _____ pounds per hour. The
system shall be of the single tank design and shall guarantee oxygen removal to not more than 0.005 ccs/liter in the 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.
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 tem-
perature. 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 con-
tact with un-deaerated water, shall be constructed of Type 316 stainless steel.
Automatic vent valve shall be thermostatically controlled to provide a fast means of venting when a sudden buildup of gases
occurs, such as seen at start up. The manual vent valve shall have an orifice for continuous minimum venting. Venting rate shall not
exceed 0.1 of 1% of the rated deaerator capacity at 5 psig.
The deaerated water storage tank shall have _____ minutes of storage and have a capacity of
_____ gallons measured to overflow. The tank shall be _____ diameter x ____ long. An 11" x 15" elliptical manhole shall be pro-
vided 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.
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.
1.1 Optional
The tank shall be factory-insulated and lagged with blanket insulation, pins, clips, and a durable steel jacket. Block-type insulation
is not acceptable. The blanket insulation is to be 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.
Load Specifications
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%
H1-9
02-02
1.2 Optional
The tank shall be factory-lined with a high quality baked epoxy lining. The lining is to be applied to a sandblasted (SSPC-SP-5)
white metal surface. Spray-apply 4 to 6 coats with each dry coat being approximately 1.5 mils dry for a total thickness of 6 mils dry
minimum. Baking schedule for intermediate coats to be 10 to 20 minutes at 250 to 300 F and final baking to be 1-1/2 hours at 350
to 400 F. Lining to be Holliday spark tested using low voltage and a wet sponge to ensure uniform coating free of pin holes. Mag-
nesium anodes shall not be acceptable in this application. The lining is to meet requirements of FDA and MID of the USDA. The
lining is to be suitable for temperatures up to 250 F.
1.3 Optional
The magnesium or 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.
1.4 Optional
The high temperature diffuser or sparge tube shall be located beneath the normal tank water level. The tube shall be constructed of
2 inch pipe. This tube shall provide even distribution and blending of high-temperature condensate returns.
1.5 Optional
The chemical feed quill shall be located beneath the normal tank water level. The quill material shall be constructed of stainless
steel. The tube shall provide even distribution and blending of chemical.
1.6 Optional
The basic deaerator shall be equipped with the following trim and accessories. Piping on packaged units shall comply with ASME
Power Piping Code B31.1.
2.0 Make Up Valve and Controller

2.1 Option - Mechanical
____ " inlet water regulating lever valve with ______ body and _______ connections. The valve Cv shall not exceed ______ and be
rated for _____ gpm at ______ psig inlet pressure. The pressure drop across the valve shall not exceed a delta-P of 10 psig. This
valve shall be suitable for temperatures up to 300 F. The valve manufacture shall be _______, Model _____ . This valve shall be
mechanically controlled by an external float cage with cast iron body and 8" stainless steel float. The float cage manufacturer shall
be __________, Model ______.
2.2 Option - Electronic
______" inlet water motorized regulating valve with steel body and threaded NPT connections. Motor shall be 110V bi-directional,
with a permanently lubricated gear train, and be directly coupled to the valve stem. The valve Cv shall not exceed _____ and be
rated for_____ gpm at ______ psi inlet pressure. Valve shall not exceed a delta-P of 10 psig. This valve shall have teflon seats and
be suitable for temperatures up to 300 F. The motorized valve manufacturer shall be __________. This valve shall be electroni-
cally 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 manufac-
turer shall be Cleaver-Brooks Model TW82. A solenoid valve and float switch are not acceptable. (Available only in the U.S.)
2.3 Option - Pneumatic
_______" inlet water diaphragm actuated regulating valve with cast iron body and _____ connections. The valve shall be globe
type with proportional control and a spring opposed diaphragm actuator arranged for 3 - 15 psig operating signal. The valve shall
be normally open on loss of air. The valve Cv shall not exceed _____ and be rated for ______ gpm at ______ psig inlet pressure.
Valve shall not exceed a delta-P of 10 psig. This valve shall have stainless steel trim with TFE packing and be suitable for tempera-
ture up to 410 F. The diaphragm actuated valve manufacturer shall be ___________, Model _____. This valve shall be pneumati-
cally 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 instru-
ment air supply to 3 - 15 psig for proper operation.
H1-10
02-02
2.4 Optional
The make up valve shall include a ANSI Class 125 lb three-valve bypass with inlet Y-type cast iron strainer. Strainer screen to be
removable and of stainless steel construction.
3.0 Steam Pressure Reducing Station

_______" steam pressure reducing valve with cast iron body and _____ connections. The valve shall be a self-contained unit capa-
ble 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 _____.
_______" 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 _________.
3.3 Optional
The steam pressure reducing valve shall include a three valve bypass with Y-type cast iron strainer. Strainer screen to be removable
and of stainless steel construction.
3.4 Optional
Quantity ______, _______ " relief valves sized to relieve full capacity of the pressure reducing valve in the event of its failure.
Valves to meet Paragraph UG-125 of ASME 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____________.
3.5 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.)
3.6 Optional
Low level alarm switch. 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. (Not required with electronic make up controller.)
3.7 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 _______.
3.8 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.
4.0 Boiler Feedwater Pump And Motor Set

4.1 Option - Intermittent
Quantity________, turbine type boiler feedwater pump and motor set. Centrifugal type pumps are not acceptable in this applica-
tion. Pump to be rated for _____ gpm at _____ feet TDH with ______ feet NPSH required. Pump to be ______ materials of con-
struction and have ______ seals for a maximum water temperature of 250 F. Pump impeller to be hydraulically balanced. The
pump shall be mounted on a steel baseplate and flexibly coupled with an OSHA type coupling guard to a ____ hp, _____ phase,
H1-11
02-02
______ Hz, ______ Volt, _______ rpm, ________enclosure motor. Motor to be non-overloading at the rated condition without
using any portion of the service factor. Pump and motor set to be factory aligned prior to shipment. Pump manufacturer to
be______________, Model ________, size ____ " x _______".
4.2 Option - Continuous
Quantity ______, centrifugal type boiler feedwater pump and motor set. Turbine type pumps are not acceptable in this application.
Pump to be rated for _____ gpm at ______ feet TDH with ____ feet NPSH required. Pump to be _______ materials of construction
as 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-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 sup-
plied with the pump and shipped loose for field installation to provide minimum bypass flow.
4.3 Optional
The stand shall elevate the deaerator tank to provide the net positive suction head required by the pump at the rated condition to
prevent cavitation plus a 1-1/2 foot safety factor. The stand shall be constructed of heavy square steel tubing for the legs and 1/4"
steel plate covering the floor.
5.0 Control Panel

5.1 Optional - Base
Control panel shall be in a NEMA 1 enclosure and wired to the National Electric Code. The wire shall be black number coded. The
assembly is to contain individual motor starters with 120 Volt holding coil and fuse protection. Individual green oil-tight pump run
lights shall be provided. All switches and lights to have nameplate identification. The assembled panel shall be given a factory con-
tinuity test prior to shipment.
5.2 Optional - Electric Components
Audible and visual high and low water alarm function shall be provided by a bell or horn with silence switch and individual red 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.
5.3 Standard
The deaerator shall have a gauge glass assembly that covers the entire tank diameter. The gauge glass shall be quartz, 0.625 inch
diameter by 24 inch maximum length. Each length of glass shall be furnished with a bronze gauge cock set and protector rods.
The deaerator shall be supplied with a pressure gauge that has a 4-1/2 inch dial with a 0-60 psig range and a thermometer with a 50
to 300 F range. Packaged units are required to have both gauges bracket-mounted at eye level.
The deaerator is to be hand cleaned with a solvent to SSPC- SP-1 standards prior to painting. Prime coated to not less than 1 mil
thick and 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.
H1-12
02-02
Section H2
SPRAYMASTER DEAERATORS (Duo-Tank)
CONTENTS
FEATURES AND BENEFITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-3
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-4
ILLUSTRATIONS
Figure H2-1. Spraymaster Duo-Tank Supports and Saddles, Details and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-4
Figure H2-2. Spraymaster Deaerator (Duo-Tank) Dimensions and Ratings - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . .H2-5
TABLES
Table H2-1. Spraymaster Deaerator Duo-Tank Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-3
H2-1
02-02
Spraymaster Deaerators (Duo Tank) Feedwater Systems
The Duo Tank product combines a surge tank with a Spraymaster deaerator into a single combined vessel, providing a complete
engineered and packaged system.
The Cleaver-Brooks designed deaerator assures high purity 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.
H2-2
02-02
Feedwater Systems Spraymaster Deaerators (Duo Tank)
FEATURES AND BENEFITS Low Profile Design:
The Duo Tank product combines a surge tank with a Spray- Low head room allows for installation in space restricted
master deaerator in to a single combined vessel, providing the areas.
following features and benefits in addition to the benefits of
the deaerator and surge tank independently. Two-Stage Deaeration in a Common Vessel:
Surge Section Includes a Protective Lining:
Packaged for easy maintenance.
As a deterrent to corrosion of vessel steel due to dissolved
gases, the vessel is lined with an epoxy coating. Packaged Units for Cost Effective Installation:
Double Inner Head Separates the Deaerator Pressure Vessel Complete packages are pre-fabricated in the Cleaver-Brooks
From Surge Tank: manufacturing facility to ensure piping alignment and
control wiring function. The unit is disassembled, match
Ensures the deaerator and surge tank are two separate marked for efficient field re-assembly.
vessels while structurally attached for space considerations.
This also limits heat transfer from the deaerator pressure
vessel to the surge atmospheric vessel, preventing energy PRODUCT OFFERING
loss due to surge tank water boiling. Information in this section applies directly to Cleaver-Brooks
packaged Spraymaster Deaerators in duo-tank arrangement
Vented and Insulated Gap Between the Deaerator and Surge ranging from 7000 to 280,000 lbs/hr.
Tank:
The product offering for Duo-Tank packaging is a combination
Insulation is placed between the double inner head to further of the product offering for the Spraymaster Deaerator and the
limit heat transfer from the deaerator pressure vessel to the Surge Tank. The combined package product offering for Duo-
surge atmospheric vessel. A vent is placed between the Tank products is shown Table H2-1.
double inner head to allow moisture evaporation eliminating
corrosion potential.
Table H2-1. Spraymaster Deaerator Duo-Tank Offering

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

Dimensions and ratings are shown in Figures H2-1 and
H2-2.

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
H2-4
02-02
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.
8. Two water and steam inlets used, one shown.
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.
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
H2-5
02-02
STORAGE TANK DETAIL AND DIMENSIONS
SPRAYMASTER SM-7D SM-15D SM-30D SM-45D SM-70D SM-100D SM-140D 8 8

MODEL NO. SM-200D SM-280D
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 5165 10835 17720 24440 38450 52310 68045 80290 106475
(lbs)
Tank Cap-Deaerator 230 300 600 900 1400 2000 2800 4000 5600
(Gal to Overflow)
Storage Cap (Min) 16 10 10 10 10 10 10 10 10
Tank Cap-Rec Section 160 300 600 900 1400 2000 2800 4000 5600
(Gal to Flooded)
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 4 7 6-1/2 8 14-1/2 26-1/2 27-1/2

L
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
WW 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
H2-6
02-02
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 to C Anchor Bolt Holes 82 110 148 169-1/2 230-1/2 269 265 137 294
L L
C3 Outside Width 49 62 66 71 76 81 86-1/2 102 112
D4 C to C Anchor Bolt Holes 46 59 63 68 73 78 79-1/2 99 101

L L
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)

23 Level Alarms (1 NPT), (optional)
Sizes listed for items 22 thru 29
24 Level Control (1-1/2 NPT), (optional)
are for tank connections only.
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)
H2-7
02-02
application.
1.0 Deaerator and Surge Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-8

2.0 Make Up Valve And Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-10
3.0 Steam Pressure Reducing Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-10
4.0 Boiler Feedwater Pump And Motor Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-11
5.0 Make Up Valve and Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-11
6.0 Transfer Pump and Motor Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-12
7.0 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-13
1.0 Deaerator and Surge Tank

Cleaver-Brooks Model _________ spray type, pressurized, horizontal deaerator is rated at _____ pounds per hour. The system
shall be guarantee oxygen removal to not more than 0.005 CCS/liter in the 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.
The surge tank shall receive returning condensate and supplement make up water to maintain the desired operating level. Conden-
sate and make up water mix into a blended temperature, as determined by the percentage of each. The surge tank shall be vented to
atmosphere. The collected water is then transferred to the deaerator.
The collected water shall be admitted to the deaerator through a single spring-loaded, self-cleaning, adjustable stainless steel spray
valve, which shall provide proper internal vent condensing and water distribution at any load between 5 and 100 percent of rated
capacity. The water temperature in the primary heating and vent concentrating section is to be raised within 2 or 3 F of steam tem-
perature 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 tempera-
ture. 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.
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.
The deaerated water storage tank section shall have _____ minutes of storage and have a capacity of _______ gallons measured to
overflow. An 11" x 15" elliptical manhole shall be provided for access. All nozzles 3" and under shall be 3000 lbs forged steel cou-
plings and over 3" shall be 150 lbs flat face flanges. Heads to be ASME torispherical type constructed of ASTM A516 GR 70 car-
bon steel with a minimum thickness of 0.25 inches. Shell plate to be fabricated of ASTM A36 carbon steel with a minimum
thickness of 0.25 inches. The tank shall be designed in accordance with ASME, Section VIII of the Pressure Vessel Code for 50
psig at 650 delta-F and stamped accordingly. Certification shall be required. Joint efficiencies to be 70% circumferential per Table
UW-12, which does not require stress relieving or nondestructive examination.
The surge tank section shall have __________ minutes of storage and have a capacity of _______ gallons flooded. An 11" x 15"
elliptical manhole shall be provided for access. All nozzles shall be 3000 lbs forged steel couplings. Heads to be ASME torispheri-
cal 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 fabricated of ASTM A36 carbon steel with a minimum thickness of 0.25 inches.
The 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.
H2-8
02-02
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
1.1 Optional
The surge tank section shall be designed in accordance with Section VIII of the ASME Pressure Vessel Code for ________ psig,
and stamped accordingly. Certification shall be required. Joint efficiencies to be 70% circumferential per Table UW-12, which does
not require stress relieving or nondestructive examination.
1.2 Optional
The duo tank shall be factory-insulated and lagged with blanket insulation, pins, clips, and a durable steel jacket. Block-type insu-
lation 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") min-
imum and head thickness of 12 gauge (0.1046") minimum.
1.3 Standard
The surge tank section shall be factory-lined with a high quality baked epoxy lining. The lining is to be applied to a sandblasted
(SSPC-SP-5) white metal surface. Spray-apply 4 to 6 coats, with each dry coat being approximately 1.5 mils dry, for a total thick-
ness of 6 mils dry minimum. Lining to be Holliday spark tested using low voltage and a wet sponge to ensure uniform coating free
of pin holes. Magnesium anodes shall not be acceptable in this application. The lining is to be suitable for temperatures up to 212
F.
1.4 Optional
The deaerated water storage tank section shall be factory-lined with a high quality baked-on epoxy lining. The lining is to be
applied to a sandblasted (SSPC-SP-5) white metal surface. Spray-apply 4 to 6 coats with each dry coat being approximately 1.5
mils dry for a total thickness of 6 mils dry minimum. Baking schedule for intermediate coats to be 10 to 20 minutes at 250 to 300
F and final baking to be 1-1/2 hours at 350 to 400 F. Lining to be Holliday spark tested using low voltage and a wet sponge to
ensure uniform coating free of pin holes. Magnesium anodes shall not be acceptable in this application. The lining is to meet
requirements of FDA and MID of the USDA. The lining is to be suitable for temperatures up to 250 F.
1.5 Optional
1.6 Optional
1.7 Optional
1.8 Optional
The basic deaerator section shall be equipped with the following trim and accessories. Piping on packaged units shall comply with
ASME Power Piping Code B31.1.
H2-9
02-02
2.0 Make Up Valve And Controller

rated for _____ gpm at ______ psi inlet pressure. The pressure drop across the valve shall not exceed a delta-P of 10 psig. This
valve shall be suitable for temperatures up to 300 F. The valve manufacture shall be ___________, Model _____ . This valve shall
be mechanically controlled by an external float cage with cast iron body and 8" stainless steel float. The float cage manufacturer
shall be ___________________, Model ______.
______" inlet water motorized regulating valve with steel body and threaded NPT connections. Motor shall be 110V bi-directional
type with a permanently lubricated gear train, and be directly coupled to the valve stem. The valve Cv shall not exceed _____ and
be rated for_____ gpm at ______ psig inlet pressure. Valve shall not exceed a delta-P of 10 psig. This valve shall have 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.)
Valve shall not exceed a delta-P of 10 psig.This valve shall have stainless steel trim with TFE packing and be suitable for tempera-
ture up to 410 F. The diaphragm actuated valve manufacturer shall be ___________, Model _____. This valve shall be pneumati-
cally 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 instru-
ment air supply to 3 - 15 psig for proper operation.
2.4 Optional
The make up valve shall include an ANSI Class 125 lb three-valve bypass with inlet Y-type cast iron strainer. Strainer screen to be

250 lb class with stainless steel trim and an adjustable pilot. The valve manufacturer shall be ____________, Model _____.
globe type with proportional control and a spring opposed diaphragm actuator arranged for ______ psig operating signal. The valve
valve manufacturer shall be __________, Model ____. This valve shall be pneumatically controlled by an external transmitter. The
transmitter set pressure shall be adjustable. The transmitter manufacturer shall be ______________, Model ____.
3.3 Optional
3.4 Optional
H2-10
02-02
Relieving set pressure to be 50 psig. Relief valve manufacturer to be ________________, Model _______.
3.5 Optional
3.6 Optional
3.7 Optional
_______, Model _______.
3.8 Optional
4.0 Boiler Feedwater Pump and Motor Set

be_____________, Model ________, size ____ " x _______".
Pump to be rated for _____ gpm at ________ feet TDH with ____ feet NPSH required. Pump to be _______ materials of construc-
tion as defined by the Hydraulic Institute and have _______ seals for a maximum water temperature of 250 F. Pump impeller to be
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.
4.3 Optional
The basic surge tank shall be equipped with the following trim and accessories. Piping on packaged units shall comply with ASME

____ " inlet water regulating lever valve with ______ body and _______ connections. The valve Cv shall not exceed ______, and
shall be rated for _____ gpm at ______ psi inlet pressure. The pressure drop across the valve shall not exceed a delta-P of 10 psig.
This valve shall be suitable for temperatures up to 300 F. The valve manufacture shall be ____________, Model _______ . This
valve shall be mechanically controlled by an external float cage with cast iron body and 8" stainless steel float. The float cage man-
ufacturer shall be _______________, Model __________.
H2-11
02-02

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 electron-
ically controlled by a solid state control with internally mounted capacitance probes. The electronic solid state control shall be able
turer shall be Cleaver-Brooks, Model TW82. A solenoid valve and float switch are not acceptable. (Available only in the U.S.)
_______" 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.
ture up to 410 F. The diaphragm actuated valve manufacturer shall be ___________, Model _______. This valve shall be pneu-
matically 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.
5.4 Optional
5.5 Optional
High-level alarm switch. This shall be an externally mounted float-type switch. The switch shall make contact on rise and break on
5.6 Optional
Low-level alarm switch. This shall be an externally mounted float-type switch. The switch shall make contact on fall and break on
5.7 Optional
6.0 Transfer Pump And Motor Set

Quantity ______, centrifugal type transfer pump and motor set. Turbine type pumps are not acceptable in this application. Pump to
be rated for _______ gpm at ________ feet TDH with ______ feet NPSH required. Pump to be _______ materials of construction
as defined by the Hydraulic Institute, and have _______ seals for a maximum water temperature of 212 F. Pump impeller to be
a ______ hp, ______ phase, _______ Hz, ______ Volt, _____ rpm, _______ enclosure motor. Motor to be non-overloading at the
6.1 Optional
The duo stand shall elevate the deaerator and surge tank sections to provide the net positive suction head required by the pump at
the rated condition to prevent cavitation. The stand shall be constructed of heavy square steel tubing for the legs and 1/4" steel plate
covering the floor.
H2-12
02-02
7.0 Control Panel

7.1 Optional - Base
tight lights.
fused.
7.3 Standard
The deaerator and surge section shall have a gauge glass assembly that covers the entire tank diameter. The gauge glass shall be
quartz 0.625 inch diameter by 24 inch maximum length. Each length of glass shall be furnished with a bronze gauge cock set and
protector rods.
The deaerator section shall be supplied with a pressure gauge that has a 4-1/2 inch dial with a 0-60 psig range and a thermometer
with a 50 to 300 F range. Packaged units are required to have both gauges bracket-mounted at eye level.
The surge tank section shall be supplied with a thermometer with a 50 to 300 F range.
The duo tank is to be hand cleaned with a solvent to SSPC- SP-1 standards prior to painting. Prime coated to not less than 1 mil
Unit is to be knocked down for shipment. Piping is to be matched marked. Three, bound, Operating and Maintenance manuals to be
H2-13
02-02
NOTES
H2-14
02-02
Section H3
BOILERMATE DEAERATORS
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-3
RETURN ON INVESTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-9
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-10
ILLUSTRATIONS
Figure H3-1. Boilermate Deaerator Dimensions and Ratings - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-6
Figure H3-2. Boilermate Tank Supports and Saddles, Details and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-8
TABLES
Table H3-1. Cleaver-Brooks Boilermate Deaerator Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-5
H3-1
02-02
Boilermate Deaerators Feedwater Systems
The Cleaver-Brooks designed deaerator assures high purity 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.
H3-2
02-02
Feedwater Systems Boilermate Deaerators
FEATURES AND BENEFITS Auto Vent Valve Eliminates Gases at Start-Up:
The following features and benefits apply to the Boilermate Atmospheric contamination virtually eliminated for
Deaerator product line. The Boilermate design uses a packed incoming water.
column to deaerate the water.
Exceeds ASME Recommendations for Oxygen Level:
Less Mechanical Movement of Deaerator Components: Cleaver-Brooks deaerator is guaranteed to remove oxygen
The water spray valve is the only internal moving concentrations to 0.005 cc/liter while operating between 5
component within the deaerator vessel. and 100%capacity.
Carbon dioxide concentration is practically reduced to a
Two-Stage Deaeration in a Common Vessel: zero.
Integral Level Control Automatically Introduces Cold Water
Packaged for easy maintenance. Make-Up to Supplement Condensate Only When Necessary to
Meet Boiler Demand:
ASME Code Design (Section VIII):
Saves Btus by accepting condensate before cold make-up
Assures deaerator vessel quality in materials and fabrication water. Maintains a minimal water level within the deaerator
to meet safety requirements. vessel to prevent damage to the boiler feedpumps, and to
maintain system operation.
Internal Stainless Steel Vent Condenser:
Protects deaerator vessel against corrosive gases while Variety of Tank Sizes to Handle Volume-Swings in Conden-
providing a means for removal of corrosive gases from sate Return:
boiler feedwater. Provides flexibility for selecting a tank for specific
applications to limit the loss of hot condensate to drain.
Self-Cleaning Water Spray Valve:
Maintains deposit-free surface. Packaged Units for Cost Effective Installation:
Reduces maintenance requirements. Complete packages are pre-fabricated in the Cleaver- Brooks
manufacturing facility to ensure piping alignment and
control wiring function. The unit is partially disassembled,
Internal Automatic-Check Valve Prevents Steam Back-Flow:
match marked for efficient field re-assembly.
The water spray valve is normally closed at no flow.
Prevents steam back flow through the water spray valve at no Internal Pump Suction Vortex Breakers:
flow conditions. Eliminates the problems of loss in NPSHA and cavitation
associated with the creation of vortices within pump suction
Removable Water Spray Inlet Assembly: piping.
Flanged assembly allows easy access for maintenance and/
or inspections. Vessel Corrosion Protection When Off-Line:
Optional epoxy lining.
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.
H3-3
02-02
PRODUCT OFFERING Steam pressure gauge.
Information in this section applies directly to Cleaver-Brooks Feed water thermometer.

packaged boilermate deaerators ranging from 1,500 lbs/hr at Required tappings.
50 F makeup to 135,000 lbs/hr at 200 F make-up. Larger
capacities can be obtained by using two columns. The Boiler- Optional Equipment
mate deaerator product offering is shown in Table H3-1. Steam pressure reducing valve.
The Boilermate deaerator is a pressurized packed column, low Three valve bypass and strainer (PRV).
maintenance system designed to remove dissolved oxygen in
boiler feed water to 0.005 cc per liter or less and eliminate car- Water level controller with make-up valve.
bon dioxide. A typical deaerator package includes the packed Three valve bypass and strainer (MUV).
column and storage tank mounted on a stand of appropriate
height along with all operating controls, feed pumps assem- Steam relief valves.
bled and piped (typically knocked down for shipment and field High water alarm.
assembly). The tank conforms to Section VIII of the ASME
Code. Low water alarm.
The packed column design is best for handling high-tempera- Low water pump cut off.
ture returns. The column is constructed of a carbon steel cas- High-temperature condensate diffuser tube (over 227
ing with a stainless steel liner. Built into a flange on top of the F).
column is a spring loaded self-cleaning water spray nozzle and
an automatic and manual vent valve. Boiler feed pump and motor sets.
From experience, large industrial plants and utilities have Recirculation orifice or relief valve.
learned that the most practical and economical way to remove Suction shutoff valve.
oxygen from feedwater is through mechanical deaeration. The
Boilermate deaerator economically effects oxygen removal Suction strainer.
through a design that is trouble free in performance. Suction flexible fitting.
Raw water, untreated and not deaerated, contains as much as Discharge check valve.
ten cubic centimeters of corrosion-causing oxygen per liter.
Oxygen in water corrodes and shortens the life of boiler feed Discharge shutoff valve.
lines, boilers and condensate return lines. Discharge pressure gauge.
The Cleaver-Brooks designed deaerator assures high purity Discharge manifold.
effluent by removing oxygen and other dissolved gases in
boiler feed. Thus, it is the answer to long-lasting boiler equip- Overflow drainer.
ment for industrial and commercial boiler users. Built of cor- Control panel.
rosion-resistant alloys for lifetime service, the deaerator
employs those basic principals of gas removal proved to most Chemical feed quill.
effective and economical to every boiler owner. Contact your Vacuum breaker.
local Cleaver-Brooks authorized representative for component
and sizing information. Insulation and lagging.
The design of the Boilermate deaerator offers simplicity in Sentinel relief valve.
both operation and service. The exchange packing, the heart of Tank drain valve.
the deaerator, requires no maintenance. There are no moving
parts to adjust or maintain. Installation is simple and quick. Back pressure relief valve.
Standard Equipment Magnesium anode (not available with lined tanks).
Boilermate column. Epoxy lining.
Deaerator storage tank. Stand.
Stainless steel exchange packing. Packaging
Deaerator water inlet atomizing valve. Fully packaged, factory piped and wired.
Gauge glass. Half packaged, suitable for field erection with

Deaerator manual and automatic vent valve.
H3-4
02-02
Table H3-1. Cleaver-Brooks Boilermate Deaerator Selection Guide
140 140
120 120
42
100
INLET CAPACITY - LBS/HR X 1000 WATER
100
80 36
80
MODEL
60 60
30
40 40
24
20
20 20
16
12
8
50 70 90 110 130 150 170 190
FEEDWATER MIX TEMPERATURE - F
*DEARERATOR CAPACITY LBS/HR
MODEL NO
BM-8 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) 250 350 410 560 960 1,275 1,810 2,390
Including Packing
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.
H3-5
02-02

Dimensions and ratings for Boilermate Deaerators are shown
in Figures H3-1 and H3-2.
(9" FOR MODEL 8 & 16)
.5" NPT AUTO.
VENT VALVE
"D" NPT. MANUAL
VENT VALVE
B
B
2" NPT. INSPECTION
"C"
PORT (PLUGGED) 3 5 1 1 1
(1.5" NPT. FOR
MODELS 8 & 12)
"S" 0 "T" "E" "F" "G" "J" "H" "K" "L"
2 DIA. HOLE
IN LIFTING LUGS 6
"A"
(NOTE 18)
"R" 12
20 13
(NOTE 12) 2
TANK "P"
DIA.
21
8 9 10
14
"M"
(NOTE 1) 6
15 11 (NOTE 2) 4 7
18
17 (NOTE 3) STAND HEIGHT

16 VARIES PER
PROJECT
REQUIREMENTS
19 (NOTE 4)
"D4" "B2"
(4) "E5"E HOLES
"C3" FOR "F6" E BOLTS "A1"
FRONT VIEW SIDE VIEW
1. Mounted at dim. "M" (top of tank) on non-packaged units.
2. Tank mounted on non-packaged unit.
3. Packaged units only. Mounted on left end, right side of stand on 48" dia. 1070 gal 54" dia. 1500 gal as shown.
9. Tank is built to ASME Code.
11. Add suffix "P" to Model no. for packaged units (BMP-24).
12. Dimension "R" will change depending on controls required- contact your local Cleaver-Brooks authorized representative.
13. No interconnecting piping or wiring furnished on non-packaged units unless specified, contact your local Cleaver-Brooks authorized representative
for specific piping or wiring furnished on packaged assemblies.
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 H3-1. Boilermate Deaerator Dimensions and Ratings - Sheet 1 of 2

H3-6
02-02
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)
Figure H3-1. Boilermate Deaerator Dimensions and Ratings - Sheet 2 of 2
H3-7
02-02
TANK SUPPORT LEGS STANDARD ON 110, 330, SADDLES STANDARD ON 1070 &
430 & 800 GALLON TANKS 1500 GALLON TANKS
FRONT HEAD FRONT HEAD
"E" "A" "E" "A"
(4) 1.125"E HOLES

(4) .875" E HOLES FOR .75" E BOLTS
FOR .75" E BOLTS "D" "C"
"C" "D"
"H"
"F"
6
"B" "B"
"F" "G"/2
"G"
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
Figure H3-2. Boilermate Tank Supports and Saddles, Details and Dimensions
H3-8
02-02
RETURN ON INVESTMENT Theoretically, it takes approximately 8 ppm of sodium sulfite

as Na2S03 to scavenge 1 ppm of dissolved O2
Payback for a pressurized deaerator verses an atmospheric
boiler feed system is based on the additional capital expendi-
ture required divided by the yearly operating cost savings. The Makeup Water
differential in yearly operating costs are in the following areas: Increase makeup water is required because of lost flash steam,
lost exhaust steam, and additional surface blowdown. This
Flash steam
additional make-up water can be associated to a cost. Makeup
Exhaust steam cost should be a combination of the utility charge plus pretreat-
ment equipment consumable costs.
Blowdown
Chemical treatment Sewer
Make-up water Utilities often base a sewer charge on make-up water usage. If
Sewer it is metered, the additional surface blowoff should only be
considered.
Intangibles
Intangibles
Flash Steam
It is difficult to calculate a cost savings for items such as
A percentage of the high-pressure condensate returns will reduced flue gas emission due to higher plant efficiencies of
flash to steam and be lost in an atmospheric vessel application. steam recovery and the prevention of boiler thermal shock.
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 relates to the water temperature. Lowering the dis-
solved oxygen content below what is naturally present, based
on mix water temperature at atmospheric pressure, requires the
addition of a chemical treatment program. The most common
oxygen scavenger used is sodium sulfite. Sodium sulfite reacts
with dissolved oxygen as follows:
2Na2SO3 + O2 2Na2SO4
H3-9
02-02
application.
1.0 Deaerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-10
2.0 Make Up Valve and Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-11
3.0 Steam Pressure Reducing Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-12
4.0 Boiler Feedwater Pump And Motor Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-12
5.0 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-13
1.0 Deaerator
Cleaver-Brooks Model _________ packed column type, pressurized, horizontal deaerator is rated at _____ pounds per hour at ____
F mixed inlet water temperature. The system shall be of the single tank design and guarantee oxygen removal to not more than
0.005 CCS/liter in the 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.
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 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 gases are discharged to atmosphere through the vent outlet. All internal surfaces, which come in con-
tact with un-deaerated water, shall be constructed of Type 316 stainless steel.
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, Sec-
tion VIII of the Pressure Vessel Code for 50 psig at 650 F and stamped accordingly. Certification shall be required. Joint efficien-
cies to be 70% circumferential per table UW-12, which does not require stress relieving or nondestructive examination.
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.
1.1 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
Load Specifications

Make up 25 psig Minimum
Pumped Low Temp Returns 10 psig Minimum
High Temp Returns Not To Exceed 30%
H3-10
02-02
are to be located on 18" centers and holding clips attached. The steel jacket or lagging shall have a shell thickness of 22 gauge
(0.299") minimum and head thickness of 12 gauge (0.1046") minimum.
1.2 Optional
The tank shall be factory-lined with a high quality baked-on epoxy lining. The lining is to be applied to a sandblasted (SSPC-SP-5-
63) white metal surface. Spray-apply 4 to 6 coats with each dry coat being approximately 1.5 mils dry for a total thickness of 6 mils
dry minimum. Baking schedule for intermediate coats to be 10 to 20 minutes at 250 to 300 F and final baking to be 1-1/2 hours at
350 to 400 F. Lining to be Holliday spark tested using low voltage and a wet sponge to ensure uniform coating free of pin holes.
Magnesium anodes shall not be acceptable in this application. The lining is to meet requirements of FDA and MID of the USDA.
The lining is to be suitable for temperatures up to 250 F.
1.3 Optional
1.4 Optional
1.5 Optional
1.6 Optional
The basic deaerator shall be equipped with the following trim and accessories. Piping on packaged units shall comply with ASME

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 ______.
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
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.)
ture up to 410 F. The diaphragm actuated valve manufacturer shall be ________, Model _____. This valve shall be pneumatically
controlled by an external proportional type sensor. The sensor shall be a 14" displacer that produces a pneumatic output signal. The
H3-11
02-02
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.
2.4. Optional

250 lb class with stainless steel trim and an adjustable pilot. The valve manufacturer shall be _____ Model _____.
3.2. Option - Pneumatic
globe type with proportional control and a spring opposed diaphragm actuator arranged for ____ psig operating signal. The valve
valve manufacturer shall be _________ Model ____. This valve shall be pneumatically controlled by an external transmitter. The
transmitter set pressure shall be adjustable. The transmitter manufacturer shall be __________________, Model _______.
3.3 Optional
3.4 Optional
Relieving set pressure to be 50 psig. Relief valve manufacturer to be ___________________ , Model ______.
3.5 Optional
3.6. Optional
3.7. Optional
____________, Model _______.
3.8 Optional
4.0 Boiler Feedwater Pump And Motor Set

H3-12
02-02
be_____________, Model ________, size ____ " x _______".
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 250 F. Pump impeller to be
a _____ hp, ______ phase, _______ Hz, ______ Volt, _____ rpm, _______ enclosure motor. Motor to be non-overloading at the
4.3 Optional
The stand shall elevate the deaerator tank to provide the net positive suction head required by the pump at the rated condition to
prevent cavitation plus a 1-1/2 foot safety factor. The stand shall be constructed of heavy square steel tubing for the legs and 1/4"
steel plate covering the floor.
5.0 Control Panel

5.1 Optional - Base
5.2. Optional - Electric Components
tight lights.
Control circuit transformer to supply 110-120 volts, single-phase power supply. The transformer shall be mounted, wired and
fused.
5.3 Standard
The deaerator shall have a gauge glass assembly that covers the entire tank diameter. The gauge glass shall be quartz 0.625 inch
diameter by 24 inch maximum length. Each length of glass shall be furnished with a bronze gauge cock set and protector rods.
The deaerator shall be supplied with a pressure gauge that has a 4-1/2 inch dial with a 0-60 psig range and a thermometer with a 50
to 300 F range. Packaged units are required to have both gauges bracket-mounted at eye level.
The deaerator is to be hand cleaned with a solvent to SSPC- SP-1 standards prior to painting. Prime coated to not less than 1 mil
Unit is to be knocked down for shipment. Piping is to be matched marked. Three bound Operating and Maintenance manuals to be
H3-13
02-02
NOTES
H3-14
02-02
Section H4
SURGE TANKS
CONTENTS
ILLUSTRATIONS
Figure H4-1. Surge Tank Dimensions and Ratings - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-4
Figure H4-2. Surge Tank Supports and Saddles, Details and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-6
TABLES
Table H4-1. Surge Tank Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-3
H4-1
02-02
Surge Tanks Feedwater Systems
This section contains information on the complete line of surge tanks ranging in sizes from 300 to 3000 gallon capacities.
The Cleaver-Brooks Surge Tank products provide additional storage time and handle volume-swings in condensate returns.
Because condensate return volume is largely unpredictable, a surge tank provides a means to collect intermittent condensate
returns and supply water at a relative constant volume, while limiting discharge to drain. Contact your local Cleaver-Brooks autho-
rized representative for component sizing information.
H4-2
02-02
Feedwater Systems Surge Tanks
FEATURES AND BENEFITS Table H4-1. Surge Tank Product Offering

MODEL NO. FLOODED CAPACITY (GAL.)
The following features and benefits apply to Cleaver-Brooks
Surge Tank Products. SRG-300 300
SRG-450 450
SRG-600 600
ASME Heads:
SRG-900 900
Assures vessel quality in materials and fabrication. SRG-1200 1200
SRG-1400 1400
1/4" Thick (Minimum) Shell: SRG-1600 1600
SRG-2000 2000
Quality construction.
SRG-2500 2500
Longer material life. SRG-3000 3000
NOTE: Model number (example, SRG-300) is: SRG = surge tank.
Boosts Condensate Return Pressure: 300 = 300 gal. capacity.
Acts as a collecting point for low pressure and gravity water makeup to supplement condensate only when necessary
returns. to meet boiler demand. This translates into reduced fuel costs
Allows pumping of returns to a pressurized vessel. for heating boiler feedwater.
Standard Equipment
Accepts Gravity Returns:
Surge tank.
Vessels are vented to atmosphere, therefore providing no
pressure resistance that would inhibit gravity return. Thermometer.
Gauge glass.
PRODUCT OFFERING Required tappings, and manway.
Information in this section applies directly to Cleaver- Brooks Optional Equipment
package surge tanks ranging from 300 to 3,000 gallon capac-
ity. Contact your local Cleaver-Brooks authorized representa- ASME code tank.
tive for larger capacities. The product offering for surge tanks Water level controller with make-up valve.
is shown in Table H4-1.
Three valve bypass and strainer.
Surge tanks can reduce dependance on cold, untreated raw
water to replace boiler system losses, by collecting condensate Suction shutoff valve.
for re-use in the boiler. Dedicated surge tanks are required Suction strainer.
when intermittent peak loads of condensate can exceed the
surge capacity of the deaerator. Suction flexible fitting.
The surge tank receives returning condensate and is supple- Discharge check valve.
mented by raw make-up water to maintain the desired operat- Discharge shutoff valve.
ing level. Condensate and make-up water mix into a blend
temperature as determined by the percentage of each. The Discharge pressure gauge.
surge tank is vented to atmosphere. Discharge manifold.
Surge tanks are designed to work with the deaerator. They can High water alarm.
be packaged with transfer pumps, stand and controls of the
same sturdy construction as the deaerator. Custom arrange- Low water alarm.
ments are also available. Contact local Cleaver-Brooks autho- Low water pump cut off.
rized representative for component and sizing information.
Condensate diffuser tube.
Surge tanks provide additional storage time and handle vol-
ume swings in condensate return. Surge tanks are used when Control panel.
gravity or pumped condensate returns do not have enough Transfer pump and motor.
pressure to enter the deaerator on their own. Water and treat-
ment costs are reduced by recycling condensate that has Recirculation orifice or relief valve.
already been treated. Insulation and lagging.
Integral control automatically introduces cold
H4-3
02-02
Epoxy lining. Half packaged, suitable for field erection with
Magnesium anode (not available with lined tanks).
Chemical feed quill. DIMENSIONS AND RATINGS
Drain valve. Dimensions and ratings for surge tanks are shown in
Stand. Figure H4-1 and H4-2.
Packaging
Fully packaged, factory piped and wired.
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 P to Model no. for packaged units (SRG45-P).
9. Using Warren #377 float cage - dimension N may change with other controls - contact your local Cleaver-Brooks authorized 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.
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 CL to CL 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 CL to CL 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
Figure H4-1. Surge Tank Dimensions and Ratings - Sheet 1 of 2
H4-4
02-02
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 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
NPT NPT NPT NPT NPT NPT NPT NPT NPT 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)
16 Level Alarms (1 NPT (Optional) Sizes Listed for items15 thru 18

are for Tank Connections Only.
17 Level Control (1-1/2 NPT) (Optional)
18 Recirculating Connection (1 NPT) (For Each Pump)
Fighure H4-1. Surge Tank Dimensions and Ratings - Sheet 2 of 2
H4-5
02-02
TANK CAPACITY (GALLONS) VENT CAPACITY CHART
300 450 600 900 1200 1400 1600 2000 2500 3000 CAPACITY
SIZE (NPT)
(lbs/hr)
AA 55-1/2 55 79 93-1/2 N/A N/A N/A N/A N/A N/A
1 175
AB 59-1/2 59 83 99-1/2 N/A N/A N/A N/A N/A N/A
1-1/4 350
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
1-1/2 525
AD 29-1/2 34-1/2 34-1/2 38 N/A N/A N/A N/A N/A N/A
2 1000
AE 5 6-1/8 6-1/8 7-1/4 N/A N/A N/A N/A N/A N/A 2-1/2 1600
AF 2 2 2 3 N/A N/A N/A N/A N/A N/A 3 2800
AG 4 4 4 6 N/A N/A N/A N/A N/A N/A 4 4800
AH 5/8 3/4 3/4 3/4 N/A N/A N/A N/A N/A N/A 5 10500
AJ 12-1/2 14-1/2 15 15-1/2 N/A N/A N/A N/A N/A N/A 6 17000
AK 3/4 7/8 7/8 7/8 N/A N/A N/A N/A N/A N/A 8 35000
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 Values given based on:
1) 50 ft. equivalent pipe length.
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 2) Schedule 40 pipe
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 3) 2 psi back pressure
4) Vent capacities should be com-
AP N/A N/A N/A N/A 46-1/2 57 57 67 67 77-1/2 pared with anticipated venting
AR N/A N/A N/A N/A 38 44-3/4 44-3/4 52 52 62 needs. Oversized vents are avail-
able.
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
Figure H4-2. Surge Tank Supports and Saddles, Details and Dimensions
H4-6
02-02
application
1.0 Surge Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-7

2.0 Make Up Valve and Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-8
3.0 Transfer Pump and Motor Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-9
4.0 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-9
1.0 Surge Tank
Cleaver-Brooks Model _________________ shall be an atmospheric, horizontal Surge Tank.
The surge tank shall receive returning condensate and supplement make up water to maintain the desired operating level. Conden-
sate and make up water mix into a blended temperature, as determined by the percentage of each. The surge tank shall be vented to
atmosphere. The collected water is then transferred to the deaerator.
The surge tank shall have _______ minutes of storage and have a capacity of _______ gallons 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".
The surge tank loads shall be as specified in the following table.
Load Specifications
Make up 20 psig Minimum
Low Temp Returns
High Temp Returns
1.1 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.
1.2 Optional
The tank shall be factory-insulated and lagged with blanket insulation, pins, clips, and a durable steel jacket. Block-type insulation
is not acceptable. The blanket insulation is to be 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.
1.3 Optional
The tank shall be factory-lined with a high quality ___________ epoxy lining. The lining is to be applied to a sandblasted (SSPC-
SP-5) white metal surface. Spray-apply 4 to 6 coats, with each dry coat being approximately 1.5 mils dry, for a total thickness of 6
mils dry, minimum. Lining to be Holliday spark tested using low voltage and a wet sponge to ensure uniform coating free of pin
holes. Magnesium anodes shall not be acceptable in this application. The lining is to be suitable for temperatures up to ______ F.
1.4 Optional
H4-7
02-02
1.5 Optional
The high-temperature diffuser or sparge tube shall be located beneath the normal tank water level. The tube shall be constructed of
2" pipe. This tube shall provide even distribution and blending of high-temperature condensate returns.
1.6 Optional
1.7 Optional
The basic surge tank shall be equipped with the following trim and accessories. Piping on packaged units shall comply with ASME

____ " inlet water regulating lever valve with ______ body and _______ connections. The valve Cv shall not exceed ______, and
shall be rated for _____ gpm at ______ psig inlet pressure. The pressure drop across the valve shall not exceed a delta-P of 10 psig.
This valve shall be suitable for temperatures up to 300 F. The valve manufacture shall be _________, Model _______ . This valve
shall be mechanically controlled by an external float cage with cast iron body and 8" stainless steel float. The float cage manufac-
turer shall be ____________, Model __________.
type, with a permanently lubricated gear train, and directly coupled to the valve stem. The valve Cv shall not exceed _____ and be
rated for_______ gpm at ________ psig inlet pressure. Valve shall not exceed a delta-P of 10 psig. This valve shall have teflon seats
and be suitable for temperatures up to 300 F. The motorized valve manufacturer shall be _________. This valve shall be electron-
ically controlled by a solid state control with internally mounted capacitance probes. The electronic solid state control shall be able
turer shall be Cleaver-Brooks, Model TW82. A solenoid valve and float switch is not acceptable. (Available only in the U.S.)
_______" 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.
ture up to 410 F. The diaphragm actuated valve manufacturer shall be ___________, Model _______. This valve shall be pneu-
matically 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.
2.4 Optional
2.5 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. Float cage construction shall be cast iron. (Not required with electronic make up controller.)
2.6. Optional
Low level alarm switch. This shall be an externally mounted float-type switch. The switch shall make contact on fall and break on
rise. Float cage construction shall be cast iron. (Not required with electronic make up controller.)
H4-8
02-02
2.7 Optional
3.0 Transfer Pump and Motor Set (Optional)

Quantity ______, centrifugal type transfer pump and motor set. Turbine type pumps are not acceptable in this application. Pump to
be rated for _______ gpm at ________ feet TDH with ______ feet NPSH required. Pump to be _______ materials of construction
as defined by the Hydraulic Institute, and have _______ seals for a maximum water temperature of 212 F. Pump impeller to be
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 sup-
plied with the pump and shipped loose for field installation to provide minimum bypass flow.
3.1 Optional
The stand shall elevate the surge tank to provide the net positive suction head required by the pump at the rated condition to prevent
cavitation. The stand shall be constructed of heavy square steel tubing for the legs and 1/4" steel plate covering the floor.
4.0 Control Panel

4.1 Optional - Base
tight lights.
fused.
4.3 Standard
The surge tank shall have a gauge glass assembly that covers the entire tank diameter. The gauge glass shall be quartz 0.625 inch
diameter by 24-inch maximum length. Each length of glass shall be furnished with a bronze gauge cock set and protector rods.
The surge tank shall be supplied with a thermometer with a 50 to 300 F range.
The surge tank is to be hand cleaned with a solvent to SSPC- SP-1 standards prior to painting. Prime coated to not less than 1 mil
Unit is to be knocked down for shipment. Piping is to be matched marked. Warranty period to be twelve months after start-up or
eighteen months after shipment, whichever comes first.
H4-9
02-02
NOTES
H4-10
02-02
Section H5
BOILER FEED SYSTEMS
CONTENTS
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-3
Simplex Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-3
Duplex Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-3
Dual Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-4
Triplex Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-4
Boiler Feedwater Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-4
SELECTION GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-4
Optional Steam Preheating Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-4
PACKAGE CONCEPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-10
Intermittent (On-Off) Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-10
Pump Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-10
Pump Total Dynamic Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-10
Pump Material of Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-10
Receiver Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-11
Receiver Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-11
Optional Steam Preheater Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-11
Preheater Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-11
Make-up Valve Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-11
H5-1
02-02
Boiler Feed Systems Feedwater Systems
ILLUSTRATIONS
Figure H5-1. Dimensions and Ratings for Boiler Feed Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-5
TABLES
Table H5-1. Boiler Feedwater System Tank Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-3
Table H5-2. Simplex and Duplex System Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-6
Table H5-3. Dual System Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-7
Table H5-4. Triplex System Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-8
Table H5-5. Internal Steam Heater Assemblies for High Pressure System (30-250 psig Steam),
Thermostatic Regulating Valve with Pressure Reducing Attachment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-9
Table H5-6. Internal Steam Heater Assemblies for Low Pressure System (10-15 psig Steam),
Thermostatic Regulating Valve without Pressure Reducing Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-10
This section contains information on Cleaver-Brooks Boiler Feed Systems. Cleaver-Brooks boiler feed systems help maintain peak
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.
H5-2
02-02
Feedwater Systems Boiler Feed Systems
FEATURES AND BENEFITS based on boiler size, pump requirements (flow, pressure, hp),
and water storage requirements (tank size). Contact your local
The following features and benefits apply to Cleaver-Brooks Cleaver-Brooks authorized representative for detailed compo-
Boiler Feed system products. nent sizing information.
All Pumps Deliver the Required Capacity at 210 F: Table H5-1 shows available tank sizes for boiler feedwater sys-
tems.
Guaranteed pump performance.
When equipped with an automatic steam preheater, feedwater
temperature can be maintained at 210 F. At this higher tem-
All Pumps Have Mechanical Seals (Standard):
perature, oxygen and carbon dioxide are released, reducing
Reduces maintenance when compared to packing type seals. corrosion problems in the boiler. Pre-heating is recommended
if return condensate constitutes 50% or less of the feedwater
Tank Includes a Protective Lining: required.
The vessel is lined with an epoxy coating, deterring Cleaver-Brooks Packaged Feedwater Systems include pumps,
corrosion of vessel steel due to dissolved gases. control panel with magnetic starters, and necessary switches.
Systems are available in simplex, duplex, dual and triplex
Specifically Designed for Compatibility With Cleaver-Brooks arrangements. Custom arrangements are also available. Acces-
Boilers: sories include high temperature diffuser tube, automatic pre-
heater, make-up valves, electrolytic corrosion inhibitor, and
Quick, accurate equipment selection.
ASME tanks.
Single source responsibility.
Proven performance. for information on alternate Cleaver-Brooks/Aurora Pump
Feed Systems.
Provides Additional Storage Time and Handles Volume-
Swings in Condensate Return: Simplex Units
Feedwater tank collects intermittent condensate returns and Simplex units include one pump set complete with open drip-
supplies water at a relative constant volume. roof motor on steel channel base with flexible coupling
between pump and motor, one large receiver mounted on struc-
Minimizes problem from unpredictable condensate flow
tural steel stand, complete with make-up valve, gauge glass
rates.
with shutoff valves, thermometer, and suction piping from
receiver to pump with Y-type strainer, flexible hose and gate
Boosts Condensate Return Pressure: valve.
Acts as a collecting point for low pressure and gravity
returns. Duplex Units
Allows the introduction of returns to a high pressure vessel. Duplex units are similar to simplex units, but with two pumps
and one receiver. Magnetic starters (where required) are
Accepts Gravity Returns: mounted in a NEMA I enclosure, with manual transfer switch
for standby pump.
Vessels are vented to atmosphere, providing no pressure
resistance that would inhibit gravity return.
Table H5-1. Boiler Feedwater System Tank Capacities
Internal Pump Suction Vortex Breakers:
Eliminates the problems of loss in NPSHA and cavitation CAPACITY (GAL.)
associated with the creation of vortices within pump suction 45
piping. 75
100
200
PRODUCT OFFERING 270
Information in this section applies directly to Cleaver- Brooks 340
Feed Systems for low and high pressure (15 - 300 psig) boilers 500
(15 - 800 horsepower). Selection of Boiler Feed Systems is 750
1000
H5-3
02-02
Dual Unit SELECTION GUIDE

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

Dimensions and ratings for boiler feed systems are shown in
Figure H5-1.
H5-4
02-02
1" NPT SENTINAL

VALVE CONNETION
NOTE:
1. Control panel not furnished with single phase motor.

2. Dim. H may not reflect overall unit width. Overall width may be greater due to pump/motor bases extending past stand posts and varying control panel depths,
3. All above dimensions while sufficiently accurate for layout purposes, must be confirmed for construction by certified dimension prints.
VENT CAPACITY CHART

45 75 100 200 270 340 500 750 1000 CAPACITY

SIZE (NPT)
(#/hr)
A 18 24 24 30 36 36 42 48 48
4 4800
B 69 75 75 89 95 95 109 115 115
5 10,500
C 64 70 70 84 90 90 104 110 110
6 17,000
D 55 58 58 69 72 72 83 86 86
8 35,000
E 35-1/2 33 47-1/2 58-1/2 54-1/2 69-1/2 73 85 117
Values given based on:
F 26-1/2 26-1/2 26-1/2 39-1/2 39-1/2 39-1/2 44 44 44 1) 50 ft. equivalent pipe length
2) Schedule 40 pipe
G 43 40 55 67 63 78 84 96 128
3) 2 psi back pressure
H 34 34 34 43-1/2 43-1/2 43-1/2 49 49 49 4) Vent capacities should be
compared with anticipated vent-
J 2 2 2 3 3 3 3 3 3 ing needs. Oversized vents are
K* 4 4 4 4 4 4 4 4 4 available.
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
Figure H5-1. Dimensions and Ratings for Boiler Feed Systems
H5-5
02-02
Table H5-2. Simplex and Duplex System Selection

ACTUAL PUMP DISCHARGE PRESSURE (PSI)
TANK
30 105 130 155 205 255 305
BOILER EVAP TANK SIZE
HR RATE CAP. DIA. X
BOILER OPERATING PRESSURE (PSI) MAKE-UP
LENGTH
VALVE
15 100 125 150 200 250 300 (IN.)
15 1.0 45 18 x 43 P-D-1/2 P-2D-1 P-2E-1-1/2 P-2F-2 P-3E-3 2-3F-3 P-4F-5 3/4

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

TANK
30 105 130 155 205 255 305
HR RATE CAP. DIA. X
BOILER OPERATING PRESSURE (PSI) MAKE-UP
LENGTH
VALVE
15 100 125 150 200 250 300 (IN.)
15 1.0 45 18 x 43 P-D-1/2 P-2D-1 P-2E-1-1/2 P-2F-2 P-3E-3 2-3F-3 P-4F-5 3/4

5.0 2.4 2.3 3.0 2.0 2.1 3.2
20 1.4 45 18 x 43 P-D-1/2 P-2E-1 P-2F-2 P-2F-2 P-3F-2 P-4E-3 P-4F-5 3/4
5.0 4.1 5.0 3.0 4.5 2.8 3.2
5.0 4.1 5.0 4.1 4.5 4.8 4.0
5.0 4.1 5.0 4.1 4.5 4.8 4.0
40 2.8 75 24 x 40 R-E-1/2 R-2F-2 R-2G-3 R-3F-3 R-4F-3 R-4G-5 R-5I-7-1/2 3/4
7.0 6.9 5.6 6.9 6.7 5.8 7.0
50 3.5 75 24x 40 R-E-1/2 R-2F-2 R-3F-3 R-3F-3 R-4G-5 R-4I-7-1/2 R-5I-7-1/2 3/4
7.0 6.9 7.9 6.9 8.5 6.9 7.0
60 4.1 100 24 x 55 S-F-1/2 S-2G-2 S-3G-3 S-3G-3 S-4G-5 S-4IA-7-1/2 S-5IA-10 3/4
10 8.3 10 8.3 8.5 8.3 10
70 4.8 100 24 - 55 S-F-1/2 S-2I-3 S-3G-3 S-3I-5 S-4I-5 S-5I-7-1/2 S-5IA-10 3/4
10 11 10 11 11.3 12 10
80 5.5 200 30 x 67 T-G-1/2 T-2I-3 T-3I-3 T-3I-5 T-4I-5 T-2II-15 T-2II-15 1
12 11 15 11 11.3 17 14
100 6.9 200 30 x 67 T-H-3/4 T-2IA-3 T-3I-3 T-3IA-5 T-4IA-7-1/2 T-2II-15 T-2II-15 1
17 15 15 14 14 17 14
125 8.6 270 36 x 63 V-H-3/4 V-3I-3 V-3IA-5 V-L-10 V-2II-15 V-2II-15 V-2EE-20 1
17 18 18 21 22 17 17
150 10 270 36 x 63 V-I-3/4 V-3IA-5 V-K-7-1/2 V-L-10 V-2II-15 V-2K-15 V-2L-20 1
20 25 21 21 22 20 20
200 14 340 36 x 78 W-IA-1 W-K-7-1/2 W-L-10 W-2II-15 W-2K-15 W-2L-20 W-3K-20 1
28 28 28 26 27 28 27
250 17 340 36 x 78 W-P-1-1/2 W--L-7-1/2 W-2K-15 W-2K-15 W-2EE-15 W-3K-20 W-3EE-25 1
45 37 36 34 32 32 32
300 21 500 42 x 84 X-P-1-1/2 X-L-7-1/2 X-2EE-15 X-2EE-15 X-2L-15 X-3L-25 X-3L-25 1-1/2
45 37 41 38 38 42 38
350 24 500 42 x 84 X-R-2 X-2EE-10 X-2L-15 X-2L-15 X-3L-25 X-3GG-25 X-4L-25 1-1/2
50 45 50 45 47 48 45
400 28 750 48 x 96 Y-R-2 Y-2FF-10 Y-2L-15 Y-2GG-15 Y-3GG-25 Y-4GG-30 Y-4GG-30 1-1/2
50 50 50 52 56 58 52
500 35 750 48 x 96 Y-GG-3 Y-2GG-15 Y-2GG-15 Y-2JJ-15 Y-4GG-30 Y-3KK-30 1-1/2
68 65 61 66 66 70
600 41 1000 48 x 128 Z-HH-5 Z-2JJ-15 Z-2JJ-15 Z-2KK-20 Z-3KK-30 1-1/2
75 81 72 81 83
700 48 1000 48 x 128 Z-HH-5 Z-2JJ-15 Z-2KK-20 Z-2KK-20 Z-3KK-30 1-1/2
75 81 83 81 83
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.
H5-7
02-02
Table H5-4. Triplex System Selection
TANK 30 105 130 155 205 255 305

MAKE-UP
HR RATE CAP. DIA. X BOILER OPERATING PRESSURE (PSI)
VALVE
LENGTH
300 (IN.)
15 100 125 150 200 250
50 3.5 200 30 x 67 T-E-1/2 T-2F-2 T-3F-3 T-3F-3 T-4G-5 T-4I-7-1/2 T-5I-7-1/2 1

7.0 6.9 7.9 6.9 8.5 6.9 7.0
60 4.1 200 30 x 67 T-F-1/2 T-2G-2 T-3G-3 T-3G-3 T-4G-5 T-4IA-7-1/2 T-5IA-10 1
10 8.3 10 8.3 8.5 8.3 10
70 4.8 200 30 x 67 T-F-1/2 T-2I-3 T-3G-3 T-3I-5 T-4I-5 T-5I-7-1/2 T-5IA-10 1
10 11 10 11 11.3 12 10
80 5.5 200 30 x 67 T-G-1/2 T-2I-3 T-3I-3 T-3I-5 T-4I-5 T-2II-15 T-2II-15 1
12 11 15 11 11.3 17 14
100 6.9 200 30 x 67 T-H-3/4 T-2IA-3 T-3I-3 T-3IA-5 T-4IA-7-1/2 T-2II-15 T-2II-15 1
17 15 15 14 14 17 14
125 8.6 270 36 x 63 V-H-3/4 V-3I-3 V-3IA-5 V-L-10 V-2II-15 V-2II-15 V-2EE-20 1
17 18 18 21 22 17 17
150 10 270 36 x 63 V-I-3/4 V-3IA-5 V-K-7-1/2 V-L-10 V-2II-15 V-2K-15 V-2L-20 1
20 25 21 21 22 20 20
200 14 340 36 x 78 W-IA-1 W-K-7-1/2 W-L-10 W-2II-15 W-2K-15 W-2L-20 W-3K-20 1
28 28 28 26 27 28 27
250 17 340 36 x 78 W-P-1-1/2 W-L-7-1/2 W-2K-15 W-2K-15 W-2EE-15 W-3K-20 W-3EE-25 1
45 37 36 34 32 32 32
300 21 500 42 x 84 X-P-1-1/2 X-L-7-1/2 X-2EE-15 X-2EE-15 X-2L-15 X-3L-25 X-3L-25 1-1/2
45 37 41 38 38 42 38
350 24 500 42 x 84 X-R-2 X-2EE-10 X-2L-15 X-2L-15 X-3L-25 X-3GG-25 X-4L-25 1-1/2
50 45 50 45 47 48 45
400 28 750 48 x 96 Y-R-2 Y-2FF-10 Y-2L-15 Y-2GG-15 Y-3GG-25 Y-4GG-30 Y-4GG-30 1-1/2
50 50 50 52 56 58 52
500 35 750 48 x 96 Y-GG-3 Y-2GG-15 Y-2GG-15 Y-2JJ-15 Y-4GG-30 Y-3KK-30 1-1/2
68 65 61 66 66 70
600 41 1000 48 x 128 Z-HH-5 Z-2JJ-15 Z-2JJ-15 Z-2KK-20 Z-3KK-30 1-1/2
75 81 72 81 83
700 48 1000 48 x 128 Z-HH-5 Z-2JJ-15 Z-2KK-20 Z-2KK-20 Z-3KK-30 1-1/2
75 81 83 81 83
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.
H5-8
02-02
Table H5-5. Internal Steam Heater Assemblies for High Pressure System (30-250 psig Steam), Thermostatic Regulating
Valve with Pressure Reducing Attachment
HEATING RATE (GPM) MINIMUM MAXIMUM

SIZE OF STEAM MINIMUM STEAM
MODEL 50F 100F 150F STEAM STEAM
CONTROL VALVE & SUPPLY LINE
NUMBER TEMP TEMP TEMP SUPPLY SUPPLY
STRAINER (INCHES) (INCHES)
RISE RISE RISE PRESSURE PRESSURE
25PT-5-.75 17 9 6 3/4 1 30 50
25PT-5-.75 3/4 1 50 100
25PT-5-.5 1/2 3/4 100 125
25PT-5-.5 1/2 3/4 125 150
25PT-5-.5 1/2 3/4 150 200
25PT-5-.5S 1/2 3/4 200 250
25PT-5-.1 28 13 9 1 1-1/4 30 50
25PT-5-.75 3/4 1 50 100
25PT-5-.75 3/4 1 100 125
25PT-5-.5 1/2 3/4 125 150
25PT-5-.5 1/2 3/4 150 200
25PT-5-.5 1/2 3/4 200 250
25PT-5-1.25 37 18 12 1-1/4 1-1/2 30 50
25PT-5-.1 1 1-1/4 50 100
25PT-5-.75 3/4 1 100 125
25PT-5-.75 3/4 1 125 150
25PT-5-.5 3/4 1 150 200
25PT-5-.5 3/4 1 200 250
25PT-5-1.5 53 26 18 1-1/2 2 30 50
25PT-5-1.25 1-1/4 1-1/2 50 100
25PT-5-1 1 1-1/4 100 125
25PT-5-.75 3/4 1 125 150
25PT-5-.75 3/4 1 150 200
25PT-5-.75 3/4 1 200 250
25PT-5-2 92 42 28 2 2-1/2 30 50
25PT-5-2 2 2-1/2 50 100
25PT-5-1.25 1-1/4 1-1/2 100 125
25PR-5-1 1 1-1/4 125 150
25PR-5-1 1 1-1/4 150 200
25PT-5-.75 3/4 1 200 250
25PT-5-2.5 140 68 45 2-1/2 3 30 50
25PT-5-2 2 2-1/2 50 100
25PT-5-1.5 1-1/2 2 100 125
25PT-5-1.5 1-1/2 2 125 150
25PT-5-1.25 1-1/4 1-1/2 150 200
25PT-5-1 1 1-1/4 200 250
25PT-5-3 190 90 60 3 4 30 50
25PT-5-2.5 2-1/2 3 50 100
25PT-5-2 2 2-1/2 100 125
25PT-5-2 2 2-1/2 125 150
25PT-5-1.5 1-1/2 2 150 200
25PT-5-1.25 1-1/4 1-1/2 200 250
NOTE: Not applicable for steam pressure over 250 psi, if available steam pressure is over 250 psi, contact your local Cleaver-
H5-9
02-02
Table H5-6. Internal Steam Heater Assemblies for Low Pressure System (10-15 psig Steam), Thermostatic Regulating
Valve without Pressure Reducing Attachment
HEATING RATE (GPM) SIZE OF STEAM MINIMUM STEAM

MODEL NUMBER 50F 100F 150F CONTROL VALVE & SUPPLY LINE
TEMP RISE TEMP RISE TEMP RISE STRAINER (INCHES) (INCHES)
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.
PACKAGE CONCEPT Pump Flow

Cleaver-Brooks line of packaged catalog feed systems is based One Boiler Horsepower is equal to an evaporation rate of
on the following parameters. 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
Intermittent (On-Off) Pump Operation
determine the number of gallons per minute. The result of this
As the water level in the boiler falls to a certain level, contacts calculation is 0.069 gallons per minute, which is the theoretical
close in the float switch on the boiler and the pump starts. As evaporation rate for each boiler horsepower. When selecting
the water level in the boiler rises to a certain level, the contacts the boiler feed pump flow, it is necessary to provide for excess
open in the float switch on the boiler and the pump stops. The capacity to take care of the boiler load without running the
operation repeats as the water levels drop again. pump continuously. For this reason, selections for intermittent
boiler feed pumps are based on a value of 1-1/2 to 2 times the
The intermittent operation, normally used on Cleaver-Brooks
theoretical evaporation rate.
firetube boilers, is well suited to the regenerative turbine
pump, for the following reasons:
Pump Total Dynamic Head
The pump covers a broad range of pressures, which covers a
wide boiler pressure range. 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
Comparatively low capacities are ideal for the small and pressure, plus static head differences, plus friction losses in the
medium range boilers. piping, valves and any other equipment between the pump and
The pump is allowed to operate at a nearly constant head- the boiler.
capacity point and not over the entire pump curve as with con- EXAMPLE: Boiler operating at 100 psig.
tinuous operation using a modulating feedwater valve, nor-
mally used on large industrial watertube boilers. CALCULATION: 100 psig (oper) + 5 psig (loss) x 2.31 (con-
stant) 0.96 (specific gravity) = 225 TDH.
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. Pump Material of Construction
Material of construction for a boiler feed pump should be care-
The pump is flexibly coupled to the motor, which reduces the
fully selected for compatibility of the liquid being pumped. In
possibility of heat transfer from the liquid being pumped to the
general, the Cleaver-Brooks bronze-fitted pump is best suited
driver.
for most applications. Factors that will affect this decision are
H5-10
02-02
water quality and treatment. An example: In situations when 1. The risk of damage to the boiler caused by thermal shock
alkalinity is higher than a pH of 8.5, do not use a bronze-fitted is reduced.
pump. There is no substitute for experience in selecting mate-
2. The dissolved oxygen content can be reduced, slowing
rials for pump construction. Previous experience in handling a
corrosion and showing a savings in the chemical treatment
particular application should be the main criteria.
program of the boiler. Oxygen in 212 F feedwater is
roughly 1.8 cc/liter as opposed to 50 F feedwater, which
Receiver Size is 5.9 cc/liter. The American Society of Engineers, in a
The receiver should be sized for a capacity sufficient to allow paper called Consensus On Operating Practices For The
feed water for a minimum of 10 to 15 minutes of boiler opera- Control of Feedwater and Boiler Water Quality in Modern
tion at rated horsepower. Industrial Boilers, suggests dissolved oxygen limits that
should be considered. A preheater by no means deaerates
The run time is essential because of unpredictable surges of water to an acceptable level by itself.
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.
Preheater Components
Preheater Components include the following:
If it is known that the receiver will see 100% make-up with no
returns, a five minute capacity tank can be substituted. The 1. Perforated heater tube, also referred to as a diffuser or
reduced storage capacity is acceptable, since the receiver will sparge tube. The tube is located under the water level in the
have a steady predictable load. tank, and its purpose is steam distribution.
2. Regulating valve to control the incoming steam supply.
Receiver Construction When the steam supply pressure is between 10-15 psi, a
Standardly, tanks are protected by three coats of a two-part, air one-element regulating valve (temperature sensor) is used.
cured, epoxy lining or by an optional hot-dipped galvanization On higher pressure packages, when the steam supply is
process. between 30-250 psi, a two-element regulating valve,
sensing pressure and temperature, is used. The two-
The receivers are manufactured as a non-code tank for venting element regulating valve is furnished and packaged with
to atmosphere. As an option, Cleaver-Brooks offers receivers higher steam supply pressures, instead of one element
constructed for ASME Section VIII, Division 1 of the ASME regulating valve for added safety, even through the receiver
Pressure Vessel Code. When an ASME Code receiver is is vented and pressurization should not occur.
required, contact your local Cleaver-Brooks authorized repre-
sentative for additional factors to be considered in this applica- 3. Strainer for arresting any dirt or scale carried over with the
tion. Coded tanks supplied will normally be furnished unlined supply steam. For its protection, the strainer is located
because of possible increased operating temperature limita- upstream of the regulating valve.
tions. 4. Pressure gauge for monitoring down stream steam pressure
from the regulating valve.
Optional Steam Preheater Size 5. Sentinel valve to warn if the receiver is pressurized, if the
Three basic factors are considered when sizing a preheater: regulating valve fails, or a vent becomes plugged. The
valve is not required by a code, but is added for safe
1. The heating rate in gallons per minute. It is generally
operation.
assumed the same as the total evaporation rate of the
boilers being supplied with water, unless otherwise
specified. Make-up Valve Size
2. The temperature rise required to raise the temperature in The valves are sized for the maximum theoretical evaporation
the tank based on condensate returns and make-up water rate of the boiler, with no condensate return as a supplement.
mixed inlet temperature to 212 F. The sizing criteria makes the water level in the receiver self-
adjusting for any loss of condensate return.
3. The available steam supply pressure at the regulating valve
is generally assumed the same as the operating pressure of These parameters are based on more than 60 years experience
the boiler from which the steam is being tapped, unless at Cleaver-Brooks in the packaged boiler room equipment
otherwise specified. market, and should not be ignored.
Two basic benefits are gained by supplying a preheat package.
H5-11
02-02
Boiler Feed System shall be Cleaver-Brooks Model _______________________ (Specify simplex, duplex, dual, or triplex) pack-
aged boiler system suitable for ______gpm, at a discharge pressure of ___________ psig. (Refer to Tables H5-4, 5, and 6.)
The unit shall consist of the following components:
One (substitute two for duplex or dual; three for triplex) bronze-ringed, pump(s) 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.
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, thermom-
eter and gauge glass.
Tank size shall be __________ inches diameter with _______ gallon capacity.
One fresh water makeup valve consisting of a ____________ inch float type mechanical valve suitable for tight shutoff against 100
psig inlet pressure.
Piping between the receiver and the pump shall consist of one (substitute two for duplex or dual; three for triplex) section(s) con-
taining a gate valve(s), one flexible hose(s) and Y-type strainer(s) to ensure minimum pressure drop between receiver and pump.
One (substitute two for duplex or dual,; three for triplex) 1750 rpm, 60 Hz, drip-proof motor(s) for __________ phase, _______
Volt operation. Motor(s) shall not be loaded in excess of NEMA
service factor for integral drip-proof motors.
Provide gauge glass (with shutoff valves) of proper size and tank thermometer.
H5-12
02-02
Section H6
CHEMICAL FEED SYSTEMS AND METERING PUMPS
CONTENTS
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-3
ILLUSTRATIONS
Figure H6-1. Manual System Dimensions (By-Pass Feeders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-4
Figure H6-2. Manual System Dimensions (Shot Feeders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-4
Figure H6-3. Automatic System Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-5
TABLES
Table H6-1. Automatic Chemical Feed System Pump Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-3
H6-1
02-02
Chemical Feed Systems and Metering Pumps Feedwater Systems
This section contains information on a complete line of manual and automatic chemical feed systems and associated metering
pumps. These products are used to treat boiler feed water and condition blowdown sludge to protect the boiler against corrosion
and scaling.
H6-2
02-02
Feedwater Systems Chemical Feed Systems and Metering Pumps
FEATURES AND BENEFITS DIMENSIONS AND RATINGS

Dimension and rating information is shown in Figures H6-1
Complete Standard Packaging Provides: through H6-3, and Table H6-1.
Lower installation costs.
Easy installation. ENGINEERING DATA
The V-5 Simplex Piston Pump and V-5 Duplex Piston Pump
Alternative Materials of Construction: are used in this system.
Product selection to match system requirements. These pumps are of the high pressure, low volume, reciprocat-
ing plunger, positive placement type, ideal for use in feeding
Custom Pump Selection: chemicals to hot water and steam boilers. These pumps are
Piston or diaphragm. 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
Direct Drive, Clamp Mounted Agitator:
for positive protection at all times. Max pump discharge pres-
Ability to mix and dilute powdered materials. sure is 1000 psig.
Ease of maintenance. The stroke can be simply and quickly adjusted by loosening
the nut and turning the head screw to the desired length stroke;
Adjustable Pump Parameters: then, re-tighten nut against the slide. The stroke adjustment
(0 to maximum capacity) may be performed while the pump is
Ability to adjust pump output based upon system
running or when the pump is shut down.
requirements.
Controls chemical cost. Table H6-1. Automatic Chemical Feed System Pump Ratings
Standard 6" Funnel on Manual Chemical Feed Systems:

MODEL TYPE STROKING PISTON GPH
RATE DIA MAX
Less product loss due to spillage. (IN.)
SIMPLEX
PRODUCT OFFERING V-5 - 1560 (Std)A 60 5/8 6.20
Cleaver-Brooks chemical feed systems treat feedwater and V-5 - 1530 30 5/8 3.10
condition blowdown sludge where an extra measure of protec-
V-5 - 1460 60 1/2 3.30
tion against corrosion and scaling is required. Automatic sys-
tems are available for single- or multiple-boiler installations. V-5 - 1430 30 1/2 1.65
They are fully packaged and can be equipped with either pis- V-5 - 1360 60 3/8 1.62
ton or diaphragm pump(s) capable of accurately injecting V-5 - 1330 30 3/8 0.81
chemical from 0 to 6.2 gph at up to 1000 psig.
V-5 - 1260 60 1/4 1.00
Automatic Systems V-5 - 1230 30 1/4 0.50
Tank materials: polyethylene, stainless steel, carbon steel or DUPLEX

overpack (steel tank with polyethylene liner and cover). V-5 - 2560 (Std) A 60 5/8 12.40B
Tank sizes: 30 to 200 gal. V-5 - 2530 30 5/8 6.20B
Pressures: up to 1000 psig. V-5 - 2460 60 1/2 6.60B
Agitator included. V-5 - 2430 30 1/2 3.30B
Manual Shot Feeders V-5 - 2360 60 3/8 3.24B
Manual shot feeders are used for batch feeding of chemicals V-5 - 2330 30 3/8 1.72B
into closed loop or low makeup water systems. They are com- V-5 - 2260 60 1/4 2.00B
pletely assembled and ready for installation for:
V-5 - 2230 30 1/4 1.00B
Pressures: 125 to 300 psig.
A. Unless otherwise specified, Model V-5 - Type 1560 pumps will be
shipped for Simplex systems and Model V-5 - Type 2560 for Duplex sys-
Capacities: 3/4 to 30 gal. tems.
B. For both pumping heads.
Specifications subject to change without notice.
H6-3
02-02
C CONNECTIONS
TANK A B OVER-
WIDTH BODY ALL
CAPACITY (INCH) (INCH) HEIGHT IN OUT SAMPLE
(INCH)
3/4 Gal 4-1/2 12 31-3/4 1/2 3/8 1/2

1 Gal 6 10 28 1/2 3/8 1/2
1-1/2 Gal 6 12 30 1/2 3/8 1/2
2 Gal 8 10 28 1/2 3/8 1/2
2-1/2 Gal 8 12 30 1/2 3/8 1/2
5 Gal 10 15 33 1/2 3/8 1/2
10 Gal 10 29 47 1/2 3/8 1/2
18 Gal 14 32 50 1/2 3/8 1/2
25 Gal 18 28 46 1/2 3/8 1/2
By Pass Feeders Include:

Tank
1/2" screwed inlet
3/8" screwed outlet
3/8" flow control valve
Sight glass with gauge valves and guards
1/2" sample valves
6" diameter funnel
Tanks 5 gallon capacity and larger have three 12-inch support legs.
Figure H6-1. Manual System Dimensions (By-Pass Feeders)
TANK A B BODY C CONNECTIONS

CAPACITY WIDTH (INCH) OVER-
(INCH) ALL
HEIGHT IN OUT SAMPLE
(INCH)
3/4 Gal 4-1/2" 12" 26" 1/2" 1/2" 1/2"

1 Gal 6" 10" 23" 1/2" 1" 1/2"
1-1/2 Gal 6" 12" 25" 1/2" 1" 1/2"
2 Gal 8" 10" 23" 1/2" 1" 1/2"
2-1/2 Gal 8" 12" 25" 1/2" 1" 1/2"
5 Gal 10" 15" 27" 1/2" 1" 1/2"
10 Gal 10" 29" 42" 1/2" 1" 1/2"
18 Gal 14" 32" 45" 1/2" 1" 1/2"
25 Gal 18 28 41 1/2 1 1/2
Shot Feeders Include:

Tank
1/2" screwed inlet
1/2" or 1" screwed outlet
1/2" sample valve
6" diameter funnel
Tanks 5 gallon capacity and larger have three support legs.
Figure H6-2. Manual System Dimensions (Shot Feeders)
H6-4
02-02
Feedwater Systems Chemical Feed Systems and Metering Pumps
STAINLESS & CARBON

STEEL TANKS
CAPACITY DIMENSIONS (INCHES)

(GAL.) A B C D E F
C
B A 50 23 58 31 17 22 18
100 36 61 31 20 31 27
150 36 66 36 20 31 27
200 36 78 48 20 31 27
D
F E
POLYETHYLENE TANKS
CAPACITY DIMENSIONS (INCHES)

(GAL.) A B C D
B
D A 30 18 30 13 51
55 22 34 17 63
100 28 42 18 73
150 31 47 18 78
OVER PACK CHEMICAL SYSTEMS
50OP-1V5 The Over Pack chemical feed system is recommended for

90
almost all industrial applications. A polyethylene liner and cover
are inserted into a steel tank with welded steel frame and pump
support.
17
22
Figure H6-3. Automatic System Dimensions
(Rev 7/97)
H6-5
02-02
The following specifications are provided by Cleaver-Brooks to assist you in specifying your customers requirements.
1.0 General
Provide completely preassembled, packaged chemical feed system(s)/chemical metering pump(s), as manufactured by
_______________. Package shall be hydraulically and electrically tested at the factory and shall be assembled to the fullest extent
possible. Package shall be furnished with all required lubricants, special tools, and installation instructions.
2.0 Pump
Pump capacity shall be adjustable through 100% of the range by manual micrometer dial while the pump is running or stopped.
Pump stroking speed shall not exceed 60 spm.
The pump shall be sized to deliver the required capacity at 85% of maximum stroke length. Stroke adjustment shall be a variable
micrometer type mechanism, with the plunger powered through its entire travel. Lost motion designs are not acceptable.
The pump shall include an automatic vent and refill mechanism on the hydraulic side, which operates once each stroke. The pump
shall have an external hydraulic relief valve which is adjustable.
Double ball check valves shall be provided on the discharge to ensure accurate repeatable metering. The pump valves shall be
removable for cleaning or replacement without the need to disturb suction or discharge piping.
The pump shall be field convertible to automatic stroke adjustment without the use of special tools, and without the need to replace
any major frame parts.
The pump shall be furnished with a factory-mounted driver suitably sized for continuous operation at the maximum relief setting.
The motor shall be (integrally mounted direct coupled flange mounted with flexible coupling). No belts or pulleys should be used in
the drive train or for capacity adjustment.
3.0 Feed System

Complete chemical feed system(s) shall be furnished suitable for handling ___________________. Each system will consist of
______ pump(s), tank, piping, and accessories as defined below. Manufacturer will select all materials in contact with the chemical
and guarantee their suitability for the particular service. Pump(s) shall be mounted below the tank.
4.0 Tank
The tank(s) shall be constructed of (polyethylene/304SS/316SS/other) and furnished with a hinged or removable cover. Tank shall
include connections for pump suction, drain, level gauge, chemical fill, dilution water, and relief valve return piping. Drain connec-
tion shall be separate from pump suction connection. Drain shall be located in the bottom of the tank for complete emptying of con-
tents.
Tank shall be furnished with (drain valve) (level switch) (level gauge).
5.0 Mixer
An angle plate mount mixer with 304SS shaft and propeller shall be furnished. The mixer propeller shall operate at 1750 rpm. The
purpose of the mixer shall be to (mix liquids/dissolve powder in liquid/create and maintain a suspension).
H6-6
02-02
Section H7
FILTERS
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-3
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-3
Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-3
DIMENSIONS, RATINGS, AND SIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-3
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-5
Chlorine, Organics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-5
Particles Down to 10-Micron Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-5
Sand, Heavy Sediment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-5
Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-5
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-6
ILLUSTRATIONS
Figure H7-1. Dimensional Data, Filter System Without Regeneration Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H7- 4
TABLES
Table H7-1. Model CF Activated Carbon Media Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-6
Table H7-2. Model MF Multi-Layered Media Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-7
Table H7-3. Model SF Sand Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-8
Table H7-4. Model IF Iron Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-8
Table H7-5. Engineering Data (Filters) (Page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-9
H7-1
02-02
Filters Feedwater Systems
This section contains information on water filters used for the removal of impurities from raw water. Filters discussed here remove:
Chlorine and organics.
Particles down to 10-micron size.
Sand and heavy sediment.
Iron.
H7-2
02-02
Feedwater Systems Filters
FEATURES AND BENEFITS Locking bayonet cover.

Fine slotted tubular PVC distributor.
Complete Range of Sizes and Filter Media Available:
Automatic time clock operation.
Precisely match customer needs (system specific).
Automatic Units 20" - 42" Diameter:
Pre-Engineered Packaged Units Shipped From Stock: Structural steel legs.
Short lead times. Double hot-dipped galvanized interior and exterior.
Minimum down time. ML and AC filters are epoxy lined with prime coat
exterior.
Industrial Grade Multiport Control Valve: 20" - 30" have access handhole in top head and lower
Long lasting. sideshell.
High reliability. 36" - 42" have 11" x 15" elliptical manhole in top head.
Easy maintenance. PVC radial distribution.
Automatic time clock operation.
Backwash Control Actuated On a Time Clock, Pressure Dif-
ferential Switch, or Water Meter Basis: Automatic Units 48" Diameter and Larger:
Versatility. Adjustable jack support legs.
Prime coat exterior.
Inlet and Outlet Pressure Gauges and Sample Cocks:
12" x 16" elliptical manhole in top head.
Easy monitoring of system performance.
Header and lateral distribution system.
Fully Assembled Manifold Piping: Inlet and outlet pressure gauges.
Ease of installation, lower installation costs. Air relief valve.
Flanged tank openings.
Heavy Duty Steel Tanks With Galvanized or Prime Coat Ex-
terior Finish (Specialty Linings Optional): Automatic time clock operation.
Corrosion resistance and longer life.
Optional Equipment
Premium Grades of Filter Media: ASME code tanks.
Optimum performance. Specialty tank linings.
Skid mounted, fully pre-piped and wired.
PRODUCT OFFERING
Automatic operation by pressure differential or water meter.
The need for special filter equipment for removal of impurities
can be readily determined by raw water analysis. Where filters Manual backwash controls.
are recommended, cost is quickly recovered by eliminating Backwash with water from auxiliary source.
need for frequent equipment cleaning and servicing, inefficient
performance, damage to system components, and premature
equipment failure. DIMENSIONS, RATINGS, AND SIZING
Dimensions for filter systems without regenerant tanks are
Standard Equipment shown in Figure H7-1.
Automatic Units 12" - 16" Diameter:
Skirt type tanks.
Epoxy lined interior.
Painted exterior.
H7-3
02-02
SYSTEM DIMENSIONS OTHER APPLICABLE DIMENS IONS

FILTER
TANK SINGLE TWIN TRIPLE QUAD
SIZE (IN) W H C D E F G I J
AxB L1 L2 L3 L4
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 H7-1. Dimensional Data, Filter System Without Regeneration Tanks
H7-4
02-02
Sizing Chlorine, Organics

In addition to service flow, the selection of a filter system must CB activated carbon filters (Table H7-1) remove free chlorine,
take into account the available backwash flow rate. This is the some dissolved organics and sediment, down to 40-micron par-
most important function in the proper operation of a filter. A ticle size, from boiler makeup water. By removing sediment,
periodic backwash and rinse is required to cleanse and reclas- activated carbon filters also help control sludge buildup in boil-
sify the filter media. ers. They protect pretreatment equipment by: 1) removal of
free chlorine, which is corrosive and attacks the ion exchange
Backwash flow rates are always higher than service flow rates
resin cross-linking agent in water softeners and dealkalizers,
and therefore limit the filter size that can be installed. As a
and the membranes in reverse osmosis equipment, and 2)
general rule, select the largest filter that can be back washed
removing organics which promote fouling in ion exchange
with the flow rate available at the point of filter installation.
beds, that can contaminate water supplies and cause foaming
Then note the service flow rate for the filter selected. If it is not
in boilers and heat exchange equipment.
adequate for the flow to be treated, a twin filter installed in par-
allel is required. Periodic backwashing is required to remove collected matter
from the filter bed.
A parallel installation will increase the service flow and permit
each filter to be back washed separately with the existing water Flow rates: 3 to 226 gpm.
supply.
Tank sizes: 12" to 72" dia.
Generally, lower flows produce higher quality water and a
Operating temperatures: 40 F to 120 F.
larger volume of treated water between backwashing.
Cleaver-Brooks rates the performance of each filter as follows: Particles Down to 10-Micron Size
Superior Multilayered filters (Table H7-2) are used for finer levels of fil-
Recommended for most applications under all tration and for handling heavy flow rates. They remove sedi-
operating conditions. ment, suspended solids and colloidal matter, down to 10-
micron particle size, from boiler makeup water. They are
Best quality water. highly effective in controlling sludge buildup. Periodic back-
Maximum on line time between backwashing. washing is required to remove collected matter from the filter
bed.
Lowest pressure loss.
Flow rates: 8 to 393 gpm.
Recommended for influent suspended solids loads up to
or greater than 300 ppm. Tank sizes: 12" to 60" dia.
High Operating temperatures: 40 F to 120 F.
Well suited for many applications.

Sand, Heavy Sediment
Very good quality water.
Sand filters (Table H7-3) can handle heavy loads in controlling
Moderate on line time between backwashing. sludge buildup. They remove heavy, large-particle sediment
and suspended solids, down to 40-micron size, from makeup
Increased pressure loss.
water. Periodic backwashing is required to remove collected
Recommended for influent suspended solids loads less matter from the filter bed.
than 300 ppm.
Utility
Flow rates listed are at peak design: operation at higher
flows not recommended.
Satisfactory water quality. Iron
Shorter on line time. Cleaver-Brooks iron filters (Table H7-4) remove both soluble
Higher pressure loss. and insoluble iron, suspended solids and colloidal matter down
to 40-micron particle size from boiler makeup water. They are
Recommended for influent suspended solids loads less used to control sludge buildup caused by iron precipitation.
than 150 ppm.
H7-5
02-02
Water pH must be at least 6.2. Occasional regeneration with potas-

sium 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.
Table H7-1. Model CF Activated Carbon Media Filter
MODEL WATER QUALITY TANK

SIZE
NUMBER BACK- FILTER FLOOR
PIPE SUPERIOR HIGH UTILITY DIA OPER
WASH MEDIA SPACE HEIGHT
SIZE x WT
RATE LOAD REQ'D
FLOW PRESS. FLOW PRESS. FLOW PRESS. SIDE
RATE LOSS RATE LOSS RATE LOSS SHELL
CFB-
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.
H7-6
02-02
Table H7-2. Model MF Multi-Layered Media Filter
MODEL WATER QUALITY TANK

SIZE
NUMBER BACK- FILTER FLOOR
PIPE SUPERIOR HIGH UTILITY DIA OPER
WASH MEDIA SPACE HEIGHT
SIZE x WT
RATE LOAD REQ'D
MFB-
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.
H7-7
02-02
Table H7-3. Model SF Sand Filter

WATER QUALITY TANK
MODEL
NUMBER BACK- SIZE
PIPE DIA FILTER FLOOR
SUPERIOR HIGH UTILITY WASH MEDIA SPACE HEIGHT OPER
SIZE x WT
RATE LOAD REQ'D
SFB-
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 H7-4. Model IF Iron Filter

WATER QUALITY TANK
MODEL
NUMBER BACK- SIZE
PIPE DIA FILTER FLOOR
SUPERIOR HIGH UTILITY WASH MEDIA OPER
SIZE x SPACE HEIGHT WT
RATE LOAD REQ'D
IFB-
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
H7-8
02-02
Table H7-5. Engineering Data (Filters) (Page 1 of 2)

DRAIN
MODEL TANK SIZE PIPE FREE SUPPT NO. SERV PRESS. PEAK PRESS. BACK SHIP OP
MEDIA PIPE
SIZE (CU-FT) BOARD BED OF FLOW LOSS FLOW LOSS WASH WT WT
NUMBER SIZE
(DIA x HT) (IN.) (IN.) (LBS) DIST (GPM) (PSIG) GPM) (PSIG) GPM (LBS) (LBS)
(IN.)
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
H7-9
02-02
Table H7-5. Engineering Data (Filters) (Page 2 of 2)

DRAIN
MODEL TANK SIZE PIPE FREE SUPPT NO. SERV PRESS PEAK PRESS BACK SHIP OP
MEDIA PIPE
SIZE (CU-FT) BOARD BED OF FLOW LOSS FLOW LOSS WASH WT WT
NUMBER SIZE
(DIA x HT) (IN.) (IN.) (LBS) DIST (GPM) PSIG) (GPM) (PSIG) GPM (LBS) (LBS)
(IN.)
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
H7-10
02-02
The following sample specifications are provided by Cleaver-Brooks to assist you in meeting your customers requirements.
1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H7-11

2.0 Mineral Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-11
3.0 Upper Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-11
4.0 Lower Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-11
5.0 Main Operating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-11
6.0 Filter Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-12
7.0 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-12
8.0 Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-12
9.0 Guarantees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H7-12
1.0 General
Furnish, install, and place in service an assembled vertical, pressure type, water 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.
2.0 Mineral Tank

The mineral tank(s) shall be of welded construction of tank quality carbon steel. It shall be _____ " diameter with a _____ " straight
shell with reinforced openings for pipe connections and an 11" x 15" manhole in the top head (for tank 30" diameter and smaller;
two (2) 4" spin off handholes are provided in the top head and lower sideshell). The mineral tank shall be rated for 100 psig work-
ing 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 ship-
ment.
Options: 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.)
A minimum freeboard of 50% shall be provided for backwash expansion above the normal filter media bed level.
3.0 Upper Distributor

The upper distributor system shall be of the single point baffle type. Constructed of Schedule-40 galvanized steel and fittings.
4.0 Lower Distributor

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.
5.0 Main Operating Valve

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.
Pressure gauges and sample cocks to be provided on the inlet and outlet of the filter system.
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.
The regeneration sequence shall be the accepted standard, which is backwash, fast flush, and return to service.
H7-11
02-02
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.)
The pipings shall be galvanized Schedule-40 galvanized steel with galvanized fittings.
All face piping shall be preassembled to the tank in a professional manner.
6.0 Filter Media

The filter media shall be S (No. 26 sand) for removal of sand and heavy sediment from water.
The filter media shall be ML (Multi-Media) consisting of reverse grading of fine gravel, coarse gravel, red flint sand, and activated
carbon.
The filter media shall be M (Manganese Greensand) that will be periodically regenerated with potassium permanganate (KMnO4).
The filter media shall be AC (Granular Activated Carbon).
7.0 Controls
Regeneration shall be controlled by a fully automatic time clock control (TCC) which is fully adjustable or a remote manual con-
troller. For fully automatic operation, the regeneration shall be initiated by a calendar clock. A pointer shall indicate the cycle of
operation at all times.
When two (2) filters, or more, are required, a lockout shall be provided to allow only one (1) unit to regenerate at any one time.
In the event of a power failure, a complete regeneration can be performed by manual operation of the external pilot valve.
Control Options: Regeneration to be initiated by head loss across the filter(s). A delay timer is to be provided to prevent false back-
washing due to pressure surges in the system.
8.0 Instructions
A complete set of installation and operating instructions shall be included.
9.0 Guarantees
Attrition loss of mineral is guaranteed not to exceed 3% per year for a period of three (3) years.
All mechanical equipment is guaranteed for one (1) year against any defects in workmanship or materials. Any part proving defec-
tive will be replaced or repaired within this period.
The manufacturer guarantees that under actual operating conditions, the mineral shall not be washed out of the system during the
service run or backwashing period; that the turbidity and color of the 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 tur-
bidity or by dirt, while operating as noted on manufacturers instructions.
H7-12
02-02
Section H8
SOFTENERS
Models SSE & FSE Models SMR
CONTENTS
MODELS SSE & FSE FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-3
MODELS SMR FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-4
Standard Equipment - SSE & FSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-5
Standard Equipment - SMR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-5
Optional Equipment - SSE & FSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-5
Optional Equipment - SMR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-5
Operating Specifications - SMR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-5
DIMENSIONS, RATINGS AND SIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-6
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-6
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-6
Sizing Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-6
SAMPLE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-18
H8-1
02-02
Softeners Feedwater Systems
ILLUSTRATIONS
Figure H8-1. SSE Model (Size 30 - 1200) Softener Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-7, 8

Figure H8-2. FSE Model (Size 30 - 600) Softener Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-9, 10
Figure H8-3. Crossover Twin (Size 30-300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-11
Figure H8-4. SMR Dimensions (Size 150-1050 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-12
Figure H8-5. Water Softener Sizing Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-17
TABLES
Table H8-1. SSE Water Softener Ratings Polybond Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-13
Table H8-2. FSE Water Softener Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-14
Table H8-3. FSE Water Softener Ratings with Crossover Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-15
Table H8-4. SMR Water Softener Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-16
This section contains information on Cleaver-Brooks cation, ion exchange, and water softeners available in package designs for
virtually any commercial or industrial application. Softeners should be used whenever raw water hardness exceeds 5 ppm.
Cleaver-Brooks water softeners remove hardness, preventing scale buildup on heat transfer surfaces, while maintaining peak boiler
efficiency. Removing hardness also reduces the need for chemical treatment used to control scale.
H8-2
02-02
Feedwater Systems Softeners
MODELS SSE & FSE FEATURES AND control after a power loss. A capacitor operates the
microprocessor in case of short term power loss.
BENEFITS
Quality Constructed Tanks:
An easy-to-read LCD display continuously displays system
status and allows instant access to current operating
Two types of softener resin tanks are available to meet
conditions, including flow rate, total treated flow, remaining
environmental requirements. Both rugged lined steel or
capacity, valve position and many more important features.
fiberglass lined plastic (FRP) vessels are available.
The display is illuminated for easy reading, even in low-light
conditions. Self-diagnostic electronics provide 24-hour per
Exclusive Polybond tanks are made of industrial grade day review of the system, and stores historical data to allow
steel. The tank interior is lined with a heat-fused virgin system optimization and simplify troubleshooting. A built-in
polyethylene lining, creating a 40-60 mil thick, resilient, and speaker can transmit this System Performance Analysis
non-corrosive tank within a tank. The lining material is Food (SPA) data via regular telephone lines to a remote service
and Drug Administration (FDA) listed. All surfaces that center for computerized troubleshooting, or, data can be
contact water during system operation, including valve recorded for later transmission.
flanges and openings, are covered with the lining material,
so that water never touches bare steel, providing maximum
Controls have a look-ahead feature. The main memory
protection against rust and corrosion. In addition, gasketed
monitors operation, tracks data, then adjusts regenerations
tank openings provide dry thread closures, eliminating
automatically for high- and low-water use periods.
coated threads which can be weak spots in tank linings.
All controls are designed for use with Fleck regeneration

All tanks are 100% spark tested to ensure the integrity of the
valves as well as traditional valve nest operated systems. Pre-
tank lining.
wired components with indexed cables make installation
quick and simple, and eliminate the need for complicated
All steel tanks up to 48 in diameter are hot-quench wiring diagrams and wiring connection instructions. Low
phosphatized prior to the application of a 4- 6 mil thick voltage 24-volt operation simplifies installation and
exterior epoxy coating for further protection against rust and minimizes electrical hazards.
corrosion, providing years of good appearance on the job.
Tanks over 48 diameter are coated with a zinc oxide-rich
Two models are available to meet varying needs: EDS/EDT,
protective coating, suitable for field painting where desired.
and VF.
Fiberglass tanks are available for applications where

EDS/EDT controls are capable of operating one or two
environmental conditions or budgetary constraints prevail.
softener tanks in single, parallel, or alternating modes.
They are especially useful in providing rust and corrosion
protection. All FRP tanks are provided with a minimum of
5 year warranties. 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
Electronic Demand Programmable (ED) Controls
softening capacity remains in each tank. If water demand
ED controls offer precise control over water softener increases, the system can be expanded by adding more
operation. All controls have state-of-the-art electronics, and softener tanks, and the control can be reprogrammed to
are microprocessor-based and completely programmable. handle the larger system. If one softener tank is taken of-line,
Operating efficiency combines with ease of use -- a 4-button the VF control adjusts the remaining tanks to maintain the
keypad and alphanumeric LCD display permit easy same system flow rate. It also staggers tank regeneration to
programming and observation of system functions (no prevent all tanks from being exhausted simultaneously, thus
complicated jumper pins or dip switches to set). Simple maintaining sufficient softened water flow to the boiler or
programming prompts the operator through set-up. Model process need.
code programming makes set-up as easy as selecting model,
pipe size, salt dosage, water hardness, and time. Controls
In variable mode, the VF control monitors flow rate and
perform all calculations to minimize set-up errors.
switches tanks into service to meet changes in system
An EEPROM memory retains all programmed and demand, thus making sure that sufficient softened water is
accumulated data, eliminating the need to re-program the available, and that each tank is efficiently used.
H8-3
02-02
Versatile Control Valve:

All resins are in solid bead form with uniform particle size,
Each softener control valve is a low-lead brass, mechanically
clean and free of dirt and extraneous matter which might
actuated, hydraulically balanced, self-cleaning six (6)
interfere with the ion exchange process.
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 All resins rest on a bed of quartz particles that have been
regeneration water use. 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
The valve is fitted with a fixed orifice eductor nozzle and
bottom of the tank. The quartz is washed and dried to remove
self-adjusting backwash flow control. The bypass body, like
debris and fines.
the main control valve, is actuated by a mechanical drive.
The valve is capable of stepping through all regeneration
phases without electrical power. Automatic Self-Adjusting Backwash and Rinse Controls
This feature assures maximum cleansing of the resin bed
Brine System and Salt Storage 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
Positive action brine piston eliminates the need for constant
adjustments.
line pressure at the salt storage tank, minimizing brine tank
overflows.
Availability:
Timed tank refill provides highly reliable brine levels and All softener systems are available from stock, with short lead
salt usage. Salt dosage is easily changed from the system times.
control, eliminating the need to empty salt tanks or change
fill-plug locations to make minor adjustments. Optional Skid Mounting:
Tanks may be ordered skid-mounted for easy handling and
Simple protected brine well design eliminates the need for easier and lower-cost field installation.
gravel subfill and minimizes brine tank maintenance.
Efficient Water Distributors:
High density FDA approved polyethylene tank and cover Inlet water distributors are designed to produce uniform flow
provide maximum strength and corrosion resistance. through the entire resin bed and thus ensure maximum
exchange capacity with low pressure loss.
High Quality Softener Resins
All water softeners contain a high-quality, high-capacity, MODELS SMR FEATURES AND BEN-
solvent-free synthetic ion exchange resin, that exchanges the EFITS
hardness minerals of calcium and magnesium ions with
soluble sodium ions, a soft and non-scaling mineral that does Automatic Control Center Engineered for Efficient Trouble-
not build up on pipes to cause hot spots and weaknesses. All Free Service Includes:
resins have a minimum exchange capacity of 30,000 grains
per cubic foot when regenerated with 15 pounds of salt per Industrial grade multi-valve with integral brine injector.
cubic foot. Resins provide efficient exchange capacity at Electrically operated cycle controller with position indicator.
lower salt dosages (20,000 grains per cubic foot at 5 pounds
of salt per cubic foot). In addition to softening water, resins Automatic backwash flow control.
also provide iron and manganese removal from the water. The exclusive multi-valve design, features five hydraulically-
Softener resins are stable over the entire pH range. operated diaphragm valve assemblies conveniently arranged.
The valve seats are positioned vertically in the valve casting,
They are suitable for high flow rates and high hardness reducing the possibility of dirt or debris lodging in the seat
waters, and are physically stable at high temperatures. area. This design provides a positive shut-off with no leaking
Resins feature low attrition loss, and minimum backwash or dripping, as is often the case with horizontally-positioned
water is required. valve seats.
H8-4
02-02
Single unit softeners are provided with an automatic bypass Optional Skid Mounting:
valve that provides service water during regeneration. Cycling Ease of installation in the field; lower installation cost.
of the diaphragm assemblies is smooth and entirely free of
water hammer.
System of Non-Clogging Strainers Arranged in a Radial
Network:
Automatic Self-Regulating Brine Injector:
Assures uniform flow through the entire resin bed,
Assures efficient brining without time-consuming field resulting in maximum exchange capacity from the resin
adjustments. with low pressure loss.
Automatic Brine Maker, Includes Heavy Gauge Polyethylene Eliminates wasted capacity in the bottom area of the resin
Brine Tank for Maximum Strength and Corrosion Resistance: tank.
Platform brine system allows use of pure, clean, efficient salt

pellets or nuggets, eliminating costly and time consuming brine
tank cleaning. PRODUCT OFFERING
The system eliminates need for gravel subfills, reducing Water softeners require periodic regeneration with salt brine.
shipping weight and freight costs.
Automatic brine valve provides reliable refill of the brine Standard Equipment - SSE & FSE
system with fresh water and is fully serviceable. All critical seal Single, duplex, triplex, or quadraplex unit systems include
areas of the brine valve are designed to prevent corrosion or resin tank(s), brine tank, resin, piping, multi-position piston
scaling to assure trouble-free operation. valves, flowmeters and electronic demand controller.
High Capacity Resin, Adaptable to Wide Range of Applications: Single tank exchange capacities: 30,000 to 1,200,000 grains.
High exchange capacity (30,000 grains per cubic foot at 15 lbs. Tank sizes: 9 to 48 diameter standard (larger diameters
salt dosage). available).
Operating temperatures: 40 to 100 F.
Efficient exchange capacity at lower salt dosages (20,000 Water meter for automatic regeneration.
grains per cubic foot at 6 lbs. salt). 24 Volt operation.
Iron and manganese removal. Heat fused polyethylene lined steel or FRP tanks.
Stability over entire pH range. Standard Equipment - SMR

Suitable for high flow rates. Single, twin, or triple unit system includes resin tank(s),
Suitable for high hardness waters. brine tank, resin, face-piping, diaphragm, valve nest and
cycle controller.
Physically stable at high temperatures.
Size range in capacities: 30,000 to 2,100,000 grains.
Low attrition loss.
Minimum backwash water required.
Automatic Self-Adjusting Backwash And Flush Controls:
Optional Equipment - SSE & FSE
Assures maximum cleansing of the resin bed during backwash
and prevents loss of costly resin across the entire operating ASME Code tank construction.
range of 30-100 psig. Alternating Parallel or Variable Flow operation.
Eliminates the need for troublesome and time consuming field Skid mounting, pre-wired and pre-piped.
adjustments because the flow control is pre-sized at the factory.
High temperature operation.
Available From Stock: Alternate linings and external coatings.
Short lead time or minimum down time.
H8-5
02-02
Optional Equipment - SMR 2. Time On-Line

ASME Code tank construction. Single softeners should be sized to stay on-line for at least one
day. For continuous usage when an alternating twin softener is
Water meter for automatic regeneration.
used, each tank should be sized to stay on-line for 8-12 hours.
Alternating operation.
3. Water Hardness
Skid mounting, pre-wired and pre-piped.
To size the softener, the total water hardness must be deter-
External corrosion protection. mined in grains per gallons. If the analysis report is in terms of
parts per million or milligrams per liter (these are equal),
Operating Specifications divide by 17.1 to correct to grains per gallon.
Pressure Range: 25 to 100 psig. 4. Water Usage
Temperature: Standard equipment suitable for water up to When the flow rate is constant, multiply the flow rate (gpm) by
100 F. Above 100 F, special fitted valves are available. minutes on line. For example, 50 gpm for 480 minutes (8
Specify water temperature when ordering. hours) = 24,000 gallons. When the flow rate is not in constant
use, use actual gallons used, or calculate gallons used based on
Electrical: 120 Volt, 60 Hz is standard. Alternate voltages
boiler make-up rates.
and frequencies available. Specify electrical requirements
when ordering. Transformers for control operation voltage 5. Exchange Capacity
will be supplied with the SSE &FSE, SMR with MX
Exchange rate is expressed in grains, and varies with salt dos-
controls.
age as follows:
Power: 6 Watts per cycle controller.
15 pounds of salt per cu-ft = 30,000 grains capacity (best
water quality, least efficient).
DIMENSIONS, RATINGS AND SIZING
10 pounds of salt per cu-ft. = 25,000 grains capacity (good
water quality, medium efficiency).
Dimensions
6 pounds of salt per cu-ft. = 20,000 grains capacity (poorest
Dimensions for the SSE Model Polybond lined Steel Softeners water quality, most efficient). For boiler make-up water, the
(sizes 30 - 1200) are shown in Figure H8-1. higher water quality - 15 pounds salt dosage per cu-ft. - is
recommended.
Dimensions for the FSE Model FRP Softeners (sizes 30 - 600)
are shown in Figure H8-2.
Sizing Calculations
Dimensions for the Model SMR Softeners (sizes 150-1050) l. Single Softener. (Water usage per day x water hardness =
are shown in Figure H8-4. capacity required.) For example:
10,000 gallons per day x 15 gpg hardness = 150,000 grains
Ratings per day capacity required.
Softener capacity and flow ratings are shown in Table H8-1, Select a Model (SSE 150) from the literature. Then select the
Table H8-2, Table H8-3 and Table H8-4. pipe size to meet flow rate requirements.
2. Alternating Twin Softeners
Sizing
Flow rate x hardness x minutes on line = capacity required. For
Five things are required to size a softener:
example:
1. Flow Rate/Pressure Loss
Flow rate = 40 gpm. Hardness = 15 gpg. 40 x 15 x 480
Softeners have two published flow rates: minutes on line = 288,000 grains.
Continuous - Used for sizing when actual flows are known. Select a Model (SSE 300) from the literature. Then select
This rating of a softener will generally produce a pressure pipe size based on flow rate requirements. When the gallons
loss of 15 psig. of make-up is not known, use Figure H8-5 to calculate
softener capacity required per hour. When less than 6 hours
Peak - Used to establish the absolute upper limits of a
is expected between regeneration of a twin softener, two
softener. This rating of a softener will produce a pressure
brine makers are required.
loss of 25 psig.
H8-6
02-02
C
B A
BRINE
FRONT VIEW OF 36" TANK

SHOWN REDUCED
F
PLAN VIEW
TREATED
RAW WATER
WATER
C
A
B
D E
Figure H8-1: (1 of 2)SSE Models (Size 30-1200) Softener Dimensions
H8-7
02-02
MODEL D E F
NUMBER (in.) (in.) (in.) INLET/ DRAIN
A B C SIZE
OUT-
(in.) (in.) (in.)
SSE
SINGLE TRIPLE SINGLE TRIPLE SINGLE TWIN TRIPLE QUAD LET (in.) (in.).
TWIN QUAD TWIN QUAD
30-1 10 40 46 18 18 38 38 32 46 58 71 1 3/4
60-1 12 52 58 18 18 38 38 34 50 66 82 1 3/4
90-1 1
14 66 72 18 24 38 41* 36 54 75 124 3/4
90-11/2 11/2
120-11/2 72 11/2
18 66 24 24* 41 41 46 68 74 112 3/4
120-2 77 2
150-1 72 1
18 66 24 24 41 41 46 68 90 112 3/4
150-11/2 77 11/2
210-11/2 72 11/2
24 24 24 50 50 52 80 108 136 1
6 77
210-2 2
300-11/2 72 11/2
24 66 24 24 50 50 52 80 108 136 1
300-2 77 2
450-2 77 2
30 66 30 30* 50 50* 64 98 132 166 1 1/2
450-3 81 3
600-2 82 2
36 71 39 39* 48 48* 79 119 159 242 1 1/2
600-3 86 3
750-2 2
42 71 86 39 39* 48 48* 85 131 177 266 2
750-3 3
900-3 42 71 86 39 39* 48 48* 85 131 177 266 3 2
1200-2 48 71 86 52 52* 60 60 * 104 156 212 316 3 2
* denotes Dual brine tank on a quadruple unit.
Figure H8-1 (2 of 2)SSE Models (Size30-1200) Softener Dimensions
H8-8
02-02
BRINE
TREATED
RAW WATER
WATER
A
C
B
D
E
FRONT VIEW
RIGHT SIDE VIEW
Figure H8-2: (1 of2) Model FSE (Size 30-600) Softener Dimensions
H8-9
02-02
MODEL D E F PIPE SIZE (in.)

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

4
150-11/2 17.6 73 80 24 41 68 11/2 3/

4
210-11/2 24 75 82 24 50 80 11/2 1
300-11/2 24 75 82 24 50 80 11/2 1
Figure H8-3: FSE-CRS Crossover Twin Dimensions (Size 30-300)
H8-11
02-02
1
MODEL NUMBER HEIGHT WIDTH SINGLE TWIN TRIPLE
(IN) (IN) LL1 L2 L3
SMR-150-1 29
SMR-150-1 1/4 30
72 50 88 126
SMR-150-1 1/2 30
SMR-150-2 34
SMR-210-1 1/4 32
SMR-210-1 1/2 32
73 54 96 138
SMR-210-2 36
SMR-210-2 1/2 37
SMR-300-1 1/2 38
SMR-300-2 42
76 60 108 156
SMR-300-2 1/2 43
SMR-300-3 44
SMR-450-1 1/2 38
SMR-450-2 42
82 66 114 162
SMR-450-2 1/2 43
SMR-450-3 44
SMR-600-1 1/2 44
SMR-600-2 48
89 81 135 189
SMR-600-2 1/2 49
SMR-600-3 50
SMR-750-2 48
SMR-750-2 1/2 101 49 81 135 189
SMR-750-3 50
SMR-900-2 54
SMR-900-2 1/2 94 55 90 150 218
SMR-900-3 56
SMR-1050-2 54
SMR-1050-2 1/2 106 55 90 150 218
SMR-1050-3 56
Figure H8-4: SMR Dimensions (Size 150-1050)
H8-12
02-02
Table H8-1. SSE Water Softener Ratings Polybond Lined Steel
BACK-
CONT PEAK
RESIN PRESS
MODEL EXCHANGE SERV SERV PRESS WASH TANK MANIF FLOW SALT
QYT DROP
NUMBER CAPACITY FLOW FLOW DROP FLOW DIMENSIONS PIPE SENSOR STORAGE
SIZE SIZE CAPACITY
(in.) (in.) (lbs)

MIN SOF R BRINE
SSE MAX GR CU-FT GPM PSI GPM PSI GPM
GR (in.) (in.)
30-1 30,000 20,000 1 8 4 12 7 2 10x40 18x38 1 1 400
60-1 60,000 40,000 2 16 10 24 20 3 12x52 18x38 1 1 400
90-1 21 15 29 25 1
90,000 60,000 3 5 14x66 18x38 1 400
90-1-1/2 24 9 36 16 1-1/2
120-1-1/2 32 12 48 22 1-1/2 11/2

120,000 80,000 4 7 18x66 24x41 700
120-2 32 7 48 12 2 1
150-1 40 13 58 25 1 1
150,000 100,000 5 7 18x66 24x41 700
150-11/2 40 6 60 11 1-1/2 11/2
210-11/2 45 15 60 25 1-1/2 11/2

210,000 140,000 7 15 24x66 24x50 1,000
210-2 56 8 84 15 2 2
300-11/2 45 15 58 25 1-1/2 11/2

300,000 200,000 10 15 24x66 24x50 1,000
300-2 77 15 107 25 2 2
450-2 87 15 118 25 2 2
450,000 300,000 15 20 30x66 30x50 1,500
450-3 120 12 180 18 3 3
600-2 94 15 125 25 2 2
600,000 400,000 20 25 36x71 39x48 1,500
600-3 160 15 240 25 3 3
750-2 85 15 120 25 2 2
750,000 500,000 25 40 42x71 39x48 2,500
750-3 200 13 270 22 3 3
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 2,500
Flow rates and resin capacities are based on a single tank.
H8-13
02-02
Table H8-2. FSE Water Softener Ratings, Fiberglass Softeners
CONT PEAK
MODEL EXCHANGE RESIN PRESS PRESS BACK- TANK
SERV SERV
NUMBER CAPACITY QYT DROP DROP WASH DIMENSIONS MANIF FLOW SALT
FLOW FLOW FLOW PIPE SENSOR STORAGE
SIZE SIZE CAPACITY
FSE MAX GR MINGR CU-FT GPM PSI GPM PSI GPM SOF R BRINE (in.) (in.) (lbs)
(in.) (in.)
30-1 30,000 20,000 1 10 4 20 9 2 9X48 18x38 1 1 400
60-1 60,000 40,000 2 16 10 24 30 3 12x52 18x38 1 1 400
90-1 21 15 29 25 1 1
90,000 60,000 3 5 14x65 18x38 400
90-1-1/2 24 9 36 16 11/2 11/2
120-1-1/2 32 12 48 20 11/2 11/2

120,000 80,000 4 7 17X58 24x41 700
120-2 32 7 48 10 2 1
150-1 38 13 52 25 1 1
150,000 100,000 5 7 17X71 24x41 700
150-11/2 40 6 60 15 11/2 11/2
210-11/2 45 15 60 25 11/2 11/2

210,000 140,000 7 15 24x71 24x50 1,000
210-2 56 8 84 15 2 2
300-11/2 45 15 58 25 11/2 11/2

300,000 200,000 10 15 24x71 24x50 1,000
300-2 77 15 107 25 2 2
450-2 450,000 300,000 15 87 15 118 25 20 30x72 30x50 2 2 1,500
600-2 94 15 125 25 2 2
600,000 400,000 20 25 36x72 39x48 1,500
600-3 160 15 240 25 3 3
H8-14
02-02
Table H8-3. FSE Water Softener Ratings, Fiberglass Softeners with Crossover Controls
CONT PEAK
MODEL EXCHANGE RESIN PRESS PRESS BACK- TANK
SERV SERV
NUMBER CAPACITY QYT DROP DROP WASH DIMENSIONS MANIF FLOW SALT
FLOW FLOW FLOW PIPE SENSOR STORAGE
SIZE SIZE CAPACITY
FSE MAX GR MINGR CU-FT GPM PSI GPM PSI GPM SOF R BRINE (in.) (in.) (lbs)
(in.) (in.)
30-1 30,000 20,000 1 16 15 22 25 2 9x48 18x38 1 1 400
60-1 60,000 40,000 2 16 15 22 25 3 12x52 18x38 1 1 400
90-1 90,000 60,000 3 17 15 23 25 5 14x65 18x38 1 1 400
90-11/2 90,000 60,000 3 24 10 36 18 5 14x65 18x38 11/2 11/2 400
12011/2 120,000 80,000 4 32 14 46 23 7 17x58 24x41 11/2 11/2 700
150-11/2 150,000 100,000 5 35 15 48 25 7 17x71 24x41 11/2 11/2 700
210-11/2 210,000 140,000 7 40 15 54 25 15 24x71 24x50 11/2 11/2 1,000
300-11/2 300,000 200,000 10 45 15 52 25 15 24x71 24x50 11/2 11/2 1,000

(FSE-CRS Crossover Systems Are Only Available In Twin Alternating Configurations.)
H8-15
02-02
Table H8-4. SMR Water Softener Ratings
MODEL EXCHANGE TANK SALT PER REC

MANIF CONT PEAK BACK-
NUMBER CAPACITY DIMENSIONS SALT REGEN WATER
RESIN PIPE SERV SERV WASH DRAIN
CAPACITY METER
SIZE FLOW FLOW FLOW PIPE SIZE
BRINE MAKER SIZE
MAX MIN CU-FT SOFR BRINE (LBS) MAX MIN (in.)
SMR IN. GPM GPM GPM
GR GR (in.) (in.) LBS LBS (in.)
150-1 1 33 43 1 1
150-1-1/4 150,000 100,000 5 1-1/4 37 51 10.0 20x54 24x60 700 75 30 1
150-1-1/2 1-1/2 58 82 1-1/2
150-2 2 70 98 1-1/2
210-1-1/4 1-1/4 41 56 1-1/2 1

210-1-1/2 210,000 140,000 7 1-1/2 64 86 13.5 24x54 24x60 700 105 42 1-1/2
210-2 2 77 105 1-1/2
210-2-1/2 2-1/2 115 160 2T
300-1-1/2 1-1/2 63 91 1-1/2 1

300-2 300,000 200,000 10 2 81 113 20.0 30x54 24x60 600 150 60 1-1/2
300-2-1/2 2-1/2 140 190 2T
300-3 3 163 230 2T
450-1-1/2 1-1/2 67 89 1-1/2 1

450-2 450,000 300,000 15 2 79 110 20.0 30x60 30x60 900 225 90 1-1/2
450-2-1/2 2-1/2 122 170 2T
450-3 3 140 190 2T
600-1-1/2 1-1/2 71 93 1-1/2 1 1/2

600-2 600,000 400,000 20 2 85 120 30.0 36x60 39x60 1500 300 120 2T
600-2-1/2 2-1/2 140 190 2T
600-3 3 175 250 2T
750-2 2 81 110 1-1/2 1 1/2

750-2-1/2 750,000 500,000 25 2-1/2 140 190 30.0 36x72 39x60 1500 375 150 2T
750-3 3 160 230 2T
900-2 2 90 130 2T 2
900-2-1/2 900,000 600,000 30 2-1/2 150 215 45.0 42x60 42x60 1800 450 180 2T
900-3 3 185 270 2T
1050-2 2 86 120 2T 2
1050-2-1/2 1050K 700K 35 2-1/2 145 200 45.0 42x72 50x60 2500 525 210 3
1050-3 3 175 250 3
A. Continuous service flow at a pressure loss not exceeding 15 psig.

B. Peak service flow at a pressure loss not exceeding 25 psig.
T denotes turbo type water meter.
H8-16
02-02
ITEMS THAT MUST BE KNOWN

1. Capacity of generator in lbs of steam per hour.
2.% Make-up.
3. Water hardness.
4. Hours operated each day.
PROCEDURE
1. Lay a straight edge from lbs steam/hour (line A) to the% make-up (line D) and obtain the DBMS make-up flow from line B.
2. Lay a straight edge from the gpm make-up (line B) to the water hardness (Line E) and obtain the hardness removal re-
quired for each hour of generator operation from line C.
3. Calculate the hardness removal required each day by multiplying the value obtained in step 2 by the hours operated each
day.
NOTE: In situations where softened water is required for loads in addition to boiler requirements, the total gpm flow for the
softener is the total of both requirements. Then using lines B and E, the required grain removal per hour can be determined.
EXAMPLE
10,000 lbs steam/hour
15% make-up
8 hours daily operation
Water hardness 10 grains per gallon
FROM NOMOGRAPH
Feedwater make-up is 3 gpm.
Hardness removal required is 1800 grains per hour.
Hardness removal required each day - 8 x 1800 - 14,400 grains.
SOFTENER SELECTION
Select a softener that will meet both flow rate and exchange requirements. For 24 hour operation and to provide a continuous
supply of soft water, a twin unit is required. For the above example, An ACC-SAB-60-1 Twin could be used to provide 24
hour operation. This model would provide 1 day operation between regeneration periods. To provide 8 hour a day operation,
the ACC-SAB-60-1 single unit would permit 3 days between regeneration periods.
Figure H8-5: Water Softener Sizing Chart
H8-17
02-02
The following sample specifications are provided to you by Cleaver-Brooks to assist you in meeting your customers requirements.
1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-18

2.0 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-18
3.0 Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-20
4.0 Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-23
5.0 Skid Mounting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-23
6.0 Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-23
1.0 General
Furnish, install, and place in operation an Automatic Water Softener System similar or approved equal to Cleaver-Brooks Model
(SSE: lined steel tank/ FSE: 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).
2.0 Equipment
2.1 Tanks 10 Through 36 Diameter (Steel Polybond: Standard SSE)
Softener tanks shall be made of butt-welded industrial grade carbon steel designed for a working pressure of 125 psi (____bar)
dynamic and hydrostatically tested at 50% excess of the working pressure. Each tank shall be _______ m) diameter with a _______
m) overall tank height. Tank support(s) shall be of a skirt-ring type welded to the tank(s) lower head. The tank(s) shall be equipped
with a resin loading port and a drain/resin removal port (14 and larger).
Steel tank(s) shall be provided with a Polybond lining of inert non-leachable virgin polyethylene material at least 40-60 mils
thick permanently bonded to the tank interior by heat fusion. The tank lining shall meet the requirements of the United States Food
and Drug Administration (USFDA). The tank lining shall be chemically inert so as not to react with water, media, acids, caustic
soda, chemicals or water-borne contaminants. The tank exterior shall be degreased, pre-cleaned, and phosphatized and shall have
an exterior coating of high gloss epoxy enamel 4 to 6 mils thick. Tank openings shall be 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.
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.
2.1 Tanks 42 Through 48 Diameter (Steel Polybond: Standard SSE)
Softener tanks shall be made of butt-welded industrial grade carbon steel designed for a working pressure of 100 psi (____bar)
dynamic and hydrostatically tested at 50% excess of the working pressure. Each tank shall be _______ m) diameter with a _______
m) overall tank height. Tank support(s) shall be strap-type steel legs permanently welded to the lower tank head. The tank(s) shall
be equipped with a resin loading port and a drain/resin removal port.
Steel tank(s) shall be provided with a Polybond lining of inert non-leachable virgin polyethylene material at least 40-60 mils
thick permanently bonded to the tank interior by heat fusion. The tank lining shall meet the requirements of the United States Food
and Drug Administration (USFDA). The tank lining shall be chemically inert so as not to react with water, media, acids, caustic
soda, chemicals or water-borne contaminants. The tank exterior shall be degreased, precleaned, and phosphatized and shall have an
exterior coating of high gloss epoxy enamel 4 to 6 mils thick. Tank openings shall be 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.
H8-18
02-02
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.
2.1 Tanks 9 Through 36 Diameter (Fiberglass Reinforced Plastic: Standard FSE)
Softener tank(s) shall be made of fiberglass reinforced ABS plastic. The exterior sideshell shall be reinforced by a continuous rov-
ing 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.
2.1 Tanks 20 Through 42 Diameter (SMR Standard)
2.2 Tank Option
Pressure vessels shall be provided in accordance with ASME Section VIII. Working pressure will be 100, 125 or 150 psig and
hydrotested to 150% of stamped and certified rating.
2.3 Tank Option
Provide tank with high temperature internal epoxy lining at 8-10 mil DFT. Exterior tank surface will be cleaned and coated with a
corrosion-resistant zinc-rich primer suitable for epoxy coating in the field.
2.4 Tank Option
Provide tank with a baked phenolic internal epoxy lining at 8-10 mil DFT. Exterior tank surface will be cleaned and coated with a
corrosion-resistant zinc-rich primer suitable for epoxy coating in the field.
2.5 Tank Option
Provide tank with an external coating of a high gloss epoxy paint 2-4 mil DFT.
2.6 Distribution System - Models SSE & FSE
The soft water collector and backwash water distributor shall be non-clogging design with slot size slot 0.010 inch in width. Single
point and hub radial laterals will be used to ensure adequate distribution of flow during service, backwash and regeneration. Later-
als will be made of Schedule 80 PVC and designed for low pressure drop-in service.
The distributor system will be fully covered by a minimum of 2 inches of quartz underbedding. The quartz shall be washed and
dried to remove debris and fines, and screened not to exceed 16 mesh size by 3/16-inch particle size.
2.6 Distribution System - SMR
2.7 Main Operating Valve SSE / FSE 30 to 1200
The control valve shall have _______inch _______ cm) NPT (BSP) inlet and outlet connections. It shall be a low lead brass
mechanically-actuated, hydraulically-balanced, self-cleaning piston six-position type to accomplish the regeneration steps of back-
wash, 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 capa-
ble of being manually stepped through regeneration without electrical power.
H8-19
02-02
2.8 Brine System and Salt Storage
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 emp-
tying salt tanks or moving fill plugs.
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 oper-
ated plastic brine pick up designed to provide positive shut off to prevent air from entering the system.
2.9 Brine System Option
A pressurized brine control system will be provided to introduce brine into the softener vessels. A timed brine controller, non-cor-
rosive 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.
2.10 Resin
Each softener tank shall be provided with _______ cubic feet of high capacity sulphonated styrene divinylbenzene based synthetic
ion exchange resin having a minimum exchange capacity of 30,000 grains per cubic foot when regenerated with 15 pounds of salt
per cubic foot. The resin shall be solid, with uniform particle size, clean and free of dirt and extraneous matter that might interfere
with 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.
2.11 Flow Control
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 con-
trols will be connected for ease of removal for inspection and service as needed.
2.12 Piping
Contractor shall furnish and install all interconnecting pipe and isolation valves. Drain connections from the control valve shall
have an air gap conforming to local codes and to permit observation and sampling of backwash and regeneration water.
2.13 Gauge and Sample Valve Option
Manufacturer shall provide two pressure gauge and sample valve assemblies or contractor installation in the inlet and outlet piping.
Pressure gauges and sample valves will be stainless steel or other non-corrosive design.
3.0 Control Options
3.1 Single Units EDS Control
The softener system will be controlled by a single computer-based demand (meter) initiated controller. The controller shall be
capable of operating either 1 or 2 units in single, twin alternating, or parallel 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.
H8-20
02-02
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.
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 wir-
ing 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.
3.2 Duplex Twin Alternating Units EDT Control
The softener system will be controlled by a single computer-based demand (meter) initiated controller. The controller shall be
capable of operating 2 units in twin alternating, or parallel 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 program-
ming 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.
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 wir-
ing assemblies will be conformally coated to MIL specifications suitable for use in humid environments. A water-tight enclosure
3.3 Variable Flow Multiple Tank Systems VF Control
The system will be supplied with a single computer-based demand (meter) initiated controller capable of operating systems with 2
to 4 units. In addition to traditional parallel or alternating operating conditions, the control can operate in a variable 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.
system. On multiple vessel systems flow and operational data for each unit shall be independently displayable. A resettable totaliz-
ing flow counter will be included to measure total water processed.
The control shall be self diagnostic and capable of emitting an audible signal and error-specific messages if it detects a system
allow system optimization through evaluation of actual water usage. If an error is detected the controller will be capable of auto-
matically 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 suit-
ably 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
This meter-initiated system allows all units to be in service at the same time. Regeneration is immediate based on a batch count. A
built in interlock does not allow more than one unit to be in regeneration at a time.
H8-21
02-02
3.4 Cross Over Twin Units CSR Control
The softener system will be supplied with a computer-based demand (meter) initiated controller. The control will utilize alphanu-
meric, 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 self-diagnostic and capable of emitting an audible signal and error specific messages if it detects a system
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. The control will be mounted directly in the valve cover. Electrical installation will only
require plugging in the transformer and connecting the flowsensor cable.
3.5 Time Clock Units TC Control
The softener(s) will be provided with a 7 day timer allowing recharge to occur at a user adjustable time of day or night. The timer
shall be capable of being set to skip one or more days between regenerations. Electrical operation is 120V, 60Hz, 1ph.
3.6 Flowsensors 1 Models
_______ Hall effect tubo 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 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 50 gpm (____lpm). The flowmeter housing
shall be brass.
3.7 Flowsensors 1.5 x 2 Models
_______ Hall effect tubo 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 shaft riding on a sapphire bearing. The sensor shall be
made in such a way that it can be installed and removed with simple hand tools. Pipe size of the sensor(s) shall be 1.5 inch
(_______cm) x 2 inch _______ cm). It shall have a minimum flow of 2 gpm (____lpm), and a peak flow of 100 gpm (_____lpm).
The flowmeter housing shall be brass.
3.8 Flowsensors 3 and larger
_______ 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 231 gpm (_____lpm) [for 3 ].
_____12 gpm (____lpm) 394 gpm (_____lpm) [for 4] 25 gpm (____lpm) 999 gpm (_____lpm) [for 6]
H8-22
02-02
4.0 Instructions
A complete set of instructions for installation and operation of the softener system will be included.
5.0 Skid Mounting Options
The softener system will be provided skid-mounted with all units pre-piped by the manufacturer. Each unit will be isolatable and a
system bypass valve shall come installed in the plumbing header. Inlet and outlet connections will terminate in convenient locations
near the skid edge. All plumbing shall be supported by Unistrut or equivalent anchors and members.
Inter-tank hydraulic tubing and 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 hydrau-
lically and electrically tested before shipment. Prior to shipping, the system will be drained before packaging. Partial disassembly
may be required for shipment. All assemblies will be marked to allow simple reconnection.
5.1 Steel Softeners Model 30 to 300
Tanks 10 to 24 diameter will be mounted on a 4 channel iron skid (5.4 lb. per foot, ASTM grade A-36) The skid will be cross-
braced with similar 4 channel or angle iron. All steel surfaces will be cleaned and painted with a high gloss epoxy top coat match-
ing the softener vessel color.
braced with similar 6 channel or angle iron. All steel surfaces will be cleaned and painted with a high gloss epoxy top coat match-
ing the softener vessel color.
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.
6.0 Guarantee
Attrition loss of mineral is guaranteed not to exceed 3% per year for a period of 3 years.
All mechanical equipment is guaranteed for 1 year against any defects in workmanship or materials. All EDS, EDT, and VF con-
trols are guaranteed for 3 years against M & W. Consult specific product warranty for mineral and brine tank information.
The manufacturer guarantees that under actual operating conditions, the mineral shall not be washed out of the system during ser-
vice or backwash cycles when operated under the instructions and guidelines set forth in the operation manual.
H8-23
02-02
1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-24

2.0 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-24
3.0 Regeneration Initiation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-25
4.0 Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-26
5.0 Skid Mounting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-26
6.0 Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-27
1.0 General
Furnish, install, and place in operation an Automatic Water Softener System similar or approved equal to Cleaver-Brooks Model
SMR_______, having tank(s) with _______ cu-ft. of ion exchange resin per tank. Soft water output to be _______ gallons per tank
per regeneration with _______ lbs of salt, based on _______ grains per gallon compensated hardness. Service flow rate per tank
_______ gpm at a pressure loss through softener system not exceeding _______ psig.
2.0 Equipment
2.1 Tanks
Softener tank(s) shall be of welded construction of tank quality carbon steel. Each tank shall be _______ diameter with a _______
straight side shell height. The tank(s) shall have threaded openings for pipe connections and an 11" x 15" manhole in the top head
(for tanks 30" diameter and smaller; two 4 x 6 handholes should be provided in the top head and lower side shell). The tank(s)
shall be rated for 100 psig working pressure and 150 psig test pressure. Support legs will be the strap-type permanently welded to
the lower tank head. The tank(s) shall have their exterior and interior protected with a hot dipped galvanized application after fabri-
cation. 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 8-10 mils DFT, with rust resistant prime coat, external coating 2-3 mils DFT.
2.4 Tank Option

Provide baked phenolic internal lining 4-5 mils DFT, with rust resistant prime coat, external coating 2-3 mils DFT.
2.5 Tank Option

Provide Safety Blue epoxy finish paint 6-8 mils DFT over exterior tank and valve surfaces. To be applied on channel iron surface if
applicable.
H8-24
02-02

The upper distribution system shall be a single point baffle constructed of Schedule-40 galvanized steel pipe and fittings.
The lower distribution system shall be of the hub end radial type constructed of PVC with slotted full flow non-clogging replace-
able ABS strainers and covered with a subfill of 1/8 x 1/16 gravel.
2.8 Main Operating Valves

The main operating valves shall be a nest of individual diaphragm valves. The valves shall have cast iron bodies with Buna-N dia-
phragm and stainless steel and brass internal parts. The valves shall be slow opening and closing, and free of water hammer. There
shall be no contact of dissimilar metals within the valves and no special tools shall be required to service the valves. Valves can be
operated either hydraulically or pneumatically.
2.9 Brine System

The brine system shall be platform type with dry salt storage compartment, 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 oper-
ating 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.
3.0 Regeneration Initiation
3.1 Control
A NEMA 12rated factory mounted and wired electrical enclosure with all timing and sequencing controls for each softener shall be
manufactured and provided by the same vendor providing the water treatment hardware.
The controls shall include an automatic regeneration sequencer having the capability of providing site adjustable regeneration steps
of backwash brine injection, brine displacement, 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.
The 12-Day electrical time clock controller shall be fully adjustable to initiate regeneration at any hour of the day and any day of
the week.
H8-25
02-02
3.2 Control Option

Single Automatic Reset Meter and Alternator (Twin Softeners Only)
The twin water softener shall be equipped with a single _______ (disc) (turbo) water meter, AWWA rated, in the common outlet
header. At a pre-set gallonage the automatic reset head of the meter will send a 120 volt signal to an alternator that will direct the
signal to regenerate the unit presently on-stream. Upon completion of regeneration, that softener will remain off stream in the
stand-by position. This sequence will repeat on an alternating basis each time the preset gallonage of soft water has passed through
the meter. A lockout shall be provided to allow only one unit to regenerate at any one time.
3.3 Control Option

MX Electronic Programmable Controls (Two or Three Tanks)
The system will operate with two or three media tanks each having a dedicated paddle wheel type 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.
*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
*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.
*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.
When the primary media tank regenerates the next media tank in sequence shall become the primary.
As each media tanks user set volume is reached it will immediately be taken off-line, regenerated, and placed immediately back
on-line or standby depending on treated water flow demand.
The controller shall be capable of continuously determining the exhaustion rate of each media tank thus automatically avoiding the
possibility of a simultaneous regeneration attempt. Simultaneous regenerations are not possible.
The exchange capacity of each softener can be the same or different. Flow or peak flow rate indication shall be continuously dis-
played for each unit. The continuous flow range is 0-999 flow units per minute (gallons, cu.ft., liters, cu-m, etc.). Cumulative vol-
ume totalization to eight (8) digits shall be continuously displayed for each unit.
4.0 Instructions
A complete set of installation instructions and operating instructions shall be furnished.
5.0 Skid Mounting (Pre-pipe and Pre-wire)

5.1Mineral Tank skid mount Option.
The softener mineral tanks shall be shall be mounted on a 4" channel iron skid (7.25 lbs per foot, ASTM grade A-36). The skid
shall be cross-braced with a 4" channel or angle iron,. All steel surfaces shall be prime coated. All interconnecting piping shall be
the same material as the valve nest manifold piping and shall be assembled by the manufacturer. This shall include inlet and outlet
bronze isolation valves for each tank, and a bronze system bypass valve. Inlet and outlet headers shall be installed and terminate at
the skid edge. All piping shall be suitably supported by Unistrut supports anchored to the skid. Electric wiring, where applicable,
H8-26
02-02
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
5.1Mineral Tank skid mount Option.
The softener mineral tanks shall be shall be mounted on a 4" channel iron skid (7.25 lbs per foot, ASTM grade A-36). The skid
shall be cross-braced with a 4" channel or angle iron. The entire area under the polyethylene briner shall be covered with a 1/4
steel plate All steel surfaces shall be prime coated. All interconnecting piping shall be the same material as the valve nest manifold
piping and shall be assembled by the manufacturer. This shall include inlet and outlet bronze isolation valves for each tank, and a
bronze system bypass valve. Inlet and outlet headers shall be installed and terminate at the skid edge. All piping shall be suitably
supported by Unistrut supports anchored to the skid. Electric wiring, where applicable, shall be complete between all inter unit
controls and require only a single power source connection. The inter unit wiring shall be contained in Flextite 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
6.0 Guarantee
Attrition loss of mineral is guaranteed not to exceed 3% per year for a period of 3 years.
All mechanical equipment is guaranteed for 1 year against any defects in workmanship or materials. Any part proving defective
will be replaced or repaired within this period.
The manufacturer guarantees that under actual operating conditions the mineral shall not be washed out of the system during the
service run or backwashing period; that the turbidity and color of the 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.
H8-27
02-02
Notes
H8-28
02-02
Section H9
DEALKALIZERS
CONTENTS
DIMENSIONS, RATINGS AND SIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-3
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-3
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-3
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-3
Sizing Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-4
ILLUSTRATIONS
Figure H9-1. Dealkalizer Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-5
TABLES
Table H9-1. Automatic Dealkalizer Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-4
Table H9-2. Dealkalizer Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-6
H9-1
02-02
Dealkalizers Feedwater Systems
Information in this section applies directly to Cleaver- Brooks dealkalizers ranging from 10,000 to 980,000 grain capacity.
Cleaver-Brooks chloride cycle dealkalizers are similar to water softeners except that, instead of cation resin, they use a strong
anion resin to remove selective negatively charged ions from the raw water supply.
Dealkalizers require use of softened water, and are installed down stream from the water softener, and before the deaerator. Deal-
kalizers 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 chemi-
cals by as much as 90%, and cuts fuel costs by minimizing blowdown.
H9-2
02-02
Feedwater Systems Dealkalizers
FEATURES AND BENEFITS ASME code tank construction.

Water meter for automatic or semi-automatic regeneration.
Reduces Bicarbonate Alkalinity, Thereby Minimizing CO2
Skid mounting.
Production:
NEMA 12 or 4 control panels.
Decreased chemical consumption.
External corrosion protection.
Decreased condensate line corrosion.
Operating requirements include a continuous source of soft-
Lower blowdown rates.
ened water at 30 to 100 psig, 40 F to 100 F. Electrical ser-
Reduces fuel consumption. vice, 120 Vac, 60 Hz, 5A.
Increased cycles of concentration.
DIMENSIONS, RATINGS AND SIZING
Uses a Strong Base Anion Resin With a Combination of
Salt/Caustic Soda Regeneration: Dimensions
Produces a higher operating capacity and a more consistent Dealkalizer dimensions are shown in Figure H9-1.
effluent quality.
Provides some silica reduction. Ratings
Increases feed water pH. Dealkalizer ratings are shown in Table H9-2.
PRODUCT OFFERING Sizing

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

Resin FLOW FLOW BACK- BRINE SALT WATER
MODEL PIPE RATE SALT CAUSTIC METER
SIZE RESIN CAPA Tank RATE WASH TANK CAP
BRINER REGEN
NUMBER Size NORM B REGEN C
MAX RATE SIZE SIZE
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.
H9-4
02-02
MODEL NO. DS DB G H W L L1
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 H9-1. Dealkalizer Dimensions
H9-5
02-02
Table H9-2. Dealkalizer Ratings

MODEL RESIN TANK DATA FLOW RATES BRINE TANK DATA CAUSTIC DATA
NO TANK PIPE RESIN FRRE GRAVEL BACK SLOW FAST TANK SALT SALT/ BRINE NaOH/ NaOH
(ACC- SERVI CAPACITY
SIZE SIZE BOARD 1/8X1/16 WASH RINSE RINSE SIZEA CAP. REGN RATE REGN RATE
DAB) (DIA X HT) (IN.) FT3 (IN.) (LBS)
(GPM) (GRAINS)
(GPM) (GPM) (GPM) (LBS) (LBS) (GPM) (LBS) (GPM)
10 9x48 3/4 1 16 15 2 10000 1.0 0.71 2.0 18x31 225 4 0.17 0.4 0.42
5 8000
20 12x54 1 2 18 30 4 20000 1.4 0.99 2.8 18x31 225 8 0.22 0.8 0.54
10 16000
30 14x60 1 3 21 45 6 30000 2.0 1.38 4.4 18x31 225 12 0.30 1.2 0.76
15 24000
40 16x60 1-1/4 4 20 60 8 40000 2.4 1.95 5.9 22x36 375 16 0.43 1.6 1.08
20 32000
50 20x54 1-1/4 5 25-1/2 100 10 50000 4.3 2.38 7.5 22x36 375 20 0.52 2.0 1.33
25 40000
80 24x54 1-1/4 8 20-1/2 200 16 80000 6.5 3.45 12.0 22x36 375 32 0.76 3.2 1.88
40 64000
140 30x60 1-1/2 14 23 300 28 140000 10 6.90 21.5 24x50 550 56 1.52 5.6 3.77
70 112000
200 36x60 2 20 24-1/2 400 40 200000 15 8.5 30 24x60 650 80 1.87 8.0 4.72
100 160000
250 36x72 2 25 28 400 50 250000 15 13.9 40 24x60 650 100 3.05 10.0 7.85
125 200000
330 42x72 3 33 29 600 66 330000 20 15.5 50 30x60 850 132 3.4 13.2 8.91
165 264000
420 48x72 3 42 29 1000 88 420000 25 21.4 65 38x60 1650 168 4.7 16.8 12.18
210 336000
550 54x72 3 55 27-1/2 1300 110 550000 32 30 85 38x60 1350 220 6.6 22.0 17.3
275 440000
680 60x72 3 68 27-1/2 1800 136 680000 40 37.5 100 42x60 1700 272 8.3 27.2 21.4
340 544000
980 72x72 3 98 27-1/2 2600 196 980000 60 53.4 150 48x60 2200 392 10.0 39.2 26.4
490 784000
A. Tank size = diameter x height.
H9-6
02-02
1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-7

2.0 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-7
3.0 Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-9
4.0 Test Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-10
5.0 Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-10
6.0 Skid Mounting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-10
7.0 Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-10
1.0 General
Furnish, install, and place in operation an Automatic Chloride Cycle Dealkalizer system, similar or approved equal to 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.
Service flow rate per tank ________ gpm at a pressure loss through the dealkalizer system not exceeding _______ psig. The deal-
kalizer shall be supplied by a boiler manufacturer that will be responsible for the total boiler room system.
2.0 Equipment
2.1 Tanks 9" Through 16" Diameter
Dealkalizer tank(s) shall be of welded construction, tank quality carbon steel. Each tank shall be _______ " diameter with a
_______ " straight side shell height. The tank(s) shall have reinforced openings for pipe connections and a 4" diameter access
opening in the top head. The tank(s) shall be rated for 100 psig working pressure and 150 psig test pressure. Tank support(s) shall
be of a skirt ring type design, welded to the tank(s) lower head. The tank(s) shall have the exterior protected with a 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.
Dealkalizer tank(s) shall be of welded construction, tank quality carbon steel. Each tank shall be __________ " diameter with a
___________" straight side shell height. The tank(s) shall have reinforced openings for pipe connections and an 11" x 15" manhole
in the top head (for tanks 30" diameter and smaller; two 3" spin off handhole should be provided in the top head and lower 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 per-
manently 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.
Dealkalizer tank(s) shall be of welded construction, tank quality carbon steel. Each tank shall be _______ " diameter with a
________ " straight side shell height; the tanks shall have reinforced openings for pipe connections and 12" x 16" manhole in the
top head. The tank(s) shall be rated for 100 psig working pressure and 150 psig test pressure. Support legs will be the adjustable
jack type. The tank(s) shall have the exterior protected with a rust inhibiting primer and the interior shall have an epoxy lining 4-6
mils DFT, prior to shipment. A minimum freeboard of 50% shall be provided for backwash expansion above the normal ion
exchange resin bed level.
2.4 Tank Option
Provide pressure vessel in accordance with ASME Section VIII. Working pressure to be 100, 125 or 150 pounds, and hydrotested to
150, 187.5 or 225 psig, stamped and certified.
2.5 Tank Option
Provide high-temperature epoxy internal lining 10-12 mils DFT, with rust resistant prime coat, external coating 2-3 mils DFT.
2.6 Tank Option
Provide baked phenolic internal lining 4-5 mils DFT, with rust resistant prime coat, external coating 2-3 mils DFT.
H9-7
02-02

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.
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).
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).
2.9 Main Operating Valve
Each Dealkalizer shall have an automatic multiport diaphragm type, slow opening and closing, and free of water hammer. The
valve shall consist of 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 dealka-
lizer system. The valve guides, seats and diaphragm shall be constructed of Noryl plastic. The valve shall have inlet and outlet pres-
sure gauges and sample cocks.
2.10 Brining System
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 adjust-
ment of salt dosage without removing the brine valve. The tank shall be of polyethylene construction. It shall be _______ " diame-
ter x ______ " shell height, and have storage capacity of lbs of salt.
2.11 Caustic System
The caustic system shall be designed to pump directly from customer-purchased drums or carboys of 50% liquid caustic soda with
no caustic handling necessary.
Components of the caustic system shall be as follows:
One (1) caustic feed metering pump
One (1) moveable pump stand
One (1) pressure switch
One (1) 30 minute automatic reset timer mounted in protective box
One (1) blend valve for adjustment of concentration
The metering pump shall be of the diaphragm type for corrosion resistance and have a capacity of _______ gallons per minute.
2.12. Resin
Resin shall be of a premium grade high capacity synthetic quaternary ammonium devinylbenyene type, to be furnished in the chlo-
ride form. It shall be stable over the entire pH range, have good resistance to bead fracture, and be insoluble in all common sol-
vents. The resin shall be capable of 10,000 grains per cubic foot capacity when regenerated with 4 lbs of NaCl and 0.4 lbs of
NaOH.
2.13 Piping
Manufacturer to furnish dealkalizer tank, with assembled valve manifold piping. Contractor shall furnish and install interconnect-
ing piping. Drain shall have an air gap conforming to local codes to permit observation of discharge backwash water and manufac-
turer shall provide a valved drain at the lowest point of the dealkalizer system.
2.14 Flow Control
An automatic backwash control shall be provided to maintain a proper backwash and fast flush flows over wide variations of oper-
ating 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.
H9-8
02-02
3.0 Control Options

Regeneration shall be controlled by a fully automatic time clock control which is fully adjustable or can be controlled by a remote
manual controller. For fully automatic operating the regeneration shall be initiated by calendar clock. A pointer indicates the cycle
of operation at all times.
3.1 Standard Gallon Register Meter
Each Dealkalizer tank shall be equipped with a ______ " (disc), or (turbo), standard gallon register meter to record the amount of
dealkalized water produced. The time clock will initiate the regeneration sequence.
3.2 Signal Register Meter
Each dealkalizer tank shall be equipped with a _________ " (disc), or (turbo) meter with a signal register head. The head shall send
a ___ volt electrical signal to an audible alarm upon reaching the hand set gallonage. The signal will continue until reset by the
operator. Regeneration will be initiated by a push-button on the cycle controller of the exhausted unit.
3.3 Automatic Reset Register Meters
Each dealkalizer tank shall be equipped with a _____ " (disc), or (turbo) meter with automatic reset head. The head shall send a 120
volt signal to the dealkalizer cycle controller to initiate regeneration at a preset gallonage. The head will automatically reset to this
gallonage.
3.4 Single Automatic Reset Meter and Altwinator (Twin Dealkalizers Only)
The twin chloride cycle dealkalizer shall be equipped with a single _____ " (disc), or (turbo) water meter in the common outlet
header. At a preset gallonage the automatic reset head of the meter will send a 120 volt signal to an altwinator that will direct the
signal to regenerate the unit presently on stream. Upon completion of regeneration, that dealkalizer will remain off stream in the
standby position. This sequence will repeat on an alternating basis each time the preset gallonage of dealkalized water has passed
through the meter.
3.5 Two Tanks - Alternating
The system will operate with two media tanks each having a dedicated 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.
The exchange capacity of each dealkalizer can be the same or different.
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.
3.6 (Two) (Three) Tanks - Parallel
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:
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.
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.
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.
The networked controls shall be capable of continuously determining the exhaustion rate of each media tank, thus automatically
avoiding the possibility of a simultaneous regeneration attempt. Simultaneous regenerations are not possible.
The exchange capacity of each dealkalizer can be the same or different.
H9-9
02-02
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.
A regeneration start delay time interval can be user programmed for 0 to 16 hours to allow for brine make-up or regeneration feed-
water recovery.
4.0 Test Kit

A test kit shall be furnished to measure the dealkalizer performance. It shall be of the methylorange type to detect alkalinity.
5.0 Instructions
A complete set of installation instructions and operating instruction shall be furnished.
6.0 Skid Mounting Options

The dealkalizer system shall be completely skid mounted. Tanks 9" through 16" diameter shall be mounted on a 3" channel iron
skid (9 lbs per foot, ASTM Grade A-36). The skid shall be cross-braced with 3" channel or angle iron, and the entire skid covered
with a 1/4" steel plate. All steel surfaces shall be prime coated.
Tanks 20" through 30" diameter shall be mounted on a 3" channel iron skid (9 lbs per foot, ASTM Grade A-36). The skid shall be
cross-braced with a 3" channel or angel iron, and the entire area under the polyethylene briner shall be covered with a 1/4" steel
plate. All steel surfaces shall be prime coated.
Tanks 36" through 42" diameter shall be mounted on a 4" channel iron skid (13.8 lbs per foot, ASTM Grade A-36). The skid shall
be cross-braced with 4" channel or angel iron, and the entire area under the polyethylene briner shall be covered with a 1/4" steel
Tanks 48" through 72" diameter shall be mounted on a 6" channel iron skid (15.3 lbs per foot, ASTM Grade A-36). The skid shall
be cross-braced with 6" channel or angle iron, and the entire area under the polyethylene briner shall be covered with 1/4" steel
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.
All inter tank hydraulic or pneumatic tubing shall be installed as part of the skid package.
All polyethylene briners shall be supported on the skid by a 12" high steel band welded to the skid.
The mineral tanks are to be bolted to the skid. Permanent attachment, or welding, will not be acceptable.
Lifting lugs, rings, etc., will be suitably located for single point lifting of the entire skid mounted system.
The entire skid mounted system shall be both hydro and electrically tested as a unit by the manufacturer before shipment. The sys-
tem shall be completely drained after hydro testing.
7.0 Guarantee
The manufacturer of the dealkalizer equipment shall guarantee his equipment as follows:
A. All parts found defective in material or workmanship within a period of one year after installation shall be repaired or
replaced.
B. The dealkalizer shall reduce the alkalinity of the water to 10 ppm or to 10% of the influent alkalinity.
C. Loss of resin by attrition shall not exceed 3% per year for 3 years.
The manufacturer of the dealkalizer equipment must have been engaged in the manufacturing of this size equipment for a period of
not less than 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 fur-
nished in bound booklet form.
H9-10
02-02
Section H10
BLOWDOWN SEPARATORS
CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-3
Standard and Optional Equipment Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-3
DIMENSIONS, RATINGS, SIZING AND SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-5
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-5
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-10
ILLUSTRATIONS
Figure H10-1. Blowdown Separator Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-4
Figure H10-2. Automatic Drain Water Aftercooler (18DF) Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-5
Figure H10-3. Automatic Drain Water Aftercooler (20AO) Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-6
Figure H10-4. Model 5D Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-7
Figure H10-5. Separator Floor Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-8
Figure H10-6. Separator Wall Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-9
TABLES
Table H10-1. Boiler Blowdown Separator Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-4
Table H10-2. Cooling Water Line and Valve Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-6
H10-1
02-02
Blowdown Separators Feedwater Systems
This section contains information on blowdown separators, which are used to provide safe and economical flash purification to
enhance blowdown effectiveness.
H10-2
02-02
Feedwater Systems Blowdown Separators
FEATURES AND BENEFITS Cleaver-Brooks blowdown separators are compact, and can be
quickly installed with few connections. Accessories include
leg or wall brackets, drain tempering fitting, strainer, tempera-
Fast, Safe, Low-Cost Way to Separate Steam and Water and
ture regulating valve, thermometer, pressure gauge and
Remove Harmful Dissolved Solids.
flanges.
Protects boiler surfaces from severe scaling or corrosion
problems. Pressure ranges:
0 to 300 psig, standard.
Economical Flash Purification Process for Enhancing Blow-
301 to 1600 psig, special.
down Effectiveness.
Available with ASME U stamp.
Reduce drain water temperature to meet state and local
requirements.
Standard and Optional Equipment Selection
The Design is Quiet, with Noise Levels Held Below 90 dBA, For dimensions and sizing of blowdown separators, refer to
so no Exhaust Head is Required. Figure H10-1 and Table H10-1.
For manual drain water tempering, use Aftercooler model 5D
CB Blowdown Separators are Compact, and Can Be Quickly
and specify drain diameter.
Installed with Few Connections.
For automatic control of drain water temperature, use
Stainless steel striking plate greatly extends separator life.
18DF___ or 20AO___ Aftercooler. 20AO Aftercooler is
required in some areas to automatically regulate the tempera-
Momentum of Water is Speeded by Spiral Baffle Centerwise ture of the water to the drain. Check local codes to ascertain if
to Drain. Drain is Completely Filled - No Center Void. it is required in your area.
Tangential inlet and small diameter prompt high velocity
A temperature regulating valve should be used when the blow-
spinning for release of steam.
down temperature going to the drain needs to be less than 212
F. (See Table H10-2 to select cooling water line and valve
All Interior Surfaces Slant Toward Drain, Making Unit Self- size.)
Draining, Self-Drying for Longer Life.
Use a solenoid valve and thermostat when the cooling water
Proven Performance. pressure exceeds 80 psig.
1. Model 18 DF Aftercooler (Figure H10-2). Nonclogging
Demonstrated Durability. automatic drain tempering fitting with stainless steel mixing
tongue (on 4" and larger) to provide thorough mixing of influ-
Universal Adaptability. ent 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
PRODUCT OFFERING valve and thermometer are furnished. When ordering, state
Boilers that supply steam for power, process or heating appli- cold water inlet size.
cations require periodic and more often, frequent, blowdowns 2. Model 20AO Jacket Type After Cooler (Figure H10-3).
to prevent buildup of harmful solids. Blowdown protects Required in some areas. Has mixing holes corresponding to the
boiler surfaces from severe scaling or corrosion problems that cold water inlet size. The lower portion is designed with wells
would otherwise result. to accommodate automatic control bulb and thermometer.
Cleaver-Brooks blowdown separators use a safe, economical When ordering state cold water inlet size.
flash purification process for enhancing blowdown effective- 3. Temperature Regulator Valves (Figures H10-2 and H10-3).
ness. Steam is rapidly separated from blowdown water and Automatically control the flow of cold water by responding to
vented out the top of the blowdown separator in a cyclonic temperature changes at the thermostatic bulb. The 6" capillary
spinning action. Water and dissolved solids are flushed out the tube allows installation in the cold water line while the 11"
bottom drain. bulb is mounted in the lower portion of the aftercooler. The
The design is quiet, with noise levels held below 90 dBA, so valve size should correspond to the cold water inlet.
no exhaust head is required. Internal pressures do not exceed 5 4. Thermometer. Bi-metal, drawn steel case, rust resistant and
psig. Blowdown water is cooled to 120 F by a drain temper- finished in oven baked enamel. Six inch brass stem with 1/4"
ing device, designed to meet state and local codes. NPT bushing provided for use with Model 18 DF and Model
20 AO Aftercoolers.
H10-3
02-02
INSPECTION PORT
V VENT
A 1/4
SS WEAR PLATE
9 I INLET
H 1/2 PL
A A
MODEL NO. A20B A34B A56B 14
H Dimension 22 34 56
A Dimension 9-3/4 10-1/4 11
I Inlet size Determined by blowdown valve size.
:V Vent size Select from Table H10-1.
D Drain size Select from Table H10-4.
PL Plate size 5/16 or 3/8. May be determined by D DRAIN
codes.
HEADS SA 516-70
SECTION A-A SHELL SA 53B
COUPLINGS SA 105
MODEL NO. ________ MAWP WEAR PLATE SA 240-304
250 PSIG AT 450 F BAFFLES SA 240-304
NOZZLES SA 53B, SA 106-B
FINISH RED OXIDE PRIMER
Figure H10-1. Blowdown Separator Dimensions
Table H10-1. Boiler Blowdown Separator Sizing

VALVE
SIZE 1" 1-1/4" 1-1/2" 2" 2-1/2"
Separator
Model H
Model H
Model H
Model H
Model H
Dim. I D V I D V I D V I D V I D V
Generator
Op psig
0-15 14 1 2 2-1/2 20 1-1/4 3 4 20 1-1/2 3 4 20 2 4 5 34 2-1/2 5 6
16-50 20 1 2 2-1/2 20 1-1/4 3 4 34 1-1/2 3 4 34 2 4 5 34 2-1/2 5 6
51-100 20 1 3 2-1/2 34 1-1/4 4 4 34 1-1/2 4 4 34 2 5 5 34 2-1/2 6 6
101-125 34 1 3 3 34 1-1/4 4 4 34 1-1/2 4 4 34 2 5 5 56 2-1/2 6 6
126-150 34 1 3 3 34 1-1/4 4 4 34 1-1/2 4 5 56 2 5 6 56 2-1/2 6 6
151-175 34 1 3 4 34 1-1/4 4 4 34 1-1/2 4 5 56 2 5 6 56 2-1/2 6 8
176-200 34 1 3 4 34 1-1/4 4 5 56 1-1/2 5 5 56 2 6 6 56 2-1/2 6 8
201-225 34 1 4 4 56 1-1/4 4 5 56 1-1/2 5 5 56 2 6 6 56 2-1/2 8 8
226-300 56 1 4 4 56 1-1/4 4 5 56 1-1/2 5 6 56 2 6 8 56 2-1/2 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.
(Rev 7/97)
H10-4
02-02
5. Solenoid Valve. Automatically controls cooling water to easy and expedient means of installation. Standard height
aftercooler. Non-magnetic stainless steel body; micro-finished, raises separator 18 inches from floor, or when aftercoolers are
hardened pilot valve ball. Has two-wire control circuit (120/ provided, additional height is provided.
60). Well immersion hot water control provided for actuating
9.Separator Wall Brackets (Figure H10-6). For wall mounting
solenoid valve.
where floor space is limited, or where desired installation is at
6. The Model 5D Drain Tempering Fitting (Figure H10-4). a level higher than leg height of 18 inches.
Simple type of aftercooler for adding cooling water with man-
ual control. It has cold water inlet for adding cooling water to DIMENSIONS, RATINGS, SIZING AND
drain for tempering to 120 F. Inlet is sized for minimum influ-
ent water conditions of 60 F water at 40 psig pressure with SELECTION
100 sq-ft of supply. When ordering, state Model 5 D (Drain Dimensions, ratings, sizing, and selection information are pre-
Diameter); i.e. for 4" drain use Model 5D 4. sented in Table H10-2.
7. Armstrong Strainer. Cast iron with .045 stainless steel
screen. Install in cold water line to protect temperature regula- ENGINEERING DATA
tor valve or solenoid valve shown in adjacent column.
Engineering data are shown in Figure H10-1 and Table H10-2.
8. Separator Floor Stand (Figure H10-5). Provides and excel-
lent means for supporting separators. Constructed of sturdy
angle iron. They come attached to the separator to provide an
A D F H CWI
2-1/2 2 6 18 1/2 F
2-1/2 2 6 18 3/4 D
2-1/2 2-1/2 7 18 3/4
4 3 7-1/2 20 3/4 A
4 3 7-1/2 20 1
4 4 9 20 1 CWI COLD WATER INLET
4 4 9 20 1-1/4 STAINLESS STEEL MIXING
4 5 10 20 1-1/4 TONGUE SUPPLIED ON
MODELS 18DF4 AND LARGER
4 5 10 20 1-1/2
4-1/2 6 11 20 1-1/2 H 1/4 NPTF CONNECTION TO
4-1/2 6 11 20 2 ACCOMODATE BIMETALLIC
THERMOMETER
NOTES:
1. Temperature regulator valve bulb is installed in
lower section of the aftercooler so that the bulb 1 NPTF CONNECTION TO ACCOMODATE
senses mixed water temperature. Valve is modulating TEMPERATURE REGLUATOR VALVE
so that the right amount of cold water is added to SENSING BULB
cool the drain water to the desired temperature set
on the valve. Valve range is 110 to 150 F.
2. Regulator Valve has composition seat to ensure

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

shut-off when not blowing down. Valve should be
protected with C.1. Strainer with .045 mesh.
Figure H10-3. Automatic Drain Water Aftercooler (20AO) Dimensions
Table H10-2. Cooling Water Line and Valve Sizing

SEPARATOR 1 1-1/4" 1-1/2 2" 2-1/2"
INLET SIZE
COOLING
WATER 40 60 80 40 60 80 40 60 80 40 60 80 40 60 80
PRESS. (PSIG)
GENERATOR OPERATING PRESSURE (50 TO 70 F COOLING WATER TEMPERATURE)
0-50 1/2 1/2 1/2 1 1 3/4 1-1/4 1 1 1-1/4 1-1/4 1-1/4 1-1/2 1-1/2 1-1/4
51-100 1 3/4 3/4 1 1 1-1/2 1-1/4 1-1/4 1 1-1/2 1-1/4 1-1/4 2 2 2
101-125 1 3/4 3/4 1-1/4 1 1 1-1/4 1-1/4 1-1/4 2 1-1/2 1-1/4 2 2 2
126-175 1 1 1 1-1/4 1-1/4 1 1-1/4 1-1/4 1-1/4 2 2 1-1/2 2-1/2 2 2
176-225 1 1 1 1-1/4 1-1/4 1-1/4 1-1/2 1-1/4 1-1/4 2 2 2 2-1/2 2 2
226-250 1-1/4 1-1/4 1 1-1/4 1-1/4 1-1/4 1-1/2 1-1/4 1-1/4 2 2 2 2-1/2 2 2
251-300 1-1/4 1-1/4 1 1-1/4 1-1/4 1-1/4 1-1/2 1-1/4 1-1/4 2 2 2 2-1/2 2-1/2 2
GENERATOR OPERATING PRESSURE (71 TO 80 F COOLING WATER TEMPERATURE)
0-50 3/4 1/2 1/2 1 1 1 1-1/4 1 1 1-1/4 1-1/4 1-1/4 2 1-1/2 1-1/2
51-100 1 3/4 3/4 1-1/4 1 1 1-1/4 1-1/4 1-1/4 2 1-1/2 1-1/4 2 2 2
101-125 1 1 3/4 1-1/4 1-1/4 1 1-1/4 1-1/4 1-1/4 2 2 1-1/2 2-1/2 2 2
126-175 1 1 1 1-1/4 1-1/4 1-1/4 1-1/2 1-1/4 1-1/4 2 2 2 2-1/2 2 2
176-225 1 1 1 1-1/4 1-1/4 1-1/4 1-1/2 1-1/4 1-1/4 2 2 2 2-1/2 2-1/2 2
226-250 1-1/4 1-1/4 1 1-1/4 1-1/4 1-1/4 1-1/2 1-1/4 1-1/4 2-1/2 2 2 2-1/2 2-1/2 2
251-300 1-1/4 1-1/4 1-1/4 1-1/2 1-1/4 1-1/4 2 1-1/2 1-1/2 2-1/2 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, 60 or 80 and read the desired valve and line size.
H10-6
02-02
B D H CWl H
2-1/2 2 5 3/4
COLD WATER
INLET - NPTF
2-1/2 2-1/2 5 3/4
4 3 7 1
4 4 7 1-1/4
D
4 5 7 1-1/2
4-1/2 6 7 2
Furnish and install a manual drain water aftercooler Model 5D ____ and with a ____ cold water connection.
NOTE:
1. Temperature regulator valve bulb is installed in lower section of the aftercooler so that the bulb senses mixed water tem-
perature. Valve is modulating so that the right amount of cold water is added to cool the drain water to the desired temper-
ature set on the valve. Valve range is 110 to 150 F.
2. Regulator Valve has composition seat to ensure tight shut-off when not blowing down. Valve should be protected with
C.1. Strainer with .045 mesh.
4. 16DS Same as 18DF Without Flanges.
Figure H10-4. Model 5D Dimensions
H10-7
02-02
For Screwed or Beveled Connections, Factory Fabricated 2" x 2" x 1/4" Angle Permissible Load 6000 lbs
If 18DF, 16DS, or 20AO Aftercooler is furnished with separator, see dimension chart for separator height A. A
dimension is determined by separator drain size D. This provides adequate height for the aftercooler and elbow
when required.
A dimension will always be 18" when separator is furnished without an aftercooler.
D A
2 22
2-1/2 23
3 24
4 25
5 30
6 34
For Flanged Connections Factory Fabricated 2" x 2" x 1/4" Angle Permissible Load 6000 lbs.
If 18DF, 16DS, or 20AO Aftercooler is furnished with flanged connections on both ends, use dimension chart to
determine separator height "A".
"A" dimension will always be 18" when separator is furnished without an aftercooler.
D A
2 28
2-1/2 30
3 31
4 32
5 33
6 35
Figure H10-5. Separator Floor Stand
H10-8
02-02
SEPARATOR WALL BRACKET 2 X 2 X 1/4" ANGLE
USE MODEL 20 W/20" SEPARATOR

MODEL A B C D
20 21 14 - 13
34 21 14 - -
56 35 28 14 -
NOTE:
1. DIMENSION C IS FOR MODEL 56 ONLY.
2. DIMENSION D IS FOR MODEL 20 ONLY.
Figure H10-6. Separator Wall Bracket
H10-9
02-02
The following sample specification is provided by Cleaver-Brooks to assist you in meeting your customers requirements.
1.0 Blowdown Separator

Furnish and install Cleaver-Brooks Model _____ blowdown separator with I=______, D=_____, V=______, and _______ plate
thickness.
The separator shall be manufactured in accordance with ASME Code for 250 psig design and tested to 375 psig.
Provide separator with National Board stamping and "U" symbol. (Necessary in Michigan and Utah, optional elsewhere.)
The separator shall be furnished with ______________ (screwed, weld bevel, 150# flanged or 300# flanged) connections.
The separator shall include a stainless steel striking plate at the point of inlet impingement and shall be furnished by Cleaver-
Brooks.
2.0 Accessories
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.
Furnish a bi-metal thermometer with necessary adaptor bushing for use with _________ (18DF or 20AO) aftercooler.
Furnish a ______ cast iron strainer with .045 stainless steel screen ahead of the ________ (TRV or solenoid valve) to protect said
valve against foreign matter.
Furnish and install an automatic drain water aftercooler, Model ________ (18DF or 20AO) with a ______ cold water connection
for a _________________ (TRV or solenoid valve and thermostat) (See Figure H10-2 or H10-3).
Provide a ___________ temperature regulator valve to automatically control the flow of cold water by responding to temperature
changes sensed at the thermostatic bulb in the aftercooler fitting.
The accessory separator floor stand and wall mounting bracket are shown in Figures H10-5 and H10-6.
H10-10
02-02
Section H11
BLOWDOWN HEAT RECOVERY SYSTEMS
CONTENTS
BHR-S and BHR-M Series (High Pressure Steam Applications) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-3
BHR-LPS Series (Low Pressure Steam Applications) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-3
BHR-S and BHR-M Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-3
BHR-LPS Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-4
BHR-LPS Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-4
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-4
ILLUSTRATIONS
Figure H11-1. Blowdown Heat Recovery System Selection and Payback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-5
Figure H11-2. Model BHR S Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-8
Figure H11-3. Model BHR-S Ratings/Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-9
Figure H11-4. Model BHR-M Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-10
Figure H11-5. Model BHR-M Ratings/Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-11
Figure H11-6. Model BHR-LPS Dimensions and Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-12
H11-1
02-02
Blowdown Heat Recovery Systems Feedwater Systems
This section contains information on Cleaver-Brooks Blowdown Heat Recovery Systems used to recover energy from blowdown
water and use the energy to preheat make-up water. Cleaver-Brooks heat recovery systems encompass the following models:
Model BHR-S Series for single boiler applications.
Model BHR-M Series for multiple boiler applications.
Model BHR-LPS Series for low pressure steam applications.
H11-2
02-02
Feedwater Systems Blowdown Heat Recovery Systems
FEATURES AND BENEFITS Cools Blowdown Before Discharging Into Sewer:

Helps comply with local codes on high temperature liquids
BHR-S and BHR-M Series (High Pressure to drain without adding cooling water to drain.
Steam Applications)
Specifically Designed for Low Pressure Boiler Applications:
Integrated System Automatically Adjusts to Changing De- No need to modify or redo high pressure systems to try and
mands: make them work in a low pressure application.
Recovers 90% of heat normally lost.
Automatically controls surface blowdown flow to maintain
PRODUCT OFFERING
the desired concentration of dissolved solids within the
boiler. BHR-S and BHR-M Series
Automatically controls boiler dissolved solids. Continuous boiler surface blowdown is the most effective
method of purging destructive solids from any steam boiler
Compact Size for Convenient Placement: system. However, this protective procedure also results in a
constant and costly heat loss, unless a blowdown heat recovery
Reduced installation costs. system is used.
Removable Shell for Easy Inspection and Cleaning: Cleaver-Brooks blowdown/heat recovery systems adjust auto-
matically to changing system demands, and recover 90% or
Reduces maintenance costs. more of the heat normally lost during boiler surface blowdown
operation.
Significant Fuel Savings for Any Size Boiler:
The blowdown/heat recovery systems will usually result in a
It transfers the blowdown heat to the make-up, thereby payback in a few short months from fuel savings alone. Refer
decreasing fuel costs. to Figure H11-1 for selection and payback calculations.
Saves chemical costs by reducing blowdown. The Cleaver-Brooks Packaged Blowdown Heat Recovery Sys-
tem serves two primary functions.
Blowdown is Cooled Before Discharging Into the Sewer:
1. It automatically controls the surface blowdown to maintain
Complies with discharge water codes. the desired level of total dissolved solids (TDS) in the boiler,
reducing the amount of blowdown to a minimum.
BHR-LPS Series (Low Pressure Steam Ap- 2. It recovers the heat from the high temperature blowdown,
plications) and transfers it to the incoming cold make-up water, maximiz-
Blowdown Flow Concurrent With and Proportional to Make- ing boiler efficiency. Use of BHR also improves deaerator effi-
up Flow: ciency by reducing surges caused by adding large amounts of
cold make-up water to the system.
Higher heat transfer, greater efficiency.
The control valve within the unit performs two functions. The
valve senses the flow of make-up, and positions itself to main-
Each Boiler Has Its Own Heat Exchanger, Sample Valve,
tain the desired ratio of blowdown and make-up flows. As a
Throttling Valve, and Make-Up Flow Switch:
result, the dissolved solids concentration within the boiler is
Easier to adjust and monitor each boiler individually. maintained automatically.
The proportioning control also provides for very effective heat
Level of Dissolved Solids or Specific Conductance Can Be recovery since hot blowdown flows only when there is a corre-
Adjusted: sponding flow of cold water (make-up).
Prevents foaming, priming or scaling without wasting excess
Model BHR-M Systems for multiple boiler installations
energy.
include a flow control valve for each boiler. This allows for
proportioning the overall system blowdown between different
Packaged for Easy Installation: boilers, which may be operating at different loads. A strainer
Saves money on installation costs. and sampling valve are also provided for each boiler, with a
sample cooler mounted on the system. Thus, all boilers can be
H11-3
02-02
sampled at one convenient location.

The heavy duty blowdown heat exchangers are uniquely
designed to handle the blowdown on the tube side. This allows
many tube side passes, which ensures maximum heat transfer,
and maintains high 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 regu-
larly, a cleaning schedule can be established for each
exchanger.
BHR-LPS Series
Cleaver-Brooks Model BHR-LPS systems are designed for
boilers operating up to 30 psig and features a brazed plate
exchanger - dedicated to each boiler - up to a maximum of
three boilers. The plate exchanger is designed to improve ther-
mal exchange efficiency. The BHR-LPS also features an on/off
flow switch that is synchronized to each boiler feed pump.
The BHR-LPS includes plate exchanger, on/off flow switch,
outlet thermometer and interconnecting piping.
BHR-LPS Selection
Make-up = minimum flow (total - all boilers) - 3-1/2 gpm (The
make-up valve to feedwater tank should be on/off type to
ensure minimum 3-1/2 gpm flow).
Maximum flow (each boiler) - 15 gpm.
Maximum pressure - 65 psig.
Blowdown, maximum flow (each boiler) - 3 gpm
Design pressure -30 psig at 274 F

Dimensions and ratings for Model BHR-S are shown in
Figures H11-2 and H11-3.
Dimensions and ratings for Model BHR-M are shown in
Figures H11-4 and H11-5.
Dimensions and ratings for Model BHR-LPS are shown in
Figure H11-6.
.
H11-4
02-02
Figure H11-1. Blowdown Heat Recovery System Selection and Payback (Sheet 1 of 3)
H11-5
02-02
H11-6
02-02
H11-7
02-02
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 28 64 64 100 100
REF
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 H11-2. Model BHR -S Dimensions
H11-8
02-02
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 H11-3. Model BHR-S Ratings/Capacities
H11-9
02-02
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 H11-4. Model BHR-M Dimensions
H11-10
02-02
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 H11-5. Model BHR-M Ratings/Capacities
H11-11
02-02
MODEL NO. A B
BHR-3LPS 15 -
BHR-6LPSA 26 11
BHR-9LPS 37 22
A. Two-boiler system is shown.
Figure H11-6. Model BHR-LPS Dimensions and Ratings
H11-12
02-02
The following sample specifications are provided by Cleaver-Brooks to assist you in specifying your customers requirements.
1.0 BHR-S Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-13

2.0 BHR-M Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-13
3.0 BHR-LPS Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-14
1.0 BHR-S Series

Furnish ______ Cleaver-Brooks Model BHR-S Package blowdown heat recovery system designed to handle a maximum blow-
down rate of _______ gpm (2 to 22) and a maximum make-up rate of _______ gpm (48 to 180).
The heat recovery system shall be designed for a boiler of _______ hp (150 - 1500), hp operating at _______ psig (35 to 250). The
unit shall be designed to cool the blowdown to within 30 F of the make-up water temperature. The unit shall have a 250 psig rating
at 400 F.
The heat recovery system shall consist of a differential temperature control valve that shall automatically regulate the blowdown of
make-up 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.
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.
A heat treated stainless steel valve seat and plunger shall manually control the blowdown flow by a handwheel.
A blowdown thermometer Weksler Type 152 shall be furnished at the blowdown outlet.
The entire system shall be supported by steel channel legs with 3/4" diameter holes for customer-supplied 5/8" diameter anchor
bolts.
The system will be painted with a hard enamel coating.
2.0 BHR-M Series

Furnish ______ Cleaver-Brooks Model BHR-M package blowdown heat recovery system designed to handle a maximum blow-
down rate of _______ gpm (2 to 22) and a maximum make-up rate of _______ gpm (48 to 180).
The heat recovery system shall be designed for boilers of ______ hp (250 - 1500), hp operating at _______ psig (35 to 250). The
unit shall be designed to cool the blowdown to within 30 F of the make-up water temperature. The unit shall have a 250 psig rating
at 400 F
The heat recovery system shall consist of a differential temperature control valve that shall automatically regulate the blowdown
and make-up 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.
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.
H11-
02-02
A heat treated stainless steel valve seat and plunger shall manually control, the blowdown flow by means of a handwheel. A blow-
down outlet thermometer Weksler Type 152 shall be furnished at the blowdown outlet.
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.
A SC-22 sample cooler with isolation valves and interconnecting piping will be supplied.
bolts.
The system will be painted with a hard enamel finish coating.
3.0 BHR-LPS Series

Furnish _______ Cleaver-Brooks Model BHR-LPS blowdown heat recovery system, designed to handle a maximum make-up rate
of 3 gpm (per boiler) and a maximum make-up rate of 15 gpm (per boiler). The system shall be designed for boiler(s) of hp _____
(50 - 250) operating at psig _____ (10 -30). The unit shall be ASME stamped and rated for 30 psig at 274 F.
The system shall consist of a brazed plate heat exchanger (one for each boiler) capable of recovering at least 90% of the available
heat. The exchanger shall be constructed of copper with a 1" FPT inlet and outlet connections for the make-up and a 3/4" FPT inlet
and a 1" FPT outlet connection for the blowdown. All other connections shall be sweat-soldered for strength. The system shall be
designed to operate with on/off boilers. The system shall be electronically tied to the on/off circuit for the boiler feed pumps
through a flow switch to the (each) boiler. Sampling of blowdown from the (each) boiler shall be by an on/off valve located on the
blowdown outlet. A blowdown outlet thermometer, Weksler Type 152, shall be furnished at the blowdown outlet to monitor the
cooled blowdown temperature. The system shall be pre-piped and mounted on channel legs for ease of assembly in the field. The
legs shall have 9/16" diameter holes for customer-supplied anchor bolts.
The system will be painted with a hard enamel finish coating.
H11-14
02-02
Section H12
FLASH TANK HEAT EXCHANGERS
CONTENT
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-3
Standard Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-3
Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-3
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-3
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-3
ILLUSTRATIONS
Figure H12-1. Model FTE Flash Tank Heat Exchanger Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-4
Figure H12-2. Model AHR Flash Tank Heat Exchanger Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-5
Figure H12-3. Flash Tank Exchanger Blowdown System Selection & Payback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-6
This section contains information on Cleaver-Brooks Flash Tank Heat Exchangers. Flash tank heat exchangers are used on applica-
tions when operating pressures exceed 25 psig and continuous blowdown heat recovery is desired.
H12-1
02-02
Flash Tank Heat Exchangers Feedwater Systems
Notes
H12-2
02-02
Feedwater Systems Flash Tank Heat Exchangers
FEATURES AND BENEFITS steel, is integral with the ASME approved flash tank. The
space saving system includes floor supports, liquid level con-
trol, three indicating thermometers, and a safety valve as stan-
Flashing:
dard equipment.
Hot, high-pressure blowdown water from each boiler is
piped to individual flow control valves on the inlet manifold. Standard Offering
Pressure drops across the flow control valve to 5-20 psig,
causing the blowdown water to flash into a mixture of steam Flash separator with stainless steel coil heat exchanger.
and water. Floor supports.
Separation Steam/Water: Liquid level controller.
An entrainment baffle directs the mixture around the inside Liquid level indicator, brass body Michigan gauge.
of the tank in a centrifugal motion. Efficient baffling Temperature control panel with three indicating
separates the dirty blowdown water from the clean steam. thermometers (drain temperature, make-up inlet, make-up
outlet).
Discharge:
Safety Valve.
Steam then rises through the top of the flash tank and is piped
to the feedwater heater, or wherever low pressure steam is ASME Code Construction (150# Design).
required. The remaining hot, dirty water flows out the bottom
of the flash tank to a heat exchanger for additional heat Major Components
recovery, or to a blow-off tank or sewer. Blowdown system.
Flashtank.
Heat Recovery:
In addition to the heat recovered as flashed steam, the heat Heat exchanger.
exchanger will transfer the remaining heat normally lost Stand.
during blowdown, to the cold make-up water as it flows to
the feedwater heater. Optional Equipment
Drain valve and level control.
PRODUCT OFFERING
Sample coolers and assembly.
Flash tank heat exchangers are used when operating pressures
exceed 25 psig and continuous blowdown heat recovery is Flow control valve and assembly.
desired for cost savings. They consist of an ASME approved Manifold.
and stamped flash tank and a blowdown heat exchanger. Water
from continuous blowdown enters the tank and separates into Safety valve.
steam and water. The steam, normally at 5 psig, can be Gauge glass.
returned to the deaerator to help meet heating needs. Hot water
leaves the flash tank at temperatures of 220 F, or more. It goes Pressure gauge.
into the heat exchanger, where it heats cold makeup water Gauge panel.
entering the system.
Level alarm.
The systems quickly pay for themselves with fuel savings
resulting from recycled heat that would otherwise be wasted. Level alarm control panel.
The Model FTE (Figure H12-1) is a conventional plate and Thermometers for exchanger operation.
frame type blowdown heat recovery system available in sizes
ranging from 10 to 20 gpm blowdown and 10 to 200 gpm ENGINEERING DATA
makeup.
Engineering data, system selection, and payback are shown in
The Model AHR (Figure H12-2) is available in sizes ranging Figure H12-3.
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
H12-3
02-02
73
37
CAPACITY (MAX)
MODEL NO. A
BLOWDOWN MAKE-UP
FTE-10I A 10 gpm 100 gpm 48"
FTE-20I A 20 gpm 200 gpm 48"
FTE-10E B 10 gpm 100 gpm 72"
FTE-20E B 20 gpm 200 gpm 72"
NOTE: A. Internal type float assembly (shown).

B. External type float assembly.
Figure H12-1. Model FTE Flash Tank Heat Exchanger Dimensions
H12-4
02-02
BLOW- MAKEUP
MODEL DOWN A B C D E F G H
(GPM)
(GPM)
ACC-AHR-39 3 9 96 44 44-1/4 8 1 2-1/2 1-1/2 3/4

ACC-AHR-315 3 15 97 50 36 10 1 2-1/2 1 1
ACC-AHR-612 6 12 110 49 50 10 1-1/2 3 1-1/2 3/4
ACC-AHR-630 6 30 111 53 46 12 1-1/2 3 1 1-1/4
ACC-AHR-1020 10 20 100 44 42 16 1-1/2 4 2 1-1/4
ACC-AHR-1050 10 50 106 50 44 16 1-1/2 4 2 1-1/2
ACC-AHR-2040 20 40 140 67 62 18 1-1/2 6 2 1-1/2
ACC-AHR-3060 30 60 172 76 85 18 1-1/2 6-8 2 1-1/2
ACC-AHR-20100 20 100 140 67 62 18 1-1/2 6 2 2
ACC-AHR-30150 30 150 132-1/2 67 52-1/2 24 1-1/2 6-8 2 2-1/2
NOTE: Dimensions in inches.
Figure H12-2. Model AHR Flash Tank Heat Exchanger Dimensions
H12-5
02-02
Figure H12-3. Flash Tank Exchanger Blowdown System Selection & Payback (Sheet 1 of 4)
H12-6
02-02
H12-7
02-02
H12-8
02-02
H12-9
02-02
The following sample specification is provided by Cleaver- Brooks to assist you in specifying your customers requirements.
Model FTE
1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-10
2.0 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-10
Model AHR
1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-11
2.0 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-11
3.0 Multiple Boiler Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-11
Model FTE
1.0 General
Provide Cleaver-Brooks Model FTE-_____________ packaged flash tank heat exchanger system designed to handle a maximum
blowdown rate of 10 to 20 gpm, and a maximum makeup rate of 100 to 200 gpm.
The heat recovery system shall be designed for boilers of 300-3600 hp operating at 25 to 250 psig. The unit shall be designed to
cool the blowdown to within 25 F of the makeup water temperature. The tank shall have a 100 psig rating at 300 F.
The heat recovery systems flash tank shall have an ASME Code design pressure at 100 psig and an internal flash tank pressure of
_____ psig (5 to 15). The flash tank shall be 18" diameter x 30" high, and shall be complete with a blowdown inlet manifold, stain-
less steel wear plate, centrifugal entrainment baffle, steam outlet, Armstrong 3LD level control flat and drain valve, 1/2" drain con-
nections, gauge glass assembly, and a 1/2" Consolidated # 1543H safety valve.
The system shall also have a plate and frame heat exchanger, consisting of plates manufactured of AISI 316 stainless steel. These
plates shall be assembled in packs and bolted in a frame, with each adjacent pair of plates forming a channel with the liquid flowing
in alternate channels. Between the plates shall be a one piece gasket made of EPDM. The exchanger shall have a maximum temper-
ature limitation of 100 psig at 300 F. The system shall have interconnecting piping of steel and stainless steel.
A flow control assembly shall be furnished for each boiler. The assembly shall consist of a _____" Hancock #4595 flow control
valve rated at 300 psig, bronze construction, and a ______" cast steel strainer with a stainless steel screen, and have a 250 psig pres-
sure rating.
A 0-100 psig flash tank pressure gauge shall be furnished.
bolts.
A high level alarm switch Mercoid # 123, rated at 125 psig, shall be furnished. The switch shall be mounted and piped on the unit,
and shall include two (2) isolation valves.
The system shall be painted with Cleaver-Brooks finish paint.
2.0 Optional Equipment

2.1 A SC-22 Sample Cooler with isolation valves and interconnecting piping shall be supplied for a single boiler application. With
each additional boiler, a sample valve assembly shall be added and manifolded to the sample cooler.
2.2 An alarm panel, including an audio and visual alarm for high level, shall be provided. The alarm panel shall be complete with a
silencing switch and a push-to-test switch. The alarm panel shall be prepiped, wired, and mounted on the unit.
2.3. A gauge panel shall be provided, and shall include thermometers for makeup in, makeup out, and blowdown drain. Each ther-
mometer shall have a 3" diameter dial with reading of 50-300 F. A tank pressure gauge shall also be included in the gauge panel.
The tank pressure gauge shall have a 4-1/2" diameter dial with reading of 0-100 psig. The panel shall be prepiped and mounted on
the unit.
2.4 A Warren 377 external float control shall be provided, with Warren 320L valve and a 1-1/2" mechanical drain control valve.
H12-10
02-02
Model AHR
1.0 General
Furnish Cleaver-Brooks Model ACC-AHR ____ packaged flash tank coil type heat exchanger system, designed to handle a maxi-
mum blowdown rate of ____ gpm (3 to 30) and a maximum makeup rate of _____ gpm (9 to 150).
The system shall be designed for boilers of (130-2200) hp operating at (0-600) psig. The unit shall be designed to cool the blow-
down to within 30 F of the makeup water temperature. The unit shall have a 150 psig rating at 365 F.
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.
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.
A gauge panel shall be furnished and shall include dial thermometers for indicating makeup inlet temperature, makeup outlet tem-
perature and blowdown outlet temperature. The gauge panel shall be prepiped and mounted on the unit.
The entire system shall be supported by steel legs with 3/4" diameter holes for customer-supplied 1/2" diameter bolts. The system
will be painted with Cleaver-Brooks blue finish paint.
2.0 Optional Equipment

A SC-325 Sample Cooler with isolation valves and interconnecting piping shall be supplied for a single boiler application. With
each additional boiler, a sample valve assembly shall be added and manifolded to the sample cooler.
3.0 Multiple Boiler Operation

A manifold assembly shall be necessary for multiple boiler installations and shall consist of the necessary piping with threaded
connections for the customer-supplied continuous blowoff valves.
H12-
02-02
NOTES
H12-12
02-02
Section H13
SAMPLE COOLERS
CONTENTS
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H13-3
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H13-3
ILLUSTRATIONS
Figure H13-1. Sample Cooler (SC-22) Dimensions 4
Figure H13-2. Performance Curves for Hot Water Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H13-4
Figure H13-3. Sample Cooler (SC-42) Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H13-5
Figure H13-4. Performance Curves for Steam Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H13-5
TABLES
Table H13-1. Sample Cooler Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H13-3
H13-1
02-02
Sample Coolers Feedwater Systems
This section contains information on Cleaver-Brooks sample coolers. The Model SC22 and SC42 Sample Coolers are used to cool
boiler water samples under pressure so that an accurate sampling can be made. When boiler water samples are taken without being
properly cooled (while under boiler pressure), as much as 20% of the sample can flash to steam, causing inaccurate measurement
of boiler water quality.
H13-2
02-02
Feedwater Systems Sample Coolers
FEATURES AND BENEFITS tem. The Model SC-22 sample cooler is simple, compact and
designed to cool boiler samples with minimum disturbance to
system pressure. The 316 stainless steel tubing is a continuous,
Heavy Duty All Stainless Steel Wetted Parts:
jointless, coil arrangement. The tubing is maintenance-free,
SC-22 cools hot water samples up to 850 F and 2000 psig. rated for 850 F at 2000 psig. The shell is also 316 stainless
steel, rated at 450 F, 250 psig.
SC-42 cools steam or water samples up to 1000 F and 5000
psig. The design has baffling on the shell side to achieve high cool-
ing water flow which minimizes pressure drop, vibration and
True Counterflow Cooling: scaling. The shell can be easily removed for inspection and/or
cleaning without disconnecting sample or water lines.
Effective baffling on the shell side produces full counter flow
with high cooling water flow and minimum pressure drop,
vibration and scaling.
NOTICE
Proper temperature achieved.
The Model SC-22 Sample Cooler is not generally rec-
Compact Design: ommended for steam samples. Use SC-42 for steam
sample cooler information.
SC-22 3-1/2" square x 5-1/2" long compact size. Easily
mounted in cooling water piping without using brackets or
special supports. DIMENSIONS AND RATINGS
SC-42 3-1/2 square x 11-1/4 long mounted in cooling Dimensions for Model SC-22 are shown in Figure H13-1, and
water piping without using brackets or special supports. in Figure H13-3 for Model SC-42. Ratings are shown in Table
H13-1.
Stainless Steel Coil:
Single continuous tube with no joints assures long, ENGINEERING DATA
maintenance free operation. Refer to Figures H13-2 (hot water) and H13-4 (steam) for per-
formance curves. For example, the hot water samples show the
Removable Shell: relationship of outgoing sample temperature to incoming cool-
ing water temperature for various sample temperatures (diago-
Shell can be easily removed for inspection and/or cleaning
nal lines) and flow rates (Scale at left). Example: If the water
without disconnecting sample water lines.
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
Lowest Cost: dotted line at 0.25 gpm to 400 F inlet temperature. Read 18 F
Largest heat transfer surface per unit of cost of any sample temperature approach. Sample pressure drop will be approxi-
coolers. mately 6.5 psig. Sample will cool to 88 F, (70 F coolant + 18
F approach).
PRODUCT OFFERING
The sample cooler is a low-pressure-drop system for monitor-
ing boiler water quality without shutting down the boiler sys-
Table H13-1. Sample Cooler Ratings
MODEL SHELL TUBE TUBE SHELL & HEAD AREA WEIGHT

NO. DESIGN DESIGN MATERIAL MATERIAL
SC-22 250 psig @ 2000 psig @ 1/4" OD SSA 304 Stainless 1.2 sq-ft 9 lbs
450oF 850oF
SC-42 450 psig @ 5000 psig @ 1/4 OD 304 SS 2.4 sq-ft 12 lbs
650oF 1000oF 316 SS
A. Tubing is 300 series stainless steel with chemical and physical properties equal to, or better
than T304.
H13-3
Figure H13-1. Sample Cooler (SC-22) Dimensions
MODEL SC-22 (2.4 SQ-FT) SAMPLE

3 GPM COOLING WATER PRESS.
1PSIG PRESSURE DROP DROP
(PSIG)
APPROACH TEMPERATURE F
Figure H13-2. Performance Curves for Hot Water Samples
H13-4
Feedwater Systems Sample Coolers
Figure H13-3. Sample Cooler (SC-42) Dimensions
SAMPLE DATA MODEL SC-42 SAMPLE

3 GPM COOLING WATER PRESS.
LB/ CC/ DROP
GPM HR 1 PSIG PRESSURE DROP (PSIG)
MIN
APPROACH TEMPERATURE F
Figure H13-4. Performance Curves for Steam Samples
H13-5
Furnish _______ Cleaver-Brooks Model SC-22 sample cooler(s) consisting of 304 stainless steel head and shell, jointless coiled
T304 stainless steel tubing, and a carbon steel mounting bracket.
The sample cooler shall be of compact bolted design and shall require no larger space than 3-1/2" square x 5-1/2". The tubing and
shell shall be removable for cleaning without disturbing connections. The cooling water connections shall be 3/8" FPT and the
sample tube connections shall be
1/4" OD.
The tubing shall be rated at 2000 psig at 635 F. The surface area shall be 1.2 sq-ft.
Furnish _______ Cleaver-Brooks Model SC-42 sample cooler(s) consisting of 304 stainless steel head and shell, jointless coiled
T304 stainless steel tubing, and a carbon steel mounting bracket.
The sample cooler shall be of compact bolted design and shall require no larger space than 3-1/2" square x 11". The tubing and
shell shall be removable for cleaning without disturbing connections. The cooling water connections shall be 3/8" FPT and the
sample tube connections shall be
1/4" OD.
The tubing shall be rated at 5000 psig at 1000 F. The surface area shall be 2.4 sq-ft.
H13-6
02-02
Section I
SYSTEM FUNDAMENTALS
Boiler Selection Considerations I1
Hot Water Systems I2
Steam Systems I3
General Engineering Data I4
Ia
02-02
General System Fundamentals
Notes
Ib
Section I1
BOILER SELECTION CONSIDERATIONS
CONTENTS
BOILER TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1- 3
Scotch Marine - The Classic Firetube Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-3
Firebox boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4
Commercial Watertube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4
Industrial Watertube Boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4
Flexible Watertube (Bent Tube) Boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4
Membrane Watertube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4
Cast Iron Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4
Electric Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4
BOILER SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-4
Codes and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-5
Steam or Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-6
System Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-6
Heating Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-6
Process Load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-6
Combination Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-7
Defining Load Variations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-7
System Load Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-7
Load Tracking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-7
Number of Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-8
Back-Up Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-8
Type of Load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-8
Downtime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-8
Boiler Turndown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-8
Performance Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9
Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9
Combustion Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9
Thermal Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9
Boiler Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9
Fuel-to-Steam Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9
Stack Temperature and Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9
Excess Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-9
Radiation and Convection Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10
Heating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10
Flue Gas Passes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10
Integral Boiler/Burner Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10
Special Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10
Replacement Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10
PAYBACK ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10
Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-12
I1-1
02-02
Boiler Selection Considerations System Fundamentals
ILLUSTRATIONS
Figure I1-1. Annual Gas Cost as a Function of Gas Use and Unit Price . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-14
Figure I1-2. Annual Gas Cost as a Function of Gas Use and Unit Price (Expansion of Figure I1-1) . . . . . . . . . . . . . . . . . I1-15
Figure I1-3. Annual Fuel Oil Cost as a Function of Fuel Oil Use and Unit Price . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-16
Figure I1-4. Annual Fuel Oil Cost as a Function of Fuel Oil Use and Unit Price (Expansion of Figure I1-3) . . . . . . . . . . I1-17
Figure I1-5. System Efficiency Improvement as a Function of Incremental Component Efficiency Gain . . . . . . . . . . . . . I1-18
Figure I1-6. Annual Savings as a Function of Annual Fuel Cost and System Efficiency Improvement . . . . . . . . . . . . . . . I1-19
Figure I1-7. Annual Savings as a Function of Annual Fuel Cost and System Efficiency Improvement
(Expansion of Figure I1-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-20
TABLES
Table I1-1.Common Boiler Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-3
Table I1-2. Considerations for Selecting a Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-5
Table I1-3. Load Demand Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-7
Table I1-4.Typical Firetube Boiler Fuel Consumption Rates - Natural Gas (MM/Btu/hr) . . . . . . . . . . . . . . . . . . . . . . . . . I1-11
Table I1-5. Typical Firetube Boiler Fuel Consumption Rates - No. 6 Oil (gal/hr) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-12
Table I1-6. Typical Firetube Boiler Fuel Consumption Rates - No. 2 Oil (gal/hr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-13
Perhaps no other piece of equipment is more important to a facility than the boiler. Proper boiler selection, to meet the needs of the
application, is a critical factor in the design of any steam or hot water system.
This section provides information to consider when selecting a boiler. This information is divided into three main subsections:
1. Boiler Types
Typical boiler types are 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 num-
ber 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.
For additional definitions, refer to the glossary at the end of The Boiler Book.
I1-2
02-02
I1-3
02-02
BOILER TYPES be necessary to use very thick shell and tube sheet material.
For this reason, a watertube boiler is generally used if pressure
The boilers discussed in this book are packaged boilers. This above 350 psig design is needed.
concept has been around for more than 60 years. The packaged
boiler originated with Cleaver-Brooks, when a pre-engineered Firetube boilers are usually built similar to a shell and tube
assembly was supplied to a customer to eliminate his need to heat exchanger. A large quantity of tubes results in more heat-
purchase separate components, and then try to make them ing surface per boiler horsepower, which greatly improves heat
work together. The packaged boiler has proven to be a suc- transfer and efficiency.
cessful concept - with more than 150,000 Cleaver-Brooks Firetube boilers are rated in boiler horsepower (BHP), which
units around the world. should not be confused with other horsepower measurements.
There are many types of packaged boilers available. Table I1-1 The furnace and the banks of tubes are used to transfer heat to
compares common boiler types and their features. the water. Combustion occurs within the furnace and the flue
The following is an overview of different types of boilers. gases are routed through the tubes to the stack outlet. Firetube
boilers are available in two, three and four pass designs. A sin-
Scotch Marine - The Classic Firetube Boiler gle pass is defined as the area where combustion gases travel
the length of the boiler. Generally, boiler efficiencies increase
The Scotch Marine style of boiler has become so popular in with the number of passes.
the last 40 years that it frequently is referred to simply as a
firetube boiler. Firetube boilers are available for low or high Firetube boilers are available in either dryback or wetback
pressure steam, or for hot water applications. Firetube boilers design. In the dryback boiler, a refractory-lined chamber, out-
are typically used for applications ranging from 15 to 1500 side of the vessel, is used to direct the combustion gases from
horsepower. A firetube boiler is a cylindrical vessel, with the the furnace to the tube banks. Easy access to all internal areas
flame in the furnace and the combustion gases inside the tubes. of the boiler including tubes, burner, furnace, and refractory, is
The furnace and tubes are within a larger vessel, which con- available from either end of the boiler. This makes mainte-
tains the water and steam. nance easier and reduces associated costs.
The firetube construction provides some characteristics that The wetback boiler design has a water cooled turn around
differentiate it from other boiler types. Because of its vessel chamber used to direct the flue gases from the furnace to the
size, the firetube contains a large amount of water, allowing it tube banks. The wetback design requires less refractory main-
to respond to load changes with minimum variation in steam tenance; however, internal pressure vessel maintenance, such
pressure. as cleaning, is more difficult and costly. In addition, the wet-
back design is more prone to water side sludge buildup,
Steam pressure in a firetube boiler is generally limited to because of the restricted flow areas near the turn around cham-
approximately 350 psig. To achieve higher pressure, it would ber.
Table I1-1. Common Boiler Types

CAST MEMBRANE FLEXIBLE INDUSTRIAL VERTICAL
ELECTRIC FIREBOX FIRETUBE
IRON WATERTUBE WATERTUBE WATERTUBE FIRETUBE
Efficiency Low Medium High Medium High Medium Medium Low/Medium

Floor Space Low Very Low Very Low Medium Medium/ Low High Very Low
Required High
Maintenance Medium/High Medium Medium/High Low Low Medium High Low
Initial Cost Medium Low/Medium High Low Medium/ Low/Medium High Low
High
No. of Options Low Medium Medium Low/Medium High Medium High Low
Available
Pressure HW/LPS HW/LPS HPS HW/LPS HPS HW/LPS HW/LPS HW/LPS High Temp HW HW/LPS
Range to 600 psig to 900 PSIG HPS to 150
HPS to 350 HPS to 900 psig
psig 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 Heating/ Heating/ Heating/ Heating Heating/ Heating Process Heating/
Applications Process Process Process Process Process
Comments Field Field
Erectable Erectable
I1-4
02-02
System Fundamentals Boiler Selection Considerations
For more information on specific firetube boiler products, refer shock. Flexible watertube boilers are available in size ranges
to Section A. from 2 to 9 MMBtu/hr input. Flexible watertube boilers are
available for low pressure steam or hot water applications.
Firebox boilers Field erectable packages are also available.
The firebox boiler uses similar tube attachment techniques as For more information on flexible watertube boilers, refer to
the firetube boiler. Its combustion chamber is not round, like Section B.
the firetubes cylindrical furnace. The firebox boiler is typi-
cally manufactured to low pressure steam or hot water applica- Membrane Watertube Boilers
tions. The firebox boiler is a compact, economical unit and
The membrane watertube boiler is available for low or high
serves as a good fit for seasonal use and when efficiency is not
pressure steam or hot water applications. High outputs are
the driving factor. Sizes range from 12 to 337 horsepower.
available in a compact design and should be considered where
space is limited. Sizes range from 34 to 143 horsepower.
Commercial Watertube Boilers
For more information on membrane type commercial water-
Commercial watertube boilers typically produce steam or hot tube boilers, refer to Section B.
water for commercial, or modest-size applications. There are a
wide variety of types, sizes, capacities, and design pressures
Cast Iron Boilers
available. Commercial watertube boilers can be membrane
type, straight tube, modular, etc. They can be either atmo- Cast iron boilers are limited to low-pressure steam or hot water
spherically fired or utilize power burners. applications, and typically range in size from 25 to 200 horse-
power. One advantage of the cast iron boiler is its modular
For more information on commercial watertube boilers, refer
design, which includes sections for field erection.
to Section B.
For more information on cast iron boiler products, contact your
Industrial Watertube Boilers local Cleaver-Brooks authorized representative.
The industrial watertube boiler typically produces steam or
Electric Boilers
hot water primarily for industrial process applications, and is
used less frequently for heating applications. In the watertube Electric boilers are noted for being clean, quiet, easy to install,
design, tubes contain steam and/or water and the products of and compact. Because there are no combustion considerations,
combustion pass around the tubes. Typically, watertube an electric boiler has minimal complexity (no fuels or fuel han-
designs consist of multiple drums. A steam drum (upper) and dling equipment) with easily replaceable heating elements.
mud drums (lower) are connected by the tubes, which form
An electric boiler may be the perfect alternative to supply low
both the convection section and the furnace area.
or high pressure steam or hot water where the customer is
Packaged industrial watertube boilers are typically rated in restricted by emission regulations. In areas where the cost of
pounds of steam per hour output at operating conditions and electric power is minimal, the electric boiler could be the best
range from 10,000 to 134,000 lbs/hr. choice. Sizes range from 9 kW to 3,375 kW output.
Industrial watertube boilers are noted for their fast steaming For more information on electric boilers, refer to Section B.
capability. Steam is generated very rapidly because of the rela-
tively low water content. This allows them to respond quickly BOILER SELECTION
to changing load demands.
Six criteria should be considered when selecting a boiler to
The industrial watertube boiler design makes it capable of meet the application needs. The criteria are:
generating either saturated or superheated steam. When appli-
cations dictate superheated steam usage, large or fluctuating 1. Codes and standards requirements
steam loads, or high pressures (greater than 350 psig), an 2. Steam or Hot Water
industrial watertube boiler should be considered.
3. Boiler load
For more information on industrial watertube boilers, refer to
Section C. 4. Number of boilers
5. Performance considerations
Flexible Watertube (Bent Tube) Boilers
6. Special considerations
Flexible watertube boilers are a common type of boiler used
for heating applications because of their resistance to thermal
I1-5
02-02
Codes and Standards Most areas have established a maximum temperature at

which water can be discharged to the sewer. In this case, a
There are a number of codes and standards, laws, and regula-
blowdown separator aftercooler is required.
tions covering boilers and related equipment that should be
considered when designing a system. Regulatory requirements Most state, local or provincial authorities require a permit to
are dictated by a variety of sources and are all focused prima- install and/or operate a boiler. Additional restrictions may
rily on safety. For more information on how the various rules apply in non-attainment areas where air quality does not
affect boiler selection and operation, you may want to contact meet the national ambient air quality standards and emission
your local Cleaver-Brooks authorized representative. Here are regulations are more stringent.
some key rules to consider:
For all new boilers with inputs over 10 MMBtu/hr, U.S.
The boiler industry is tightly regulated by the American Federal emission standards apply, including permitting and
Society of Mechanical Engineers (ASME) and the ASME reporting procedures.
Codes, which governs boiler design, inspection, and quality
Limits on fuel sulfur content are frequently set at 0.5%
assurance. The boilers pressure vessel must have an ASME
maximum.
stamp. (Deaerators, economizers, and other pressure vessels
must also be ASME stamped). A full-time boiler operator may be required. Operator
requirement depends on the boilers size, pressure, heating
The insurance company insuring the facility or boiler may
surface or volume of water. Boilers can be selected which
dictate additional requirements. Boiler manufacturers
minimize the requirements, either by falling under the
provide special boiler trim according to the requirements of
requirements and being exempt or with special equipment
the major insurance companies. Special boiler trim items
that gives the operator more freedom in the facility.
usually pertain to added safety controls.
Most states or provinces require an annual boiler inspection.
Some industries, such as food processing, brewing, or pharma-
There may be other requirements on piping as well.
ceuticals, may also have additional regulations that have an
impact on the boiler and the boiler room. Before beginning the selection process, refer to Table I1-2,
which shows multiple considerations for selecting a packaged
A UL, ULC, cUL, CSA or CGA listing, or Canadian
boiler.
Registration Number (CRN) may be required. State, local, or
provincial authorities may require data on the boiler controls
or basic design criteria.
Table I1-2. Considerations for Selecting a Boiler

BOILER SELECTION
COMMERCIAL
WATERTUBE
WATERTUBE
CAST IRON
FLEXTUBE
FIRETUBE
ELECTRIC
VERTICAL
FIREBOX
SPECIAL
REQUIREMENT OR
OHIO
APPLICATION
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 X X
psig, or Superheat
A. With Flue Gas Recirculation/ Model CB (LE) Option.
I1-6
02-02
Steam or Hot Water System Load

Now that you have a general overview of the types of boilers In addition to the system load considerations provided in this
and code and standards requirements, its time to look at the section, many excellent reference manuals are available to help
facilitys application in order to see how the boiler will be further define specific load details and characteristics. For more
used. Keep in mind, the primary purpose of the boiler is to information, refer to the ABMA Firetube Engineering Guide,
supply energy to the facilitys operations - for heat, manufac- the ASHRAE Handbook, or contact your local Cleaver-Brooks
turing process, laundry, kitchen, etc. The nature of the facil- authorized representative.
itys operation will dictate whether a steam or hot water boiler
System load is measured in either Btus or pounds of steam (at a
should be used.
specific pressure and temperature). When discussing the sys-
Hot water is commonly used in heating applications with the tem load, we will include references to both steam and hot
boiler supplying water to the system at 180 F to 220 F. The water. However, not all situations or criteria apply to both. It
operating pressure for hot water heating systems usually is 30 would be nearly impossible to size and select a boiler(s) with-
psig to 125 psig. Under these conditions, there is a wide range out knowing the system load requirements. Knowing the sys-
of hot water boiler products available. If system requirements tem load provides the following information:
are for hot water of more than 240 F, a high temperature
The boiler(s) capacity, taken from the maximum system load
water boiler should be considered.
requirement.
For more information on application considerations for hot
The boiler(s) turndown, taken from the minimum system
water boilers and hot water systems, refer to Hot Water Sys-
load requirement.
tems, Section I2.
Conditions for maximum efficiency, taken from the average
Steam boilers are designed for low pressure or high pressure
system load requirement.
applications. Low pressure boilers are limited to 15 psig
design, and are typically used for heating applications. High Determining the total system load requires an understanding of
pressure boilers are typically used for process loads and can the type(s) of load in the system. There are three types of loads:
have an operating pressure of 75 to 700 psig. Most steam heating, process, and combination.
boiler systems require saturated steam.
Steam and hot water boilers are defined according to design Heating Load
pressure and operating pressure. Design pressure is the maxi- A heating load is typically low pressure steam or hot water, and
mum pressure used in the design of the boiler for the purpose is relatively simple to define because there is not a great deal of
of calculating the minimum permissible thickness or physical instantaneous changes to the load. And, once a heating load is
characteristics of the pressure vessel parts of the boiler. Typi- computed, the number can easily be transferred into the equip-
cally, the safety valves are set at or below design pressure. ment size requirements. A heating load is used to maintain
Operating pressure is the pressure of the boiler at which it nor- building heat. Cooling loads, using steam to run an absorption
mally operates. The operating pressure usually is maintained chiller, also are included when computing a heating load. Char-
at a suitable level below the setting of the pressure relieving acteristics of a heating load include large seasonal variations
valve(s) to prevent their frequent opening during normal oper- but small instantaneous demand changes. The boiler should be
ation. sized for the worst possible weather conditions, which means
that true capacity is rarely reached.
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) Process Load
steam quality. One example of an application where super- A process load is usually a high pressure steam load. A process
heated steam may be required is with a steam turbine. The tur- load pertains to manufacturing operations, where heat from
bines blades require very dry steam because the moisture can steam or hot water is used in the process. A process load is fur-
destroy the blades. When very high pressure or superheated ther defined as either continuous or batch. In a continuous load,
steam is required, an industrial watertube boiler should be the demand is fairly constant - such as in a heating load. The
selected. batch load is characterized by short-term demands. The batch
For more information on application considerations for steam load is a key issue when selecting equipment, because a batch-
boilers and steam systems, refer to Section I3, Steam Systems. type process load can have a very large instantaneous demand
that can be several times larger than the rating of the boiler. For
I1-7
02-02
example, based on its size, a heating coil can consume a large Daily Variation. Daily variation can occur due to variations in
amount of steam simply to fill and pressurize the coil. When the work hours, or the heat required at various times of the day
designing a boiler room for a process load with instantaneous or weekend. Minimum and maximum seasonal variations
demand, a more careful boiler selection process should take mentioned earlier may already reflect these changes if they
place. occur daily. If not, the minimum and maximum daily loads
should be included.
Combination Load The seasonal and daily variations define the size of the load
Many facilities have a mixture of loads - different types of pro- that the boiler(s) must handle. Seasonal and daily variations
cess loads and combinations of heating and process loads. The also help define the number of boilers and turndown require-
information just given on heating and process loads should be ments.
taken into consideration when dealing with a combination Instantaneous Demand. Instantaneous demand is a sudden
load. peak load change that is usually of short duration. These types
of loads are sometimes hidden. Many machines or processes
Defining Load Variations are rated in pounds of steam per hour or Btu/hr as running
Loads vary and a power plant must be capable of handling the loads, under balanced operating conditions, and there is no
minimum load, the maximum load, and any load variations. recognition given to cold startup, peak or pickup loads.
Boiler selection is often dictated by the variation in load The instantaneous load demand is important to consider when
demand, rather than by the total quantity of steam or hot water selecting a boiler to ensure that these load variations are taken
required. into account. If the instantaneous demand is not included in
the system load calculations, the boiler(s) may be undersized.
There are three basic types of load variations: seasonal, daily,
and instantaneous.
System Load Summary
Seasonal Variations. For a heating system, seasonal variations The load demand matrix shown in Table I1-3 can be used as a
can mean no demand in the summer, light demand in the fall work sheet in determining the minimum, maximum, and aver-
and spring, and heavy demand in the winter. Manufacturing age system loads.
operations often have seasonal variations, because the demand
for production may vary. When selecting boiler equipment, the
Load Tracking
minimum and maximum load for each season should be deter-
mined. Load tracking is the ability of a boiler to respond to changes in
steam or hot water demand. Most often associated with pro-
Table I1-3. Load Demand Matrix

MINIMUM WEIGHTED AVERAGE MAXIMUM
Heating Load 1
Heating Load 2
Heating Load 3
Total Heating Load
Process Load 1
Process Load 2
Process Load 3
Total Process Load
Instantaneous Load
Total Load
Utilize a load demand matrix to analyze each load and determine minimum, average, and maximum load require-
ments.
I1-8
02-02
cess loads, load tracking focuses on the boilers ability to sup- Downtime
ply a constant volume of steam at the required pressure. Another way to determine whether a backup boiler is a wise
The ability of the boiler to track a variable load depends on the decision is to compute the cost of downtime to the owner or the
boiler type, burner turndown capability, feedwater valve con- user, as shown in the following three examples:
trol, and combustion control design. If the analysis of the load A chemical company manufactures dry cell battery com-
shows highly variable load conditions, a more complex control pound in a batch process. The process temperature must be
package may be necessary. This type of control is achieved maintained within 2 degrees. The boiler shuts down on a
with sophisticated boiler management systems. For more flame failure. They have 20 minutes to recover steam or
information on these types of systems, refer to Controls, Sec- the batch is scrap. The value of the product is $250,000.
tion D, or contact your local Cleaver-Brooks authorized repre-
sentative. A Midwestern insurance company building has comfort
heat supplied by one boiler. There are over 2000 workers
If the application has instantaneous load demands, whereby a in the building. The boiler shuts down due to a failed gas
large volume of steam is required for a short period of time, a valve. Outside, its 11F. Inside, the temperature continues
boiler with a large energy storage reserve, such as a firetube, to drop and, at 1:30 in the afternoon, all 2,000 workers are
should be considered. If the application dictates large vari- sent home.
ances in load demand, where the load swings frequently for
long periods of time, the best choice is probably a watertube A meat processing company makes its entire packaged
type boiler, because it contains less water and can respond to ham line in a Southern plant. It operates 24 hours a day,
the variances more rapidly. every day. A single boiler provides heat for curing, steriliz-
ing, and cleaning. The boiler goes down due to a lack of
In all cases, operation of the burner should be taken into feedwater. Each hour of steam loss results in four hours of
account in selecting a boiler(s) to meet system demand. The lost production.
burner will require proper operating controls that can accu-
rately sense the varying demands and be capable of the turn-
Boiler Turndown
down requirements. The boiler feedwater valve and control
design are also critical if load swings are expected. Boiler turndown is the ratio between full boiler output and the
boiler output when operating at low fire. Typical boiler turn-
Number of Boilers down 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
Back-Up Boilers
burner will modulate down to 40 horsepower.
When selecting the boiler(s), consideration should be given to
The ability of the burner to turn down reduces frequent on and
back-up equipment to accommodate future expansion, emer-
off cycling. Fully modulating burners are typically designed to
gency repairs, and maintenance. There are a number of consid-
operate down to 25% of rated capacity. At a load that is 20% of
erations for a backup boiler.
the rated capacity, the boiler will turn off and cycle frequently.
Type of Load A boiler operating at low load conditions can cycle as fre-
quently as 12 times per hour, or 288 times per day. With each
Heating systems and non-critical loads that do not result in a
cycle, pre- and post-purge air flow removes heat from the
sudden loss of production generally have little or no backup.
boiler and sends it out the stack. The energy loss can be elimi-
While this is not recommended, it is still common practice.
nated by keeping the boiler on at low firing rates. Every time
These types of applications rely on the ability to make repairs
the boiler cycles off, it must go through a specific start-up
quickly to reduce downtime. The risk involved in having no
sequence for safety assurance. It requires about one to two
backup is a total loss of heat when the boiler is not in service.
minutes to place the boiler back on line. And, if theres a sud-
When process or heating loads use multiple boilers during den load demand, the start-up sequence cannot be accelerated.
peak times, and one boiler during most other times, the avail- Keeping the boiler on line assures the quickest response to load
ability of an additional boiler to provide full backup during changes. Frequent cycling also accelerates wear of boiler com-
maximum demand should be considered. ponents. Maintenance increases and, more importantly, the
chance of component failure increases.
In applications with critical steam or hot water requirements,
laws or codes may require a backup. Even if laws or codes do As discussed earlier, boiler(s) capacity requirement determined
not require a backup, there are many cases where the operation by many different types of load variations in the system. Boiler
cannot tolerate downtime. For example, a hotel uses hot water over-sizing occurs when future expansion and safety factors
24 hours a day, seven days a week. During periods of mainte- are added to assure that the boiler is large enough for the appli-
nance or in an emergency, a backup boiler is required. cation. If the boiler is oversized, the ability of the boiler to han-
I1-9
02-02
dle minimum loads without cycling is reduced. Therefore, has little bearing on combustion efficiency. A well- designed
capacity and turndown should be considered together for burner will operate with as little as 15 to 20% excess air, while
proper boiler selection to meet overall system load require- converting all combustibles in the fuel to thermal energy.
ments.
Thermal Efficiency
Performance Considerations Thermal efficiency is the effectiveness of the heat transfer in a
Three important considerations pertain to fuels, emissions, and boiler. It does not take into account boiler radiation and con-
efficiency. All three have important impact on boiler perfor- vection losses - for example, from the boiler shell, water col-
mance, and can affect long-term boiler operating costs. umn piping, etc.
Fuels Boiler Efficiency

Remember, from an operating perspective, fuel costs typically The term boiler efficiency is often substituted for combus-
account for approximately 10% of a facilitys total operating tion or thermal efficiency. True boiler efficiency is the measure
budget. Therefore, fuel is an important consideration. Nor- of fuel-to-steam efficiency.
mally, the fuels of choice are natural gas, propane, or light oil.
Increasingly stringent emission standards have greatly reduced Fuel-to-Steam Efficiency
the use of heavy oil and solid fuels such as coal and wood. Of Cleaver-Brooks guaranteed boiler efficiencies are fuel-to-
the fossil fuels, natural gas burns cleanest and leaves less resi- steam efficiencies.
due; therefore less maintenance is required.
Fuel-to-steam efficiency is the correct definition to use when
It can be advantageous to supply a boiler with a combination determining boiler efficiency. Fuel-to-steam efficiency is cal-
burner that can burn two fuels independently - for example, oil culated using either of two methods, as prescribed by the
or natural gas. A combination burner allows the customer to ASME Power Test Code, PTC 4.1. The first method is input-
take advantage of peak time rates, which substantially output. This is the ratio of Btu output divided by Btu input x
reduces the costs of a therm of gas when operating off peak 100.
by merely switching to the back up fuel. Dual fuel capability
also is beneficial if the primary fuel supply must be shut down The second method is heat balance. This method considers
for safety or maintenance reasons. stack temperature and losses, excess air levels, and radiation
and convection losses. Therefore, the heat balance calculation
Some waste streams can be used as fuel in the boiler. In addi- for fuel-to-steam efficiency is 100 minus the total percent stack
tion to reducing fuel costs, firing an alternate fuel in a boiler loss and minus the percent radiation and convection losses.
can greatly reduce disposal costs. Waste streams are typically
used in combination with standard fuels to ensure safe opera-
Stack Temperature and Losses
tion and to provide additional operating flexibility.
Stack temperature is the temperature of the combustion gases
Emissions (dry and water vapor) leaving the boiler. A well-designed
boiler removes as much heat as possible from the combustion
Emission standards for boilers have become very stringent in gases. Thus, lower stack temperature represents more effective
many areas, because of the new clean air regulations. The abil- heat transfer and lower heat loss up the stack. The stack tem-
ity of the boiler to meet emission regulations depends on the perature reflects the energy that did not transfer from the fuel
type of boiler and burner options. For more information, refer to steam or hot water. Stack temperature is a visible indicator
to Emissions, Section E. of boiler efficiency. Any time efficiency is guaranteed, pre-
dicted stack temperatures should be verified.
Efficiency
Stack loss is a measure of the amount of heat carried away by
Efficiency is used in the measure of economic performance of dry flue gases (unused heat) and the moisture loss (product of
any piece of equipment. In the boiler industry, there are four combustion), based on the fuel analysis of the specific fuel
common definitions of efficiency, but only one true measure- being used, moisture in the combustion air, etc.
ment. Following are the definitions and how to measure effi-
ciency. Excess Air
Excess air provides safe operation above stoichiometric condi-
Combustion Efficiency
tions. A burner is typically set up with 15 to 20% excess air.
Combustion efficiency is the effectiveness of the burner only Higher excess air levels result in fuel being used to heat the air
and relates to its ability to completely burn the fuel. The boiler
I1-10
02-02
instead of transferring it to usable energy, increasing stack Floor space required.

losses.
Total space requirements.
Radiation and Convection Losses Access space for maintenance.

Radiation and convection losses will vary with boiler type, Size and characteristics of the boiler to be replaced, including
size, and operating pressure. The losses are typically consid- location of existing piping, the boiler stack and utilities.
ered constant in Btu/hr, but become a larger percentage loss as Boiler weight limitations.
the firing rate decreases.
With little or no access to the boiler room, the cast iron boiler
Boiler design factors that also impact efficiencies of the boiler and some bent-tube type boilers can be carried into the boiler
are heating surface, flue gas passes, and design of the boiler room in sections or pieces and easily assembled, with no
and burner package. welding required.
Heating Surface Electric boilers should also be considered, especially since

they do not require a stack.
Heating surface is one criterion used when comparing boilers.
Boilers with higher heating surface per boiler horsepower tend Vertical firetube boilers have a small floor space requirement.
to be more efficient and operate with less thermal stress. Many
packaged boilers are offered with five square feet of heating PAYBACK ANALYSIS
surface per boiler horsepower as an optimum design for peak
efficiency. 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
Flue Gas Passes
process. The procedure presented can be applied to equipment
The number of passes that the flue gas travels before exiting selection and the economic evaluation of alternative systems.
the boiler is also a good criterion when comparing boilers. As
the flue gas travels through the boiler it cools and, therefore, The effect of a single piece of equipment can be a significant
changes volume. Multiple pass boilers increase efficiency part of the overall transfer of energy from the fuel burned to the
because the passes are designed to maximize flue gas veloci- thermal energy of the steam or hot water delivered. The perfor-
ties as the flue gas cools. mance of equipment, such as the boiler, stack gas recovery sys-
tems (economizers), condensate recovery systems (deaerators,
etc.), oxygen trim systems, and blowdown heat recovery sys-
Integral Boiler/Burner Package
tems, should be considered. Efficiency gains from each piece
Ultimately, the performance of the boiler is based on the abil- of equipment need to be evaluated individually in the context
ity of the burner, the boiler, and the controls to work together. of the overall system to determine the incremental fuel cost
When specifying performance, efficiency, emissions, turn- savings.
down, capacity, and excess air all must be evaluated together.
Savings from efficiency gains are used to evaluate the payback
The efficiency of the boiler is based, in part, on the burner
potential of the equipment. Payback simply refers to the time
being capable of operating at optimum excess air levels. Burn-
period that will elapse before the cumulative cost savings will
ers not properly designed will produce CO or soot at these
equal the incremental capital cost of the equipment selected.
excess air levels, foul the boiler, and substantially reduce effi-
ciency. In addition to the boiler and burner, the controls In summary, this section provides a procedure and a set of
included on the boiler (flame safeguard, oxygen trim, etc.) can tables and figures to assist in assessing the economic justifica-
enhance efficiency and reduce overall operating costs for the tion of purchasing higher performance equipment or additional
customer. A true packaged boiler design includes the burner, energy savings equipment (e.g., economizers, oxygen trim con-
boiler, and controls as a single, engineered unit. trols, etc.). This procedure may also be used to evaluate the
operating cost impact of different system configurations.
Special Considerations The tables and figures provided are not unique to Cleaver-
Brook products. Therefore, the procedures may be applied to
Replacement Boilers any thermal energy consuming system. Before proceeding,
If the boiler is to be placed in an existing facility, there are a product related information (e.g., efficiency and fuel consump-
number of considerations: tion rates) should be obtained for each specific product.
I1-11
02-02
Having defined a basic system configuration, and having iden- cost ($/MMBtu). Figure I1-2 provides a more detailed graph
tified equipment that would yield incremental performance for lower gas usage applications. Save the annual fuel cost
improvement (and investment), the payback analysis sequence value for Step 5.
is straight forward and can be summarized as follows:
(Note that the figures referenced in this discussion are located
1. Estimate boiler fuel consumption rate. at the end of this section.)
2. Estimate annual fuel use. Figures I1-3 and I1-4 are used to determine annual fuel cost
for oil fuels based on annual oil use (thousand gal/yr) and oil
3. Estimate annual fuel cost.
cost ($/gal). Figure I1-4 provides a more detailed graph for
4. Determine potential incremental efficiency improvement. lower oil usage application. Save the annual fuel cost value for
Step 5.
5. Estimate potential annual fuel savings.
Step 4: Incremental Efficiency Improvement
6. Determine the payback period for the investment.
If an improvement is being added to a boiler (economizer, oxy-
7. Refine the analysis.
gen trim, etc.) that is designed to improve the efficiency of the
The remainder of this section outlines the step-by-step proce- boiler by x percent (incremental efficiency gain). Use Figure
dure to be used in conjunction with the figures and tables. I1-4 to take the base system efficiency (bottom) and the incre-
mental efficiency gain (right side) to determine the actual
Remember, the lowest cost product is not necessarily the most
improvement in the system efficiency to be used for the cost
economic choice. In fact, most often it is not the best choice!
savings in Step 5.
Step 1: Boiler Fuel Consumption Rate
Step 5: Annual Fuel Savings
Use Tables 11-4, I1-5, and I1-6 to compare the fuel consump-
Use Figure I1-6 to determine the annual fuel savings based on
tion rates of two boiler configurations with different fuel-to-
the annual fuel cost and system efficiency improvement (right
steam efficiency or, as a base fuel rate for a given boiler config-
side of graph). Figure I1-7 provides for a more detailed graph
uration. Find the appropriate boiler size and the efficiency on
for lower fuel cost applications.
the table to find the associated fuel consumption.
Step 6: Payback Period
Step 2: Annual Fuel Usage
The payback period is the years required to recover the capital
Multiply the hourly fuel consumption rates by the annual
investment. To determine payback simply divide the capital
hours of operation to determine the annual fuel usage rate.
cost of the equipment by the annual savings.
Step 3: Annual Fuel Cost
To determine the amount of capital available based on a known
Figures I1-1 and I1-2 are used to determine annual fuel cost payback period, multiply the annual savings by the payback
for natural gas based on annual gas use (billion Btu/yr) and gas period required.
Table I1-4. Typical Firetube Boiler Fuel Consumption Rates - Natural Gas (MM/Btu/hr)
AVERAGE
BOILER EFFICIENCY
OUTPUT
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
I1-12
02-02
Table I1-5. Typical Firetube Boiler Fuel Consumption Rates - No. 6 Oil (gal/hr) A
AVERAGE
BOILER EFFICIENCY
OUTPUT
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 I1-6. Typical Firetube Boiler Fuel Consumption Rates - No. 2 Oil (gal/hr) A
AVERAGE
BOILER EFFICIENCY
OUTPUT
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.
Step 7: Refine the Analysis Example

It should be recognized that the tools provided herein are Consider the following payback analysis example. Assume that
intended to provide a quick mechanism to focus on an appro- a project requires a three-year payback for any incremental
priate equipment configuration and scope. The graphs pro- capital investment. Also assume that an 800 hp firetube boiler
vided should permit you to quickly identify candidate firing No. 2 oil and operating at 85% efficiency has a cost of
equipment options that economically qualify and, therefore, $1/gal. Assume the average load is 50% of rated capacity for
merit more serious evaluation. the anticipated 5000 hours per year of operation. The questions
are:
Additional economic issues (maintenance, necessity of equip-
ment, etc.) should be considered by final conclusions are What is the yearly savings attributable to adding an oxygen
reached. trim control system designed to improve efficiency 1.3% to
the boiler?
for additional information. How much capital may be allocated to purchase this
equipment and fall within the three-year payback guideline?
I1-13
02-02
Step 1: Estimate Boiler Fuel Consumption Rate

Using Figure I1-4, an average output of 400 hp at 85% effi-
ciency will use approximately 112.5 gal/hr (interpolated
between 86% at 11 gal/hr and 84% at 114 gal/hr) of No. 2 fuel
oil.
Step 2: Estimate Annual Fuel Use
112.5 gal/hr x 5000 hr/yr = 562,500 gal/yr annual fuel con-
sumption 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/gal fuel price line (right scale).
Looking to the left, the annual fuel cost (left scale) is shown to
be $560,000.
Step 4: Determine Potential Incremental Efficiency Improve-
ment
Based on an average efficiency improvement attributable to
the trim control of 1.3% for No. 2 oil. Refer to Figure I1-3 and
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 I1-7 and find the intersection of $560,000
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
$9,000.
Step 6: Determine the Payback Period for the investment (or
the Allowable Incremental Capital)
Multiply $9,000 times the three years required to get $27,000.
Step 7: 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 $9,000 annual fuel savings determined in Step 5. Then
repeat Step 6 with the combined savings figure.
Assuming there are no other economic factors to be consid-
ered, the analysis has shown that the project payback criteria
can be met provided the installed oxygen trim control will cost
no more than $27,000. Clearly, purchase of the added control
is this example would be a good investment. The equipment
purchase cost would be recouped in less than three years and
the customer would enjoy $9,000 annual savings thereafter
that will grow with fuel price increases and escalation.
I1-14
02-02
Figure I1-1. Annual Gas Cost as a Function of Gas Use and Unit Price
I1-15
02-02
Figure I1-2. Annual Gas Cost as a Function of Gas Use and Unit Price (Expansion of Figure I1-1)
I1-16
02-02
Figure I1-3. Annual Fuel Oil Cost as a Function of Fuel Oil Use and Unit Price
I1-17
02-02
Figure I1-4. Annual Fuel Oil Cost as a Function of Fuel Oil Use and Unit Price (Expansion of Figure I1-3)
I1-18
02-02
Figure I1-5. System Efficiency Improvement as a Function of Incremental Component Efficiency Gain
I1-19
02-02
Figure I1-6. Annual Savings as a Function of Annual Fuel Cost and System Efficiency Improvement
I1-20
02-02
Figure I1-7. Annual Savings as a Function of Annual Fuel Cost and System Efficiency Improvement (Expansion of Figure I1-6)
I1-21
02-02
Notes
I1-22
02-02
Section I2
HOT WATER SYSTEMS
CONTENTS
MECHANICAL CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-3
Code Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-3
Boiler Selection Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-3
Air Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-3
Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4
Pumping Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4
Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4
Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-6
Domestic Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-6
Heating/Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-7
Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-7
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-8
High Temperature Water Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2- 8
CONTROL CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-8
Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-8
Lead/Lag Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-9
Temperature Setbacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-10
Heat Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-10
WATER CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-13
Water Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-13
Chemical Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-13
Make-up Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-13
Ethylene Glycol as Heat Transfer Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-14
SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-14
ILLUSTRATIONS
Figure I2-1.Typical Expansion Tank Piping Arrangement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-5
Figure I2-2. Typical Pump Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-6
Figure I2-3. Pressure Temperature Chart for Firetube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-6
Figure I2-4. Plug Cock or Gate Valve (Manual Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-11
Figure I2-5. Two-Position Valve (Electric or Pneumatic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-11
Figure I2-6. Throttling or Modulating Valve (Electric or Pneumatic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-11
Figure I2-7. Three-Way Mixing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-11
Figure I2-8. Three-Way Mixing Valve (Bypass Arrangement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-12
Figure I2-9. Three-Way Diverting Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-12
Figure I2-10. Intermittent Secondary Pump Operation (On-Off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-12
Figure I2-11. Water Temperature Constant Thru Zone By-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-12
Figure I2-12. Continuous Secondary Pump Operation with Two-Position Valve (Valve Open) . . . . . . . . . . . . . . . . . . . . I2-13
Figure I2-13. Continuous Pump Operation with Two -Position Valve (Valve Closed) . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-13
Figure I2-14. Primary Loop Circuit, Constant Speed Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-16
I2-1
04-02
Hot Water Systems System Fundamentals
Figure I2-15. Primary Loop Circuit with Secondary Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-17

Figure I2-16. Individual Zone Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-18
Figure I2-17. Primary Loop Circuit with Three-Way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-19
Figure I2-18.Four-Way Valve System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-20
Figure I2-19. Multiple Boiler Lead/Lag, Primary/Secondary Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-21
TABLES
Table I2-1.Circulation Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-5
This section provides design considerations for boiler applications in hot water systems. The information provided is intended to
create an awareness of the various considerations that should be evaluated to ensure a successful installation and long boiler life.
I2-2
04-02
System Fundamentals Hot Water Systems
MECHANICAL CONSIDERATIONS Specific load mix, often caused by early fall or late spring heat-
ing loads, can require additional considerations. When the
minimum heating load is 10% of the maximum heating load,
Code Considerations the heating load is: 9,300,900Btu/hr.
Boilers constructed in accordance with Section IV, Heating
Heating Load @ 10% = 930,090Btu/hr
Boilers, of the ASME Boiler and Pressure Vessel Code can be
operated with water temperature up to 250 F with a maximum Domestic Water = 1,000,000Btu/hr
design pressure of 160 psig.
TOTAL LOAD = 1,930,090Btu/hr
Boilers for operation over 250 F or 160 psig must be con-
When the light heating load only is imposed, the demand on
structed in accordance with Section I, Power Boilers, of the
the boiler is only 14% of its rated capacity. A third, smaller
ASME Boiler and Pressure Vessel Code.
unit should be considered for light load conditions, unless
Due to limitations of control and safety settings, desired oper- the boiler has a burner with a 10:1 turndown ratio.
ating temperatures between 240 F and 250 F may require the
When multiple boilers are used, care must be taken to assure
use of a Section I boiler. System operating pressure must not
proper proportional flow through each of the units. If flow is
exceed 90% of the relief valve pressure setting.
not properly balanced, wide variations in boiler firing rates can
Consideration should be given to system piping to ensure it occur and, in extreme cases, the resulting outlet water tempera-
meets all applicable codes. For example, when Section I boil- tures may not be at the desired point.
ers are used, the piping must be in accordance with B31.1
In summary, the seasonal and daily variations define the size of
ASME Power Piping Code.
the load that the boilers must handle. The maximum load will
be used, along with backup requirements, to set the plant
Boiler Selection Considerations capacity. Seasonal and daily variations are used to help select
When a hot water system is laid out, all of the components the number of boilers and turndown requirements. In some
must be selected to work together to achieve the design intent. applications, there is a mixture of loads. These may be differ-
The design intent could include criteria such as: system flexi- ent types of process loads or combinations of heating and pro-
bility, maximum efficiency, heating/cooling, domestic hot cess loads. It is usually best to analyze them individually, and
water, heat storage, fuel capability, etc. Selection and opera- then combine them for each season.
tion of the boiler(s) in relation to the other system compo-
nents, and in support of the design intent, are important Air Removal
considerations.
Air removal in a hot water boiler is important for two main rea-
Selection of a boiler to support the design intent of the hot sons. Air contains oxygen, which can cause corrosion of metal
water system is dependent on several site-specific variables, surfaces. And, air acts as an insulator and can affect heat trans-
such as those just listed. In addition, one of the most important fer as well the operation of temperature controls.
selection factors is the maximum continuous rating of the boil-
All Cleaver-Brooks hot water outlet connections include a dip
ers, which is dependent on the load imposed by the heat
tube, which extends 2 to 3 inches into the boiler. The dip tube
users and the nature of the load. For example, consider an
does not allow any air, which may be trapped at the top of the
installation with a maximum load of 10,300,900 Btu/hr. Of
drum, to get back into the system.
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 pro- Because any oxygen or air which is released in the boiler will
vided through means of a heat exchanger. 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
Based on the maximum load conditions just described, consid-
the expansion or compression tank or fitted with an automatic
eration might be given to a 310 horsepower firetube boiler (1
air vent valve. Any air that is trapped at the top of the boiler
boiler horsepower = 33,472 Btu/hr). However, to ensure sys-
will find its way out of the boiler through this tapping.
tem flexibility, and to provide some degree of stand-by for
unscheduled outage, common practice would dictate the Dip tube assemblies furnished for external mounting into the
installation of two units, each with a capacity of 65% of the boiler return connection, or system air separators, may also be
maximum load. That is; two 200 horsepower units, or equipped with an air vent tapping. These devices will remove
6,695,000 Btu/hr each. 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
Based on the example just mentioned, it is apparent that boiler
drum, it is still necessary to pipe the boiler air vent into the
capacity selection, based on peak loading, is fairly straight for-
expansion or compression tank or into an automatic air vent
ward.
valve.
I2-3
04-02
Expansion Tank Select a pump that meets both the flow and feet of head
requirements for the system. The operating or design point of
An expansion tank serves one primary function in a hot water the pump is the point at which the vertical and horizontal lines
system. It provides a means for the system water to expand, as intersect the pump curve. This point is also commonly referred
it is heated, without significantly increasing system pressure. to as the duty point.
Expansion tanks are also often used as the receiver for the air
removed from the boiler. This is convenient if the expansion Pump Location
tank does not have a bladder or diaphragm. If the expansion
It is recommended that the system circulating pumps take suc-
tank has a bladder or diaphragm, the air from the boiler must
tion from the outlet connection on the boiler and that they dis-
be removed by an automatic type air vent piped directly to the
charge to the system load in order to put the boiler and the
air vent tapping on the top of the boiler.
expansion tank on the suction side of the pump. This location is
Proper expansion tank design will account for the desired sys- preferred because it decreases potential for air entry into the
tem pressure and changes in the specific volume of water from system and does not impose the system head on the boiler.
60 F (ambient temperature) to the maximum operating tem-
It is common practice to install a standby system circulating
perature of the boiler and related system. To design the expan-
pump, to accommodate scheduled pump maintenance without
sion tank, you must first know the total volume of water in the
shutting the system down. Usually, both the main and standby
flooded boiler and system. For flooded values for a Cleaver-
circulating pumps are located adjacent to the boilers in the
Brooks boiler, refer to the boiler products section. You will
boiler room.
need to estimate the water volume in the system by consider-
ing the diameter and length of system piping and including the
volume of water contained in system heat exchangers. Pump Operation
Pumps are normally started and stopped by manual switches. It
Expansion tanks are usually charged with air or an inert gas
is also desirable to interlock the pump with the burner so that
such as nitrogen. Nitrogen is often used in high temperature
the burner cannot operate unless the circulating pump is run-
water applications due to its low corrosive nature. Regardless
ning.
of the charging media, expansion tanks are charged at a pres-
sure slightly higher than the static pressure on the tank with
the system at ambient temperature. As the water in the system Pump Capacity
is heated, the air or gas cushion in the expansion tank com- Table I2-1 can be used to determine the maximum gpm circu-
presses, allowing the water to expand without significant vari- lating rate in relation to full boiler output and system tempera-
ations to the system pressure. ture drop. Knowing the boiler size and expected system
For more information on sizing expansion tanks, refer to the temperature drop, the maximum circulation rate can be
ASHRAE Guide Book, or contact your local Cleaver-Brooks selected.
Circulation
A typical expansion tank piping arrangement is shown in Fig-
ure I2-1. The system should be piped and the controls configured to
ensure continuous flow of system water through the boiler
Pumping Equipment under all operating conditions. Constant circulation through
the boiler results in a more even water temperature and elimi-
nates the possibility of stratification within the boiler and sys-
Pump Type tem. Constant circulation reduces the possibility of thermal
Centrifugal type pumps are typically used for system circulat- stresses to the boiler and subsequent pressure vessel failure.
ing pumps, because of their proven durability, efficiency, and
ability to pump the required flow and pressure. Minimum Circulation
Although there are many types of centrifugal pumps available As a rule of thumb, the minimum continuous circulation rate
with varying characteristics, most applications use a pump through the boiler under operating conditions is one gallon per
with a curve similar to Figure I2-2. minute per boiler horsepower.
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 Maximum Circulation
at 60 F = 1 psig). At the point where the line intersects the The maximum circulation in gallons per minute through the
pump curve, draw a vertical line to determine the gallon per boiler is based on system design temperature drop, and maxi-
minute flow the pump will pump at the given feet-of-head. mum Btu output rating of the boiler. Table I2-1 shows the max-
I2-4
04-02
Table I2-1. Circulation Rates

BOILER OUTPUT
10 20 30 40 50 60 70 80 90 100
HP (X 1000)
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
Figure I2-1. Typical Expansion Tank Piping Arrangement
I2-5
04-02
tem pressure drop calculation. As a rule of thumb, there is a

pressure drop of less than 3 feet of head (1 psi = 2.31 feet of
head) through Cleaver-Brooks boilers.
Pressure Requirements
In a hot water boiler, the pressure/temperature relationship is
critical. Unlike a steam boiler, where the pressure and tempera-
ture 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 Fire-
tube and Model 4 hot water boilers. Similar charts are provided
Figure I2-2. Typical Pump Curve in the specific boiler product sections. To use the chart, locate
the maximum system operating temperature (High Limit Con-
imum circulation rates for firetube boilers. For information on trol Setting) on the bottom line. Draw a straight line to the min-
specific boiler circulation rates, refer to the boiler products imum recommended boiler operating pressure curve. At the
section. point where the lines intersect, draw a horizontal line to the left
of the chart and find the necessary pressure.
Pressure Drop
Domestic Hot Water
When sizing the system circulating pump, it is necessary to
account for the system line losses. Proper sizing will allow the Hot water systems are often used as the energy source to pro-
pump to overcome the system pressures in order to deliver the vide domestic hot water. The hot water for personal washing
proper flow through the system. The boiler is part of the sys- (showers, laundry, etc.) and, in some cases, light industrial pro-
Figure I2-3. Pressure Temperature Chart for Firetube Boilers
I2-6
04-02
cess, is often provided through the incorporation of a heat are critical issues of design consideration that will dictate suc-
exchanger in the system. cess or failure of the installation.
Physically, the heat exchanger provides a separation of the hot The overall system design intent must be the comfort heating,
water system water from the domestic water which, in turn, or cooling, of the individuals who occupy the building. How-
allows the fluids to be of different chemical make-up. This ever, if either the boiler or chiller cannot be used because they
provides integrity and proper water treatment for the hot water are being repaired, the system intent has failed.
system, and proper water treatment, while providing potable
Why would a boiler or chiller fail? With respect to the boiler,
water in the secondary loop.
consider a scenario where heating is required in the early
Space requirements for the domestic water heat exchanger morning and early evening. During the day, cooling is
vary considerably based on specific application. However, typ- required. To meet the demand, the boiler is maintained in a hot
ically, the required space is quite small. For example, Cleaver- stand-by mode. When the system demands heat, the pumps and
Brooks can provide domestic water coils integral to the boiler control valves shift to send boiler water to the system. What
that require no additional floor space, and only need room for comes back to the boiler is the chilled water (relatively cold)
the associated domestic water loop piping. In this type of sys- from the system. The result - THERMAL SHOCK. It is
tem, typically, there is a low volume of domestic water stored. assumed that a similar, but opposite, phenomenon exists within
The heat exchanger system must be sized to maintain mini- the chiller.
mum desired temperature at maximum load conditions. This is
What can the system designer do to minimize the potential
an excellent application for fairly continuous domestic water
problem when single pipe systems are designed?
loads.
Provide slow acting valves that slowly bleed the system
In many cases, domestic hot water can, and should, be pro-
water into the boiler during the cooling/heating mode
vided by including a shell and tube (or plate and frame) heat
changeover.
exchanger as part of the hot water system. Isolation and ser-
vices of the heat exchanger can be performed without remov- Specify boilers that minimize problems resulting from
ing the hot water heating system from service. Thermal Shock. Refer to the Cleaver-Brooks Flextube Boiler
product section, Section B1.
When it is apparent that large domestic water demands are
required for a short period of time, consideration should be Select and specify boiler operating controls and system
given to incorporating a storage tank in the domestic water controls that maximize equipment protection without
loop. In most applications of this type, the heat exchanger is sacrificing the heating/cooling comfort needs of the
incorporated into the storage tank and the hot water system individuals.
fluid is pumped through the tube side of the exchanger and
Possibly include accumulator tanks into the system.
the domestic hot water is on the shell side.
Domestic water heat exchangers provide physical separation Accumulators
of the two media and, therefore, considerable flexibility with
respect to flow and temperature. Such systems, however, are Hot water systems inherently have considerable energy capac-
not trouble free. Scaling or fouling of the heat exchanger sur- ity. Once the heating system is on-line, the flywheel affect
face can occur, process controls can fail, etc. To maintain opti- has a tendency to smooth out the minor spikes and valleys that
mum operating efficiency of the domestic water circuit, occur during the typical heating load. However, some systems
serviceability of the equipment should always be considered dictate the requirement for load, or heat shedding, to maximize
during system design. operating efficiency or the availability of additional heat to sat-
isfy load demand peaks. When load shedding or heat storage
needs exist within the same system, an accumulator tank or
Heating/Cooling
heat accumulator, is an ideal fit.
Heating/cooling systems are often called single pipe sys-
When hot water systems include large demand heat users that
tems. In a single pipe system, the water is either heated by a
are brought into service quickly through controls and valving,
boiler or cooled by a chiller to meet the comfort demand.
the increased load demand is immediately realized by the
Special care and consideration must be given to system design boiler. To minimize the impact of the condition and to add to
when the heating (hot water) and cooling (chilled water) sys- the total available energy for the system, accumulators or stor-
tems share common distribution piping. The type of boilers age tanks can be used. Proper sizing of accumulator tanks
selected; control systems for both heating and cooling; and requires careful analysis of the load peaks that are to be
type of load - heat in the morning, cooling in the afternoon - addressed and the minimum/maximum temperature swings
that can be tolerated in the system.
I2-7
04-02
The control system, including circulating pumps, will be CONTROL CONSIDERATIONS

dependant on the specific application of the accumulator and
the design of the storage tank, such as stratification tanks and
baffle tanks. Temperature Control
Although accumulators are not common in most heating sys- Boiler Water Temperature Control
tems, they do provide heat storage capacity and equipment
protection and should be considered in complex hydronic sys- As with all pieces of mechanical equipment, rapid changes in
tem designs. temperature will cause thermal stress to a boiler pressure ves-
sel. The degree of stress and subsequent failure is directly
related to the frequency and degree at which the thermal
Safety stresses are applied. Also, in hot water applications, too low of
The highest level of consideration in any system design should a boiler water outlet temperature can cause condensation of
be the safety of personnel. Good safety practices are essential flue gases and subsequent fireside corrosion. In order to avoid
in hot water, as well as in steam systems. For example, consid- these types of problems, certain parameters must be considered
eration for safe discharge of water from the relief valves is when designing a hot water control system.
important. For hot water heating boilers (ASME Section IV;
1. Minimum Outlet Temperature
160 psig/250 F maximum) a flexible connection between the
safety valve and the discharge pipe is recommended. The dis- Fireside corrosion occurs when flue gases are cooled below the
charge piping must be properly arranged and supported so that dew point. Cooling of the flue gases occurs when hot flue gases
its weight does not bear upon the valve. come in contact with cool pressure vessel surfaces. To prevent
this, minimum operating temperatures must be maintained to
High Temperature Water Boilers keep the flue gases above the dew point. The minimum water
outlet temperature is typically 170 F. The minimum return
As required by ASME Boiler and Pressure Vessel Code, boil- water temperature is typically 150 F. For exact temperatures
ers for operation over 250 F or 160 psig must be constructed refer to the specific boiler section. Maintaining minimum out-
in accordance with ASME Section I, Power Boilers. Due to let temperatures will help prevent harmful condensing of flue
limitations of control and safety settings, an operating temper- gases.
ature above 240 F will required the use of a Section I boiler.
2. Maximum Outlet Temperature
Design pressures above 125 psig will require Cleaver-Brooks
review, regardless of the operating temperature. Use Figure I2- The maximum temperature rating for all Cleaver-Brooks
3 for the operating temperature and recommended minimum ASME Section IV boilers is 250 F. Due to limitations of con-
boiler operating pressure. Also, please ensure that there is control and safety settings, desired operating temperatures above
tinuous water flow trough the boiler. 240 F may require the use of a Section I boiler and a high tem-
perature hot water system. For high temperature water, ASME
Depending on horsepower requirements, operating tempera- Section I, the boilers maximum outlet temperature depends
ture, design pressure, and water flow rate, there could be some upon its design pressure. For information on high temperature
limitations that affect recommended boiler size or maximum water applications, contact your local Cleaver-Brooks autho-
Btu rating. Cleaver-Brooks is in a better position to review and rized representative for further information.
comment on the design criteria if the evaluation is performed
at the design stage of the project. Contact your local Cleaver- 3. Temperature Drop Across the Boiler
Brooks authorized representative on any high temperature The maximum temperature drop from supply to return is
water applications. Provide the following details for review: directly related to the circulation rate through the boiler and
Supply and return temperatures. 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 (is it constant or variable?). flow rate versus temperature drop charts.
Operating pressure. Even though design temperature drops can be up to 100 F,
Describe load characteristics. care must be taken when applying boilers into these systems.
At no time should the system temperature drop provide return
Provide detail of system and sequence of operation. water at a temperature that could cause flue gas condensation
If a system schematic is available, forward a copy to and subsequent fireside corrosion.
your local Cleaver-Brooks authorized representative. 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
I2-8
04-02
of a cold boiler. To prevent damage to the pressure vessel and to ensure that the minimum flow requirements for the boiler
refractory, a warm-up from a cold (ambient) boiler to operat- will be met at all times. These valves must be slow moving to
ing temperature is normally accomplished through manual ensure that rapid temperature changes are not taking place in
operation at the low-fire rate. Automatic operation from a cold the boiler return water temperature.
start is not recommended without proper control sequencing,
Temperature control at the heat users is normally accom-
as is available with the CB-HAWK control.
plished through diverting or two-position valves controlled by
In multiple boiler installations when a second cold boiler is a room or duct thermostat. Temperature control of heat users
being brought into the system, a means should be provided to will be discussed in more detail later in this section.
slowly introduce flow of system water into the return. The
boilers temperature should not be increased any quicker than Lead/Lag Systems
1 F per minute. Even when the boiler has reached return water
temperature, a means must be provided for a slow warm-up of A Lead/Lag system sequences the on-off firing and modula-
the boiler from a stand-by to an operational condition. This tion of multiple boilers to meet the system load demand.
will provide proper warm-up of the refractory within the boiler The key to the design of a lead/lag control in a hot water sys-
as well as ensure that the pressure vessel is at operating tem- tem is the realization that temperature changes in a hot water
perature. Under these conditions, a means should be provided system are inherently slow. This also means that a change in
to hold the burner in the low-fire position a minimum of 30 boiler output does not result in immediate changes in overall
minutes if the burner has not operated within the last 4 hours. system temperature. The control system must be designed to
5. Rapid Replacement of Boiler Water take into account the lag times and allow for fine tuning.
The most common causes of cold water slugs returning to a Lead/lag systems are available in two basic types. Lead/lag
boiler are: 1) cycling of individual zone pumps and, 2) the start - unison modulation and lead/lag start - lead/lag modula-
main circulating pump cycling off, allowing the boiler to con- tion. Please refer to Controls, Section 8, for a more detailed
tinue to operate. These situations cause a boiler that is operat- description of these two systems.
ing between 170 and 250 F to experience high flow rates of In general, with hot water systems, lead/lag start - unison mod-
possibly ambient temperature water, thus causing excessive ulation would be the most practical system. This is due to the
thermal stress. To determine the rate at which cold water can fact that with hot water boilers, the load imposed on a particu-
be introduced into an operating boiler, refer to the specific lar boiler is directly related to the rate of water flow through it.
boilers temperature drop/flow rate charts. If the flow rate through two boilers is equal, they must have the
6. One additional item that must be considered when deciding same Btu output to maintain a constant supply header tempera-
upon boiler outlet water temperatures is boiler auxiliaries, ture. The following example illustrates the problem associated
which may require certain temperatures. For example, a hot with not having unison modulation with two equally sized
water boiler firing a No. 6 fuel oil may require temperatures in boilers in a lead/lag sequence.
excess of 200 F, when heating the oil in an oil preheater with Boiler #1 Boiler #2
boiler water. The operating temperatures needed will depend
upon the fuel oil temperatures required for proper atomization 200hp 200hp
of the fuel. If water temperatures cannot be maintained at the Flow = 500gpm Flow = 500gpm
required levels, an electric preheater must be sized accordingly
to provide the additional heat. Firing rate = 100% Firing rate = 25%
Return temperature = 160 F
System Temperature Control Required header temperature = 190 F
Since the minimum outlet temperature for a boiler is limited, it The Btu output of a 200hp boiler at 100% firing rate is
is sometimes desirable to regulate the water temperature going 6,695,000 Btu/hr. The same boilers output at 25% is
to the heat users. This is normally done by regulating the tem- 1,673,750 Btu/hr. Each boiler has a flow of 500 gpm or 4071
perature of the main supply and/or the water temperature at the lb/min. Since it takes 1 Btu to change 1 pound of water 1 F,
heat users. we can determine the outlet temperature of each boiler.
The most common way to vary the system supply temperature Boiler #1
is through the use of a three- or four-way control valve. These
control valves will blend a portion of return water with boiler 6,695,000 Btu/hr 60 min/hr = 111,583 Btu/min
supply water to maintain the desired system supply tempera- 111,583 Btu/min output divided by the 4071 lbs/min flow rate
ture. When applying these types of valves, care must be taken yields a temperature rise of 27.4 F.
I2-9
04-02
Boiler #2 system after being off for a period of time (standby hot condi-
tion), that it be operated at its lowest firing rate for a minimum
1,673,750 Btu/hr 60 min/hr = 27,895 Btu/min
of 30 minutes.
27,895 Btu/min output divided by the 4071 lbs/min flow rate
yields a temperature rise of 6.9 F. Temperature Setbacks
With a return temperature to both boilers at 160 F, it can be In the interest of conserving energy, it is sometimes desirable
seen that the outlet temperature of boiler #1 would be approxi- to set back the system supply temperatures based on time of
mately 187 F and the outlet temperature of boiler #2 would be day, day of week, or outdoor air temperature. Since the boiler
almost 167 F. Since the flow through both boilers is equal, the water temperature requires that a minimum outlet temperature
mixed temperature to the header would be approximately be maintained, resetting the boiler temperature is normally not
177 F. practical. Resetting the supply water temperature is normally
This scenario becomes even further complicated when more accomplished through a three- or four-way control valve. One
than two boilers are in a system, and when they are of varying important item to keep in mind when setting back tempera-
sizes. When the boilers are different sizes, the flow through the tures, is how the control valve reacts when returning the system
boilers must be proportional to the capacity and firing rate of to the higher temperature. Control valve operation should not
the boilers. For example, the load on a smaller boiler may be instantaneous. It is extremely important to ensure that the
exceed rated capacity while the larger boiler is cycling off, valve does not travel from a fully closed to a fully open posi-
resulting in inefficiencies and potential thermal shock damage tion instantaneously. This would cause high flow rates of rela-
to the pressure vessel and refractory. To ensure the flow tively cold water to return to the boiler, causing thermal stress
through a particular boiler is proportional to its size and firing and possible pressure vessel damage.
rate, controls and motorized valves should be incorporated. Individual zones should not normally be set back by turning off
The control system required to perform this can become quite individual circulating pumps. In determining whether or not
sophisticated; however, reliable operation and a savings in this practice would be acceptable, the flow rate of the zone ver-
repair and maintenance costs will be realized. sus the entire system flow rate must be considered. If the zone
The stand-by boiler must be kept in mind when designing a has a high flow rate compared to other zones, cycling of pumps
system with lead/lag operation. If there is continuous flow can cause serious problems with cold slugs of water being
through all boilers, regardless of whether or not they are firing, returned to the boiler, resulting in thermal stress and subse-
the stand-by boiler will have an outlet temperature equal to the quent pressure vessel failure.
return temperature. This, again, will create a situation where a
blended temperature is getting to the common supply header. Heat Users
This is normally avoided by installing a motorized valve at the
Selection of the type, size, quantity and location of heat users is
outlet or return to each boiler. The position of the valve is dic-
job specific, and is usually determined by the project design
tated by the status of the boiler. The valve will generally have
engineer.
two positions. When the boiler is at header temperature and
supplying hot water to the system, the valve would be at its Typical load groupings are shown on the hot water system lay-
position for maximum design flow through the boiler. When outs shown in Figures I2-14 thru 12-19. The groupings will
the boiler is in stand-by, the valve would be positioned for the naturally be varied, depending on actual job layout and the
minimum flow rate required by the boiler. Maintaining the individual load and temperature requirements.
minimum flow rate will prevent stratification of temperatures
The following heat users are most commonly used in hot water
within the boiler. The valve positions become more compli-
heating systems:
cated and numerous when boilers of unequal sizes are applied
in the same system. Keep in mind, flow through the boilers 1. Radiators
must be proportional to the output of the boilers.
2. Convectors
Provisions should be made in the lead/lag control system to
3. Coils in Ducts
maintain a boiler in a hot standby condition. This normally
requires intermittent firing at low fire to maintain a set point 4. Fin Coils
slightly lower than the main supply set point.
5. Blast Coils
To ensure that refractory as well as the pressure vessel are at a
6. Unit Heaters
proper operating temperature, all lead/lag controls must ensure
that the burners return to low fire prior to turning the burners 7. Unit Ventilators
off. It is recommended that once a boiler is brought into the
8. Unit Ventilators with Face and Bypass Dampers
I2-10
04-02
Figure I2-4. Plug Cock or Gate Valve Figure I2-6. Throttling or Modulating Valve (Electric or
(Manual Operation) Pneumatic)
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 adja-
Figure I2-5. Two-Position Valve cent to the heat user will also start the fan on devices such as
(Electric or Pneumatic) unit heaters.
9. Radiant Panel - Inside

10. Process Heating
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.
Figure I2-7. Three-Way Mixing Valve
I2-11
04-02
Figure I2-8. Three-Way Mixing Valve

(Bypass Arrangement)
Figure I2-10. Intermittent Secondary Pump Operation (On-Off)
Throttling or Modulating Valve (Electric or
Pneumatic)
Throttling or modulating valves are used to control water flow controlled by the temperature of the process itself.
to heat users such as: blast coils, unit heaters, and unit ventila-
tors. See Figure I2-6. Throttling or modulating valves are pre- Three-way Mixing Valve (By-pass Arrangement)
ferred to two-position valves since they provide more uniform The three-way mixing valve with bypass arrangement (Figure
heating and a relatively constant flow of return water. I2-8) is commonly used on fin coils, coils, panels, and process
loads and is preferred to the three-way mixing valve arrange-
Three-way mixing valve ment, since it assures a flow of return water. When fin coils or
Three-way mixing valves (two inlets, one outlet) are used to coils are controlled by a three-way valve, a room or duct ther-
control water temperatures going to inside radiant panels or mostat usually operates the valve.
process loads. See Figure I2-7. If a pump is used, its capacity
governs the quantity of water flowing through the heat user. Three-way Diverting Valve
The pump usually operates (on-off) in response to a high limit A three-way diverting valve (one inlet, two outlets) arrange-
room thermostat (without heat anticipation feature). ment can be used in the same manner as the three-way mixing
When used on inside radiant panels, the three-way valve is valve (by-pass arrangement). See Figure I2-9. In either case,
usually controlled by a room thermostat or by the temperature the position of the valve allows more or less water to flow
of the water going to the panel. through the coil or through the by-pass. Either position of the
valve assures return water flow to the boiler.
When used on process loads, the three-way valve is usually
Figure I2-9. Three-Way Diverting Valve

Figure I2-11. Water Temperature Constant Thru
Zone By-Pass
I2-12
04-02
In Figure I2-11, the 5 gpm at 250 degrees entering the zone by-
pass leaves the zone by-pass at approximately the same tem-
perature. If desired, the supply water temperature could be var-
ied 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
Figure I2-12. Continuous Secondary Pump Operation with drop from supply to return, and a 20 degree drop
Two-Position Valve (Valve Open) across the heat user.
Primary-Secondary Pumping The 2-position valve could be controlled by a room thermostat

or by the temperature of the water entering or leaving the heat
1. Intermittent Secondary Pump Operation (on-off) user.
The secondary pump operates in response to a high limit room When the 2-position valve is closed, (Figure I2-13) the contin-
thermostat (without heat anticipation feature), a duct thermo- uously operating secondary pump is circulating 15 gpm at
stat, or actual temperature of the water entering or leaving the approximately 210 F. As long as this satisfies the load require-
heat user. See Figure I2-10. ments, the valve remains closed.
A tee can actually be used as a mixing valve with this system. The 5 gpm at 250 F entering the zone by-pass line leaves the
Also, wide ranges and good control of temperature drops are zone by-pass at approximately the same temperature.
available to the designer. (In the example just given, there is a
60 degree drop from supply to return, but only a 20 degree Continuous secondary pump operation provides continuous
drop across the heat user). When the pump is off, there is no controlled heat input into each zone.
flow in the secondary zone. The amount of water entering the
zone by-pass flows through the zone by-pass to the return WATER CONSIDERATIONS
header.
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 com-
mon to find oils, greases, weld slag, and other contaminates
within the system. If the foreign materials remain, the boiler
could be affected by loss of heat transfer on heat exchanger
surfaces and/or an acidic water condition. Boiler life may be
reduced as a result of an unclean system.
Your authorized Cleaver-Brooks representative or water treat-
ment company will be able to recommend a chemical cleaning
or boil-out procedure. Also, refer to the boiler operating and
instruction manual for more details.
Chemical Treatment
Figure I2-13. Continuous Pump Operation with Two -Position It is recommended that chemical treatment be provided for the
Valve (Valve Closed) initial fill of the system. Generally, chemicals will be required
I2-13
04-02
to prevent scale formation, promote elimination of dissolved ene glycol and water is commonly used.
gases and control pH.
When using ethylene glycol certain design limitations are
Most hot water boilers operate in a closed system and are con- important, due to the characteristics of the fluid versus the
sidered to require little attention for water treatment. Experi- characteristics of water. These characteristics are: Elevated sat-
ence has shown, however, few systems can be considered uration temperature, decreased thermal conductivity and spe-
completely closed. Loss of water can occur from pump pack- cific heat, and increased viscosity and density. In addition,
ing, glands, air venting devices, and threaded or flanged pipe ethylene glycol degrades when it is heated above the manufac-
connections. A means must be provided to chemically treat the turers specified maximum film temperature.
raw water make-up. This is generally accomplished through
The following design parameters must be considered when
the use of a shot-type chemical feeder. For information on shot
operating with ethylene glycol solutions. For industrial water-
type chemical feeders refer to Section 19.
tube boiler parameters, or for conditions not covered in the fol-
lowing, contact your local Cleaver-Brooks authorized
Make-up Water representative.
It has been generally accepted in system design that hot water 1. Maximum Glycol Concentration
boilers are in a closed system and, therefore, no make-up
water is needed. This is not always the case. Untreated make- Firetube:60%
up water is a leading cause for failures of hot water boilers. In Flexible Watertube: 60%
the design stage of a hot water system, provisions must be Model 4 Watertube: 50%
made for properly introducing, metering, and treating make-up 2. Maximum Outlet Temperature
water.
Firetube: up to 300 F
Flexible Watertube: 200 F
Introducing Make-up Water
Model 4 Watertube: 200 F
A recommended means for introducing make-up water to a hot
water system is shown in Figure I2-1. This method ensures all 3. Internal Circulation
air is removed from the make-up water. It also ensures the A. For firetube boilers, the size of the supply and return con-
water temperature is tempered prior to being introduced to the nections are decreased based on the design temperature drop
boiler, thus reducing the risk of thermal shock. and the system pump gpm.
B. A minimum continuous gpm flow rate through the boiler
Metering Make-up Water
corresponding to a 40 F system drop is recommended. For
The purpose of metering the make-up water to a hot water sys- firetube boilers operating between 250 -
tem is to prevent potential problems that can tend to damage 300 F, use a flow rate based on a 30 F system drop.
an otherwise well planned installation. Figure I2-1 shows the
4. Expansion Tank
recommended location for a water meter, which is used to
measure the amount of make-up water used by the system. The a. An inert gas pressurizing blanket is preferred due to the over-
meter is necessary, as it may be the only means to identify a pressure requirements.
system loss of water. Knowledge of make-up water usage will
5. Over-Pressure Required:
alert the operator to investigate the cause of the system water
loss. This allows the operator to fix the problem and properly A. Firetube
treat the make-up water prior to experiencing any additional
170 - 250 F operating temperature - recommend 40 psig
problems.
minimum operating pressure.
In some cases, depending on the preference of the customer,
250 - 300 F operating temperature - recommend 100 psig
no automatic means for make-up water is provided. Instead, a
minimum operating pressure.
low water alarm is used in the expansion tank to alert the oper-
ator of a loss in system water and a need for system make-up. B. Flexible Watertube - recommend 50 psig minimum operat-
The operator can then diagnose the system loss and properly ing pressure.
treat the make-up water. A low water alarm is only practical
C. Model 4 Watertube - recommend 50 psig minimum operat-
where full- time operators are employed.
ing pressure.
Ethylene Glycol as Heat Transfer Medium 6. Depending upon the application, process boilers may need to
be sized to limit continuous duty to 80% of maximum boiler
On applications requiring freeze protection, a mixture of ethyl- rating.
I2-14
04-02
Individual expansion tanks are shown for clarity. One

NOTICE expansion tank for multiple boilers is typically sufficient
when sized properly.
Generally, Firetube boilers up to 350 horsepower and
a maximum operating temperature of 200 F can be
operated without consideration of Btu de-rating.
NOTICE
7. A means should be provided to routinely monitor the condi-
tion of the system fluid. Frequent analysis during the first six When working with individual zone circuits, where
months of operation and semi-annual checks thereafter are rec- one zone may have a large quantity of water, and
ommended. where the zone circulating pump has a high gpm
compared to other zones, cooling down of the wa-
8. Excessive use of inhibitors can create precipitation of solids ter can cause a serious problem in rapid replacement
causing reduced circulation and reduced heat transfer. of boiler water when the pump is started. For this rea-
9. Always alert your local Cleaver-Brooks authorized repre- son, it is recommended that all circulating pumps run
sentative of a system to be designed for glycol mix. Additional continuously to permit constant circulation through
product modifications may be necessary, based on size, boiler the relief or bypass device.
model and operating temperature.
10. The temperature rating of the glycol is also important. In
general, use a product with a minimum temperature rating of
175 F above the boiler operating temperature.
SYSTEM DIAGRAMS
Hot Water System Layout Schematics:
The system layouts (Figures I2-14 through 12-19) are
intended to be used as a general guide for use with 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.
I2-15
04-02
Figure I2-14. Primary Loop Circuit, Constant Speed Pumps
I2-16
04-02
Figure I2-15. Primary Loop Circuit with Secondary Pumping
I2-17
04-02
Figure I2-16. Individual Zone Circuits
I2-18
04-02
Figure I2-17. Primary Loop Circuit with Three-Way Valve
I2-19
04-02
Figure I2-18. Four-Way Valve System
I2-20
04-02
Figure I2-19. Multiple Boiler Lead/Lag, Primary/Secondary Pumping
I2-21
04-02
NOTES
I2-22
04-02
Section I3
STEAM SYSTEMS
CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-3
THE STEAM-GENERATING FACILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-3
Type of Application/Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-3
Operating Conditions, Requirements and Constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-3
Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-3
Condensate Return/Make-up Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-5
Water Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-5
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-5
Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-5
Stack Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-5
Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-5
Facility Requirements and Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-5
Codes and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-5
Other Federal, State, Provincial and Local Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-6
EQUIPMENT CONSIDERATIONS AND HARDWARE DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-6
Steam Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-6
Boiler Piping and Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-8
Low Pressure Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-8
High Pressure Boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-8
Boiler Feed Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-10
Boiler Feed System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-10
Surge Tanks (Condensate Receiver Tanks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-11
Deaerators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-11
Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-11
Water Treatment Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-13
The Objectives of Feedwater Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-13
Raw Water Make-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-14
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-14
Water Softeners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-15
Dealkalizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-15
Chemical Feed Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-15
Economizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-15
Blowdown Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-15
Types of Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-16
SYSTEM INTEGRATION AND OPTIMIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-16
EXAMPLE - STEAM SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-17
Boiler Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-18
Condensate Return and Feedwater System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-19
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-19
Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-19
Efficiency Enhancement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-20
System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-20
I3-1
02-02
Steam Systems System Fundamentals
ILLUSTRATIONS
Figure I3-1. Typical Steam System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-4
Figure I3-2. Schematic Diagram of a Generic Steam-Generating Facility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-4
Figure I3-3. Summary of Application/Energy-Use Audit Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-6
Figure I3-4. Recommended Safety Valve Discharge Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-9
Figure I3-5. Example of System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-20
TABLES
Table I3-1. Removal of Harmful Elements with Various Types of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-14
Table I3-2. Makeup Water Impurities, Limits and Treatment Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-14
Table I3-3. Recommended Limits for Total Suspended Solids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-16
Table I3-4. Water Test Results and Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-19
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02-02
System Fundamentals Steam Systems
INTRODUCTION draw from that information in order to address design of inte-

grated steam systems. Ultimately, the objective is to design a
A steam system consists of a steam-supply/generating facility, steam-generating facility which is economically optimal for
a steam and condensate return/water piping system, and a the demands of the steam-use facility.
steam-use facility (Figure I3-1). In this section, the discussion
is focused on the integration of the various equipment within The following is a step-by-step procedure which assists in the
the steam-generating facility. Information is offered which design of steam-generating facilities for industrial and com-
need be considered when designing a steam-supply system. A mercial use. These items are typically addressed during an
general guideline is provided which identifies major issues to application/energy-use audit of the facility.
be addressed, leading to the evaluation of system solutions and
ultimately to equipment considerations for selection and Type of Application/Load
design. Finally, an example of an audit and system design are
1. Categorize the application and load as heating/cooling,
provided for demonstration purposes.
process or combination (see Section I1, System Load).
The reader is encouraged to review the specific product sec- There are a number of institutional applications which
tions for additional information. The discussion in this section demand not only heating/cooling, but other steam or hot
applies primarily to new systems and new boiler installations. water requirements for the purpose of cooking, washing,
When modifying existing systems, other considerations may etc. Generally speaking, these institutional loads are
apply. classified as heating applications since the requirement
typically deals with heating and cooling of air and potable-
THE STEAM-GENERATING FACILITY water.
The steam-generating facility, located in the boiler room, con- At this juncture, a determination is made whether the
sists of boilers, feedwater systems, heat exchangers (e.g., boiler should be steam- or hot water-generating (see Sec-
economizers), boiler and system controls, fuel and gas han- tion I1). For the remainder of this section, it is assumed
dling equipment (e.g., fuel trains, stacks), and steam/water that a steam- generating facility is appropriately chosen.
treatment equipment and piping (Figure I3-2). The purpose of (For more information on application considerations for
the steam-generating facility is to provide energy (in the form hot water boilers and hot water systems, please refer to
of thermal energy of the steam) to drive other processes in the Section I2, Hot Water Systems.)
steam-use facility. In turn, typical steam-use facilities are
designed to meet various industrial and commercial needs Operating Conditions, Requirements and
such as comfort heating, food processing, paper corrugation, Constraints
etc.
Steam-generating facility design is unique to the specific Steam
application and it is dictated by good engineering practice, the 2. Determine the desired operating pressure. For existing
ASME code, applicable national, state, provincial and local steam-use facilities, the operating pressure has typically
codes, and utility and insurance requirements. System design been set in the past and now acts as a constraint on the
and selection depend on job specific operating requirements, system design at hand. For new facilities, slightly more
boiler room structure and venting, fuel storage, and utility ser- flexibility exists and yet operating characteristics of
vice considerations. There is therefore no simple mathemati- equipment in the steam-use facility either set or limit the
cal expression to correlate steam boiler room design and range of operating pressure of the boiler.
application. However, there are several characteristics which
help define the application and its relevant requirements. For a 3. Determine the steam load characteristics and ultimately
steam-generating facility, these characteristics include: the profile of the steam-use facility in its entirety (see
Section I1). It is important to understand both the steady-
1. Type of Application/Load state load profile as well as the transient and instantaneous
2. Operating Conditions, Requirements and Constraints demands.
3. Facility Requirements and Limitations 4. Determine the desired or necessary steam quality (dryness)
or degree of superheat. Steam quality ranges from 0 to
4. Codes and Standards 100% and is defined as the ratio of the amount of saturated
5. Other Federal, State, Provincial and Local Requirements steam vapor to the total steam amount (which may consist
of both saturated steam vapor and liquid). A 100% steam
Many of these characteristics have been thoroughly discussed quality translates to zero amount of saturated steam liquid
in other sections of The Boiler Book. The objective here is to and, in this condition, the steam is termed to be dry.
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02-02
STACK GASES
STEAM-SUPPLY/GENERATING FACILITY STEAM STEAM AND CONDENSATE STEAM-USE

RETURN PIPING SYSTEM FACILITY
FUEL AND
COMBUSTION
AIR BOILERS FEEDWATER SYSTEMS COMMERCIAL
CONTROLS SEPARATORS AND INDUS-
PIPING
STACKS BLOWDOWN SYSTEMS TRIAL HEATING,
STEAM TRAPS
ECONOMIZERS WATER TREATMENT PROCESS, AND
PUMPS
FUEL TRAINS PUMPS COMBINATION
HEAT EXCHANGERS APPLICATIONS
CONDENSATE
RETURN
MAKE-UP WATER
Figure I3-1. Typical Steam System
STACK GAS
MAKE-UP WATER
ECONOMIZER
STEAM STEAM-USE
WATER
TREATMENT FACILITY
SYSTEM
FEEDWATER BOILER(S)
SYSTEM
BLOWDOWN
SYSTEM
BOILER FEEDWATER
CONTROLS
CONDENSATE RETURN TO SEWER
Figure I3-2. Schematic Diagram of a Generic Steam-Generating Facility
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02-02
The degree of superheat refers to the amount of thermal 16. Determine the physical lengths and flow areas of stack/
energy (heat) added to the steam relative to the saturated breeching, most importantly any constraints imposed in
steam vapor point of reference, typically expressed in this area. These physical attributes will affect the stack gas
units of degrees Fahrenheit. For example, a degree of pressure which can, in turn, have an impact on combustion
superheat of 50 oF means that an additional amount of characteristics and firing rates.
heat has been added to the steam so that the final steam
temperature is 50 oF greater than the saturation tempera- Electrical Power
ture of the steam at the given operating pressure.
17. Understand the electrical power overall demand and
seasonal profiles.
Condensate Return/Make-up Water
18. Determine the electrical power costs for the facility. A
5. Determine the condensate return conditions, primarily
review of 2-3 year historical data of electric power billing
focusing on temperature, pressure and flow rate (% return).
from the local power company will assist in this area. It is
6. Calculate the make-up water requirement based on the % important to understand the demand charges separate from
condensate return. the actual electrical energy charges.
7. Determine the water charges for the specific facility under
analysis. Facility Requirements and Limitations
19. In regard to boiler room design, understand the physical
Water Discharge limitations of the facility. This understanding should
include floor space or footprint for both installation and
8. Determine the maximum temperature for water discharge,
maintenance considerations as well as height limitations
which is usually mandated by the local environmental
for equipment sizing.
governing authorities.
20. Determine noise level requirements.
9. Determine the sewer charges for the specific facility under
analysis. These twenty audit items are summarized in Figure I3-3.
Fuel Codes and Standards

10. Determine the type(s) of fuel to be combusted within the Various Codes and Standards govern the design, fabrication
boiler. Generally speaking, the fuels are limited to natural and installation of many of the boiler room components. Of
gas, propane, and fuel oil (although some other alternate primary importance is the American Society of Mechanical
fuels may be used). Engineers' (ASME) Boiler and Pressure Vessel Code. The dif-
11. Obtain a composition analysis for each fuel, which will be ferent sections of this Code specify the rules by which steam
necessary for calculating fuel usage for a given load. boilers, pressure vessels and connecting piping are to be
designed, constructed and installed.
12. Determine the fuel costs; this is necessary for the
economical optimization of boiler room design. For new Section I of the ASME Code contains rules for Power Boilers
boiler(s) installation into an existing system, a two-three which, for the case of steam boilers, are boilers designed for a
year history of fuel billing data would be helpful in the maximum allowable operating pressure (MAWP) greater than
eventual design of the steam-generating facility. 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 sys-
Combustion Air
tems involved in a typical steam plant, but has special signifi-
13. Determine the ambient air conditions in the boiler area and cance relative to Section I in that it contains Certification and
determine current fresh air supply (e.g., louvre area). Stamping requirements for boiler external piping (BEP). BEP
Primarily, the intention is to understand typical air is defined as piping from the first circumferential joint leaving
temperatures and humidity and their variance during the the boiler up to and including the required stop valve or valves.
necessary time of boiler operation. Most, if not all, of the piping included with a packaged boiler
is within the scope of BEP. This generally includes steam,
Stack Gas feedwater, blowdown, water column and instrument piping.
Section VIII of the ASME Code contains rules for unfired pres-
14. Determine any temperature limitations imposed on the
sure vessels, which may apply to deaerators, blowdown sepa-
stack gas.
rators, etc.
15. Understand the local emission requirements, which will
affect the allowable stack gas composition.
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02-02
STACK GAS
14. TEMPERATURE LIMITATIONS
15. EMISSION REQUIREMENTS
16. STACK/BREECHING PHYSICAL ATTRIBUTES
COMBUSTION AIR STEAM

STEAM-GENERATING
FACILITY 2. OPERATING PRESSURE
13. TEMPERATURE 3. LOAD PROFILE
STEAM-USE
HUMIDITY 4. QUALITY/DEGRE OF SUPERHEAT FACILITY
VARIANCE
17. ELECTRICAL POWER DEMANDS
AND PROFILE 1. TYPE OF APPLICATION/LOAD
18. ELECTRICAL COSTS
19. PHYSICAL LIMITATIONS
20. NOISE LEVEL REQUIREMENTS CONDENSATE RETURN
FUEL
10. TYPE(S) OF FUEL 5. TEMPERATURE
11. COMPOSITION ANALYSIS PRESSURE
12. FUEL COSTS PERCENT RETURN
WATER DISCHARGE MAKE-UP WATER

8. MAXIMUM TEMPERATURE 6. PERCENT MAKE-UP
9. SEWER CHARGES 7. WATER CHARGES
Figure I3-3. Summary of Application/Energy-Use Audit Items
Other Federal, State, Provincial and Local to each subsection of the overall system, categorized as: steam
Requirements boilers, boiler piping and valves, feedwater systems, water
treatment systems, heat exchangers and economizers, and
There are many other Codes and Standards which apply to blowdown systems. Stacks and controls are not discussed
other aspects of the design and installation of steam room since the intention here is to concentrate on the steam side of
equipment. For a listing of standards organizations of rele- the system. For information concerning controls and stacks,
vance to the design of steam systems, please refer to Section please refer to sections D and F, respectively. Considerations
I4. Local jurisdictions, insurance companies and individual concerning sizing of piping, steam traps, etc. are also not cov-
contracts often impose special requirements above and beyond ered in this section; those items are considered as a part of the
Code requirements, or may require compliance with special steam/condensate return handling and piping system design
Codes and Standards. It is essential that those responsible for and many references concerning these issues are available.
the planning of a boiler room installation be familiar with such
requirements.
Steam Boilers
EQUIPMENT CONSIDERATIONS AND The boiler selection process is based on an evaluation of the
system and load requirements as described above, and a com-
HARDWARE DESIGN parison with the different boiler types that are available. This
Having defined the application and obtained an understanding section defines a process and the considerations that can be
of the requirements and constraints of the steam system, it is used to select a boiler for a steam system application, based on
now important to consider basic equipment needs and hard- the requirements discussed in Section I1.
ware design. Here the concern deals with potential equipment The steam-use facility will have certain operating requirements
problems of the steam-generating facility in terms of perfor- that are used to establish the boiler design pressure. For exam-
mance and life. Specifically, the issues to be addressed when ple, heating systems often operate at low pressure (a steam
designing and integrating equipment into a workable system pressure of 8 - 10 psig), and would use a boiler that is designed
are: (1) equipment capacity, (2) operating characteristics and for 15 psig. The boiler design pressure must be higher than the
constraints of equipment, (3) maintenance issues and the operating pressure, and is usually based on common design
tradeoff with design/initial cost, and (4) the operational effects pressures. Steam quality, or the moisture content in the steam,
of each piece of hardware on the overall system operation. may also be a requirement of the facility.
The following is a discussion concerning considerations given The first step in determining the required boiler size is to deter-
I3-6
02-02
mine the number of boilers. Multiple boilers can be used to Watertube boilers are the preferred choice for pressures
divide a seasonal load into more manageable segments, even above 350 psig.
using different boiler sizes to better match the load. Additional
Higher turndown rates improve the boiler load response
boilers can be used to provide backup and minimize potential
because the boiler remains on line at low loads.
down time. Hospitals usually require a substantial amount of
backup capability. Increasing the number of boilers also adds Bent tube and electric boilers can provide quick warm-up
to the initial cost, on-going maintenance costs and complexity without thermal shock.
of the system.
Steam superheat is generally only available on the IWT
Once the number of boilers have been selected, the capacity of boiler.
the boilers can be determined. This task should not be limited
There are numerous regulatory requirements in the boiler
to matching the peak load and the total capacity of the boilers.
industry. Many boilers are listed by Underwriters Laboratories
For example, the base capacity or number of boilers should be
or a similar agency, which has tested the product to ensure that
increased if there can be a high instantaneous demand. Some
it meets their minimum standards for safety and performance.
consideration should also be given to how multiple boilers are
Emission regulations have become more common in recent
cycled to minimize the cycling and number of units in use at
years. Finally, there may be other organizations that will man-
any one time.
date requirements for an installation, such as the city, state or
Increasing the number of boilers will: insurance carrier. These requirements may prevent the use of
some boiler types.
Minimize down time and maximize reliability.
Check insurance carrier for requirements.
Provide the highest efficiency by matching load to boiler
capacity. A Package listing helps insure boiler/burner compatibility.
Increase the total installed cost of the boiler room. Construction and operating permits are usually required by
local authorities.
Allow the use of smaller boilers and support
components. Federal NSPS regulations, permits and recording applies
over 200 hp.
Increase maintenance cost.
The final stage in the selection process will be the consider-
Increase the size and complexity of the boiler room.
ation of the operating features and efficiency of the boilers.
Minimizing the number of boilers will: Initial cost is always a factor, but it should not be the only fac-
tor. For example, the boiler efficiency, turndown and mainte-
Decrease total installed cost.
nance requirements can result in much higher or lower
Reduce overall efficiency because of low-load operating costs, and can easily change the cost analysis. Some
operation. common considerations that impact overall efficiency and fuel
costs are:
Minimize maintenance costs.
Multiple fuel capabilities, including future conversions.
Provide a less complex and smaller boiler room.
More flue gas passes in a firetube boiler will increase heat
Different sized boilers can be used for the large variation in
transfer.
seasonal loads.
Heating surface area, usually 5 square feet per boiler hp in a
Total boiler capacity should include future expansion
firetube boiler.
considerations.
Higher turndown increases boiler efficiency and provides
Emission regulations may require special controls above a
quicker load response.
certain total capacity.
Lower excess air operation increases boiler efficiency.
At this stage of the selection process, some boiler types can be
eliminated based on the operating pressure and capacity Economizers can be added to most boilers, which will
requirements. (Table I1-1 in Section I1 can be used as a guide increase efficiency.
in this process). In addition, the load type may also impact the
Maintenance and down time can be important considerations
selection process. For example, watertube boilers are better
in the boiler selection. Using multiple boilers helps reduce the
suited to swing loads while firetube boilers are better for loads
potential for loss of steam generating capability.
with upset conditions. Also, bent tube boilers can be used
when quick warm up is required. Higher turndown reduces component wear and failure due to
on-off cycling.
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02-02
Critical operations should include controls to keep the Relevant highlights of the ASME Code are included. However,
standby boiler hot. for complete details, the reader should review the applicable
section of the ASME Code. In addition to the ASME Code, the
Always use duplex pumps and filters to allow maintenance
reader should determine whether there are any special, local
without shut down.
insurance or regulatory requirements.
Consider rental boilers as potential backup, and include
required piping in the plant. Low Pressure Boilers
Generally boilers with large water volumes and surface areas The ASME Code contains many recommendations for low
are more tolerant of feedwater treatment variations and load pressure steam systems. Here are excerpts that apply to design
surges. consideration.
The moisture content in steam from a steam generator is nor- Steam Line Expansion - Provisions shall be made for the
mally very small. There are conditions that can upset the nor- expansion and contraction of steam and hot water mains con-
mal operation and result in some relatively high amounts of nected to boilers by providing substantial anchorage at suitable
water carry-over. In addition, there are some applications points, and by providing swing joints when boilers are installed
which require extremely dry steam for proper operation. in batteries, so there will be no undue strain transmitted to the
There are some guidelines for maintaining high quality steam, boilers. para. HG-703.1
and methods to improve the steam quality.
Stop Valves for Single, Multiple, and Steam Boilers
Feedwater quality is the single most important element in
Steam Boilers - When a stop valve is used in the supply pipe
steam quality. General feedwater guidelines are given in this
connection of a single steam boiler, there shall be one used in
book and others. Special considerations need to be given to
the return pipe connection.para. HG-710.1
the type of boiler. There may be additional requirements based
on the boiler type and the conditions of the local water supply. Multiple Boiler Installations - A stop valve shall be used in
A water specialist should be consulted for specific require- each supply and return pipe connection of two or more boilers
ments of an installation. connected to a common system. para. HG-710.3
The steam quality from a boiler can be improved by adding an Shutoff Valves - No shutoff of any description shall be placed
external separator or an equalizing line similar to a Hartford between the safety relief valve and the boiler, nor on discharge
Loop. Such special steam piping arrangements are sometimes pipes between such valves and the atmosphere. para. HG-
used on low pressure steam boilers with small steam cham- 701.5
bers.
Safety and Safety Relief Valves - Safety and safety relief
The industrial watertube boiler offers some additional options valves shall not be connected to an internal pipe in the boiler.
for improving the steam quality. One option uses special drum para. HG-701.4
components to further remove solids, resulting in higher steam
Safety Valve Discharge Piping - A discharge pipe shall be
quality. The other option is to add a superheater to provide
used. Its internal cross-sectional area shall be not less than the
superheated steam.
full area of the valve outlet or of the total of the valve outlets
Water maintenance programs can help insure reliable steam discharging there into and shall be as short and straight as pos-
quality. sible and so arranged as to avoid undue stress on the valve or
valves. When an elbow is placed on a safety or safety-relief
Boiler concentrations may need to be adjusted for best steam
valve discharge pipe, it shall be located close to the valve out-
quality.
let. The discharge from safety or safety-relief valves shall be so
Special steam piping can be used with some boilers (such as arranged that there will be no danger of scalding attendants.
the cast iron boiler) to reduce carry-over. Para. HG-701.6 Refer to Figure I3-4.
An external separator will typically remove 90% of the Bottom Blowoff - Each boiler shall have a bottom blowoff or
moisture in a steam line. drain pipe connection fitted with a valve or cock connected
with the lowest water space practicable. The discharge piping
Superheated steam and special steam dryers are available on
shall be full size to the point of discharge. para. HG-715
industrial watertube boilers.
High Pressure Boilers

Boiler Piping and Valves
The ASME Code provides many recommendations for high
This section contains information on boiler piping and valve pressure steam boilers. Here are some excerpts that apply to
requirements for low and high pressure boilers. design considerations.
I3-8
02-02
Figure I3-4. Recommended Safety Valve Discharge Piping
Steam Line Expansion - Provisions shall be made for the preferably of one automatic non-return valve (set next to the
expansion and contraction of steam mains connected to boil- boiler) and a second valve of the outside-screw-and-yoke type
ers, by providing substantial anchorage at suitable points, so or two valves of the outside-screw-and-yoke type shall be
that there shall be no undue strain transmitted to the boiler. used. Para. 122.1.7 (A.2) (ASME B31.1)
para. PG-59.1.2
Stop-Check Valves (Non-Code Recommendations) - A prob-
Steam Stop Valves - Each boiler discharge outlet, except lem confronting the power piping designer is the selection of
safety valves or safety relief valves, or preheater inlet and out- the best size of stop check valve for his service conditions.
let connections, shall be fitted with a stop valve located at an This type valve usually has a floating disc member, hence it is
accessible point in the steam-delivery line and as near the important that the valve be sized to provide full disc lift under
boiler nozzle as is convenient and practicable. When such out- flow conditions prevailing during the major portion of the ser-
lets are over NPS2, the valve or valves used on the connection vice life of the installation. If the valve is too large for flow
shall be of the outside-screw-and-yoke rising-stem type so as conditions, the disc will float in a partially open position; this
to indicate from a distance, by the position of its stem whether may result in fluttering of the disc and rapid wear of valve
it is closed or open, and the wheel may be carried either on the parts. Conversely, if the valve is too small for flow conditions
yoke or attached to the stem. para. 122.1.7 (A.1) (ASME encountered, pressure drop will be excessive.
B31.1)
Safety Valves - No valve of any description shall be placed
When boilers are connected to a common header, the connec- between the required safety valve or valves and the boiler, nor
tion from each boiler having a manhole opening, shall be fitted the discharge pipe between the safety valve and the atmo-
with two stop valves having an ample free-blow drain between sphere. When a discharge pipe is used, the cross-sectional area
them. The discharge of this drain shall be visible to the opera- shall be not less than the full area of the valve outlet or the total
tor while manipulating the valve. The stop valves shall consist
I3-9
02-02
of the areas of the valve outlets discharging there into and shall An important factor in the condensate return and water make-
be as short and straight as possible and so arranged as to avoid up system is to ensure that contaminated condensate does not
undue stresses on the valve or valves. All safety valve or relief return to the boiler room and its associated equipment. Con-
valve discharges shall be so located or piped as to be carried densate contaminated with oil, dye, soap, etc. must be disposed
clear from running boards or platforms. Ample provision for of in a safe manner. Contaminated condensate will cause prob-
gravity drain shall be made in the discharge pipe at or near lems such as foaming, priming, unstable water level, and it will
each safety valve or safety relief valve, and where water of increase blowdown requirements.
condensation may collect. Each valve shall have an opening
The collection of clean steam condensate is desirable for sev-
gravity drain through the casing below the level of the valve
eral economic reasons. Condensate generally is capable of
seat. For iron-and-steel bodied valves exceeding 2-1/2 inch
being collected at temperatures higher than the temperature of
size, the drain hole shall be tapped not less than 3/8 inch pipe
raw water make-up. This results in significant fuel cost savings
size. Para PG-71.3 Refer to Figure I3-4, Recommended
and improved overall system efficiency. Since condensate is
Safety Valve Discharge Piping.
formed from steam, it contains little or no dissolved solids.
Safety Valve Mounting - When a boiler is fitted with two or Therefore, using collected condensate reduces chemical usage
more safety valves or safety relief valves on one connection, and associated costs as well.
this connection to the boiler shall have a cross-sectional area
Additionally, the cost of raw water make-up will be reduced by
not less than the combined area of inlet connections of all the
collecting condensate because the demand for raw water is lim-
safety valves with which it connects and shall also meet the
ited. When considering installation costs, the expected conden-
requirements of Paragraph PG-71.3. Para. PG-71.5
sate return may allow for down-sizing of the raw water make-
Blowoff Valves - The blowoff valve or valves, the pipe up supply system and other components.
between them, and the boiler connection shall be of the same
Unfortunately, condensate flow from the system may be unpre-
size except that a larger pipe for the return of condensate may
dictable. Unpredictability of returning condensate causes a
be used.
problem for the boiler, since it should have a continuous and
For all boilers . . . with allowable working pressure in excess immediately available supply of water. However, there are sev-
of 100 psig, each bottom blowoff pipe shall have two slow- eral ways to collect and store condensate so it is readily avail-
opening valves, or one quick-opening valve or cock; at the able.
boiler nozzle followed by a slow-opening valve. A slow-open-
A collection or storage tank can be incorporated to act as a res-
ing valve is a valve which requires at least five 360 degree
ervoir. Products which serve this purpose include boiler feed-
turns of the operating mechanism from fully closed to fully
water systems, surge tanks, and deaerators.
opened. On a boiler having multiple blowoff pipes, a single
master valve may be placed on the common blowoff pipe from The function of these products in the overall condensate return
the boilers, in which case only one valve on each individual and raw water make-up system is as follows. For further infor-
blowoff is required. In such a case, either the master valve or mation on this equipment, refer to the specific product sections
the individual valves or cocks shall be of the slow-opening in The Boiler Book.
type. Para. 122.1.7 (ASME B31.1)
Feedwater Valves - The feedwater piping for all [steam] Boiler Feed System
boilers . . . shall be provided with a check valve . . . between Boiler feedwater systems help maintain maximum efficiency
the check valve and the boiler. Para 122.1 (B1) (ASME and prolong the life of the boiler, when investment in a deaera-
B31.1) tor cannot be justified. Consisting of one or more feed pumps
and a corrosion resistant receiver tank, the system automati-
When two or more boilers are fed from a common source,
cally supplements condensate with make-up water to replace
there shall also be a globe or regulating valve in the branch to
system losses. When equipped with an automatic preheater,
each boiler located between the check valve and the source of
feedwater temperatures can be maintained at temperatures up
supply. Para. 122.1.7 (B.5) (ASME B31.1)
to 210 F (maximum). At this temperature, substantial amounts
of oxygen and carbon dioxide are released, reducing the
Boiler Feed Systems amount of chemicals required to protect the boiler and system
The transfer of heat from steam, regardless of process usage, from corrosion. Preheating is recommended if the return con-
will create condensate. The quantity of collectable condensate densate constitutes 50% or less of the required feedwater.
varies with the type of application. For instance, with humidi- Boiler feed systems typically combine one or more boiler feed
fication, the steam is released to the environment and the con- pumps with a tank to store condensate and make-up water.
densate is considered uncollectible. In industrial applications, These components are typically furnished as a complete pack-
condensate can typically be collected in large quantity. age with level, temperature, and pressure controls. Additional
I3-10
02-02
features such as deaeration hardware and more sophisticated water and condensate. Without deaeration, the dissolved gases
controls may be considered. can cause serious corrosion in the boiler and other system
hardware.
The purpose of the boiler feed system is to provide a reservoir
with sufficient surge capacity to accommodate intermittent Deaerators are considered essential for:
condensate flowrates, and to provide stable suction conditions
All boiler plants operating at 75 psig or more.
for the boiler feed pump(s). The selection of a boiler feedwa-
ter system is primarily driven by surge capacity. For this rea- All boiler plants with little or no standby capacity.
son, it is necessary to accurately estimate peak condensate
All boilers plants where production depends on continuous
flowrates from the steam-use facility, considering also factors
operation.
due to transient conditions such as equipment startups, piping
hydraulics, and system interactions. Once this information is All boiler plants operating with makeup water of 25% or
obtained and understood, a boiler feed tank of sufficient size more.
may be selected.
In addition to removing oxygen and carbon dioxide, deaerators
The operating characteristics of the boiler and steam-generat- also heat boiler feedwater. The large storage capacity provides
ing system have an impact on the type of controls and features an effective means for recovering heat from exhaust steam and
included in the boiler feed system. In particular, those factors hot condensate. With a deaerator, further savings result from
influencing pump selection will also have an effect on the the reduced need for oxygen-scavenging chemical treatment.
height of the boiler feedwater system, the level control system, For further information, refer to Sections H1, H2, and H3.
and suction piping design. The characteristics of the returning
condensate should also be considered when selecting feedwa- Pumps
ter system components, corrosion resistant linings, and pres-
There are five design criteria that must be considered before
sure/temperature controls.
the proper boiler feed pump can be selected.
There are many cost/benefit tradeoffs available when configur-
1. Will the pump run continuously or intermittently?
ing a boiler feed system. A partial list includes:
2. What is the temperature of the water being pumped?
Feedwater Preheat reduces thermal shock.
3. What is the pump capacity requirement in gpm?
Premium Lining/Galvanizing reduces corrosion.
4. What is the pump discharge pressure requirement?
Premium Level Control reduces overflow losses.
5. What is the NPSH (net positive suction head) required?
Code Rated Pressure Tank reduces flash steam losses.
Continuous or Intermittent Operation - Continuous or
Deaeration Hardware reduces corrosion and thermal
intermittent operation of a pump is determined by the critical
shock.
nature of the desired water level control. The water level con-
Each of these options has a direct benefit on the long-term trol requirements are primarily based on the type of boiler, but
operating costs of the system. Their increased initial costs are also affected by the load, operating pressure, and feed
must be balanced against the overall capital cost and the water temperature. Continuous operation provides better water
expected life of the system. For more information on boiler level control, but adds cost and components to the system.
feed systems, please refer to Section H5.
Boiler types with a relatively low water volume, such as water-
tube boilers, require more precise water level control than
Surge Tanks (Condensate Receiver Tanks) boiler types with a large water volume, such as firetubes. This
Surge tanks can greatly reduce dependence on cold, untreated is due to the relationship between drum (vessel) size and gal-
raw water to replace boiler system losses by collecting con- lons of water content. For example, a fifty gallon change in a
densate by gravity return for re-use in the boiler feed system. watertube boiler might represent a one inch change in water
Surge tanks are required when no other storage exists or when level, while the same fifty gallon change in a firetube boiler
intermittent peak loads of condensate can exceed the storage might only represent a fraction of an inch change in water
capacity of the deaerator. Integrated control automatically level.
introduces makeup water to supplement condensate only when
Frequent load swings will require more accurate water level
necessary to meet boiler demand. Refer to Section H4 for
control to ensure the feedwater flow matches the steam flow
more detailed information.
requirement. Frequent load swings may require continuous
feedwater control to maintain proper water level.
Deaerators
The relationship between operating pressure and feedwater
Deaeration is widely recognized as the most acceptable temperature can make water level control more critical if the
method for removing oxygen and carbon dioxide from makeup
I3-11
02-02
temperatures vary or if there is a large differential between sat- tor), plus by-pass flow requirement (in gpm) for the pump. The
uration temperature and feed water temperature. Large tem- by-pass flow is usually regulated through a fixed orifice, and is
perature differentials could result in a reduction in boiler water of sufficient quantity to prevent cavitation within the pump
level when feed water is added. The reduction is caused by a under dead head conditions. The by-pass orifice must be
quenching effect, which lowers the boiler water temperature located between the pump discharge and the modulating feed-
slightly, reducing the steam/water volume, thereby lowering water valve to allow water to recirculate back to the storage
the water level. This type of water level reduction is generally tank.
more common on smaller, low pressure boilers. Pump Discharge Pressure Requirements - Pump discharge
Selection of Pump Type (Centrifugal or Turbine) - Once the pressure requirements are calculated by determining the boiler
criteria for water level control is determined, the type of feed operating pressure and calculating the line losses between the
pump can be selected. pump and the boiler. The pump discharge pressure needs to
overcome the piping line losses, and boiler pressure in order to
Highly accurate water level control can be achieved with a get water into the boiler.
centrifugal type pump, running continuously, in conjunction
with a modulating feed water valve on the boiler. All calculations need to be converted to feet of head for pump
selection purposes. Therefore, convert boiler operating pres-
An effective but less precise means of water level control can sure to feet of head, and add to that value the equivalent length
be provided using a turbine type pump, with intermittent (on- (in feet of head) of the piping and associated valves between
off) operation. With intermittent operation, larger swings in the pump discharge and the boiler.
water level control will result.
Net Positive Suction Head (NPSH) - Every pump design has
Although not common, turbine pumps have been used in con- a certain requirement for net positive suction head. This is the
junction with a modulating feedwater valve to provide water amount of liquid in feet that must be above the pump suction
level control. In this application, a relief device must be centerline in order to prevent cavitation and to provide proper
included to discharge water back to the feedwater tank to pro- pump operation.
tect the pump from dead head pressures. Dead head pressures
can cause overheating, cavitation, and subsequent pump dam- Net positive suction head required (NPSH-R) by the pump
age. A concern of this design is the use of a relief device as a must be exceeded by the net positive suction head available
control valve, and the inherent performance and reliability fac- (NPSH-A) from the system.
tors. Calculation: NPSH-A = HP + HZ - HF - HVP
Pump Water Temperature - The temperature of the pumped NPSH-A - Available NPSH expressed in feet of fluid.
water must be specified to ensure proper design and construc-
tion. Pumps use packing or mechanical seals to seal the area HP - Absolute pressure on the surface of the liquid at the pump
between the pump shaft and the pump casing. These seals have suction location, expressed in feet. This could be atmospheric
temperature limitations and, if misapplied, the seals will fail. pressure or vessel pressure (pressurized tank).
Standard pump seals are adequate up to temperatures of HZ - Static elevation of the liquid above, or below the center-
approximately 215 F. Higher temperature seals are available line of the impeller, expressed in feet.
for temperatures up to 250 F and, for temperatures above 250
F, external water cooling is usually employed to protect the HF - Friction and entrance head loss in the suction piping,
seals. For applications above 250 F, contact your local expressed in feet.
Cleaver-Brooks authorized representative. HVP- Absolute vapor pressure of the fluid at the pumping tem-
Pump Capacity Requirements - Determining pumping perature, expressed in feet.
capacity requirements involves slightly different criteria for Cleaver-Brooks makes selections that are based on pumps hav-
centrifugal and turbine type pumps. For both pump types, the ing the lowest possible NPSH-R. This is done to provide the
maximum boiler capacity must be determined. The maximum lowest stand height and the lowest overall height of the tank.
boiler capacity, or evaporation rate, is usually calculated in There are some sacrifices which must be accepted in order to
pounds of steam per hour, and should be converted to gallons have low NPSH-R. Usually a selection with a low NPSH-R is a
per minute, and have blowdown added to it for pump selection pump that is larger and usually requires a greater horsepower
purposes. For assistance in this calculation, contact your local drive. Generally speaking, however, it is more important to
Cleaver-Brooks authorized representative. keep the overall height to a minimum than to select a pump
The pump capacity for turbine pumps, with intermittent opera- with a higher NPSH-R.
tion, should be equal to 2 times the maximum evaporation rate Pumps (General) - The design criteria for transfer pumps
of the boiler. (pumps which pump water to a deaerator) is the same as the
The pump capacity for centrifugal pumps, with continuous criteria just covered for boiler feed pumps.
operation, is equal to: evaporation rate times 1.15 (safety fac-
I3-12
02-02
Cleaver-Brooks and our authorized representatives provide a gen. Dissolved oxygen is not related to the combined oxygen
full line of pumps, and pump selection services for application contained in the water molecule H2O. All surface and rain
in both steam and hot water systems. For assistance, contact water contain dissolved oxygen, because of their contact with
your local Cleaver-Brooks authorized representative. the atmosphere. With enough contact, the dissolved oxygen
content will reach saturation for the corresponding tempera-
Water Treatment Systems ture. The solubility of oxygen is affected by solid content.
Water with a higher solid content will contain less oxygen than
Harmful elements are contained in surface and well water. distilled water. Surface water usually contains more oxygen
Surface and well water are also called raw water. A sample than well water. As the raw water temperature rises, dissolved
of the raw water should be analyzed early in the equipment oxygen is released and can cause corrosion of iron and steel.
planning stage. The analysis provides a clear definition of the Therefore, the problem caused by dissolved oxygen in boiler
particular threats posed by the water source. Your Cleaver- systems is corrosion in the boiler feedwater piping, econo-
Brooks representative can assist you in defining the harmful mizer, boiler, and steam and condensate return piping.
elements, and can help in planning a water treatment program
and in selecting the proper treatment equipment. Hence, the generation of steam from naturally occurring water
sources can be complicated by the presence of various chemi-
The following is a discussion of the elements commonly found cal constituents in the water supply. The American Society of
in raw water. Mechanical Engineers has published guidelines on boiler
Surface water usually has high suspended solids and dissolved water and boiler feedwater quality for steam boilers. Most
gases and low dissolved solids. Well water normally has high boiler installations will require some form of water treatment
dissolved solids and low suspended solids and dissolved gases. in order to conform to these guidelines. A few methods of
treatment are depicted in Tables I3-1 and I3-2.
Suspended solids represent the undissolved matter in water,
including dirt, silt, biological growth, vegetation, and insolu- The Objectives of Feedwater Treatment
ble organic matter.
Proper boiler feedwater treatment is an absolute necessity!
When minerals dissolve in water, ions are formed. The sum of Unless the boiler receives water of proper quality, the boilers
all minerals or ions in the water is the total dissolved solids or life will be shortened. The water supply for a steam system
TDS. may originate from rivers, ponds, underground wells, etc. Each
Iron can be soluble or insoluble. Insoluble iron can clog valves water supply source requires a specific analysis. Depending
and strainers and can cause excessive sludge build up in low upon the analysis, various pretreatment methods may be
lying areas of a water system. It also leads to boiler deposits employed to prepare make-up water for the boiler feedwater
that can cause tube failures. Soluble iron can interfere in many system.
processes, such as printing or the dying of cloth. In domestic The objectives of boiler water treatment in general are as fol-
water systems, porcelain fixtures can be stained by as little as lows:
0.25 ppm of iron.
1. Prevent hard scale deposits or soft sludge type deposits
Water hardness is the measure of calcium and magnesium con- which would, if present, impair the rate of heat transfer and
tent as calcium carbonate equivalents. Water hardness is the possibly result in overheating and damage to the pressure
primary source of scale in boiler equipment. vessel.
Silica in boiler feedwater can also cause hard dense scale with 2. Prevent general corrosion or pitting to assure maximum
a high resistance to heat transfer. life of the boiler at the lowest maintenance cost.
Alkalinity is a measure of the capacity of water to neutralize 3. Prevent intercrystalline cracking or caustic embrittlement
strong acid. In natural waters, the capacity is attributable to of boiler metal.
bases, such as bicarbonates, carbonates, and hydroxides; as
well as silicates, borates, ammonia, phosphates, and organic 4. Prevent carryover to assure high quality steam at an
bases. These bases, especially bicarbonates and carbonates, economical rate of continuous and intermittent blowdown.
break down to form carbon dioxide in steam, which is a major The accomplishment of these objectives will, in all cases,
factor in the corrosion of condensate lines. Alkalinity also con- involve several forms of treatment including:
tributes to foaming and carryover in boilers.
Pretreatment of the make-up water before it enters the boiler
pH is a measure of the degree of acid or base of a solution. The feedwater system.
pH scale is from 0 to 14, with 0 being the most acidic and 14
being the most basic or alkaline. Chemical treatment of the boiler water internally in the
boiler.
Dissolved oxygen is the amount of oxygen gas dissolved in the
raw water and is caused by the solubility of atmospheric oxy-
I3-13
02-02
Table I3-1. Removal of Harmful Elements with Various Types of Equipment

DISSOLVED SOFTENER CLORIDE CYCLE FILTERS DEAERATORS
CONSTITUENT DEALKALIZER
Calcium CaB 98-100% Must have soft water No Change No Change
Magnesium MgB 98-100% Must have soft water No Change No Change
HardnessA 98-100% Must have soft water No Change No Change
Sodium Na Increases No Change No Change No Change
Bicarbonate Alkalinity HCO3A No Change 90% No Change No Change
Sulfate SO4 No Change 90-95% No Change No Change
Chloride Cl No Change Increases No Change No Change
Silica SiO2A No Change 20% No Change No Change
Soluble Iron Fe 100% Must have soft water No Change No Change
Total Dissolved SolidsA No Change No Change No Change No Change
Suspended SolidsA Must Be Removed Must be removed Down to 10 No Change

Micron
Dissolved GasesA No Change Free CO2 Only See Filter To .005 cc/liter of O2
Section
NOTE: All of the above packaged water systems can be readily integrated into existing Cleaver-Brooks boiler rooms. All are designed to
accommodate boilers of any make.
A. Specifically limited by ASME guidelines on boiler feedwater quality.
B. The sum of calcium and magnesium equal the hardness. Hardness has been listed as a separate item for those analyses showing
hardness only.
Table I3-2. Makeup Water Impurities, Limits and Treatment Methods
MAKE-UP WATER TEST TYPICAL IMPURITIES TYPICAL LIMITS TREATMENT METHOD
Oxygen 6 ppm <.007 ppmA Deaeration/Chemical
Hardness 86 ppm <1.0 ppmA Softener
Suspended Matter 0.1 ppm 0.15 ppmA Blowdown
pH 6.87 7.0-10.5A Chemical
Silica 10 ppm <150 ppmB Blowdown
Alkalinity 100 ppm <700 ppmB Blowdown/Dealkalizer
Dissolved Solids 500 -mho/cm <7000 mho/cmB Blowdown
A. Limits for feedwater.

B. Limits of boiler.
In addition, the selection of pretreatment methods will depend The following are descriptions of feedwater pretreatment
upon the chemistry of the raw water and the plant operating equipment and a discussion of their functions in the overall
characteristics. In most cases, pretreatment becomes more crit- feedwater pretreatment cycle. For further information on
ical as the percentage of make-up to the system increases. equipment, refer to the specific product sections.
Raw Water Make-up Filters

Impurities in raw water make-up can be removed and con- The need for special filter equipment to remove impurities can
trolled either chemically or mechanically with various equip- be readily determined by a raw water analysis. Filters should
ment. Mechanical means of removing or controlling impurities be considered in order to remove sand, iron, chlorine, and some
will result in less chemicals being added to the boiler and sys- dissolved organics and sediments. Refer to Section H7.
tem. However, mechanical means will not remove or control
all impurities. Chemicals will still be required to provide the
desired results.
I3-14
02-02
Water Softeners These equipment selection economic tradeoffs are influenced

by size, criticality, and operating environment of the steam sys-
Water softeners should be used whenever raw water hardness
tem.
exceeds 5 ppm. A softener removes calcium and magnesium
and exchanges them with highly soluble sodium ions. Remov-
ing hardness prevents scale buildup on heat transfer surfaces Economizers
and helps maintain peak boiler efficiency. A water softener During boiler operation in typical commercial and industrial
also is the base for many sophisticated pretreatment processes applications, approximately 10-20% of the heating value of
that require the control of water hardness for proper operation. fuel is expelled with the stack gases to the atmosphere. Stack
Refer to Section H8. economizers are designed to recover significant amounts of
this stack gas energy loss, thereby vastly improving boiler sys-
Dealkalizers tem efficiency, as shown in Section G, Tables G-5 and G-6.
Dealkalizers use softened water and remove negatively There are several considerations when selecting an econo-
charged ions of bicarbonate, carbonate, sulfate nitrate, and sil- mizer:
ica. They are replaced with chloride ions. Removal of bicar-
bonate alkalinity controls formation of carbon dioxide and Gas-side Pressure Drop. Added back-pressure on the boiler
reduces the corrosion of condensate piping. Dealkalization stack affects the combustion air fan throughput capability.
reduces the need for neutralizing chemicals by as much as The economizer and combustion air fan(s) must be sized
90% and cuts fuel costs by minimizing blowdown. Refer to properly in order to assure a suitable system operation and
Section H9. capacity.
Feedwater Temperature. The feedwater to the economizer
Chemical Feed Systems must be deaerated and the temperature setpoint minimally at
Chemical feed systems treat feedwater, boiler water, and con- 220oF to prevent tube corrosion.
dition blowdown sludge where an additional measure of pro- Water-side Pressure Drop. Feedwater pumps must be sized
tection against corrosion and scaling is required. Refer to to accommodate the economizer pressure drop.
Section H6. Additionally, a continuous modulating feedwater system is
In summary, the benefits of water treatment equipment include required to ensure proper flow rates through the economizer.
improved boiler efficiency, corrosion reduction and therefore A full product line description of Cleaver-Brooks Boilermate
component life, and improved steam purity. The selection and Economizers, including sizing and performance information, is
sizing of water treatment equipment is dictated by the capacity offered in Section G.
of the steam system, the chemical constituents in the make-up
water supply, and the operating characteristics of the overall
Blowdown Systems
system. Generally speaking, the greater the treatment load (in
units of lb/hr removal), the larger the equipment. It is impor- A number of factors determine the need for boiler blowdown.
tant when designing a water treatment system that a detailed As mentioned earlier, the amount of total dissolved solids
water analysis be available as a guide. (TDS) is one. The American Boiler Manufacturers Association
(ABMA) has developed recommended limits for total and sus-
The design of the water treatment system is influenced by cost/ pended solids for different boiler operating pressures. Refer to
benefit tradeoffs in equipment selection. These influences Table I3-3 for recommended limits for total and suspended sol-
may include: ids.
Chemical Feed Systems which have low initial costs, but Other controlling factors for determining blowdown require-
significant operating costs. ments are alkalinity, suspended solids, and other chemical fac-
Component Duplexing which tends to ensure uninterrupted tors. In boilers operating over 600 psig, silica content could be
operation. the limiting factor.
Chloride Cycle Dealkalizers which reduce blowdown Solids are brought into the boiler by the feedwater. Even
losses. though the water is treated, either mechanically or chemically,
neither means of treatment is capable of removing all sub-
Filters which also reduce blowdown losses and stances. A small amount of crystallized solids will be present in
maintenance. the boiler water, which can tend to encrust surfaces.
Skid Mounting which decreases installation costs. That is, solids become less soluble in the high temperature of
Premium Regeneration Controls which may decrease the boiler water and tend to crystallize and concentrate on heat-
operating costs.
I3-15
02-02
Table I3-3. Recommended Limits for Total Suspended Solids

A controlled orifice valve is used to allow a continual, yet con-
OPERATING TOTAL SUSPENDED trolled, flow of concentrated water. Periodic adjustments are
PRESSURE SOLIDS SOLIDS
PSIG PPM PPM made to the valve in order to increase or decrease the amount
of blowdown in accordance with test analysis.
0-300 3500 300
There are a few considerations when designing a blowdown
301-450 3000 250
system:
451-600 2500 150
Local Code Requirements: If necessary, a blowdown
601-750 2000 100
aftercooler should be incorporated to bring the blowdown
751-900 1500 60 water temperature to a level acceptable to the sewer system
901-1000 1250 40 and local code requirements.
Blowdown Heat Recovery: Since the blowdown water is
ing surfaces. Internal chemical treatment is therefore required discharged at the saturated steam temperature, a significant
in order to keep harmful scale and sludge from forming. amount of energy may be expelled during blowdown. A
well-designed blowdown heat recovery system can control
Scale has a low heat transfer value and acts as an insulating blowdown rates and dissolved solids concentration while
barrier. Insulation retards heat transfer, which not only results recovering heat for make-up water preheating.
in lower operating efficiency but, more importantly, can cause
overheating of boiler metal. Overheating of boiler metal When selecting a blowdown heat recovery system, two factors
results in tube failure or other pressure vessel metal damage. should be considered: (1) tube materials and construction, and
(2) blowdown flowrate control. The high velocities and abra-
Scale is caused primarily by calcium and magnesium salts, sil- sive nature of blowdown water necessitates quality construc-
ica, and oil. Any calcium and magnesium salts, along with tion materials such as stainless steel, as well as design for
organic materials in the boiler water, are generally precipitated vibration damping. Secondly, it is important to control blow-
by the use of sodium phosphate in order to maintain these pre- down rate so as to match makeup water flow rates for optimal
cipitates or sludge in a fluid form. heat recovery.
Solids, such as sodium salts and suspended dirt, do not readily In most cases, the intermittent nature of bottom blowdown will
form scale. However, as boiler water boils, forming relatively preclude recovery of the blowdown energy losses. Moreover,
pure steam, the remaining water becomes increasingly thicker the bottom blowdown can contain suspended matter or sludge
with solids. If the concentration is permitted to accumulate, that will tend to clog a heat exchanger. With a continuous
foaming and priming will occur and the sludge can cause blowdown system, heat may certainly be recovered, transferred
harmful deposits that potentially result in overheating of the to make-up water, before the blowdown is cooled and sent to
metal. Therefore, lowering or removing concentrated solids sewer.
requires the use of boiler water blowdown.
Flash Tank Heat Exchangers: Flash tank heat exchangers
Types of Blowdown are also designed to recover heat from blowdown water, but
provide an added feature of producing low-pressure steam
There are two principal types of blowdown: manual (intermit- for deaeration. The portion of blowdown water which is not
tent) bottom blowdown and surface (continuous) blowdown. flashed either enters a blowdown heat recovery system for
Manual (Intermittent) Bottom Blowdown - Bottom blow- make-up water preheating or is discharged to sewer.
down is necessary for the proper operation of the boiler. Bot-
tom blowdown removes sludge and controls the level of TDS. SYSTEM INTEGRATION AND
On a manual system, the blowdown tappings are located at the
bottom or lowest part of the boiler, so that the dissolved solids
OPTIMIZATION
in the boiler water are lowered, and a portion of the sludge that The discussion in this section attempts to provide to the reader
accumulates in the lower portion of the boiler is removed. assistance to approach in designing and integrating various
equipment into a workable system. A workable system is one
Surface (Continuous) Blowdown - Surface blowdown
that meets the requirements and purposes of the system, has
involves a continuous, low flow of boiler water extracted from
satisfactory life and maintenance costs, and abides by all con-
the surface of the water level in order to skim off sediment, oil
straints such as pressures, temperatures, footprint, noise, emis-
and other impurities. The blowdown is regulated by a flow
sions, etc. In summary, a workable system performs the
control valve, which is adjusted as needed to control the TDS
assigned duty, given the imposed constraints and requirements.
level. The surface blowdown opening is on the top center line
of the pressure vessel and is provided with an internal collect- System optimization, on the other hand, is the process of deter-
ing pipe terminating slightly below the working water level. mining system configuration and state point conditions which
provide a maximization of some objec-
I3-16
02-02
tive such as the net present value of overall life costs. Opti- $68.04/month service charge
mized design may offer the steam-user significant savings over
$0.833/ccf consumption charge
the life of the steam-generating facility. It is the design which
maximizes profitability for the owner over time. 8. Water Discharge Max. Temp: 120 F
For a given application, there are many workable designs, but 9. Sewer Charges:
only one optimal design. The discussion in this section entails
$13.72/month service charge
a search method to approaching the optimal design. Com-
ponents/equipment are added arbitrarily and evaluated for $0.573/ccf use charge
effect on system performance and ultimately cost/benefit to
10. Types of Fuel:
the steam system owner. Obtaining the optimum design is
more involved than that presented in this section and is beyond Natural Gas
the scope of this discussion.
Light Oil considered as a back-up
EXAMPLE - STEAM SYSTEMS 11. Fuel Analysis:
The following is an example of a relatively simple low pres- Natural Gas

sure steam heating system. The entire steam-generating facil- Methane: 86.0% (vol.)
ity of an existing heating system is evaluated for replacement.
An application/energy-use audit results in the following infor- Ethane: 7.2% (vol.)
mation. Nitrogen: 6.8% (vol.)
1. Type of Application/Load: Heating SG: 0.619
2. Nominal Steam Pressure: 10 psig HHV: 21,100 Btu/lb (1000 Btu/scf)
3. Steam Load Characteristics/Profile: No. 2 Oil
The steam system operates 5 months/year. Carbon: 85.8% (wt.)
During 3 months (2160 hours) Hydrogen: 12.7% (wt.)
Minimum load: 0 Sulfur: 0.2% (wt.)
Maximum load: 5,600 kBtu/hr HHV: 19,420 Btu/lb
Average load:650 kBtu/hr 12. Fuel Costs:
During 2 months (1440 hours) Natural Gas: $4.50/MMBtu ($3.50 MMBtu interruptible)
Minimum load: 0 No. 2 Oil: $4.20/MMBtu
Maximum load: 8,100 kBtu/hr 13. Combustion Air Conditions:
Average load: 2,500 kBtu/hr Avg Temp1: 80 F
Transient loads, instantaneous demand, and sudden load Rel Hum: 60%
swings do not exist.
14. Stack Gas Temperature Limits: N/A
4. Steam Quality Requirements: 98% steam quality at boiler
pressure vessel exit 15. Emission Regulations:
5. Condensate Return Conditions: There are none currently, but requirements are in the
expected future. Site is located in a non-attainment zone.
Temperature: 200 F
16. Stack/Breeching Physical Attributes:
Pressure: 2 psig
A new single stack is to be designed by the boiler supplier.
% Return: 90%
17. Electrical Power Demand: Not applicable in this case
6. Make-up Water Requirement: 10%
7. Water Charges:
______________
1. Boiler room combustion air temperature ranges from 60 F to
100 F.
I3-17
02-02
18. Electrical Power Costs: Boiler Selection

$0.0345/kWhr on-peak As this steam generating facility is replacing an existing one,
pressure is already set at 10 psig. This system operating con-
$0.0245/kWhr off-peak
straint allows the use of a 15 psi boiler which falls under Sec-
19. Physical Limitations of Facility: None tion IV of the ASME code. In addition to pressure require-
ments, steam quality requirements need to be met. The cus-
20. Noise Level Requirements: <90 dBA
tomers system/application requirement is 98%. Most boilers
When designing a steam generating facility, necessary system offer 98.5% steam quality at low pressure; therefore this is not
capacity and approximate fuel costs need to be considered. a limitation.
This will for allow both qualitative and quantitative economic
The large amount of idle time and low-load firing apparently
analyses of different installation alternatives.
suggest a two boiler installation (boilers operate most effi-
First, required system capacity should be calculated. This is ciently near their rated capacity), with a large boiler for winter
the maximum load. and a smaller model for spring and fall. Reviewing the fuel
bill, however, indicates that an improvement in efficiency
A total capacity of 241 horsepower is required for this applica-
would not justify increased installation, maintenance and capi-
tal costs that the customer wishes to minimize. Furthermore,
8100 kBtu
hour ( 33.475
hp hour
kBtu
) = 241 hp 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
tion. Next, approximate fuel costs are calculated using the fol- boilers to be installed decided, several boiler types can be ruled
lowing:2 out immediately. Neither the Vertical Firetube nor the Model 4
Watertube Boilers are available in sufficient size for this sys-
tem. At the opposite extreme, the load is far too small for an
industrial watertube boiler. Remaining boilers include the fire-
total load = (loadi) (hoursi) box, firetube, flextube, electric and cast iron boilers. The cast
iron boiler may be ruled out because of its higher initial cost;
total load = 2160 hrs 650 kBtu/hr + 1440 2500 kBtu/hr the electric may be ruled out because of higher operating costs.
The remaining boilers, the firebox, firetube and flextube all are
= 5,004,000 kBtu
good choices for heating loads requiring low pressure steam.
(total load) ($/MMBtu) Instantaneous load is not an issue with a heating load. Like-
total fuel cost = wise, there are no large load swings to consider.
where = system efficiency (decimal)
An application under federal emission regulations (NSPS)
needs to be submitted because this installation is capable of
$4.50
MMBtu
1
(5,004,000 MBtu) 0.6 ( ) = $37,530 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
2. Efficiency should be set to 80% for process loads and 60% for expected to occur in the near future as the site is located in an
heating loads. In a heating application such as this one, the ozone nonattainment area.
operating efficiency of the system may be much lower than the
stack efficiency of the boiler. The reason for this is that the boiler
To minimize maintenance, a boiler with 5 square feet of heat-
may fire for only a few minutes in the morning. During the long
ing area per horsepower should be selected. The large water
off-cycle, heat is transferred from the boiler to its surroundings,
chamber and surface area reduce the need for cleaning, and
allowing the steam contained within the boiler to cool and con-
minimize upsets caused in water treatment. A turndown capa-
dense. When steam is again required, this lost heat must be
bility increased from the standard 4-1 would further reduce
replaced through several minutes of operation before steam may
maintenance and prolong boiler life. A 10-1 turndown, stan-
be supplied. Typical efficiencies for this type of operation range
dard on the CB and CB (LE) [low emission] Firetube Boilers
from 50 to 75%.
(250-800 hp), would result in significant fuel savings in this
I3-18
02-02
application. In a heating system such as this, eight to twelve A rule of thumb for tanks is to have a fifteen minute water sup-
cycles per hour are common. The 10-1 turndown drastically ply for boiler feed systems and a ten minute supply for deaerat-
reduces such excessive cycling and decreases purge energy ing systems. A larger tank may be used for systems with high
losses and cycling wear on components. condensate return, and a smaller tank for systems with a high
percentage of make-up. In this system, a fifteen minute water
Both the CB and CB (LE) Firetube Boilers guarantee steam
supply corresponds to 2100 lb, or 253 gallons. A 270 gallon
quality above the system requirements.
tank will be specified, allowing for the high percentage con-
The certainty of a future tightening of emission regulations densate return.
leads to a decision in favor of the 60 ppm CB (LE) Firetube
In a heating system with a firetube boiler there is neither a
Boiler3. Although both the firebox and flextube boilers may
large load swing nor a necessity for precise boiler water level
be retrofitted with low NOx burners, it is done at considerable
control. Therefore, an intermittent operation turbine style
cost. The CB (LE) Firetube Boilers ability to meet all future
pump will be selected to minimize system cost. As the feed-
emission regulations, along with its fuel savings, 10-1 turn-
water temperature is well below 215 F, there is no need for
down, and low cost for emissions reduction, make it the best
high temperature pump seals. Duplex pumps will be specified
choice.
to minimize maintenance downtime.
The customer currently carries uninterruptable gas service,
paying $4.50/MMBtu. The customer has the opportunity for Water Treatment
savings by switching to a dual fuel burner, which would allow
for interruptible service. With the gas cost reduced to $3.50/ Water treatment options include chemical, deaeration, soften-
MMBtu, and assuming that light oil at $4.20/MMBtu would ing and filtering. A test result yielded the results in Table I3-4
be used 20% of the time, the resultant fuel bill is $30,490, or a The limits for silica, alkalinity and dissolved solids are all lim-
$7,040 savings. its for the boiler water itself. These can be controlled through
The final choice in this example will be a 250 horsepower 60 blowdown (described below). The decision to control oxygen
ppm CB (LE) Firetube Boiler with a dual fuel burner. As this through chemicals has already been made. It will be necessary
is a heating load, and no expansion is foreseen, the 20% over- to include a water softener in the water treatment system to
sizing used in boiler selection for some systems is not neces- remove hardness.
sary here. In this application, the CB (LE) Firetube Boiler was
selected due to high turndown capability and the ability to Blowdown
meet future emissions regulations. These features compensate
Manual bottom blowdown should be specified. The low fuel
for the higher capital costs of other boiler choices which could
bills preclude the option of continuous blowdown with heat
meet demand.
recovery. Additional equipment necessary includes a bottom
blowdown separator and aftercooler. These are necessary to
Condensate Return And Feedwater System reduce the blowdown water temperature to the maximum
This system has 90% condensate return. This yields a make- 120F.
up water requirement of 10%. If we assume a constant spe-
cific heat, and a make-up water temperature of 40 F, a direct
mixing would result in a feedwater temperature of 184 F. Table I3-4. Water Test Results and Limits
It must first be decided whether to use a boiler feed system or a SUBSTANCE TEST RESULT LIMITS
deaerating system. In either case, this system must consist of a
Oxygen 6 ppm <0.007 ppm
water reservoir, a stand (to provide sufficient net positive suc-
tion head for the pump) and a pump. In this system, the per- Hardness 86 ppm <5.0 ppm
centage of make-up water is low, and the feedwater mix
temperature is relatively high. Oxygen in the system may be Suspended Matter 0.1 ppm <0.15 ppm
controlled by chemicals. These conditions, coupled with an pH 6.8 7.0-10.5
already low annual fuel cost, decide against additional spend-
ing for a deaerating system. Silica 10 ppm <150 ppm
Total Alkalinity 100 ppm <700 ppm

________________ Dissolved Solids 500 mho/cm <7000 mho/cm
3. The 60 ppm CB (LE) Boiler may be converted to 30 or 20 ppm
at low cost. The 60 ppm model has lower electric demands and
is predicted to meet all future requirements.
I3-19
02-02
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 eco-
nomic decision.
System Schematic
A schematic of the resulting system in shown in Figure I3-5.
MAKE-UP WATER
90% CONDENSATE RETURN
200
STACK
WATER
SOFTENER STEAM HANDLING, HEATING
10 PSIG STEAM AND CONDENSATE RETURN
SYSTEMS
250 HP
CB (LE) BOILER
PACKAGED
BOILER FEED
SYSTEM BOTTOM BLOWDOWN
STEAM
COLD WATER SEPARATOR/
SUPPLY BLOWDOWN
CHEMICAL
FEED SYSTEM AFTERCOOLER
TO DRAIN
Figure I3-5. Example of System Configuration
I3-20
02-02
Section I4
General Engineering Data
CONTENTS
STEAM PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-3

Example for Steam Pipe Chart, Pounds per Minute to Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-3
Example for Steam Pipe Chart, Pounds per Minute to Feet per Minute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-3
WATER PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-3
Hot Water Boiler Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-3
Feedwater Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-3
NATURAL GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-3
FUEL OIL PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-3
EQUIVALENT LENGTHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-10
STACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-10
Why Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-10
Stack Draft on CB Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-10
Stack Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-10
Stack Condensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-10
Stack Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-11
Stack Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-11
Stack Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-11
Stack/Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-11
FACTORS OF EVAPORATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-12
THERMODYNAMIC PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-12
Fuel Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-12
Fuel Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-12
Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-18
Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-19
31
UNIT CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-31
UNIT CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-30
STANDARD ASSOCIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-43
ILLUSTRATIONS
Figure I4-1. Steam Pipe Chart - Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-4
Figure I4-2. Steam Pipe Chart - Steam Velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-5
Figure I4-3. Pressure Drop for Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-6
Figure I4-4. Typical Stack Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-11
Figure I4-5. Typical Stack Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-11
Figure I4-6. Rain Cap Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-15
Figure I4-7. Fuel Oil Viscosity and Temperature Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-15
I4-1
02-02
General Engineering Data System Fundamentals
TABLES
Table I4-1. Gas Line Capacities, Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-7
Table I4-2. Oil Piping Pressure Drop (Viscosity = 40 SSU and Specific Gravity = 0.9) . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-8
Table I4-3. Oil Piping Pressure Drop (Viscosity = 100 SSU and Specific Gravity = 0.94) . . . . . . . . . . . . . . . . . . . . . . . . . .I4-8
Table I4-4. Oil Piping Pressure Drop (Viscosity = 500 SSU and Specific Gravity = 0.94) . . . . . . . . . . . . . . . . . . . . . . . . . .I4-8
Table I4-5. Oil Piping Pressure Drop (Viscosity = 1000 SSU and Specific Gravity = 0.96) . . . . . . . . . . . . . . . . . . . . . . . . .I4-9
Table I4-6. Oil Piping Pressure Drop (Viscosity = 5000 SSU and Specific Gravity = 0.96) . . . . . . . . . . . . . . . . . . . . . . . . .I4-9
Table I4-7. Equivalent Length of Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-10
Table I4-8. Single Boiler Vent or Stack Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-12
Table I4-9. Multiple Boilers Common Breeching and Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-12
Table I4-10. Pounds of Dry Saturated Steam per Boiler Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-13
Table I4-11. Typical Units for Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-13
Table I4-12. Detailed Requirements for Fuel Oils - Properties of Fuel Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-16
Table I4-13. Detailed Requirements for Fuel Oil Grade of Fuel Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-17
Table I4-14. Thermal Properties of Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-18
Table I4-15. Saturated Steam Properties, Temperature Table (Sheet 1 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-19
Table I4-16. Saturated Steam Properties, Pressure Table (Sheet 1 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-26
Table I4-17. Temperature Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-31
Table I4-18. Conversion Factors (Sheet 1 of 9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-32
Table I4-19. pH Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-40
Table I4-20. Salinity Indicating Readings Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-40
Table I4-21. Useful Physical Constants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-40
Table I4-22. Conversions Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-41
Table I4-23. Approximate Common Equivalents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-42
Table I4-24. Conversions Accurate to Parts per Million . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-42
This section consists of four primary areas. The first includes information to assist in sizing of steam, water, natural gas, and fuel
oil piping. It also provides information on stacks.
The second area, entitled Thermodynamic Properties, contains information on fuel oils, water, and steam, and covers viscosities,
thermal properties of water, and steam tables covering the saturated region.
The third area is Unit Conversion, which includes extensive unit conversion factors as well as an discussion of the difference be-
tween absolute and gauge pressure.
Finally, the fourth area provides a list of standard associations.
I4-2
02-02
System Fundamentals General Engineering Data
STEAM PIPING Hot Water Boiler Example
Figure I4-1 allows pressure drop to be calculated given satu- In this example, pressure drop will be calculated for a 500 hp
rated steam pressure, flow rate and pipe diameter. Although hot water boiler with a 20 F temperature differential. This
the example covers calculating pressure drop, it is possible to corresponds to approximately 1700 gpm.
work backwards to calculate pipe size, given pressure drop. Btu
500 hp x 33472 hr x hp x 1 x lb x F x 1 hr x gallon = 1680 gallons
20 F 1 Btu 60 min 8.3 lb m in
Figure I4-2 is similar to Figure I4-1, but gives steam velocity
instead of pressure drop. These illustrations are approxima- The system will use 10" nominal size schedule 40 pipe. These
tions for saturated steam only. two figures are plotted on their respective axis, giving points A
and B. A line is drawn through these two points and the
Example for Steam Pipe Chart, Pounds per Minute to remaining two axis, giving a pressure drop of.57 psig (1.3 ft. of
Pressure Drop water) and a 6.4 feet per second velocity.
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 Feedwater Example
diameter pipe. Now consider a 500 hp steam boiler. This requires approxi-
First, convert pounds/hr to pounds/min by dividing by 60: mately 40 gallons per minute of feedwater. A 2" nominal
schedule 40 pipe will be used. Plotting these figure yields
17210 60 = 285 points C and D. Drawing a line through the points as before
Next, convert psig to absolute pressure by adding 14.7: gives us a pressure drop of 2 psig, or 4.6 feet of water.
125 + 14.7 = 139.7

NATURAL GAS PIPING
Now, plot 140 (the pressure) on its corresponding axis. This
Table I4-1 shows capacity of a natural gas line for a given ini-
gives point A. Draw a line from A through B, which is the pipe
tial pressure with a 5% pressure drop. For example, consider a
diameter. Continue this line to the axis, X. This gives point C.
500 hp boiler, which requires 20,925 cu-ft / hr. A 5 psi initial
A new line is plotted from point C, through the pounds of pressure is available for 100 ft of pipe. To find the correct pipe
steam per minute axis (point D). This line ends at the pressure size, go to the line for initial gas pressure reading 5 pounds.
drop axis, for a drop of slightly more than 2.5 psi per 100 feet Now move to the right, until a number larger than 20,925
of pipe. appears. In this case, the first greater number is 30,500. The
number at the top of that column shows the appropriate pipe
Example for Steam Pipe Chart, Pounds per Minute to size, in this case 4". Table I4-1 assumes gas at 60 F, 1000 Btu/
Feet per Minute cu-ft, and a specific gravity of 0.619.
The same specifications will be used from the previous exam-
ple. FUEL OIL PIPING
For this chart, begin with pounds/min. This gives point A. Tables I4-2 through I4-6 show pressure drop for liquids with
Draw the line through the proper point (in this case, point B) specific gravities and viscosities in the ranges found for num-
on the diameter axis to the X axis (point C). Next, plot from bers 2 through 6 fuel oils.
the X axis through the appropriate pressure (point D) to get To use these tables, select the table with the appropriate viscos-
steam velocity. In this example, that corresponds to 3200 feet ity for the oil that is being used. (An oil viscosity chart is pro-
per minute. vided later in this section in Figure I4-7.) Select the line
corresponding to the required flow, and the column corre-
WATER PIPING sponding to the nominal pipe size. The intersection will give
the pressure drop in psi per 100 feet of equivalent pipe length.
Figure I4-3 allows pressure drop in psi or ft. of water to be cal-
culated for a given flow and pipe size. Like Figures I4-1 and For example, a typical No. 2 fuel oil has a viscosity 40 SSU. A
I4-2, working backwards will allow pipe size to be calculated 500 hp boiler requires up to 115 gallons per hour of No. 2 oil.
for a target pressure drop. This figure will work with either Using Table I4-2, and specifying a 1-inch nominal pipe size,
water flow in a hot water system boiler or feedwater to a steam gives 0.1 psi pressure drop at 100 gph, and 0.2 at 150 gph. Lin-
boiler. This assumes a constant viscosity and density for ear interpolation gives 0.13 psi pressure drop per 100 equiva-
water over this range of temperatures, but should not cause lent feet of pipe. Note that heavy oils require a return line,
significant error. which increases total flow requirements.
I4-3
02-02
Figure I4-1. Steam Pipe Chart - Pressure Drop
I4-4
02-02
Illustration intentionally deleted.
Figure I4-2. Steam Pipe Chart - Steam Velocity
I4-5
02-02
Figure I4-3. Pressure Drop for Water
I4-6
02-02
Table I4-1. 13
GAS LINE CAPACITIES (CU-FT/HR THROUGH 100 FT LENGTH)

IINITIAL
TOTAL
GAS
PRESS DIAMETER OF PIPE IN INCHES
PRESSUR
.DROP
E
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.
I4-7
02-02
Table I4-2. Oil Piping Pressure Drop (Viscosity = 40 SSU and Specific Gravity = 0.9)
NOMINAL PIPE SIZE (INCHES)

FUEL OIL FLOW
RATE (GPH)
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
I4-8
02-02

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
I4-9
02-02
EQUIVALENT LENGTHS cific limitations on stack/breeching size criteria. Other typical

pressure drops for the Model CB Boilers are as follows:
Table I4-7 shows equivalent lengths of pipe for various plumb-
ing fittings. Find the nominal pipe size being used in the left- A. A 4 inch to 12 inch WC drop is taken across the burner
most column. For each fitting, read the value under the in order to provide high turbulence, good mixing of fuel
appropriate heading and add this to the length of piping. This and air, and high CO2 readings for most efficient combus-
allows total system pressure drop to be calculated. (This is tion,
valid for any fluid.) 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
Table I4-7. Equivalent Length of Pipe velocities and thus increase heat transfer.
EQUIVALENT LENGTH OF STRAIGHT PIPE (FEET) For other boiler types, the draft variation could be similar. Con-
PIPE SIZE GATE GLOBE ANGLE sult you local Cleaver-Brooks authorized representative.
STANDARD STANDARD
VALV E VALVE FULL VALVE FULL
ELBOW TEE If the stack height is over 150 feet or if an extremely large
FULL OPEN OPEN OPEN
1-1/2 4 9 0.9 41 21
breeching and stack combination cause excessive draft, a sim-
ple barometric damper can be located in the breeching close to
2 5 11 1.2 54 27
the stack or chimney. This damper should only be considered
2-/1/2 6 13 1.4 64 32
after burner adjustment problems have been experienced and
3 8 16 1.6 80 40
are serious enough to warrant corrective action.
3-1/2 9 18 2.0 91 45
4 11 21 2.2 110 55 Automatic or special draft controls are not required and are not
5 13 26 2.8 140 70
recommended for use with Cleaver-Brooks boilers.
6 16 32 3.4 155 81
8 20 42 4.5 210 110
Stack Location
10 25 55 5.5 270 140 An off-set type stack connection to the stub vent on the boiler
12 30 65 6.5 320 160 is preferred and recommended. A direct vertical connection can
14 35 75 8.0 370 190 also be made, if required. A typical stack location diagram is
This table contains the number of feet of straight pipe usually allowed for standard shown in Figure I4-4.
fittings and valves.
Stack Condensation
STACKS 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.
NOTICE
Stack condensation is most likely to occur on heating boiler
For boilers over 800 hp, consult your local Cleaver- installations where light loads and intermittent firing cause a
Brooks authorized representative. cool stack condition, which results in condensation of the
water vapor in the flue gas. This condensed water accelerates
Why Used corrosion of steel stacks or breechings.
The only purpose of a vent stack on Cleaver-Brooks boilers is The following items should be considered when planning to
to conduct the products of combustion to a point of safe dis- keep stack condensation to a minimum:
charge (atmosphere). Forced draft design eliminates the need
for a stack designed to create a draft. A. The boiler should be sized as close as possible to the
true heat load. Oversized boilers should be avoided.
Stack Draft on CB Boilers B. Masonry stacks have better heat holding characteristics
Depending on the boiler model, draft variations of as much as than steel stacks.
1/2 inch W.C. at the boiler vent outlet will have no appreciable C. When steel stacks are used, stack insulation will help
effect on the Model CB burner operation. This is due to the prevent heat loss.
high pressure drops which are taken from the burner inlet to
the boiler vent outlet. See individual boiler sections for spe- D. An off-set stack (recommended) with bottom clean-out
and drain connection will prevent any condensed water
from draining back into the boiler.
I4-10
02-02
STACK TIGHT-SEAL
CLEANOUT STACK
CLEANOUT
DRAIN CONNECTION
VERTICAL STACK CONNECTION OFFSET STACK CONNECTION (RECOMMENDED)
Figure I4-4. Typical Stack Locations
Stack Weight
RAIN CAP
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. 2-0 MIN
AS REQUIRED
BY LOCAL CODE
Stack Construction TOP OR ROOF
B
The stack can be terminated several feel above the top of the
A
roof. (State and local codes may govern the stack height above
the roof.) If down drafts are unavoidable, the stack outlet can STACK DIA.
be provided with a ventilator such as the Breidert Air-X- C

Hauster or equivalent. See Figure I4-5 for typical stack con-
struction details. STACK B C
BOILER HP A (IN.)
DIAMETER (IN.) (IN.) (IN.)
Stack Material 15-20 6 15 15 12
Minimum 12 gauge steel is recommended for stack sections. If 25-40, 50A 8 20 20 16
the stack will be inaccessible, the use of a non-corrosive mate- 50-60 10 25 25 20
rial (e.g. glass lining) should be considered. 70-100A, 125A 12 30 30 24
A rain cap or hood should be used at the top of the stack to 125-200 16 40 40 32
minimize the entrance of rain or snow. See Figure I4-6 for typ- 250-350 20 50 50 40
ical rain cap details. 400-800 24 60 60 48

Figure I4-5. Typical Stack Construction
The design of the stack and breeching system must provide a
draft at the boiler outlet(s) which is within the required limits.
Stack and breeching sizes should always be provided by a rep-
Consideration must be given to operation variations (including
utable stack supplier who will design the stack and breeching
number of boilers), purge cycles, outside wind and air condi-
system based on the required system layout. Your local
tions, and the impact of other variables that may impact draft
Cleaver-Brooks authorized representative is capable of assist-
conditions. Safe and reliable burner performance requires
ing in your evaluation of the stack/breeching design.
good stack design.See Table I4-8 and further detail in the indi-
vidual boiler sections.
(Rev 7/97)
I4-11
02-02
Table I4-9. Multiple Boilers Common Breeching

B and Stack
C
MINIMUM RECOMMENDED STACK DIAMETERA
D
NUMBER OF BOILERS
A BOILER HP
2 3 4
100 FT 200 FT 100 FT 200 FT 100 FT 200 FT
STACK 15-20 9" 10" 10" 12" 11" 12"

DIA
25-40 11" 12" 13" 14" 14" 16"
STACK B C D 50A, 50-60 13" 14" 15" 16" 17" 18"

BOILER HP A (IN.)
DIAMETER (IN.) (IN.) (IN.) (IN.) 70-100. 100A 16" 17" 19" 20" 21" 23"
15-20 6 5 12 3 3 125-200 21" 22" 24" 26" 28" 30"
25-40, 50A 8 6 16 4 4 250-350 26" 28" 32" 34" 34" 40"
50-60 10 8 20 5 5
400-600 32" 34" 38" 40" 421" 46"
70-100A, 125A 12 9 24 6 6
700-800 38" 42" 44" 48" 48" 52"
125-200 16 12 32 8 8
Notes:
250-350 20 15 40 10 10 A. No barometric damper required.
400-600 24 18 48 12 12
700-800 24 21 48 12 12 Referring to Table I4-10, at 100 F and 10 psig, the following
factors can be obtained: 30.6 pounds of steam per boiler horse-
Figure I4-6. Rain Cap Details power. This factor is used to convert the from and at 212 F
rating basis:
Table I4-8. Single Boiler Vent or Stack Diameter 3060 30.6 = 100 hp rated boiler should be selected.
STACK DIAMETER
BOILER HP Same as Boiler Vent Outlet THERMODYNAMIC PROPERTIES
Size (Inches OD)
15-20 6 Fuel Oils
25-40, 50A 8 The purpose of this section is to provide technical information
50-60 10 on the various grades of fuel oils commonly used in the genera-
70-100, 100A, tion of steam and hot water. The American Society for Testing
12 and Materials (ASTM) has established numerous tests to iden-
125A
125-200 16 tify 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.
250-350 20
400-800 24 Grades No. 1 and No. 2 are considered distillate oil, while
grades No. 4 through No. 6 are considered residual oils. Distil-
late oils have a low viscosity and are relatively easy to burn.
FACTORS OF EVAPORATION Residual oils have a high viscosity and often require heating to
pump and atomize. Residual oils will also have much higher
The factor of evaporation is used to adjust rated boiler output
emission levels, and their use is frequently regulated because of
(from and at 212 F) to actual job or operating conditions.
this.
Available feedwater temperature and expected boiler operating
pressure (psig) affect the boiler output ratings which are based The viscosity ranges of fuel oils are shown in Figure I4-7.
on from and at 212 F.
Example: A boiler is to have an output of 3060 pounds of Fuel Oil Specifications
steam per hour when operating at 10 psig with feedwater at The limits on fuel oil properties are shown in Tables I4-11, I4-
100 F. What should the boiler rating be on the basis of from 12, and I4-13. Definitions of these properties are discussed
and at 212 F. next.
I4-12
02-02
Table I4-10. Pounds of Dry Saturated Steam per Boiler Horsepower
Ultimate Analysis - Ultimate analysis is a statement of the

quantities of the various elements of which a substance is com-
Table I4-11. Typical Units for Fuels posed. For fuel oils, this will likely state higher heating values
and specific gravity in addition to the percentages by weight of
GROSS HEATING each element.
ITEM
VALUES
Flash Point - The flash point of a fuel oil is an indication of the
No. 2 Oil 140,000 Btu/gal. maximum temperature at which it can be stored and handled
No 5 Oil 148,000 Btu/gal.
without serious fire hazard. The minimum permissible flash
point is usually regulated by federal, state or municipal laws
No. 6 Oil 150,000 Btu/gal. and is based on accepted practice in handling and use.
1 Therm 100,000 Btu Pour Point - The pour point is an indication of the lowest tem-
1 kW 3,413 Btu
perature 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
I4-13
02-02
point fuels are permissible where heated storage and adequate heavier grades of industrial and bunker fuel oils, viscosity is of
piping facilities are provided. An increase in pour point can major importance, so that adequate preheating facilities can be
occur when residual fuel oils are subjected to cyclic tempera- provided to permit them to be pumped to the burner and to
ture variations that can occur in the course of storage or when provide good atomization. However, it is equally important
the fuel is preheated and returned to storage tanks. To predict that the maximum viscosity under the existing conditions be
these properties, Test Method D 3245 may be required. such that the oil can be pumped satisfactorily from the storage
tank to the preheater.
Water and Sediment - Appreciable amounts of water and sed-
iments in a fuel oil tend to cause fouling of facilities for han- Density - Density alone is of little significance as an indication
dling it, and cause trouble in burner mechanisms. Sediment of the burning characteristics of fuel oil. However, when used
may accumulate in storage tanks and on filter screens or burner in conjunction with other properties, it is of value in mass-vol-
parts, resulting in obstructions to flow of oil from the tank to ume relationships and in calculating the specific energy (heat-
the burner. Water in distillate fuels can cause corrosion of ing value) of an oil.
tanks and equipment, and can cause emulsions in residual
Corrosion - The corrosion test serves to indicate the presence
fuels.
or absence of materials that could corrode copper, brass, and
Carbon Residue - The carbon residue of a fuel is a measure of bronze components of the fuel system. This property is speci-
the carbonaceous material left after all the volatile components fied only for Nos. 1 and 2 distillate fuel oils.
are vaporized in the absence of air. It is a rough approximation
Limited sulfur content of fuel oil can be required to meet fed-
of the tendency of a fuel to form deposits in vaporizing burn-
eral, state, or local legislation or regulations.
ers, such as pot-type and sleeve burners, where the fuel is
vaporized in an air-deficient atmosphere. Nitrogen - Nitrogen oxide emission regulations have been
imposed on certain combustion facilities as a function of fuel
To obtain measurable values of carbon residue in the lighter
nitrogen content. For purposes of these regulations, distillate
distillate fuel oils, it is necessary to distill the oil to remove
fuels, low nitrogen residual fuels, and high nitrogen residual
90% of it in accordance with Section 9 of Test Method D 524,
fuels have been defined by their nitrogen content. Installations
and determine the carbon residue concentrated in the remain-
are required to meet different emission standards according to
ing 10% bottoms.
the classification of the fuel being used. When regulations
Ash - The amount of ash is the quantity of noncombustible require such a distinction to be made, fuel nitrogen specifica-
material in an oil. Excessive amounts can indicate the presence tions can be needed in the contractual agreement between the
of materials that cause high wear of burner pumps and valves, purchaser and the supplier.
and contribute to deposits on boiler heating surfaces.
Distillation - The distillation test shows the volatility of a fuel
and the ease with which it can be vaporized. The test is of
greater 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 start-
ing 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 prod-
uct 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 atom-
ization.
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
I4-14
02-02
System Fundamentals
02-02
I4-15
Figure I4-7. Fuel Oil Viscosity and Temperature Curves
General Engineering Data
Table I4-12. Detailed Requirements for Fuel Oils - Properties of Fuel Oil
FUEL OIL GRADE

ASTM TEST
PROPERTY No. 4 No 5 No. 5
METHOD B No. 1 No. 2
(Light)
No. 4
(Light) (Heavy)
No. 6
Flash Point C min D 93 38 38 38 55 55 55 60

C (0.50)C (1.00)C (1.00)C (2.00)C
Water and sediment, % vol max D 1796 0.05 0.05 (0.50)
Distillation temperature C D 85
10% vol recovered, max 215
90% vol recovered, min 282
max 288 338
2/s
Kinematic viscosity at 40 C mm D 445
Minimum viscosity 1.3 1.9 1.9 >5.5
D
Maximum viscosity 2.1 3.4 5.5 24.0
Kinematic viscosity at 100 C mm2/s

Minimum viscosity 5.0 9.0 15.0
D 14.9D 50.0D
Maximum viscosity 8.9
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
E
Sulfur, % mass, max 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 mod-
ification 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 deduc-
tion 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 per-
mit 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 mm2/s and the minimum 90% recovered temperature
shall be waived.
H Where low sulfur fuel oil is required, Grade No. 6 fuel oil will be 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.
I4-16
02-02
Table I4-13. Detailed Requirements for Fuel Oil Grade of Fuel Oil
DISTILLATION
CARBON TEMPERATURES, F
FLASH POUR WATER & RESIDUE ON
ASH %
GRADE OF FUEL OIL POINT F POINT F SEDIMENT % 10%
MAX 10% 90% END
MIN MAX MAX RESIDUUM %
MAX POINT POINT POINT
MAX MAX MAX
1. Distillate oil intended for vapor- 100 0 trace 0.15 420 625
izing pot-type burners and other or
burners requiring this grade. legal
2. A distillate oil for general pur- 100 20 0.10 0.35 - 675

pose domestic heating for use in or
burners not requiring No. 1. legal
4. An oil for burner installations 130 20 0.50 0.10

not equipped with preheating or
facilities. legal
5.A residual type oil for burner 130 1.00 0.10

installations equipped with pre- or
heating facilities. legal
6.An oil for use in burners 130 2.00

equipped with preheaters permit- or
ting a high viscosity fuel, legal
I4-17
02-02
Water
The relevant properties of water are shown in Table I4-14.
Table I4-14. Thermal Properties of Water
I4-18
02-02
Steam
Steam properties are shown in Tables I4-15 and I4-16.
Table I4-15. Saturated Steam Properties, Temperature Table (Sheet 1 of 7)

ABS. PRESSURE SPECIFIC VOLUME (ft3/lb) ENTHALPY (Btu/lb) ENTROPY (Btu/lb,F)
TEMP SAT. SAT. SAT. SAT. SAT. SAT.
F PSIA IN. HG LIQUID EVAP. VAPOR LIQUID EVAP. VAPOR LIQUID EVAP. VAPOR
t p p vf vfg vg hf hfg hg sf sfg sg
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
I4-19
02-02

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
I4-20
02-02

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
I4-21
02-02

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
I4-22 (Rev 7/97)
02-02

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
I4-23
02-02

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
I4-24
02-02

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
I4-25
02-02
Table I4-16. Saturated Steam Properties, Pressure Table (Sheet 1 of 5)
ABS. SPECIFIC
TEMP ENTHALPY (Btu/lb) ENTROPY (Btu/lb,F) INTERNAL ENERGY (Btu/lb)
PRESS VOLUME (ft3/lb)
SAT. SAT. SAT. SAT. SAT. SAT. SAT. SAT.
PSIA F LIQUID VAPOR LIQUID EVAP. VAPOR LIQUID EVAP. VAPOR LIQUID EVAP. VAPOR
p t vf vg hf hfg hg sf sfg sg uf ufg ug
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
I4-26
02-02
ABS. SPECIFIC
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
I4-27
02-02
ABS. SPECIFIC
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
I4-28
02-02
ABS. SPECIFIC
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
I4-29
02-02
ABS. SPECIFIC INTERNAL

TEMP ENTHALPY (Btu/lb) ENTROPY (Btu/lb,F)
PRESS VOLUME (ft3/in2) ENERGY (Btu/lb)
PSIA F LIQUID EVAP. VAPOR LIQUID EVAP. VAPOR LIQUID EVAP. VAPOR LIQUID VAPOR
p t vf vfg vg hf hfg hg sf sfg sg uf ug
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 The following information is included for your convenience.
Note that pressures are typically given in gauge pressure. This Temperature Conversion
is the difference between the absolute pressure in the boiler and Conversions Factors 2
the absolute pressure of the surroundings. A gauge reads pres-
sure differences (in most cases, the difference between the pH Values
pressure of the substance and that of the atmosphere). There- Salinity Indicating Readings Conversion Table
fore, gauge pressure may be positive or negative (vacuum).
Gauge pressures, in U.S. (English Engineering) units, are Useful Physical Constants
referred to as psig (pounds per square inch gauge, although the Conversions Table
g is frequently omitted).
Approximate Common Equivalents
An absolute pressure is the pressure above zero pressure, which
can only be positive. Most thermodynamic tables are based on Conversions Accurate to Parts per Million
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 pres-
sure. In general, for U.S. units (psig) to convert gauge pressure
to absolute pressure, add 14.696. Conversely, to convert abso-
lute pressure to gauge pressure, subtract 14.696.
I4-30
02-02
Table I4-17. Temperature Conversion
I4-31
02-02
Table I4-18. Conversion Factors (Sheet 1 of 9)
I4-32
02-02
Table I4-18. Conversions Factors (Sheet 2 of 9)
I4-33
02-02
I4-34
02-02
I4-35
02-02
I4-36
02-02
I4-37
02-02
.Table I4-18. Conversions Factors (Sheet 7 of 9)
I4-38
02-02
I4-39
02-02
Table I4-18. Conversions Factors (Sheet 9 of 9) Table I4-20. Salinity Indicating Readings
Conversion Table
Table I4-21. Useful Physical Constants
Table I4-19. pH Values
I4-40
02-02
Table I4-22. Conversions Table
I4-41
02-02
Table I4-23. Approximate Common Equivalents Table I4-24. Conversions Accurate to Parts per Million
I4-42
02-02
STANDARD ASSOCIATIONS Factory Mutual System (FM)

1151 Boston-Providence Turnpike
American Gas Association (AGA) Norwood, MA 02062
1515 Wilson Blvd. 617-762-4300
Arlington, VA 22209
703-524-2000 FM is an association of 4 mutual insurance companies dedi-
cated to minimizing loss of insured property. Through its
American National Standards Institute (ANSI) research arm, the Factory Mutual Research Corporation, it
11 West 42nd Street investigates means of preventing and minimizing fire and other
New York, NY 10036 losses. FM laboratories provide product testing and approval.
212-642-4900
Industrial Risk Insurers (IRI)
ANSI acts as the national coordinating institution through 85 Woodland Street
which interested organizations voluntarily cooperate in estab- Hartford, CT 06105
lishing, recognizing, and improving standards. 203-520-7412
American Society of Heating Refrigerating and Air Condi- IRI is composed of stock insurance companies providing
tioning Engineers (ASHRAE) indemnity for damage caused by such perils as fire, explosion,
1791 Tullie Circle, NE and windstorm. To assist their policyholders, IRI provides an
Atlanta, GA 30329 advisory engineering service. Part of this service is the devel-
American Society of Mechanical Engineers (ASME) opment of recommendations which serve as standards for IRI
345 East 47th Street itself and its policyholders.
New York, NY 10017 Kemper Insurance Company
212-705-8500 1 Kemper Drive
The ASME develops test codes for boilers and pressure vessels Long Grove, IL 60049
and for power applications, and serves as a sponsor for ANSI 708-320-2000
in developing safety codes and standards. The HPR (Highly Protective Risk) Department of Kemper has
American Society for Nondestructive Testing developed a set of recommendation for gas and oil fired boiler
3200 Riverside Drive furnaces. These recommendations are used to determine the
Columbus, Ohio 43221 underwriting acceptability of proposals and completed instal-
lations.
American Society for Testing and Materials (ASTM)
1916 Race Street National Board of Boiler and Pressure Vessel Inspectors
Philadelphia, PA 19103-1187 1055 Crupper Avenue
Columbus, OH 43229-1183
ASTM is the largest voluntary standards development system 614-888-8320
in the world publishing standards for materials, products, sys-
tems and services. The National Board is an organization comprised of Chief
Inspectors of states and cities of the US and provinces of Can-
Canadian Standards Association (CSA) ada organized for the purpose of promoting greater safety in
178 Rexdale Blvd. the construction, installation, inspection and repair of boilers
Etobicoke, Ontario, Canada M9W 1R3 and pressure vessels.
416-747-4044
CSA, a nonprofit nongovernmental body, which promotes 1 Batterymarch Park
nationwide standards for product design, construction and per- Quincy, MA 02269-9101
formance for Canada. CSA is a recognized testing agency.
The National Electric Code is a standard established for safe
Canadian Gas Association (CGA) wiring procedures in the interest of personal safety and fire
55 Scarsdale Road protection. The code is adopted and copyrighted by the NFPA
Don Mils, Ontario M3B 2R3 (see National Fire Protection Association).
416-447-6465
National Fire Protection Association (NFPA)
CGA, a nonprofit association of manufacturers of gas utilities, 1 Batterymarch Park
provides certification service based on standards established Quincy, MA 02269-9101
by CSA.
NFPA develops and promotes standards for the purpose of
advancing the science and improving the methods of fire pro-
tection and prevention.
I4-43
02-02
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
I4-44
02-02
Glossary
Section J
GLOSSARY AND INDEX
GLOSSARY ALLOWABLE WORKING PRESSURE - See design pressure.

AMBIENT AIR - The air that surrounds the equipment. The standard
A ambient air for performance calculations is air at 80 F, 60% relative
humidity, and a barometric pressure of 29.921 in. Hg, giving a specific
ABSOLUTE PRESSURE - Pressure above zero pressure; the sum of the
humidity of 0.013 lb of water vapor per lb of dry air.
gauge and atmospheric pressures.
AMBIENT TEMPERATURE - The temperature of the air surrounding
ACCUMULATOR - (STEAM) A pressure vessel containing water and/or
the equipment.
steam, which is used to store the heat of steam for use at a late period and
at some lower pressure. ANALYSIS - Quantitative determination of the constituent parts.
ACID CLEANING - The process of cleaning the interior surfaces of ANALYSIS, ULTIMATE - Chemical analysis of solid, liquid or gaseous
steam generating units by filling the unit with dilute acid accompanied by fuels. In the case of coal or coke, determination of carbon, hydrogen, sul-
an inhibitor to prevent corrosion, and subsequently draining, washing and fur, nitrogen, oxygen, and ash.
neutralizing the acid by a further wash of alkaline water.
AQUASTAT - Water limit temperature control, a safety device often used
ACIDITY - Represents the amount of free carbon dioxide, mineral acids on boilers.
and salts (especially sulphates of iron and aluminum) which hydrolyze to
give hydrogen ions in water and is reported as milliequivalents per liter of ARRESTER - A device to impede the flow of large dust particles or
acid, or ppm acidity as calcium carbonate, or pH the measure of hydrogen sparks from a stack, usually screening at the top.
ions concentration. AS-FIRED FUEL - Fuel in the condition as fed to the fuel burning equip-
ADIABATIC FLAME TEMPERATURE - The theoretical temperature ment.
that would be attained by the products of combustion provided the entire ASH - The incombustible inorganic matter in the fuel.
chemical energy of the fuel, the sensible heat content of the fuel and com-
bustion above the datum temperature were transferred to the products of ASH-FREE BASIS - The method of reporting fuel analysis, whereby ash
combustion. This assumes: No heat loss to surroundings and no dissocia- is deducted and other constituents are recalculated to total 100%.
tion. ASH PIT - A pit or hopper located below a furnace where refuse is accu-
AIR - The mixture of oxygen, nitrogen, and other gases, which with vary- mulated and from which refuse is removed at intervals.
ing amounts of water vapor, forms the atmosphere of the earth. ASME - The American Society of Mechanical Engineers.
AIR ATOMIZING OIL BURNER - A burner for firing oil in which the oil ASPIRATING BURNER - A burner in which the fuel in a gaseous or
is atomized by compressed air, which is forced into and through one or finely divided form is burned in suspension, the air for combustion being
more streams of oil which results in the breaking of the oil into a fine supplied by bringing into contact with the fuel, air drawn through one or
spray. more openings by the lower static pressure created by the velocity of the
AIR DEFICIENCY - Insufficient air, in an air-fuel mixture, to supply the fuel stream.
oxygen required for complete oxidation of the fuel. AS-RECEIVED FUEL - Fuel in the condition as received at the plant.
AIR-FREE - The descriptive characteristic of a substance from which air ATMOSPHERIC AIR - Air under the prevailing atmospheric conditions.
has been removed.
ATMOSPHERIC PRESSURE - The barometric reading of pressure
AIR-FUEL RATIO - The ratio of the weight, or volume, of air to fuel. exerted by the atmosphere. At sea level 14.7 lb per sq in. or 29.92 in. of
AIR INFILTRATION - The leakage of air into a setting or duct. mercury.
AIR, SATURATED - Air which contains the maximum amount of water ATOMIZER - A device by means of which a liquid is reduced to a very
vapor that it can hold at its temperature and pressure. fine spray.
AIR VENT - A valved opening in the top of the highest drum of a boiler AVAILABLE DRAFT - The draft which may be utilized to cause the flow
or pressure vessel for venting air. of air for combustion or the flow of products of combustion.
ALARM - A suitable horn, bell, light or other device which when oper- AVAILABILITY FACTOR - The fraction of time during which the unit is
ated will give notice of malfunction or off normal condition. in operable condition.
ALKALINITY - Represents the amount of carbonates, bicarbonates, AXIAL FAN - Consists of a propeller or disc type of wheel within a cylin-
hydroxides and silicates or phosphates in the water and is reported as der that discharges air parallel to the axis of the wheel.
grains per gallon, or ppm as calcium carbonate.
J-1
Glossary
B BOOSTER FAN - A device for increasing the pressure or flow of a gas.

BREECHING - A duct that transports the products of combustion between
BAFFLE - A plate or wall for deflecting gases or liquids. parts of a steam generating unit or to the stack.
BAFFLE TILE - A tile for deflecting gases. BRIDGEWALL - A wall in a furnace over which the products of combus-
BAFFLE-TYPE COLLECTOR - A device in gas paths utilizing baffles so tion pass.
arranged as to deflect dust particles out of the gas stream. BRITISH THERMAL UNIT (Btu) - The mean British Thermal Unit is 1/
BAG FILTER - A device containing one or more cloth bags for recover- 180 of the heat required to raise the temperature of 1 lb of water from 32
ing particles from the dust laden gas or air which is blown through it. F to 212 F at a constant atmospheric pressure. A Btu is essentially 252
calories.
BAG-TYPE COLLECTOR - A filter in which the cloth filtering medium
is made in the form of cylindrical bags. BUCKSTAY - A structural member placed against a furnace or boiler wall
to restrain the motion of the wall.
BAROMETRIC PRESSURE - Atmospheric pressure as determined by a
barometer usually expressed in inches of mercury. BUNKER C OIL - Residual fuel oil of high viscosity commonly used in
marine and stationary steam power plants. (No. 6 fuel oil)
BASE LOAD - Base load is the term applied to that portion of a station or
boiler load that is practically constant for long periods. BURNER - A device for the introduction of fuel and air into a furnace at
the desired velocities, turbulence and concentration.
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. BURNER WINDBOX - A plenum chamber around a burner that main-
tains an air pressure sufficient for proper distribution and discharge of sec-
BLIND NIPPLE - A nipple, or a short piece of pipe or tube, closed at one ondary air.
end.
BURNER WINDBOX PRESSURE - The air pressure maintained in the
BLOWDOWN - Boiler water that is removed from the boiler in order to windbox or plenum chamber measured above atmospheric pressure.
maintain the desired concentration levels of suspended and dissolved sol-
ids in the boiler and removal of sludge. BY-PASS - A passage for a fluid, permitting a portion of the fluid to flow
around its normal pass flow channel.
BLOWDOWNSAFETY VALVE - The difference between the pressure
at which a safety valve opens and at which it closes. C
BLOWDOWN VALVE - A valve generally used to continuously regulate C - Carbon element, the principal combustible constituent of all fuels.
concentration of solids in the boiler, not a drain valve. (Often called con-
tinuous blowdown.) CaCO3 - Calcium Carbonate.
BLOW-OFF VALVE - A specially designed, manually operated, valve CALORIE - The mean calorie is 1/100 of the heat required to raise the
that connects to the boiler for the purpose of reducing the concentration temperature of 1 gram of water from Zero C to 100 C at a constant atmo-
of solids in the boiler or for draining purposes. (Often called bottom spheric pressure. It is about equal to the quantity of heat required to raise
blowdown.) one gram of water 1 C. Another definition is: A calorie is 3600/860
joules.
BLOWER - A fan used to force air under pressure.
CALORIMETER - Apparatus for determining the calorific value of a fuel.
BOILER - A closed vessel in which water is heated, steam is generated,
steam is superheated, or any combination thereof, under pressure or vac- CAPACITY FACTOR - The ratio of the average load carried to the maxi-
uum by the application of heat from combustible fuels, electricity or mum design capacity.
nuclear energy.
CARBON - Element. The principal combustible constituent of all fuels.
BOILER EFFICIENCY - The term boiler efficiency is often substituted
CARRYOVER - The chemical solids and liquid entrained with the steam
for combustion or thermal efficiency. True boiler efficiency is the measure
from a boiler.
of fuel-to-steam efficiency.
CASING - A covering of sheets of metal or other material such as fire
BOILER HORSEPOWER - The evaporation of 34-1/2 lbs of water per
resistant composition board used to enclose all or a portion of a steam gen-
hour from a temperature of 212 F into dry saturated steam at the same
erating unit.
temperature. Equivalent to 33,475 Btu/hr.
CENTRAL STATION - A power plant or steam heating plant that gener-
BOILER RATING - The heating capacity of a boiler expressed in boiler
ates power or steam.
horsepower, Btu/hour, or pounds of steam/hour.
CENTRIFUGAL FAN - Consists of a fan rotor or wheel within a housing
BOILER SHELL- The outer cylindrical portion of a pressure vessel.
that discharges air at a right angle to the axis of the wheel.
BOILER WATER - A term construed to mean a representative sample of
CHEMICAL ANALYSIS - Determination of the principal chemical con-
the circulating boiler water, after the generated steam has been separated
stituents.
and before the incoming feed water or added chemical becomes mixed
with it so that its composition is affected. CHEMICAL FEED PIPE - A pipe inside a boiler drum through which
chemicals for treating the boiler water are introduced.
BOILING - The conversion of a liquid into vapor with the formation of
bubbles. CHIMNEY - A brick, metal or concrete stack.
BOILING OUT - The boiling of highly alkaline water in boiler pressure CIRCULATION - The movement of water and steam within a steam gen-
parts for the removal of oils, greases, etc. erating unit.
J-2
Glossary
CIRCULATION RATIO - The ratio of water entering a circuit to the CONTROL VALVE - A valve used to control the flow of air, gas, water,
steam generated by that passes that circuit in a unit of time. steam or other substance.
CIRCULATOR - A pipe or tube to pass steam or water between upper CONVECTION - The transmission of heat by the circulation of a liquid
boiler drums usually located where the heat absorption is low. Also used or gas. It may be natural, with the circulation caused by buoyancy affects
to apply to tubes connecting headers of horizontal water tube boilers with due to temperature differences, or forced with circulation caused by a
drums. mechanical device such as a fan or pump.
CLEANOUT DOOR - A door placed so that accumulated refuse may be CORROSION - The wasting away of metal due to chemical action. In a
removed room a boiler setting. boiler, usually caused by the presence of O2, CO2, or an acid.
CO - Carbon monoxide. CROWN SHEET - In a firebox boiler, the plate forming the top of the fur-
nace.
CO2 - Carbon dioxide.
CRUDE OIL - Unrefined petroleum.
COLLECTOR - A device used for removing gas borne solids from flue
gas. CSD-1 - Abbreviation for the ASME standard for Controls and Safety
Devices.
COLLOID - A finely divided organic substance which tends to inhibit the
formation of dense scale and results in the deposition of sludge, or causes D
it to remain in suspension, so that it may be blown from the boiler.
DAMPER - A device for introducing a variable pressure drop in a system
COMBUSTIBLE LOSS - The loss representing the unliberated thermal used for regulating the volumetric flow of a gas, such as air.
energy occasioned by failure to oxidize completely some of the combusti-
ble matter in the fuel. DAVIT - The structure on large firetube boilers from which the front and
rear doors are suspended when opened.
COMBUSTIBLES - The heat producing constituents of a fuel.
DEAERATION - Removal of air and gases from boiler feed water prior to
COMBUSTION - The rapid chemical combination of oxygen with the its introduction to a boiler.
combustible elements of a fuel resulting in the release of heat.
DEGASIFICATION - Removal of gases from samples of steam taken for
COMBUSTION AIR - Air used in the combustion process. Air contains purity test. Removal of CO2 from water as in the ion exchange method of
oxygen which is required to combust fuel. softening.
COMBUSTION CHAMBER - See Furnace. DELAYED COMBUSTION - A continuation of combustion beyond the
COMBUSTION EFFICIENCY - The effectiveness of the burner to com- furnace. (See also Secondary Combustion.)
pletely burn the fuel. A well designed burner will operate with as little as DESIGN LOAD - The load for which a steam generating unit is designed,
10 to 20% excess air, while converting all combustibles in the fuel to use- considered the maximum load to be carried.
ful energy.
DESIGN PRESSURE - The pressure used in the design of a boiler for the
COMPLETE COMBUSTION - The complete oxidation of all the com- purpose of calculating the minimum permissible thickness or physical
bustible constituents of a fuel. characteristics of the different parts of the boiler.
CONCENTRATION - (1) The weight of solids contained in a unit weight DESIGN STEAM TEMPERATURE - The temperature of steam for
of boiler or feed water. (2) The number of times that the dissolved solids which a boiler is designed.
have increased from the original amount in the feedwater to that in the
boiler water due to evaporation in generating steam. DEW POINT - The temperature at which condensation starts.
CONDENSATE Condensed water resulting from the removal of latent DISENGAGING SURFACE - The surface of the boiler water from which
heat from steam. steam is released.
CONDUCTION - The transmission of heat through and by means of mat- DISSOCIATION - The process by which a chemical compound breaks
ter unaccompanied by any obvious motion of the matter. down into simpler constituents, as do CO2 and H2O at high temperature.
CONDUCTIVITY - (1) A material property relating heat flux (heat trans- DISSOLVED SOLID - Those solids in water which are in solution.
ferred per unit area per unit time) to a temperature difference. In Ameri-
DISTILLATE FUELS - Liquid fuels distilled usually from crude petro-
can units, it is typically defined as the amount of heat (Btu) transmitted in
leum.
one hour through one square foot of material 1 inch thick, with a temper-
ature difference of 1F between the two surfaces of the material. DISTILLATION - Vaporization of a substance with subsequent recovery
of the vapor by condensation. Often used in less precise sense to refer to
(2) The property of a water sample to transmit electric current under a set
vaporization of volatile constituents of a fuel without subsequent conden-
of standard conditions. Usually expressed as microhms conductance.
sation.
CONTINUOUS BLOWDOWN - The uninterrupted removal of concen-
DISTILLED WATER - Water produced by vaporization and condensation
trated boiler water from a boiler to control total solids concentration in
with a resulting higher purity.
the remaining water.
DOWNCOMER - A tube or pipe in a boiler or waterwall circulating sys-
CONTROL - Any manual or automatic device for the regulation of a
tem through which fluid flows downward.
machine to keep it at normal operation. If automatic, the device is moti-
vated by variations in temperature, pressure, water level, time, light, or DOWNTIME - Amount of time a piece of equipment is not operational.
other influences.
J-3
Glossary
DRAFT - The difference between atmospheric pressure and some lower EXCESS AIR - Air supplied for combustion in excess of that theoretically
pressure existing in the furnace stack or gas passages of a steam generat- required for complete oxidation.
ing unit.
EXPANSION JOINT - The joint to permit movement due to expansion
DRAFT DIFFERENTIAL - The difference in static pressure between two without undue stress.
points in a system.
EXPLOSION DOOR - A door in a furnace or boiler setting that is
DRAFT GAUGE -A device for measuring draft, usually in inches of designed to be opened by a pre-determined gas pressure.
water.
EXTERNAL TREATMENT - Treatment of boiler feed water prior to its
DRAIN - A valved connection at the lowest point for the removal of all introduction into the boiler.
water from the pressure parts.
F
DRUM - A cylindrical shell closed at both ends designed to withstand
internal pressure. FAN - A machine consisting of a rotor and housing for moving air or gases
at relatively low pressure differentials.
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 FAN PERFORMANCE - A measure of fan operation in terms of volume,
in air, and such water vapor, being a gas, is dry. total pressures, static pressures, speed, power input, mechanical and static
efficiency, at a stated air density.
DRYBACK BOILER - Firetube boiler with a refractory lined back door.
Door opens to allow maintenance and/or inspection. FAN PERFORMANCE CURVES - The graphical presentation of total
pressure, static pressure, power input, mechanical and static efficiency as
DRY GAS - Gas containing no water vapor.
ordinates and the range of volumes as abscissa, all at constant speed and
DRY-GAS LOSS - The loss representing the difference between the heat air density.
content of the dry exhaust gases and their heat content at the temperature
FEED PUMP - A pump that supplies water to a boiler.
of ambient air.
FEEDWATER - Water introduced into a boiler during operation. It
DRY STEAM - Steam containing no moisture. Commercially dry steam
includes make-up and return condensate.
containing not more than one half of one percent moisture.
FEEDWATER TREATMENT - The treatment of boiler feed water by the
DUCT - A passage for air or gas flow.
addition of chemicals to prevent the formation of scale or to eliminate
E other objectionable characteristics.
FGR - Flue Gas Recirculation or the recirculation of flue gas with com-
ECONOMIZER - Utilizes waste heat by transferring heat from flue gases bustion air to reduce NOx emissions.
to warm incoming feedwater.
FILTER - Porous material through which fluids or fluid - and solid mix-
EDR - Equivalent direct radiation is the rate of heat transfer from a radia- tures are passed to separate matter held in suspension.
tor or convector. It is equivalent to the square feet of surface area neces-
sary to transfer heat at the same rate at which it is produced by a FIN - A fin is an extended surface, a solid, experiencing energy transfer by
generator. A single boiler horsepower equals 140 ft2 EDR. conduction within its boundaries, as well as energy transfer with its sur-
roundings by convection and/or radiation, used to enhance heat transfer by
EFFICIENCY - The ratio of output to input. See also Combustion, Fuel- increasing surface area.
to-Steam and Thermal Efficiency.
FIN TUBE - A tube with one or more fins.
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 hoppers. FIRED PRESSURE VESSEL - A vessel containing a fluid under pressure
exposed to heat from the combustion of fuel.
ELECTRIC BOILER - A boiler in which electric energy is used as the
source of heat. FIRETUBE - A type of boiler design in which combustion gases flow
inside the tubes and water flows outside the tubes.
ELECTROSTATIC PRECIPITATOR - A device for collecting dust, mist
or fume from a gas stream, by placing an electrical charge on the particle FIRING RATE CONTROL - A pressure temperature or flow controller
and removing that particle onto a collecting electrode. 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
ENTRAINMENT - The conveying of particles of water or solids from the the burner on-off, high-low or in proportion to load demand.
boiler water by the steam.
FIXED CARBON - The carbonaceous residue less the ash remaining in
EQUALIZER - Connections between parts of a boiler to equalize pres- the test container after the volatile matter has been driven off in making
sures. the proximate analysis of a solid fuel.
EQUIVALENT EVAPORATION - Evaporation expressed in pounds of FLAME - A luminous body of burning gas or vapor.
water evaporated from a temperature of 212 F to dry saturated steam at
212 F. FLAME DETECTOR - A device which indicates if a fuel (liquid, gaseous,
or pulverized) is burning, or if ignition has been lost. The indication may
EVAPORATION - The change of state from a liquid to a vapor. be transmitted to a signal or to a control system.
EVAPORATION RATE - The number of pounds of water that is evapo- FLAME PROPAGATION RATE - Speed of travel of ignition through a
rated in a unit of time. combustible mixture.
J-4
Glossary
FLAME SAFEGUARD - A control that sequences the burner through GAUGE GLASS - The transparent part of a water gauge assembly con-
several stages of operation to provide proper air purge, ignition, normal nected directly or through a water column to the boiler, below and above
operation, and shutdown for safe operation. the water line, to indicate the water level in a boiler.
FLAMMABILITY - Susceptibility to combustion. GAUGE PRESSURE - The pressure above atmospheric pressure.
FLASHING - The process of producing steam by discharging water into a GRADE - Oil classification according to quality, generally based on
region of pressure lower than the saturation pressure that corresponds to ASTM specifications.
the water temperature
GRAINS PER CU-FT - The term for expressing dust loading in weight
FLASH POINT - The lowest temperature at which, under specified con- per unit of gas volume (7000 grains equals one pound).
ditions, fuel oil gives off enough vapor to flash into a momentary flame
when ignited. GRAINS (WATER) - A unit of measure commonly used in water analysis
for the measurement of impurities in water (17.1 grains = 1 part per mil-
FLUE - A passage for products of combustion. lion - ppm).
FLUE GAS - The gaseous product of combustion in the flue to the stack. GRAVITY - Weight index of fuels: liquid, petroleum products expressed
either as specific, Baume or A.P.I. (American Petroleum Institute) gravity;
FOAMING - The continuous formation of bubbles which have suffi-
weight index of gaseous fuels as specific gravity related to air under spec-
ciently high surface tension to remain as bubbles beyond the disengaging
ified conditions; or weight index of solid fuels as specific gravity related
surface.
to water under specified conditions.
FORCED CIRCULATION - The circulation of water in a boiler by
mechanical means external to the boiler. H
FORCED-DRAFT FAN - A fan supplying air under pressure to the fuel HANDHOLE - An access opening in a pressure part usually not exceed-
burning equipment. ing 6" in its longest dimension.
FOULING - The accumulation of refuse in gas passages or on heat HANDHOLE COVER - A handhole closure.
absorbing surfaces which results in undesirable restriction to the flow of
HARDNESS - A measure of the amount of calcium and magnesium salts
gas or heat.
in water. Usually expressed as grains per gallon or ppm as CaCO3.
FM - Factory Mutual.
HARD WATER - Water which contains calcium or magnesium in an
FREE ASH - Ash which is not included in the fixed ash. amount which require an excessive amount of soap to form a lather.
FUEL - A substance containing combustible used for generating heat. HEAT AVAILABLE - The thermal energy above a fixed datum that is
capable of being absorbed for useful work.
FUEL-AIR MIXTURE - Mixture of fuel and air.
HEAT BALANCE - An accounting of the distribution of the heat input,
FUEL-AIR RATIO - The ratio of the weight, or volume, of fuel to air.
output and losses.
FUEL OIL - A liquid fuel derived from petroleum or coal.
HEAT EXCHANGER - A vessel in which heat is transferred from one
FUEL-TO-STEAM EFFICIENCY - The ratio of heat added to boiler medium to another.
feedwater to produce the output steam to the amount of energy inputted
HEAT RELEASE RATE - Rate that describes the heat available per
with fuel.
square foot of heat-absorbing surface in the furnace or per cubic foot of
FURNACE - An enclosed space provided for the combustion of fuel. volume.
FURNACE PRESSURE - Pressure occurring inside the combustion HEATING SURFACE - Those surfaces which are exposed to products of
chamber; positive if greater than atmospheric, negative if less than atmo- combustion on one side and water on the other. This surface is measured
spheric, and neutral if equal to atmospheric. on the side receiving the heat.
FURNACE VOLUME - The cubic contents of the furnace or combustion HEATING VALUE - The quantity of heat released by a fuel through com-
chamber. plete combustion. It is commonly expressed in Btu per lb, per gallon, or
cu-ft.
FUSIBLE PLUG - A hollowed threaded plug having the hollowed portion
filled with a low melting point material. HIGH GAS PRESSURE CONTROL - A control to stop the burner if the
gas pressure is too high.
G
HIGH OIL TEMPERATURE CONTROL - A control to stop the burner if
GAS ANALYSIS - The determination of the constituents of a gaseous the oil temperature is too high.
mixture. HYDROCARBON - A chemical compound of hydrogen and carbon.
GAS BURNER - A burner that uses gas or fuel. HYDROSTATIC TEST - A strength and tightness test of a closed pressure
GAS PRESSURE REGULATOR - A spring loaded, dead weighted or vessel by water pressure.
pressure balanced device which will maintain the gas pressure to the
burner supply line.
I
GAUGE COCK - A valve attached to a water column or drum for check- IGNITION - The initiation of combustion.
ing water level.
IGNITION TEMPERATURE - Lowest temperature of a fuel at which
combustion becomes self-sustaining.
J-5
Glossary
ILLUMINANTS - Light oil or coal compounds that readily burn with a LUG - Any projection, like an ear, used for supporting or grasping.
luminous flame, such as ethylene, propylene and benzene.
M
INCOMPLETE COMBUSTION - The partial oxidation of the combusti-
ble constituents of a fuel. MAKE-UP - The water added to boiler feed to compensate for that lost
through exhaust, blowdown, leakage, etc.
INDUCED DRAFT FAN- A fan exhausting hot gases from the heat
absorbing equipment. MANHOLE - The opening in a pressure vessel of sufficient size to permit
a man to enter.
INERT GASEOUS CONSTITUENTS - Incombustible gases such as
nitrogen which may be present in a fuel. MANIFOLD - A pipe or header for collection of a fluid from, or the distri-
bution of a fluid to a number of pipes or tubes.
INHIBITOR - A substance which selectively retards a chemical action.
An example in boiler work is the use of an inhibitor, when using acid to MANUAL GAS SHUTOFF VALVE - A manually operated valve in a gas
remove scale, to prevent the acid from attacking the boiler metal. line for the purpose of completely turning on or shutting off the gas sup-
ply.
INJECTOR - A device utilizing a steam jet to entrain and deliver feed
water into a boiler. MANUFACTURED GAS - Fuel gas manufactured from coal, oil, etc., as
differentiated from natural gas.
INSULATION - A material of low thermal conductivity used to reduce
heat losses. MAXIMUM ALLOWABLE WORKING PRESSURE - The maximum
gauge pressure permissible in a completed boiler. The MAWP of the com-
INTEGRAL BLOWER - A blower built as an integral part of a device to
pleted boiler shall be less than or equal to the lowest design pressure deter-
supply air thereto.
mined for any of its parts. This pressure is based upon either proof tests or
INTEGRAL-BLOWER BURNER - A burner of which the blower is an calculations for every pressure part of the boiler using nominal thickness
integral part. exclusive of allowances for corrosion and thickness required for loadings
other than pressure. It is the basis for the pressure setting of the pressure
INTERLOCK - A device to prove the physical state of a required condi- relieving devices protecting the boiler.
tion, and to furnish that proof to the primary safety control circuit.
MAXIMUM CONTINUOUS LOAD - The maximum load which can be
INTERMITTENT BLOWDOWN - the blowing down of boiler water at maintained for a specified period.
intervals.
MAXIMUM INSTANTANEOUS DEMAND - The sudden load demand
INTERNAL TREATMENT - The treatment of boiler water by introduc- on a boiler beyond which an unbalanced condition may be established in
ing chemicals directly into the boiler. the boiler's internal flow pattern and/or surface release conditions.
ION - A charged atom or radical which may be positive or negative. MECHANICAL ATOMIZING OIL BURNER - A burner which uses the
IRI - Industrial Risk Insurers. pressure of the oil for atomization.
MECHANICAL DRAFT - The negative pressure created by mechanical
L
means.
LAGGING - A light gauge steel covering used over a boiler, usually com- MICRON - One millionth of a meter, or 0.000039 in. or 1/25400 in. The
bined with insulation, to provide a low temperature outer surface. diameter of dust particles is often expressed in microns.
LEAKAGE - The uncontrolled quantity of fluid which enters or leaves MINIATURE BOILER - Fire pressure vessels which do not exceed the
through the enclosure of air or gas passages. following limits:
LIBERATION - See Heat Release. 16 in. inside diameter of shell; 42 in., overall length to outside of heads at
LIMIT CONTROL - A switching device that completes or breaks an elec- center; 20 sq ft water heating surface; or 100 psi maximum allowable
trical circuit at predetermined pressures or temperatures. Also known as working pressure.
an interlock. See interlock. MMBtu - Millions of Btus (British Thermal Units).
LINING - The material used on the furnace side of a furnace wall. It is MOISTURE - Water in the liquid or vapor phase.
usually of high grade refractory tile or brick or plastic refractory material.
MOISTURE IN STEAM - Particles of water carried in steam, expressed
LOAD - The rate of output required; also the weight carried. as the percentage by weight.
LOAD FACTOR - The ratio of the average load in a given period to the MOISTURE LOSS - The boiler flue gas loss representing the difference in
maximum load carried during that period. the heat content of the moisture in the exit gases and that at the tempera-
LOW GAS PRESSURE CONTROL - A control to stop the burner if gas ture of the ambient air.
pressure is too low. MULTIFUEL BURNER - A burner by means of which more than one fuel
LOW OIL TEMPERATURE CONTROL - (Cold Oil Switch) A control to can be burned.
prevent burner operation if the temperature of the oil is too low. MULTIPORT BURNER - A burner having a number of nozzles from
LOW WATER CUTOFF - Safety device that shuts off the boiler/burner in which fuel and air are discharged.
the event of low water, preventing pressure vessel failure.
J-6
Glossary
N pH - The hydrogen ion concentration of a water to denote Acidity or Alka-

linity. A pH of 7 is neutral. A pH above 7 denotes alkalinity while one
NATURAL CIRCULATION - The circulation of water in a boiler caused below 7 denotes acidity. This pH number is the negative exponent of 10
by differences in density. representing hydrogen ion concentration in grams per liter. For instance a
pH of 7 represent 10-7 grams per liter.
NATURAL GAS - Gaseous fuel occurring in nature.
PILOT - (See also Ignitor.) A flame which is utilized to ignite the fuel at
NET POSITIVE SUCTION HEAT (NPSH) - The liquid pressure that the main burner or burners.
exists at the suction end of a pump. If the NPSH is insufficient, the pump
can cavitate. PITOT TUBE - An instrument which will register total pressure and static
pressure in a gas stream, used to determine its velocity.
NOx - Abbreviation for all of the family of oxides of nitrogen.
PITTING - A concentrated attack by oxygen or other corrosive chemicals
NOZZLE - a short flanged or welded neck connection on a drum or shell in a boiler, producing a localized depression in the metal surface.
for the outlet or inlet of fluids; also a projecting spout through which a
fluid flows. PORT - An opening through which fluid passes.
O POST PURGE - A method of scavenging the furnace and boiler passes to

remove all combustible gases after flame failure controls have sensed pilot
OIL BURNER - A burner for firing oil. and main burner shutdown and safety shut-off valves are closed.
OIL HEATING AND PUMPING SET - A group of apparatus consisting ppm - Abbreviation for parts per million. Used in chemical determinations
of a heater for raising the temperature of the oil to produce the desired as one part per million parts by weight.
viscosity, and a pump for delivering the oil at the desired pressure.
PRECIPITATE - To separate materials from a solution by the formation of
OPERATING CONTROL - A control to start and stop the burner - must insoluble matter by chemical reaction. The material which is removed.
be in addition to the high limit control.
PRECIPITATION - The removal of solid or liquid particles from a fluid.
OPERATING PRESSURE - The pressure at which a boiler is operated.
PREHEATED AIR - Air at a temperature exceeding that of the ambient
ORGANIC MATTER - Compounds containing carbon often derived air.
from living organisms.
PRESSURE - Force per unit of area.
ORIFICE - (1) The opening from the whirling chamber of a mechanical
PRESSURE DROP - The difference in pressure between two points in a
atomizer or the mixing chamber of a steam atomizer through which the
system, caused by resistance to flow.
liquid fuel is discharged. (2) A calibrated opening in a plate, inserted in a
gas stream for measure velocity of flow. PRESSURE VESSEL - A closed vessel or container designed to confine a
fluid at a pressure above atmospheric.
ORSAT - a gas-analysis apparatus in which certain gaseous constituents
are measured by absorption in separate chemical solution. PRIMARY AIR - Air introduced with the fuel at the burner.
OVERPRESSURE - Minimum operating pressure of a hot water boiler PRIMING - The discharge of steam containing excessive quantities of
sufficient to prevent the water from steaming. water in suspension from a boiler, due to violent ebullition.
OXIDATION - chemical combination with oxygen. PROCESS STEAM - Steam used for industrial purposes other than for
producing power.
OXIDIZING ATMOSPHERE - An atmosphere which tends to promote
the oxidation of immersed materials. PRODUCTS OF COMBUSTION - The gases, vapors, and solids result-
ing form the combustion of fuel.
OXYGEN ATTACK - Corrosion or pitting in a boiler caused by oxygen.
PULSATION - Rapid fluctuations in pressure.
P
PURGE - To introduce air into the furnace and the boiler flue passages in
PACKAGED BOILER - A boiler supplied with all of its components - such volume and manner as to completely replace the air or gas-air mix-
burner, controls and auxiliary equipment, designed as a single engineered ture contained therein.
package, and ready for on-site installation.
R
PACKAGED STEAM GENERATOR - See Packaged Boiler.
RADIATION LOSS - A comprehensive term used in a boiler-unit heat
PARTICLE SIZE - A measure of dust size, expressed in microns or per
balance to account for the conduction, radiation, and convection heat
cent passing through a standard mesh screen.
losses from the boiler to the ambient air.
PASS - A confined passageway, containing heating surface, through
RATED CAPACITY - The manufacturers stated capacity rating for
which a fluid flows in essentially one direction.
mechanical equipment; for instance, the maximum continuous capacity in
PERFECT COMBUSTION - The complete oxidation of all the combusti- pounds of steam per hour for which a boiler is designed.
ble constituents of a fuel, utilizing all the oxygen supplied.
RATE OF BLOWDOWN - A rate normally expressed as a percentage of
PETROLEUM - Naturally occurring mineral oil consisting predomi- the water fed.
nately of hydrocarbons.
RATING - See Load.
J-7
Glossary
RAW WATER - Water supplied to the plant before any treatment. SATURATED TEMPERATURE - The temperature at which evaporation
occurs at a particular pressure.
REACTION - A chemical transformation or change brought about by the
interaction of two substances. SATURATED WATER - Water at its boiling point.
REASSOCIATION - The recombination of the products of dissociation. SCALE - A hard coating or layer of materials on surfaces of boiler pres-
sure parts.
RECIRCULATION - The reintroduction of part of the flowing fluid to
repeat the cycle of circulation. SECONDARY AIR - Air for combustion supplied to the furnace to sup-
plement the primary air.
REDUCING ATMOSPHERE - An atmosphere which tends to 1) promote
the removal of oxygen from a chemical compound; 2) promote the reduc- SECONDARY TREATMENT - Treatment of boiler feed water or internal
tion of immersed materials. treatment of boiler-water after primary treatment.
REDUCTION - Removal of oxygen from a chemical compound. SEDIMENT - (1) Matter in water which can be removed from suspension
by gravity or mechanical means. (2) A non-combustible solid matter
REFRACTORY - Brickwork or castable used in boilers to protect metal
which settles out at bottom of a liquid; a small percentage is present in
surfaces and for boiler baffles.
residual fuel oils.
RELATIVE HUMIDITY - The ratio of the mass of water vapor present in
SEGREGATION - The tendency of refuse of varying compositions to
a unit volume of gas to the maximum possible mass of water vapor in unit
deposit selectively in difference parts of the unit.
volume of the same gas at the same temperature and pressure.
SELF-SUPPORTING STEEL STACK - A steel stack of sufficient strength
RELIEF VALVE (Safety Relief Valve) - An automatic pressure relieving
to require no lateral support.
device actuated by the pressure upstream of the valve and characterized
by opening pop action with further increase in lift with an increase in SERVICE WATER - General purpose water which may or may not have
pressure over popping pressure. been treated for a special purpose.
RESIDUAL FUELS - Products remaining from crude petroleum by SHELL - The cylindrical portion of a pressure vessel.
removal of some of the water and an appreciable percentage of the more
SLUDGE - A soft water-formed sedimentary deposit which normally can
volatile hydrocarbons.
be removed by blowing down.
RESIN - A bead-like material used in chemical exchange for softeners
SLUG - A large dose of chemical treatment applied internally to a steam
and dealkalizers.
boiler intermittently. Also used sometimes instead of priming to denote
RESISTANCE - Impediment to gas flow, such as pressure drop or draft a discharge of water out through a boiler steam outlet in relatively large
loss through a dust collector. Usually measured in inches water column intermittent amounts.
(wc).
SMOKE - Small gas borne particles of carbon or soot, less than 1 micron
RETURN FLOW OIL BURNER - A mechanical atomizing oil burner in in size, resulting from incomplete combustion of carbonaceous materials
which part of the oil supplied to the atomizer is withdrawn and returned and of sufficient number to be observable.
to storage or to the oil line supplying the atomizer.
SOFTENING - The act of reducing scale forming calcium and magnesium
RINGELMANN CHART - A series of four rectangular grids of black impurities from water.
lines of varying widths printed on a white background, and used as a cri-
SOFT WATER - Water which contains little or no calcium or magnesium
terion of blackness for determining smoke density in stack gas streams.
salts, or water from which scale forming impurities have been removed or
ROTARY OIL BURNER - A burner in which atomization is accom- reduced.
plished by feeding oil to the inside of a rapidly rotating cup.
SOLUTION - A liquid, such as boiler water, containing dissolved sub-
S stances.
SOOT - Unburned particles of carbon derived from hydrocarbons.
SADDLE - A casting, fabricated chair, or member used for the purpose of
support. SOOT BLOWER - A mechanical device for discharging steam or air to
clean heat absorbing surfaces.
SAFE WORKING PRESSURE - See Design Pressure.
SPALLING - The breaking off of the surface of refractory material as a
SAFETY VALVE - A spring loaded valve that automatically opens when
result of internal stresses.
pressure attains the valve setting. Used to prevent excessive pressure from
building up in a boiler. SPECIFIC HEAT - The quantity of heat, expressed in Btu, required to
raise the temperature of 1 lb of a substance 1oF.
SAFETY SHUT-OFF VALVE - A manually opened, electrically latched,
electrically operated safety shut-off valve designed to automatically shut SPECIFIC HUMIDITY - The weight of water vapor in a gas water-vapor
off fuel when de-energized. mixture per unit weight of dry gas.
SAMPLING - The removal of a portion of a material for examination or SPRAY ANGLE - The angle included between the sides of the cone
analysis. formed by liquid fuel discharged from mechanical, rotary atomizers and
by some forms of steam or air atomizers.
SATURATED AIR - Air which contains the maximum amount of water
vapor that it can hold at its temperature and pressure. SPRAY NOZZLE - A nozzle from which a liquid fuel is discharged in the
form of a spray.
SATURATED STEAM - Steam at the temperature and pressure at which
evaporation occurs.
J-8
Glossary
STACK - A vertical conduit, which due to the difference in density THEORETICAL AIR - The quantity of air required for perfect combus-
between internal and external gases, creates a draft at its base. tion.
STACK DRAFT - The magnitude of the draft measured at the inlet to the THEORETICAL DRAFT - The draft which would be available at the
stack. base of a stack if there were no friction or acceleration losses in the stack.
STACK EFFECT - That portion of a pressure differential resulting from THEORETICAL FLAME TEMPERATURE - See Adiabatic Flame
difference in elevation of the points of measurement. Temperature.
STACK EFFLUENT - Gas and solid products discharged from stacks. THERM - A unit of heat applied especially to gas. One therm = 100,000
Btu.
STAGNATION - The condition of being free from movement or lacking
circulation. 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
STANDARD AIR - Dry air weighing 0.075 lb per cu ft at sea level
the boiler shell.
(29.92" Barometric Pressure) and 70 oF.
THERMAL SHOCK - A cycle of temperature swings that result in failure
STANDARD FLUE GAS - Gas weighing 0.078 lb per cu ft at sea level
of metal due to expansion and contraction.
(29.92" Barometric Pressure) and 70 oF.
THERMOCOUPLE - A temperature measuring instrument.
STATIC PRESSURE - The measure of potential energy of a fluid.
TILE - A preformed refractory, usually applied to shapes other than stan-
STEAM - The vapor phase of water, unmixed with other gases.
dard brick.
STEAM ATOMIZING OIL BURNER - A burner for firing oil which is
TOTAL AIR - The total quantity of air supplied to the fuel and products of
atomized by steam. It may be of the inside or outside mixing type.
combustion. Percent total air is the ratio of total air to theoretical air,
STEAM BINDING - A restriction in circulation due to a steam pocket or expressed as percent.
a rapid steam formation.
TOTAL PRESSURE - The sum of the static and velocity pressures.
STEAM GAUGE - A gauge for indicating the pressure of steam.
TOTAL SOLIDS CONCENTRATION - The weight of dissolved and sus-
STEAM GENERATING UNIT - A unit to which water, fuel, and air are pended impurities in a unit weight of boiler water, usually expressed in
supplied and in which steam is generated. It consists of a boiler furnace, ppm.
and fuel burning equipment, and may include as component parts water
TRAP - A receptacle for the collection of undesirable material.
walls, superheater, reheater, economizer, air heater, or any combination
thereof. TREATED WATER - Water which has been chemically treated to make it
suitable for boiler feed.
STEAM PURITY- The degree of contamination. Contamination is
expressed in ppm. TRIM - Ancillary boiler components, like water level controls, pressure
controls, and temperature controls.
STEAM QUALITY - The percent by weight of vapor in a steam and
water mixture. TUBE - A hollow cylinder for conveying fluids.
STEAM SEPARATOR - A device for removing the entrained water from TUBE HOLE - A hole in a drum, heater, or tube sheet to accommodate a
steam. tube.
STRAINER - A device, such as a filter, to retain solid particles allowing a TURBULENT BURNER - A burner in which fuel and air are mixed and
liquid to pass. discharged into the furnace in such a manner as to produce turbulent flow
from the burner.
STRATIFICATION - Non-homogeneity existing transversely in a gas
stream. TURNDOWN RATIO - Ratio of maximum to minimum fuel or steam
input or boiler output.
STUD - A projecting pin serving as a support or means of attachment.
SUPERHEATED STEAM - Steam with its temperature raised above that U
of saturation. The temperature in excess of its saturation temperature is
ULTIMATE ANALYSIS - See Analysis Ultimate.
referred to as superheat.
UL LISTED - Product certification that indicates the product meets safety
SURFACE BLOWOFF - Removal of water, foam, etc. from the surface at
standards determined by Underwriters Laboratories. (ULC and cUL indi-
the water level in a boiler. The equipment for such removal.
cate Canadian requirements.)
SURGE - The sudden displacement or movement of water in a closed
UNACCOUNTED-FOR LOSS - That portion of a boiler heat balance
vessel or drum.
which represents the difference between 100 per cent and the sum of the
SUSPENDED SOLIDS - Undissolved solids in boiler water. heat absorbed by the unit and all the classified losses expressed as per
cent.
SWINGING LOAD - A load that changes at relatively short intervals.
UNBURNED COMBUSTIBLE - The combustible portion of the fuel
T which is not completely oxidized.
TERTIARY AIR - Air for combustion supplied to the furnace to supple- UNFIRED PRESSURE VESSEL - A vessel designed to withstand inter-
ment the primary and secondary air. nal pressure, neither subjected to heat from products of combustion nor an
integral part of a fired pressure vessel system.
J-9
Glossary
USE FACTOR - The ratio of hours in operation to the total hours in that WET STEAM - Steam containing moisture.
period.
WINDBOX - A chamber below the grate or surrounding a burner, through
V which air under pressure is supplied for combustion of the fuel.
WINDBOX PRESSURE - The static pressure in the windbox of a burner
VA - Volt amperes.
or stoker.
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 (CaCO3) from water through
an ion exchange of sodium with calcium and magnesium.
WATER TUBE - A tube in a boiler having the water and steam on the
inside and heat applied to the outside.
WATER VAPOR - A synonym for steam, usually used to denote steam of
low absolute pressure.
WEEP - A term usually applied to a minute leak in a boiler joint which
forms droplets (or tears) of water very slowly.
WETBACK BOILER - Firetube boiler design wherein the back portion of
the boiler has a water jacket.
WET-BULB TEMPERATURE - The lowest temperature which a water
wetted body will attain when exposed to an air current. This is the tem-
perature 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 inte-
riors.
J-10
Index
INDEX
-A-
Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-7
Activated Carbon Media Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H7-6 H7-10
Air Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-3
Application and Energy Use Audit, See Steam Systems Section
Application/Load, See Boiler Selection Consideration Section, also see Steam Systems Section
ASCII Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-21
ASME Code, see Boiler Selection Consideration Section, also see specific boiler product section
Associations, List of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-43 I4-44
Assured Low Fire Cut Off Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-30
Automatic Fuel Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-32
also see specific boiler products section
-B-
Bent Tube Boiler, see Commercial Boilers, then see Flexible Watertube Boiler Section
BLOWDOWN HEAT RECOVERY SYSTEMS (Section H-11)
Dimensions
Model BHR-M (Multiple Boiler) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-10
Model BHR-S (Single Boiler) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-8
Dimensions and Ratings
Model BHR-LPS (Low Pressure) (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-12
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-3
Product Offering
Models BHR-S and BHR-M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-3 H11-4
Model BHR-LPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-4
Ratings/Capacities
Model BHR-M (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-11
Model BHR-S (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-9
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-13 H11-14
Selection, Model BHR-LPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-4
Selection and Payback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11-5 H11-7
BLOWDOWN SEPARATOR (Section H-10)
Dimensions
5D Model Aftercooler (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-7
Automatic Drain Water (18DF) Aftercooler (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-5
Automatic Drain Water (20AO) Aftercooler (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-6
Blowdown Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-4
Engineering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-5
Floor Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-8
Sizing
Boiler Blowdown Separators (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-4
Cooling Water Line and Valve (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-6
Wall Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-9
Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-3
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-2
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10-10
Blowdown Systems, discussed, See Steam Systems Section
Blowdown, Types of I3-16
Blowdown Water Requirements, see specific boiler product section under Engineering Data
BOILER FEED SYSTEMS (Section H5), See also Steam Systems Section
Dimensions and Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-5 H5-8
Dual System Selection (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-7
Internal Steam Heater Assemblies
High Pressure Systems (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-9
Low Pressure Systems (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-10
J-11
Index
Simplex and Duplex System Selection (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5-6

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

Defining Load Variations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-7
Heating Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-6
Load Demand Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-7
Process Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-6 I1-7
System Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-6
System Load Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-7
Tracking Load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-7 I1-8
Number of Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-8
Back Up Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-8
Steam or Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-6
Turndown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-8 I1-9
Type of Load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-8
Special Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10
Replacement Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1-10
Boilers, Cast Iron, see Boiler Selection Considerations Section under Common Boiler Types
BOILERS, COMMERCIAL
ELECTRIC BOILERS (Section B4)
Dimensions
Hot Water Boilers
Models HW & CWB (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-7
Hot Water Storage Heaters
Models TWH & TWV (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-11
Vessel Sizes (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-22
Instantaneous Water Heaters
Model IWH (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-12
Steam Boilers
Model S (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-8
Model CR (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-9
Model CSB (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-10
Engineering Data
Power Supply Wire Lug Sizing Guide (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-6
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-3
Performance Data
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5
Emissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-5
Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-3 B4-5
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4
Selection Chart (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-4
Ratings
Hot Water Boilers
Model HW (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B413 B4-14
Model CWB (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-15 B4-17
Hot Water Storage Heaters
Model TWH & TWV (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-22
Instantaneous Water Heaters
Model IWH (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-24
Steam Boilers
Models S & CR (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-18 B4-19
Model CSB (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-20 B4-21
Sample Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4-25
BOILERS, COMMERCIAL, (Continued)
FLEXIBLE WATERTUBE BOILER (Section B1)
Dimensions
Hot Water (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-7
Steam (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-8
Efficiency (See Performance Data)
Emissions (See Performance Data)
Engineering Data
Breeching Arrangements (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-15
J-13
Index
Breechings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-13
Burner Characteristics (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-10
Circulating Rates, Hot Water (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-10
Clearance Requirements (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-14
Combustion Air Requirements (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-15
Flow Rates and Pressure Drop (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-9 B1-10
Fuel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-11 B1-12
Heat Release (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-10
Heating Surface (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-9
Oil Burner Supply Pump Installation (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-13
Outdoor Reset Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-13
Over Pressure Requirements (Minimum) (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-10
Pressure Drops and Flow Rates (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-9 B1-10
Pressure, Minimum Gas Required (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-12
Sound Levels (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-14
Tube Attachment (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-11
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-3
Performance Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-9 B1-10
Efficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-9
Emissions (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-9
Product Offering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-3 B1-5
Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-4 B1-5
Sizes (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-4
Ratings
Hot Water (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-6
Steam (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-6
Sample Specifications
Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-16
Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-20
BOILERS, COMMERCIAL (Continued)
MODEL 4 (Section B2)
Dimensions
Hot Water (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-8 B2-9
Steam (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-10 B2-11
Efficiency (see Performance Data)
Emissions (see Performance Data)
Fuels (see Performance Data)
Engineering Data
Flow Rates
Fuel, Air, Flue Gas (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-14
Hot Water (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-15
Gas Fuel Requirements (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-13
Gas Train, Standard (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-7
Over Pressure Requirements (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-16
Pressure Drop, Hot Water (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-15
Pressure Vessel Thickness, Minimum (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-14
Sound Levels (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-16
Stack Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-12
Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-12
Steam Nozzle Size, Recommended at Reduced Pressure (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-16
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-3
Fuel Requirements, Gas (see Engineering Data)
Performance Data
Efficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-12
Emissions
Natural Gas (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-12
No. 2 Oil (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-12
Product Offering
Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-4 B2-5
Sizes (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-3
J-14
Index
Special Insurance Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-5

Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-3 B2-4
Ratings
Hot Water (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6
Steam (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-6
Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-23 B2-28
Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2-17 B2-22
BOILERS, COMMERCIAL (Continued)
MODEL 5 (Section B3)
Dimensions
Hot Water (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-10 B3-11
Steam (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-8 B3-9
Efficiency (See Performance Data)
Emissions (See Performance Data)
Engineering Data
Boiler Reference Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-13
Circulating Rates and Temperature Drop (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-13
Flow Rates (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-13
Fuel Requirements
Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-13
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-12
Fuels
Gas (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-13
Oil (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-12
Gas Train, Standard (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-7
Over Pressure Requirements (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-15
Pressure Drop (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-14
Sound Levels (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-15
Steam Nozzle Size at Reduced Pressure (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-14
Temperature Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-14
Features and Benefits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-2
Performance Data
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-12
Emissions
Natural Gas (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-12
Oil (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-12
Product Offering
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-4 B3-5
Sizes (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-3
Special Insurance Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-5
Ratings
Hot Water (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6
Steam (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-6
Hot Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-21
Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-16
Boilers, Firebox, see Boiler Selection Considerations, under Common Boiler Types
BOILERS, FIRETUBE (Section A)
General
Comparison (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-3 A-14
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-2
Model Designation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-3
Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-2 A1-3
MODEL CB (Section A-1)
Dimensions and Weights, General
Lifting Lug Locations (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-18 A2-19
Mounting Piers (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-20
Space Required to Open Rear Head (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-18
J-15
Index
Dimensions and Weights, Hot Water, 30 psig Design Pressure

(15-100 Hp) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2-14 A2-15
(125-800 Hp) Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2-16 A2-17
Dimensions and Weights, Steam, 15-150 psig Design Pressure
(15-100 Hp) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2-10 A2-11
(125-800 Hp) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2-12 A2-13
Engineering Data
Tank Sizing Information (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-27
Boiler Room Information
Breeching (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-46
Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-44
Room Length, Typical Layout (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-45
Room Width, Typical Layout (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-45
Burners, Gas Fired
Gas Consumption, Maximum, (CFH), for Natural Gas and Propane Vapor (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-34
Gas Pressure Altitude, Minimum Required, Conversions (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-33
Gas Pressure, Minimum Required at Entrance to Gas Trains Equipped With IRI Requirements (Table) . . . . . . . . . . . . . . . A2-33
Gas Pressure, Minimum Required at Entrance to Standard and FM Gas Trains (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-31
Gas Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2-31 A2-32
Gas Trains
Components (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-36
Standard Connection Size and Location (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-34
Under and Oversized
Standard and FM (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-32
IRI (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-33
Piping Layout, Typical (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-35
Burners, Oil-Fired
No 2 Oil
Connection Size, Location, and Recommended Line Size (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-37
Piping
Multiple Boiler Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-40
Multiple Boiler Installation, Oil Pump Integral With Boiler (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-39
Multiple Boiler Installation, Remote Oil Pumps (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-39
Single Boiler Installation, Oil Pump Integral With Boiler (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-38
Single Boiler Installation, Remote Oil Pump (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-38
Transfer Tank Detail (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-42
No 6 Oil
Connection Size, Location, and Recommended Line Sizes (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-37
Piping
Bundled Lines, Typical Cross Section (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-43
Fuel Storage Tank Arrangement (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-42
Multiple Boiler Installation (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-41
Preheating System, Standard Alstrom Hot Water Safety Type (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-43
Heating Surface (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-24
Non-Return Valve Size, Recommended (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-26
Relief Valve Openings (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-8
Safety Valve Openings (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-7
Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2-27 A2-30
Sound Pressure Level Details
40 Hp (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-27
50-125 Hp (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-28
125-200 Hp (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-29
250-350 Hp (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-29
400-800 Hp (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-30
Sound Pressure Level Summary (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-27
Steam Nozzle Size, Recommended (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-26
Steam Volume and Disengaging Area (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-25
Stack
Breeching Arrangement (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-46
Breeching Size Criteria. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-44
Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-44
Water Circulation Rate and Temperature Drop for Hot Water Boilers (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-25
J-16
Index
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-3

Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-21
Efficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-21
Fuel-to-Steam (Tables)
Natural Gas, 10 psig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-22
Natural Gas, 125 psig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-22
No. 2 Oil, 10 psig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-23
No. 2 Oil, 125 psig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-23
No. 6 Oil, 10 psig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-22
No. 6 Oil, 125 psig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-22
Stack Temperature Increase for Pressures Greater than 125 psig (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-23
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-21
Levels, Uncontrolled (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-24
Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-3 A2-4
Ratings, Hot Water
(15-100 Hp) Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-6
(125-800 Hp) Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-6
Ratings, Steam
(15-100 Hp) Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-5
(125-800 Hp) Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-5
Sample Specifications, Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-57 A2-65
Sample Specifications, Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-47 A2-56
BOILERS, FIRETUBE (Continued)
MODEL CBE (Section A7)
Dimensions, General
Lifting Lug Locations (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-10
Mounting Piers (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-11
Space Required to Open Rear Head (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-10
Dimensions and Weights, (20-350 Hp)
Hot Water (30 and 125 psig Design Pressure) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-6 A7-7
Steam (30 and 125 psig Design Pressure (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-8 A7-9
Engineering Data
Blowdown Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12
Tank Sizing Information (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-15
Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12
Heating Surfaces (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-13
Non-Return Valve Sizes (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-15
Relief Valve Openings (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-14
Safety Valve Openings (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-14
Steam Nozzle Size (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-15
Steam Volume and Disengaging Area (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-13
Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-18
Room Length (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-19
Room Width (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-19
Stack Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-18
Burner/Controls Information
Gas Consumption (CFH), Maximum for Natural Gas and Propane Vapor (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-16
Gas Pressure Altitude Conversion, Minimum Required, (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-16
Gas Pressure, Minimum Required at Entrance to Standard, FM, and IRI Gas Trains (Table) . . . . . . . . . . . . . . . . . . . . . . . A7-13
Selection (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-16
Fuel Connection
Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12 A7-13
Typical Supply Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-17
Sound Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12
Stack Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-18
Features and Benefits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-3
Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-12
Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-3
Ratings, Hot Water (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-5
Ratings, Steam (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7-5
J-17
Index
Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-25 A2-29
Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-20 A2-24
MODEL CBH (Section A-5)
Dimensions, General
Mounting Piers (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-12
Space Required to Open Rear Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-10
Dimensions and Weights (25-100 Hp)
Hot Water (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-8 A5-9
Steam (15 and 150 psig Design Pressure) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-6 A5-7
Engineering Data
Burners, Gas Fired . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-12 A5-14
Gas Consumption (CFH), Maximum for Natural Gas and Propane Vapor (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-13
Gas Pressure Altitude Conversion (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-13
Gas Pressure, Minimum Required at Entrance to Gas Trains Equipped With IRI Requirements (Table) . . . . . . . . . . . . . . . A5-12
Gas Trains Components (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-13
Fuel Requirements (see Dimensions and Ratings)
Relief Valve Openings (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-10
Safety Valve Openings (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-10
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5-3
Performance Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5-4
Product Offering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5-3 A5-4
Ratings, Hot Water
(25-100 Hp), (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5
Ratings, Steam
(25-100 Hp), (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-20 A5-23
Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5-15 A5-19
BOILERS, FIRETUBE (continued)
MODEL CB-LE (Section A3)
Dimensions, General
Mounting Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60 and 78 (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-20
96 (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-21
Space Required to Open Rear Head (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-20
Weights (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6
Dimensions, Hot Water, 125-800 Hp, 30 and 125 psig Design Pressure)
60 (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-14 A3-15
78 (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-16 A3-17
96 (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-18 A3-19
Dimensions, Steam, 125-800 Hp, 15-150 psig Design Pressure)
60 (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-8 A3-9
78 (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-10 A3-11
96 (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-12 A3-13
Engineering Data
Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-33
Blowdown Tank Sizing Information (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-34
Heating Surface (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-34
Non-Return Valve Sizes (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-35
Steam Nozzle Sizes (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-35
Steam Volume and Disengaging Area (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-35
Breeching Arrangements (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-37
Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-33 A3-34
Room Length (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-36
Room Width (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-36
J-18
Index
Burners, Gas Fired . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-26

Gas Consumption, (CFH), Maximum for Natural Gas and Propane Vapor (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-28
Gas Pressure Altitude Conversion (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-28
Gas Pressure, Minimum Required at Entrance to Standard, FM and IRI Gas Trains (Table) . . . . . . . . . . . . . . . . . . . . . . . . A3-27
Gas Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-26 A3-27
Gas Trains
Connection Size and Location (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-28
Under and Oversized, Standard, FM, and IRI (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-30
Piping, Typical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-29
Burners, Oil Fired, No. 2
Connection, Size, Location and Recommended Line Sizes (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-30
Piping
Multiple Boiler Installation (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-32
Multiple Boiler Installation, Remote Oil Pumps (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-32
Single Boiler Installation, Remote Oil Pumps (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-31
Transfer Tank Detail (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-32
Typical Arrangement (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-33
Relief Valve Openings (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-7
Sound Levels
30 ppm NOx System, Predicted (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-26
Stack
Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-33
Performance Data
Efficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-23
Fuel-to-Steam, Predicted, Natural Gas (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-24
No. 2 Oil, Predicted (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-25
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-23
Stack Temperature Increase, Predicted, for Pressures Greater Than 125 psig (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-24
Emissions, Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-23
Natural Gas (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-25
Oil (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-25
Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-3
Ratings, Hot Water (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4
Combustion Air Fan, Motor Hp Requirements, 125 psig and Less (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
Ratings, Steam (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4
Combustion Air Fan, Motor Hp Requirements, 125 psig and Greater, Steam (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-5
Weights, See Dimensions, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-6
Hot Water (125-800 Hp, 30 psig, 125 psig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-45 A3-51
Steam (125-800 Hp, 15-150 psig). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-38 A3-44
MODEL CBW (Section A-4)
Dimensions, General
Mounting Piers (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-13
Space Required to Open Rear Door (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-12
Dimensions, Hot Water (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-10 A4-11
Dimensions, Steam (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-8 A4-9
Engineering Data
Tank Sizing Information (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-17
Breeching Arrangements (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-32
Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-30
Room Length (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-31
Burners, Gas Fired . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-18
Consumption (CFH), Maximum for Natural Gas and Propane Vapor (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-20
J-19
Index
Gas Pressure Altitude Conversion, Minimum Required at 700 ft (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-19

Gas Pressure Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-18
Gas Pressure, Minimum Required at Entrance to Gas Trains Equipped with IRI Requirements (Table) . . . . . . . . . . . . . . . A4-19
Gas Trains
Connection, Size, and Location IRI (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-21
Over and Undersized, Standard, FM, IRI (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-20
Piping, Typical Layout (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-22
Burners, Oil Fired
No. 2 Oil
Connection, Size, Location and Recommended Line Sizes (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-24
Piping
No. 6 Oil
Bundled Lines, Typical Cross Section (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-29
Connection Size, Location and Recommended Line Sizes (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-24
Multiple Boiler Installation (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-27
Multiple Boiler Installation, Remote Oil Pump (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-27
Oil Transfer Tank Detail (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-28
Preheating System, Schematic of Standard Alstrom Hot Water System (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-29
Typical Arrangement (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-28
Heating Surface (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-15
Non-Return Valve Size, Recommended (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-17
Relief Valve Openings (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-5
Sound Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-17 A4-18
Sound Pressure Level Summary (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-18
Stack
Breeching Size Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-30
Steam Nozzle Size (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-16
Steam Volume and Disengaging Area (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-15
Water Circulation Rates and Temperature Drop for Hot Water Boilers (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-16
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4-3
Performance Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4-14
Efficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-14
Emission Levels, Uncontrolled (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-14
Product Offering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4-3
Ratings, Hot Water (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4-5
Ratings, Steam (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4-5
Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-41 A4-48
Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4-33 A4-40
BOILERS, FIRETUBE (continued)
OHIO SPECIAL (Section A-6)
Dimensions, General
Mounting Piers (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-11
Space Required to Open Rear Head (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-10
Dimensions, Steam
CB Model Ohio Special, (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6-6 A-6-7
CBW Model Ohio Special, (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6-8 A6-9
Engineering Data
Tank Sizing Information (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-13
Boiler Information
Heating Surface (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-11
Non-Return Valve Size, Recommended (Table) A6-13
Safety Valve Openings (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-12
Stack Support Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-23
J-20
Index
Steam Nozzle Size, Recommended (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-12

Steam Volume and Disengaging Area (Table) A6-12
Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-23
Room Length (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-24
Burners
Linkage Assembly, Combination Gas and Oil (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-14
Secondary Air Flow Diagram (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-13
Burners, Gas Fired
Gas Modulating Cam (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-15
Gas Piping Layout (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-19
Gas Pressure Altitude Conversion, Minimum Required (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-16
Gas Pressure, Maximum Consumption (CFH) for Natural Gas and Propane Vapor (Table). . . . . . . . . . . . . . . . . . . . . . . . . A6-17
Gas Pressure, Minimum at Entrance to Gas Train Equipped With IRI Requirements (Table). . . . . . . . . . . . . . . . . . . . . . . . A6-15
Gas Pressure, Minimum Requirements at Entrance to Standard and FM Gas Trains (Table) . . . . . . . . . . . . . . . . . . . . . . . A6-15
Gas Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-16 A6-17
Gas Trains,
Components, Special (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-18
Connection Size and Location (Figure) A6-20
Over and Undersized for IRI Gas Trains (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-16
Over and Undersized for Standard and FM (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-16
Burners, Oil Fired
Connection Size, Locations and Recommended Line Size (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-20
Fuel Oil Consumption (See Boiler Ratings) Multiple Boiler Installation (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-22
Multiple Boiler Installation, Remote Oil Pumps (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-21
Single Boiler Installation, Remote Oil Pump (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-21
Transfer Tank Detail (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-22
Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-4
Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-3 A6-4
Ratings, Steam
CB Model Ohio Special (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-5
CBW Model Ohio Special (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-5
CB Model Ohio Special, Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-25 A6-30
CBW Model Ohio Special, Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6-31 A6-36
BOILERS, INDUSTRIAL WATERTUBE (Section C)
Industrial Watertube Boilers (Section C)
Dimensions
(Burner, see under Engineering Data)
Hot Water
Model DW (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C20 C21
Model DLW (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C22 C23
Steam
Model D (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C14 C15
Model DL & DLD (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C16 C17
Model DLDH (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C18 C19
Emissions Data
Heavy Oils
Models A, BR, CN Burners (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-28
Model CT Burner (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-29
Natural Gas
No. 2 Oil
Engineering Data
Boiler Room Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-43
Breeching
Arrangement, Boiler
Right Hand and Left Hand (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-44
J-21
Index
with Common Stack (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-45

with Separate Stacks (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-45
Arrangement, Pier, Recommended (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-44
Arrangement, Two Boilers with Separate Stacks (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-46
Stack Size Selection (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-50
Transition
Gas Outlet, Connection to Horizontal Breeching (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-49
Gas Outlet, Direct to Stack (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-48
Top Outlet (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-47
Burner Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-37/C38 C42
Data
Models A, BR, CN (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-38
Model CT (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-41
Dimensions
Model A (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-24
Model BR (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-25
Model CN (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-26
Model CT (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-27
Offering
Models A, BR, CN (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-39
Model CT (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-42
Casing, Setting, and Insulation
Arrangement of Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-34
Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-34
Enclosure Construction, D Series Boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-35
Furnace Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-35
Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-37/C-42 C43
FGR Systems
Models A, BR, CN (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-40
Model CT (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-43
Drums
Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-31
Internals and Steam Purifiers for 1,3, and 7 ppm Solids (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-32
Internals and Separator for 99.5% Dry Steam (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-32
Lower (Mud) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C30 C31
Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-30
Flame Safeguard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-37/C-42 C-43
Burner Models A, BR, CN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-37
Burner Model CT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-42 C-43
Frame, Structural . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-35 C-36
Skid Assembly (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-36
Support Drum in Skid (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-36
Furnace, Heat Output, Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C31 C33
(Hot Water) (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-31
(Steam) (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-31
Heating Surface (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-30
Steam Capacity in lbs/hr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13
Trim, Standard
Model D (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7
Model DL and DLD (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8
Model DLDH (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9
Trim, Steel 300 psig
Model D (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10
Model DL and DLD (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-11
Model DLDH (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12
Tubes, Convection, Model D, DL, DLD, DLDH (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-34
Arrangement
Baffling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-33
Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-33
Figure of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-34
Model D Series Enclosure Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-35
Model D Series Tube Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-33
Internal Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-34
Removal of Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-34
Soot Blowers
J-22
Index
Features and Benefits

Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-3
Burners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3 C4
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4
Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Models (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C6
Standard Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5 C6
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-13
Steam (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-13
FGR (Models A, BR, CN Burners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-69
FGR (Model CT Burner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-70
Hot Water Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C61 C68
Steam Boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C51 C59
Boiler Room Length, see specific boiler product section under Boiler Room Information
Boiler Room Width, see specific boiler product section under Boiler Room Information
Breeching, see Stacks; also see specific boiler product section under Engineering Data
Brine Maker Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-11
Burners, Gas Fired, see specific boiler product section
Burners, Oil Fired, see specific boiler product section
By-Pass Feeders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-4
-C-
CB-HAWK Control, see Controls Section
CB-HAWK Enhancer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D16 D22
CB70 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D9
CB100 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D7
CB110 Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-8
CB780 Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D5-D6
Carbon Monoxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E8-E9
Cast Iron Boiler, see Boiler Selection Considerations, under Common Boiler Types
CHEMICAL FEED SYSTEMS AND METERING PUMPS (Section H6)
Dimensions
Automatic System (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-5
By-Pass Feeders (Manual System) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-4
Shot Feeders (Manual System) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-4
Engineering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-3
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-3
Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-3
Manual System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-3
Ratings
Automatic Chemical Feed System Pump (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-3
Sample Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6-6
Circulating Rates, Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-5
see also specific boiler product section
Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4 I2-5
Codes and Standards, see Boiler Selection Consideration Section, also see specific boiler product section, Hot Water
Systems Section, Steam Systems Section
Combustion Air Requirements, see specific boiler product section, under Engineering Data, also see Steam Systems Section
Communications Module, see Controls Section
Condensate Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-5
Condensate Receiver Tanks, See Surge Tank Section, also see Steam Systems Section
CONTROLS (Section D)
Assured Low Fire Cutoff
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-30
J-23
Index
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-30

Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-30
Sample Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-30
Automatic Fuel Changeover
Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-32
Availability, Product/Flame Safeguard (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
CB70
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-9
Engineering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-9
Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-9
Sample Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-9
CB100E
CB110
CB780
CB-HAWK Boiler Management Control System
Engineering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-11
Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10 D-11
Sample Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-11 D-13
CB-HAWK ASCII Interface
CB-HAWK Enhancer Base Unit
Auxiliary Input Monitor
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-18
Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-18
Sample Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-18
Base Unit
Engineering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-16
Efficiency Monitor
Lead/Lag Control (See Also Lead/Lag Systems)
Outdoor Reset Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Time-of-Day Scheduling Control (Day/Night)
J-24
Index

CB-HAWK Lead/Lag Systems (Two Boiler)
CB-Link Communication Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engineering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-14 D-15
Communication Module (See CB-Link)
Flame Safeguard
Availability (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
Comparison (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
Lead/Lag Systems (Two Boiler Lead Lag)
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-25
Lead/Lag Systems (Two Boiler through Four Boiler Lead/Lag)
Low Fire Hold Control
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-28
Minimum Temperature, Low Fire Hold Control
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-29
Oxygen Trim
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-35
Engineering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-34
Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-33 D-34
Product/Flame Safeguard
Availability (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
Comparison (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
Remote Modulation
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-31
Conversion of Units, see under Engineering Data, General
-D-
Deaerators, see specific deaerator product section, also see Steam Systems Section,
DEAERATORS, BOILERMATE (Section H3)
Dimensions and Ratings (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-6 H3-7
Tank Supports and Saddles (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-8
Product Offering
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-4
Selection Guide (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-5
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-4
Return on Investment
Chemical Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-9
J-25
Index
Exhaust Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-9

Flash Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-9
Intangibles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-9
Makeup Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-9
Sewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-9
Surface Blowdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3-9
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H3-10 H3-13
DEAERATORS, SPRAYMASTER, DUO TANK (Section H2)
Dimensions and Ratings (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-5 H2-7
Product Offering (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-3
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H2-8 H2-13
DEAERATORS, SPRAYMASTER, SINGLE TANK (Section H1)
Dimensions and Ratings (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H1-6 H1-7
Product Offering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H1-3 H1-5
Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-4
Offering (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-4
Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-4 H1-5
Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-4
Return on Investment
Chemical Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-8
Exhaust Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-8
Flash Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-8
Intangibles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-8
Makeup Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-8
Sewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-8
Surface Blowdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1-8
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H1-9 H-12
DEALKALIZERS (Section H9), See also Steam Systems Section
Dimensions and Ratings (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H9-5
Product Offering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H9-3
Selection and Data Chart (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-1
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-3 H9-4
Sizing Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9-4
Dimensions, see specific product section
-E-
ECONOMIZERS (Section G) See Also Steam Systems Section
Dimensions and Weights
Cylindrical Economizers for Firetube Boiler (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4
Rectangular Economizers for Industrial Watertube Boiler (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4
Efficiencies (See Performance Data)
Engineering Data
Installation
Firetube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6 G-7
Industrial Watertube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7
Piping
Above Industrial Boiler (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8
Feedwater Piping (See Engineering Data)
Mounting to Firetube Boiler (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7
On Side of Industrial Watertube Boiler (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8
Typical Feedwater Piping (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-9 G-11
Performance Data
Efficiencies
Cylindrical Economizer for Firetube Boiler (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6
Rectangular Economizer for Industrial Watertube Boiler (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6
J-26
Index
Performance
Cylindrical Economizer for Firetube Boiler (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5
Rectangular Economizer for Industrial Watertube Boiler (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6
Product Offering
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G12 G-13
Efficiency, see Boiler Selection Considerations under Performance, see specific boiler product section under Performance Data,
see also Economizers Section
Electric Boilers, see under Boilers, Commercial
EMISSIONS (Section E)
See also Boiler Selection Consideration Section and specific product section
Carbon Monoxide (CO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8
Emission Conversion Curve (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9
Emissions Conversion Curves
CO (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9
NOx (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-10
SOx (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-10
VOC (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-11
Industrial Boilers, Calculating Annual Emissions (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-11 E-13
Nitrogen Compounds (NOx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
Choosing the Best NOx Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
Combustion Control Techniques
Burner Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
Flue Gas Recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5 E-6
Low Excess Air Firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
Low Nitrogen Fuel Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
Water/Steam Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
Control Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4
Correcting Emissions to 3% Oxygen (15% Excess Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9
Converting NOx Emissions Between PPM & LB/MMBTU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9
Effects of Fuel-Bound Nitrogen on NOx Emissions for Fuel Oils (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
Emission Conversion Curves, 3% Oxygen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-10
New Source Performance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-13
Summary of Federal EPA Rules (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-14
Post Combustion Control Methods for NOx, Selective Reduction
Catalytic (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4 E-5
Non-Catalytic (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4
Particulate Matter (PM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8
Pollutants and Control Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
Sulfur Compounds (SOx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7
Emission Conversion Curve, 3% Oxygen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-10
Sulfur Content, Effects of on SOx Emissions (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7
Units of Emission Levels, Volume or Mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8 E-9
Volatile Organic Compounds (VOCs) /Hydrocarbons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8
Emission Conversion Curve, 3% Oxygen (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-11
ENGINEERING DATA, GENERAL (Section I4)
Associations, Standard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-43 I4-44
Conversion of Units (See Unit Conversions)
Equivalent Lengths, Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-10
Table of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-10
Factors of Evaporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-12
Table of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-13
Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-3 I4-10
Equivalent Lengths (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-10
Fuel Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-3
Pressure Drop (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4-8 I4-9
Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-3
Line Capacities (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-7
Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-3
Pressure Drop (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-4
J-27
Index
Steam Velocity (Figure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-5

Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . !4-3
Pressure Drop (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-6
Stacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-10 I4-12
Breeching and Stack, Common, Multiple Boilers (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-12
Construction, Typical (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-11
Diameter, Vent or Stack, Single Boiler (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-12
Locations, Typical (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-11
Rain Cap Details (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-12
Thermodynamic Properties
Fuel Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-12 I4-17
Grade of Fuel Oil (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-17
Properties of Fuel Oil (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-16
Fuel Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-12 I4-14
Temperature and Viscosity Curves (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-15
Units for Fuel, Typical (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-13
Viscosity and Temperature Curves (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-15
Steam, Saturated Properties
Pressure (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-26 I4-30
Temperature (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-19 I4-25
Water
Thermal Properties of (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-18
Unit Conversions
Conversion Factors (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-32 I4-40
Conversion Tables (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-41
Conversions Accurate to Parts Per Million (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-42
Equivalents, Common, Approximate (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-42
pH Values (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-40
Salinity Indicating Readings (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-40
Temperature Conversion (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-31
Useful Physical Constants (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-40
Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4 I2-5
-F-
Feedwater Systems, see under specific product section
Blowdown Heat Recovery Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11
Blowdown Separators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H10
Boiler Feed Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5
Chemical Feed Systems and Metering Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H6
Deaerators, Boilermate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3
Deaerators, Duo Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2
Deaerators, Single Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1
Dealkalizers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H9
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7
Flash Tank Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12
Sample Coolers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H13
Softeners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8
Surge Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4
FILTERS (Section H7)
Chlorine, Organics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H7-5
Dimensions
Filters without Regenerant Tanks (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-4
Engineering Data (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-9/H7-10
Activated Carbon Media Filter (Model CF) (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-6/ H7-10
Iron Filter (Model IF) (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-8/H7-10
Multi-Layered Filter (Model MF) (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-7/H7-9
Sand Filter (Model SF) (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-8/H7-9
Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H7-5
Particles Down to 10-Micron Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H7-5
Product Offering
Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-3
J-28
Index
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-11 H7-12

Sand, Heavy Sediment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-5
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-5
Firebox Boilers, see Boiler Selection Considerations Section, under Common Boiler Types
Flame Safeguard, see Controls Section; also see specific boiler product sections
FLASH TANK HEAT EXCHANGERS (Section H-12)
Dimensions
Model AHR (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-5
Model FTE (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-4
Engineering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-3
Product Offering
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-3
Standard Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-3
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-10 H12-11
Selection and Payback (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H12-6 H12-9
Flexible Watertube Boilers, see under Commercial Boilers
Flow Rates, see under specific boiler product
Flue Gas Recirculation, see Emissions Sections, see also specific boiler products section
Fuel Connections, see specific boiler products section
Fuel Oil, see General Engineering Data and specific boiler product sections
-G-
Gas Consumption (Maximum CFH), see specific boiler product section under Engineering Data
Gas Pressure Altitude Conversion, see specific boiler product section under Engineering Data
Gas Pressure, Minimum Required at Gas Train Entrance, see specific boiler product section under Engineering Data
Gas Pressure Regulator, see specific boiler product under Engineering Data
Gas Train, see specific boiler product section under Engineering Data
General Engineering Data, see under Engineering Data, General
Generator, Hot Water, see Boilers, Industrial Watertube
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J1 J10
-H-
Heat Release, see specific Boiler Product Section
Heat Users, see Hot Water Systems Section
Heating Surface, see specific boiler product section
Hot Water Boilers, see specific boiler product section
HOT WATER SYSTEMS (Section 12)
Control Considerations
Heat Users
Common Heat Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-10
Control of water flow through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-10
Pumps
Primary-Secondary Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-12 I2-13
Continuous Pump Operation with two-position valve (valve closed) (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-13
Continuous Secondary Pump Operation with two position valve (valve open) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . I2-13
Intermittent Secondary Pump Operation (On-Off) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-12
Water Temperature Constant through Zone Bypass (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-12
Valves
Plug Cock or Gate (Manual Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-10
Three Way Diverting (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-12
Three Way Mixing (By Pass Arrangement) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-11 I2-12
Throttling or Modulating (Electric or Pneumatic) (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-11
Two Position (Electric or Pneumatic) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-10
Lead/Lag Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-9 I2-10
Temperature Control
Boiler Water Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-8
System Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-9
J-29
Index
Temperature Setbacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-10

Mechanical Considerations
Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-7
Air Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-3
Boiler Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-3
Circulation
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4 I2-5
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4
Circulation Rates, (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-5
Typical Pump Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-2
Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-3
Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4
Piping Arrangements (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-5
Heating/Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-7
Pressure Drop
Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-6
Pressure/Temperature for Firetube Boilers (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-6
Pumping Equipment
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-4
Typical Pump Curve (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-8
System Diagrams
Four Way Valve System (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-20
Individual Zone Circuits (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-18
Multiple Boiler Lead/Lag (Primary/Secondary Pumping) (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-21
Primary Loop Circuit, Constant Speed Pump (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-16
Primary Loop Circuit with Secondary Pumping (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-17
Primary Loop Circuit with Three Way Valve (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-19
Water Considerations
Chemical Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-13
Ethylene Glycol as a Heat Transfer Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-14
Makeup Water
Introducing Makeup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-13
Metering Makeup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-14
Water Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14
-I-J-K-L
Iron Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-8/H7-10
Lead/Lag Systems, see Controls Section, see Hot Water Systems Section, and see under specific boiler products section
Lifting Lug Locations, see specific boiler product section under Dimensions
Low Fire Hold Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-28
Low Fire Hold Control, Minimum Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-29
-M-N-O
Makeup Water, see under specific product section, see Hot Water System section, see Steam System section
Models, see under specific product section
Model 4 Commercial Boiler
Model 5 Commercial Boiler
Model 5D Blowdown Separator
Model 18 DF Blowdown Separator
Model 20AO Blowdown Separator
Model 34 Blowdown Separator
Model 56 Blowdown Separator
Model ACC-CFB Activated Carbon Filter
Model ACC-DAB Dealkalizer
Model ACC-IFB Iron Filter
J-30
Index
Model ACC-MFB Multi-layered Filter

Model ACC-SAB Softener
Model ACC-SFB Sand Filter
Model ACC-TAB Softener
Model AHR Flash Tank Heat Exchanger
Model BHR-M Blowdown Heat Recovery
Model BHR-S Blowdown Heat Recovery
Model BHR-LPS Blowdown Heat Recovery
Model BM Deaerator
Model BMP Deaerator
Model CB Firetube Boiler
Model CB70 Control
Model CB100E Control
Model CB110 Control
Model CB780 Control
Model CB-HAWK Control
Model CB-HAWK Enhancer Control
Model CB-Link Control
Model CBE Firetube Boiler
Model CBH Firetube Boiler
Model CB-LE Firetube Boiler
Model CBS-I Stack
Model CBS-II Stack
Model CBS-III Stack
Model CBW Firetube Boiler
Model CR Electric Boiler
Model CSB Electric Boiler
Model CWB Electric Boiler
Model D Industrial Watertube Boiler
Model DL Industrial Watertube Boiler
Model DLD Industrial Watertube Boiler
Model DLDH Industrial Watertube Boiler
Model DLW Industrial Watertube Boiler
Model DW Industrial Watertube Boiler
Model EC Economizer
Model FLE Commercial Boiler
Model FLX Commercial Boiler
Model FTE Flash Tank Heat Exchanger
Model HW Electric Boiler
Model ICBS Stack
Model IWH Instantaneous Water Heater
Model O2 Trim System
Model S Electric Boiler
Model SAB Softener
Model SC22 Sample Cooler
Model SC42 Sample Cooler
Model SM Deaerator
Model SMD Deaerator
Model SMP Deaerator
Model SRG Surge Tank
Model TWH Electric Storage Heater
Model TWV Electric Storage Heater
J-31
Index
Model V5 Chemical Feed System

Mounting Piers, see specific boiler product section under Engineering Data
Multi-Layered Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H7-7/H-9
-N-
Non-Return Valve Size, see specific boiler product section under Engineering Data
NOx, see Emissions Section
-O-
Ohio Special Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6-1 A6-36
Oxygen Trim Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-33 D-35
-P-Q
Particulate Matter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8
Payback Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 I1-20
Performance, see under Boiler Selection Considerations
Performance Data, see specific product section
Product Offering, see specific product section
Piping, see specific boiler product section, also see Economizers Section, General Engineering Data Section,
Hot Water Section, Steam Systems Section
Pollutants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
Preheater, see under specific product section
Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-6
see also specific product section
Pumping Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-2 I2-4
Pumps, See specific product section, also see Hot Water Systems Section and Steam Systems Section
-R-
Ratings, see specific product section
Rear Head, Space Required to Open, see specific boiler product section under Dimensions, General
Relief Valve Openings, see specific boiler product section under Engineering Data
Remote Modulation Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-31
Resin Tank Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8 H10
Return on Investment, see Deaerator product sections
-S-
Safety Valve Openings, see specific boiler product section under Engineering Data
SAMPLE COOLERS (Section H13)
Dimensions
Model SC22 (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H13-4
Model SC42 (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H13-5
Engineering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H13-3
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H13-3
Performance Curves
Model SC22 (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H13-4
Model SC42 (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H13-5
Product Offering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H13-3
Ratings
Models SC22 and SC42 (Temperature) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H13-3
Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H13-6
Sand Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H7-8 H7-9
Shot Feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H6-4
SOFTENERS (Section H8) See also Steam Systems Section
Dimensions
Model SAB (Size 30-900) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-6
Model SAB (Size 1050 - 2100) (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-7
Model TAB (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-5
J-32
Index
Engineering Data
Brine Maker Data (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-11
Flow Rates and Resin Tank Data (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-10
Resin Tank and Brine Maker Data (Tank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-10 H8-12
Softener Pressure Drop Charts (Figure)
Size 30-120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-14
Size 150-450 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-15
Size 600-900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-16
Product Offering
Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-4
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-4
Sizing
Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-8
Charts (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-13
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H8-4
Ratings (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-8 H8-9
Sample Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H8-17 H8-20
Sound Levels, see specific product section
Specifications, see specific product section
STACKS (Section F)
see also under specific boiler product section and under General Engineering Data Section
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3
Engineering Data
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5
Special Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5
Component Names and Part Numbers (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5
Arrangements, Typical Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-12/F-14
Clearance to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5/F-11 F-12
Construction and Joint Details
Model CBS-II (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-13
Model CBS-III (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-13
Model ICBS (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-14
(Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-13
Clearances for Non-Combustible Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-11
System Extension Above Boiler Room (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7
Connecting to the Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5
Weights (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-14
Expansion and Installation Concerns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7 F-11
Calculating Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8
Graphs (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8
Expansion Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7
Thermal Expansion Between Two Fixed Points (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7
Guide Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8
Cable Guying Specification for Room Level Guide (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-10
Guide and Support Assemblies, Maximum for Vertical, Horizontal, and Sloping Stack Runs (Figure) . . . . . . . . . . . . . . F-10
Support Assemblies
Stack Height, Maximum Supported (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-9
Support and Guide Assembly, Maximum for Vertical, Horizontal, and Sloping Stack Runs (Figure) F-1
Unsupported Distance, Maximum, Between Elbows, Tees, or Wyes (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8
Roof
Cable Guying Installation Details (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-12
Framing and Curb Details (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-12
Opening Size for Penetration of Roof Support Assemblies (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-11
Safety Specifications and Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5
Use of Non-Combustible Enclosure or Chase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-12
(Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-14
Product Offering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3
Application Information (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4
Selection Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3
Special Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5
J-33
Index
System Components and Part Numbers (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6

Sample Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-15
Steam Boilers, see specific boiler product section
Steam Nozzle Size, see specific boiler product section under Engineering Data
STEAM SYSTEMS (Section I3)
Equipment considerations and hardware design
Blowdown Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-15 I3-16
Boiler Feed Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-10 I3-13
Boiler Piping and Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-8 3-10
Safety Valve Discharge Piping, Recommended (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-9
Economizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-15
Steam Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-6 I3-8
Water Treatment Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-13 I3-15
Makeup Water Impurities, Limits and Treatment Methods (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-14
Removal of Harmful Elements with Various Types of Equipment (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-14
Example
Application/Energy Use Audit Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-17 I3-18
Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-19
Boiler Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-18 I3-19
Condensate Return and Feedwater System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-19
System Schematic (Figure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-20
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-19
Water Test Results and Limits (Table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-19
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-3
Steam-Generating Facility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-3 I3-6
Application/Energy use Audit Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-6
Summary of (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-6
Application Load, Type of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-3
Codes and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-5
Federal, State, Local, and Provincial Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-6
Operating Conditions, Requirements, and Constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-3 I3-5
Schematic Diagram of a Generic Steam -Generating Facility (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-4
Typical Steam System (Figure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-4
System Integration and Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-16 I3-17
Steam Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4-
19 I4-30
Steam Volume and Disengaging Area, see specific boiler product section under Engineering Data
Sulfur Compounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7/
E-10
Surface Blowdown, see specific product section
SURGE TANKS (Section H4) See Also Steam Systems Section
Dimensions and Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H4-4 H4-5
Tank Supports and Saddles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-6
Product Offering
Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4-3 H4-4
System Diagrams, Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-
16 I2-20
SYSTEM FUNDAMENTALS
See Boiler Selection Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1
See Hot Water Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2
See Steam Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3
See Engineering Data, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I4
-T-U
Tank Capacity, see under specific product section
Tank Support and Saddles, see specific deaerator product section
J-34
Index
Temperature Control, see Hot Water Systems Section

Temperature Drop, see specific boiler products section
Temperature Setbacks, see Hot Water Systems Section
Thermodynamic Properties, see General Engineering Data Section
-V-
Valves, see Hot Water Systems under Control Considerations
Vent Capacities, see under specific product section
VOCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-8
-W-X-Y-Z
Water Considerations, Hot Water Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I2-12 I2-14
Water Heaters, Instantaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4
Water Treatment Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I3-13
also see specific water treatment product sections
J-35

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The Boiler Book

Produced by the Employees of

Performance Proven Worldwide

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

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

Industrial Watertube Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C

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

Model CB-LE Boilers A3

Model CBW Boilers A4

Model CBH Boiler (discontinued) A5

Model CB Ohio Special Boilers A6

Model CBE Boilers A7

Model CEW Boilers A8

Model CEW-LN Boilers A9

Model CEW Ohio Special Boilers A10

Model CBL Boilers A11

Model ICB Boilers A12

Model ICB-LN Boilers A13

Low Excess Air:

High Steam Quality:

D Altitude, size, and fuel series limitations may apply.

Internal hot water coils. Special pilot.

Table A2-1. Model CB Steam Boiler Ratings (15 - 100 hp)

RATINGS - SEA LEVEL TO 3000 FT

APPROXIMATE FUEL CONSUMPTION AT RATED CAPACITY

Heavy Oil (gph)B - - - - 14.0 16.5 19.5 22.5 28.0

POWER REQUIREMENTS - SEA LEVEL TO 3000 FT, 60 HZ

Blower Motor hp (except gas) 1 1 1-1/2 2 2 2 2 2D 3

Gas Models (only) 1 1 1-1/2 2 2 2 2 2D 3

Oil Heater kW No. 6 Oil - - - - 5 5 5 5 5

Air Compressor Motor hp Air Compressor Belt-Driven

RATINGS SEA LEVEL TO 3000 FT J

APPROXIMATE FUEL CONSUMPTION AT RATED CAPACITY

POWER REQUIREMENTS - SEA LEVEL TO 3000 FT, 60 HZ

RATINGS - SEA LEVEL TO 3000 FT

APPROXIMATE FUEL CONSUMPTION AT RATED CAPCITY

POWER REQUIREMENTS - SEA LEVEL TO 3000 FT, 60 HZ

Blower Motor hp (except gas) 1 1 1-1/2 2 2 2 2 2D 3 3 3

Gas Models (only) 1 1 1-1/2 2 2 2 2 2D 3 3 3

Oil Heater kW No. 6 Oil - - - - 5 5 5 5 5 5 5

Air Compressor Motor hp Air Compressor Belt-Driven 2 2 2 2 2 2 2

Rated Cap. Btu Output

APPROXIMATE FUEL CONSUMPTON AT RATED CAPCITY

POWER REQUIREMENTS - SEA LEVEL TO 3000 FT, 60 HZ

Oil Heater kW No. 6 Oil 5 5 5 7-1/2 7-1/2 7-1/2 10 10 10 10 10 10

Table A2-5. Steam Boiler Safety Valve Openings

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

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 1-1/4 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

(1) 1-1/2 (1) 1-1/2 (1) 1-1/4

(1) 2 (1) 1-1/2 (1) 1

(1) 2-1/2 (1) 2-1/2 (1) 2 (1) 1-1/2