Installation Manual: General Information Open System

INSTALLATION MANUAL
STEAM GENERATOR
GENERAL INFORMATION
OPEN SYSTEM
CLAYTON INDUSTRIES CLAYTON OF BELGIUM N.V.

17477 Hurley Street Rijksweg 30
City of Industry, CA 91745 B-2880 Bornem
U.S.A. Belgium
tel : 1-626-443-9381
fax : 1-626-442-1701 tel : 32-(0)3-890.57.00
e-mail : sales@claytonindustries.com fax : 32-(0)3-890.57.01
www.claytonindustries.com e-mail : sales@clayton.be
CLAYTON NEDERLAND B.V. CLAYTON DEUTSCHLAND GmbH

Postbus 118 Lindemannstrasse 75
NL-3300 AC Dordrecht D-40237 Düsseldorf
Nederland Deutschland
tel : 31-(0)78-613.98.11 tel : 49-(0)211-23 39 79-0
fax : 31-(0)78-613.93.47 fax : 49-(0)211-23 39 79-22
e-mail : clayton@clayton.nl e-mail : info@clayton-deutschland.de
www.clayton.nl www.clayton-deutschland.de
CLAYTON DE FRANCE S.A.R.L. CLAYTON THERMAL PRODUCTS LTD

160, rue du Tuboeuf 5, Boleyn Court
F-77170 Brie Comte Robert Manor Park Industrial Estate
France Runcorn
Cheshire WA7 1SR U.K.
tel : 33-(0)1-64.05.38.24 tel : 44-(0)1928-57.90.09
fax : 33-(0)1-64.05.24.37 fax : 44-(0)1928-57.11.55
e-mail : clayton.france@wanadoo.fr e-mail : claytonindustries@btinternet.com
0191.076
INSTALLATION MANUAL
GENERAL INFORMATION-OPEN SYSTEM
CLAYTON STEAM GENERATORS E-MODELS
TABLE OF CONTENTS
CHAPTER 1 : INTRODUCTION ...................................................................................................................... 6
1.1 APPLICATION OF THE INSTALLATION MANUALS............................................................................. 6
CHAPTER 2 : POSTION OF GENERATOR AND ACCESSORIES ................................................................ 7
2.1 IMPORTANCE .......................................................................................................................................... 7
2.2 LOCAL RULES.......................................................................................................................................... 7
2.3 FLOOR DRAIN ......................................................................................................................................... 7
2.4 ACCESS TO THE STEAM GENERATOR ................................................................................................. 7
2.5 LEG MOUNTING...................................................................................................................................... 7
2.6 HEATING SECTION DIMENSIONS AND WEIGHT ............................................................................... 7
2.7 HOTWELLS AND CONDENSATE RECEIVERS ...................................................................................... 8
FIG.2.1-FLOOR DRAIN .............................................................................................................................. 9
FIG.2.2-FREE WORKING AREA TO BE RESPECTED AROUND STEAM GENERATOR .......................10
FIG. 2.3-INSTALLATION ABOVE ‘’ DRIP TRAY ‘’ ...................................................................................11
FIG. 2.4-FREE AREA AROUND RECEIVERS............................................................................................12
CHAPTER 3 : FEEDWATERTREATMENT.....................................................................................................13
CHAPTER 4 : STACK AND VENTING ARRANGEMENTS ............................................................................14
4.1 IMPORTANCE .........................................................................................................................................14
4.2 STACK ARRANGEMENTS, LOCAL RULES ...........................................................................................14
4.3 REMOVABLE FLUE PIPE ......................................................................................................................14
4.4 FREE STANDING STACK .......................................................................................................................14
4.5 MOVEMENT AND FORCES ...................................................................................................................14
4.6 BENDS......................................................................................................................................................14
4.7 INSPECTION COVER..............................................................................................................................14
4.8 STACK TEMPERATURE INDICATION AND ALARM ...........................................................................15
4.9 DRAFT REQUIREMENTS .......................................................................................................................15
4.10 RAIN CAP...............................................................................................................................................15
4.11 STACK MUFFLER.................................................................................................................................15
4.12 STACK INSULATION ............................................................................................................................15
4.13 SHUT DOWN PERIODS, COLD AREAS...............................................................................................15
4.14 STACK ADAPTER..................................................................................................................................15
4.15 CONDENSATION, GAS FIRED UNITS ................................................................................................16
4.16 ECONOMISER .......................................................................................................................................16
4.17 VENTING OF BOILER ROOM..............................................................................................................16
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FIG. 4.1-WAYS OF CONNECTING STACK TO A CLAYTON STEAM GENERATOR...............................17

FIG. 4.2-EXAMPLES OF STACK ARRANGEMENT...................................................................................18
FIG. 4.3-RAIN CAPS ( CHECK WITH LOCAL CODES )..........................................................................19
CHAPTER 5 : PIPING .....................................................................................................................................20
5.1 GENERAL ................................................................................................................................................20
5.2 STEAM DISCHARGE VALVE..................................................................................................................20
5.3 STEAM TRAP RETURN LINE .................................................................................................................20
5.4 BLOWDOWN LINE..................................................................................................................................20
5.5 BLOWDOWN TANK ................................................................................................................................20
5.6 BACK PRESSURE REGULATOR ............................................................................................................21
5.7 STEAM SAFETY VALVES........................................................................................................................21
5.8 STEAMHEADERS ....................................................................................................................................21
5.9 TEST LINE ...............................................................................................................................................21
5.10 STEAM AND CONDENSATE LINES.....................................................................................................22
5.11 PROTECTION, SHUTDOWN ................................................................................................................22
5.12 SOOTBLOW LINES................................................................................................................................22
5.13 BLOW DOWN TANK .............................................................................................................................22
FIG.5.1 :BLOWDOWN TANK .....................................................................................................................23
FIG. 5.2-INSTALLATION OF BACK PRESSURE REGULATOR ...............................................................24
FIG. 5.2A-PIPING ARRANGEMENT – BACK PRESSURE REGULATOR ................................................25
FIG. 5.3-BACK PRESSURE REGULATOR .................................................................................................26
FIG. 5.4-SAFETY VALVE OUTLET CONNECTION ..................................................................................27
FIG.5.5-EXAMPLE STEAM LINE FIG. 5.6-EXAMPLE RETURN CONDENSATE LINE.........................28
CHAPTER 6 : FUEL SYSTEMS .......................................................................................................................29
6.1 GAS FIRED STEAM GENERATORS .......................................................................................................29
6.2 OIL FIRED STEAM GENERATORS........................................................................................................30
FIG. 6.1-TYPICAL GAS PRESSURE REGULATOR INSTALLATION........................................................33
FIG. 6.2-GAS PRESSURE REGULATOR INSTALLATION ........................................................................34
FIG. 6.3 & FIG. 6.3A-TYPICAL FUEL TANK INSTALLATION ( LIGHT FUEL OIL ) ............................35
CHAPTER 7 : ELECTRICAL REQUIREMENTS.............................................................................................36
CHAPTER 8 : OPEN SYSTEM.........................................................................................................................38
8.1 INTRODUCTION .....................................................................................................................................38
8.2 HOTWELL................................................................................................................................................38
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8.3 CONNECTIONS AND ACCESSORIES FOR THE HOTWELL ...............................................................38

8.3.1.VENT LINE..........................................................................................................................................38
8.3.2.LEVEL SWITCH AND WATER SUPPLY TO HOTWELL...................................................................38
8.3.3.THERMOSTAT AND STEAM SUPPLY VALVE. ................................................................................38
8.3.4. LEVEL GAUGE............................................................................................................................39
8.3.5. THERMOMETER .........................................................................................................................39
8.3.6. INSULATION ...............................................................................................................................39
8.3.7. OVERFLOW .................................................................................................................................39
8.3.8. INDUCER-TUBES .......................................................................................................................39
8.4 WATER SUPPLY TO THE SYSTEM ........................................................................................................39
8.5 FEEDWATER SUPPLY TO GENERATOR..............................................................................................40
8.6 HOTWELL POSITION .............................................................................................................................40
8.7 BOOSTERPUMP......................................................................................................................................41
8.8 PIPE SIZES ..............................................................................................................................................41
8.8.1.SAFETY VALVE OUTLET LINES.......................................................................................................41
8.8.2.SEPARATOR TRAP LINE ...................................................................................................................43
8.8.3.STEAM GENERATOR BLOWDOWN LINE .......................................................................................43
8.8.4.BLOWDOWN TANK VENT LINE .......................................................................................................44
8.8.5.STEAM SUPPLY TO INSTALLATION................................................................................................44
TABEL 8.8- LINE SIZES FOR SINGLE INSTALLATION WITH HORIZONTAL HOTWELL ...................47
TABEL 8.9- LINE SIZES FOR SINGLE INSTALLATION WITH VERTICAL HOTWELL(E-10/E-50) ......48
TABEL 8.10- LINE SIZES FOR SINGLE INSTALLATION WITH V-- HOTWELL(E(SE)-60/E(SE)-100) .49
FIG.8.1A-DIMENSIONS H HOTWELL 200/350/800 L ( HE-9083-A ) .......................................................52
FIG.8.1B-ACCESSORIES H. HOTWELL 200/350/800 L ( HE-9084 A ) ...................................................53
FIG.8.2A-DIMENSIONS H. HOTWELL 13500/2000/3000/4000/6000 L. ( HE-9085-A )..........................54
FIG.8.2B-ACCESSORIES H. HOTWELL 13500/2000/3000/4000/6000 L. ( HE-9086-A ) ........................55
FIG.8.3A-DIMENSIONS H.HOTWELL WITH LEVEL CONTROLL 200/350/800 L. ( HE-9049-A ) ......56
FIG.8.3B-ACCESSORIES H. HOTWELL WITH LEVEL CONTROLL 200/350/800 L ( HE-9050-A ) ......57
FIG.8.4A-DIMENSOINS H. HOTWELL WITH L.C. 13500/2000/3000/4000/6000 L ( HE-9051-A ) .......58
FIG.8.4B-ACCESSORIES H. HOTWELL WITH L.C.L 13500/2000/3000/4000/6000 L ( HE-9052-A ) .....59
FIG.8.5A-VERTCAL HOTWELL ( E-10/15/20/26 ) D=320-SINGLE INSTALLATION ( 0160655 ) .......60
FIG.8.5B-VERTCAL HOTWELL ( E-10/15/20/26 ) D=320-SINGLE INSTALLATION ( 0160655 ) .......61
FIG.8.6A-VERTICAL HOTWELL ( E-40/100 ) D=500-SINGLE INSTALLATION ( 0160651 ) ..............62
FIG.8.6B-VERTICAL HOTWELL ( E-40/100 ) D=500-SINGLE INSTALLATION ( 0160651 ) ...............63
FIG.8.7A-VERTICAL HOTWELL ( SE-80 E-100/125 ) D=800- SINGLE INSTALLATION ( UB-80164 ) 64
FIG.8.7B-VERTICAL HOTWELL ( SE-80 E-100/125 ) D=800- SINGLE INSTALLATION ( UB-80164 ) 65
FIG.8.8 -BASIC FLOW DIAGRAM EOG-10/15 V--HOTWELL- SINGLE INSTALLATION ( HE-6540 ) 66
FIG.8.9 A-BASIC FLOW DIAGRAM –EOG-10/25 SEOG-40/50 V--HOTWELL 1 GEN.. ( HE-6529 ) ...67
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FIG.8.9 B-BASIC FLOW DIAGRAM –EOG-10/25 SEOG-40/50 V--HOTWELL 1 GEN. ( HE-6529 ) ....68
FIG.8.10-BASIC FLOW DIAGRAM EG-20/26 EO-20 V—HOTWELL 1 GEN. ( HE-6538 ) ..................69
FIG.8.11-BASIC FLOW DIAGRAM EOG-40 EG-50 V—HOTWELL 1 GEN. ( HE-6536 ) ....................70
FIG.8.12A-BASIC FLOW DIAGRAM EOG-60/100 V—HOTWELL 1 GEN. ( HE-6530 ) .........................71
FIG.8.12B-BASIC FLOW DIAGRAM (S)EOG-60/100 V—HOTWELL 1 GEN. ( HE-6530 ) ...................72
FIG.8.13A-BASIC FLOW DIAGRAM EOG-10/26 (S)EOG-40/50 H--HOTWELL 1 GEN. ( HE-6526 ) .73
FIG.8.13B-BASIC FLOW DIAGRAM EOG-10/26 (S)EOG-40/50 H--HOTWELL 1 GEN. ( HE-6526 ) .74
FIG.8.14A-BASIC FLOW DIAGRAM (S)EOG-60/185 H--HOTWELL 1 GEN. ( HE-6527 ) ..................75
FIG.8.14B-BASIC FLOW DIAGRAM (S)EOG-60/185 H--HOTWELL 1 GEN. ( HE-6527 ) ..................76
FIG.8.15A-BASIC FLOW DIAGRAM (S)EOG-154/604 H--HOTWELL 1 GEN. ( HE-6528 ) ................77
FIG.8.15B-BASIC FLOW DIAGRAM (S)EOG-154/604 H--HOTWELL 1 GEN. ( HE-6528 ) ................78
FIG.8.16A-BASIC FLOW DIAGRAM E-10/50 V--HOTWELL 1 GEN. BLOW DOWN TANK PM60 ( HE-
6535 ).............................................................................................................................................................79
FIG.8.16B-BASIC FLOW DIAGRAM E-10/50 V--HOTWELL – 1 GEN. BLOW DOWN TANK PM60 (
HE-6535 ) ......................................................................................................................................................80
GRAF.8.1 : DET. OF HOTWELL VOLUME IN RELATION TO CONDENSATE RETURN AND BOILER
CAPACITY ( 0-1000 L ) ...............................................................................................................................81
GRAF.8.2 : DET. OF HOTWELL VOLUME IN RELATION TO CONDENSATE RETURN AND BOILER
CAPACITY ( 0-6000 L ) ...............................................................................................................................82
END Table of contents
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INSTALLATION MANUAL
INTRODUCTION
1.Installation instructions
These instructions must be adhered to in order to achieve trouble free operation and to keep maintenance cost
as low as possible.
The installation instructions wich are to be followed are shown on the next page.
Before start-up our service engineer will check the installation by means of an installation checklist.
In case of serious deviation from the instructions which are applicable for the specific installation, the steam
generator and/or installation components delivered by Clayton are no longer covered by our warranty.
We therefore advise to follow the installation instructions correctly and to use the installation checklist
(chapter 9) before start-up is considered.
Which installation instructions are valid for your application?
A. For Clayton equipment
1. Always
- General information : CHAPTER 1

- Open system : CHAPTER 1
- Semi closed system : CHAPTER 1
- Feedwater treatment instructions : CHAPTER 2
- Flow diagram en system description (1) (2) : CHAPTER 8
- Principal wring diagram for equipment to be installed : CHAPTER 8
2. Following instructions may also be valid, depending on the application :
-Supplemental instructions for multiple boiler applications : CHAPTER 3

-Supplemental instructions for automatic start : CHAPTER 4
-Supplemental instructions for heavy oil firing : CHAPTER 5
-Supplemental instructions for shipboard installation : CHAPTER 6
-Supplemental instructions for hot water systems : CHAPTER 7
3. Installation check list
B. Other installation components : see specific instructions.
(1) : Flow diagrams and/or wiring diagrams made by the customer should be made available for
verification by the Clayton office to assure correct installation of the Clayton equipment.
(2) : Part 8 covers typical standard installations. Special applications should be verified by the Clayton
office.
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CHAPTER 1 : INTRODUCTION
1.1 APPLICATION OF THE INSTALLATION MANUALS
The instructions in the manuals general information are always valid and are completed with the instructions
open or semi-closed system.
Depending on the specific application, these basic instructions are extended with the appropriate
supplemental instructions.
At the end of each section in the manuals, you will find a number of figures and tables having the same
prefix numbers as the section.
Example : fig. 6.1. belongs to section VI.
END Chapter .1
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CHAPTER 2 : POSTION OF GENERATOR AND ACCESSORIES
2.1 IMPORTANCE
Protect your investment by following these instructions. Carefull consideration for fuel-, water-, blowdown,
electrical, venting-, and stack arrangements should be made when locating the unit.
2.2 LOCAL RULES
Regulations vary from one area to another regarding such matters as stack installation, blowdown tanks,
water and gas supply, materials to be used, official approvals, etc ....
2.3 FLOOR DRAIN
Underneath the generator (oil fired and oil/gas combination units only) a floor drain should be provided to
carry off the water used for cleaning purpose. See fig 2.1.
2.4 ACCESS TO THE STEAM GENERATOR
Provide enough access to the steam generator for proper maintenance. Keep piping out of working area, as
shown in fig 2.2. .
In general, 1 m free space around the unit is sufficient. Burner removal is done underneath the heating
section.
Attention has to be made not to run pipes in this area. See also fig. 2.2.
2.5 LEG MOUNTING
Attach the legs delivered loose with the steam generator and if possible bold the steam generator to the floor,
using shims if necessary to prevent distortion of the generator frame. The standard legs allow sufficient
space for burner removal, when the generator is mounted on a flat floor. However, when the steam generator
is placed in a drip tray, special care must be taken to make burner accessible and to make burner removal
possible.
2.6 HEATING SECTION DIMENSIONS AND WEIGHT
For removal or repair of the heating section, provision must be made to enable the evacuation of the heating
section out of the boiler room.
Therefore, sufficient space and lifting equipment is necessary.
For dimensions and weight of the heating sections : see table 2.1. on page 6.
For heating section removal height : see plan installation dimension of the steam generator.
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STEAM HEATING ECONOMISE APPROX. APPROX.

GENERATOR SECTION R HEATING ECONOMISE
MODEL DIMENSIONS DIMENSIONS SECTION R WEIGHT
WEIGHT
(diam.D(mm) x H (diam. D (mm) (kg) (kg)

(mm)) x
H (mm))
E-10/15 518 x 1166 _ 174 _
E-20/26
(S)E-40/50 581 x 1365 559 x 260 255 130
(S)E-60 697 x 1024 695 x 375 292 190
SE-80 890 x 1160 900 x 480 600 300
(S)E-100
(S)E-125
(S)E-150 1002 x1391 1010 x 472 767 400
(S)E-185
(S)E-154 1336 x 1700 1250 x 575 1320 500
(S)E-204
(S)E-254
(S)E-304/354 1336 x 2025 1250 x 575 1875 500
(S)E-404/504 1436 x 2316 1492 x 749 3000 800
(S)E 504HO/604 1436 x 2932 1492 x 749 3304 800
Table 2.1. : Dimensions and weight of heating section and economiser.
REMARK : As from generator SE-404 the economizer is delivered loose and has to be
mounted on site. See mounting instructions
2.7 HOTWELLS AND CONDENSATE RECEIVERS
Provide enough free area around hotwells and receivers to ensure easy lagging, operation and inspection.
Access to receivers must be large enough to read measuring gauges and to check or replace operating
equipment in the vicinity of a hotwell or receiver. ; see fig. 2.4..
Manholes should have free access.
Ladders should be fitted to reach the hotwell or receiver operation deck. (check with local codes).
END Chapter .2
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Fig.2.1-Floor drain
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Fig.2.2-Free working area to be respected around steam generator
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Fig. 2.3-Installation above ‘’ Drip tray ‘’
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Fig. 2.4-Free area around receivers
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INSTALLATION MANUAL
CHAPTER 3 : FEEDWATERTREATMENT
Feedwatertreatment is entirely the responsibility of the user.

The Clayton steam generator is a once trough boiler requiring continuous chemical water treatment. The
treatment and the care of the steam generator are beyond the control of the manufacturer.
Provision for water treatment should be planned when the generator is purchased. Suitable water treatment
equipment should be installed before the generator is put into service.
ADEQUATE WATER TREATMENT MUST BE USED FROM THE TIME THE GENERATOR IS FIRST
OPERATED.
The general installation instructions of PART I are to be followed to make proper water treatment possible.
FOR WATER TREATMENT INSTRUCTIONS :

SEE CLAYTON FEEDWATER TREATMENT MANUAL : OPERATING
INSTRUCTIONS
END Chapter .3
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INSTALLATION MANUAL
CHAPTER 4 : STACK AND VENTING ARRANGEMENTS
DRAFT REQUIREMENT FOR ALL E-MODELS : 0 TO -6MM WC AT

STACK CONNECTION
4.1 IMPORTANCE
Proper stack and venting arrangements are of prime importance for the efficient operation of the steam
generator.
The following instructions must be respected to assure trouble free operation of the steam generator.
4.2 STACK ARRANGEMENTS, LOCAL RULES
Stack arrangements have to comply with local rules and regulations regarding materials, installation,
pollution, maintenance, etc. ... .
4.3 REMOVABLE FLUE PIPE
Provide a removable spool piece in exhaust gas duct immediately above the steam generator to facilitate
removal of the heating coil. See fig. 4.1.
4.4 FREE STANDING STACK
Main stack outlet should not be located directly above the steam generator. A free standing stack is
recommended. The steam generator stack outlet is connected to the main stack by mains of a flue pipe,
which is sloped approx. 10 degrees towards the main stack. See fig. 4.2. .
4.5 MOVEMENT AND FORCES
No forces should be applied to the steam generator caused by weight, movement due to wind forces or due to
dilatation.
Therefore, the necessary expansion joints and/or stack anchoring equipment must be used.
4.6 BENDS
Avoid sharp bends in the flue pipes which cause too much local flow resistance and/or possible soot
accumulation.
4.7 INSPECTION COVER
Install an inspection cover in the flue pipe immediately above the steam generator stack outlet. This cover is
opened for visual inspection of the heating coil top and for cleaning of the heating coil with a water hose if
necessary
Minimum cover dimensions: diameter 400 mm. or 400x400mm.
For steam generator models E-10/15, E- 20/26, E/SE- 40, E/SE- 50 and E/SE-60 the removable pipe section
as described in 4.3. is considered as a means of inspection for the heating coil so that the inspection cover in
the flue pipe can be deleted.
As from model SE-80 install an inspection cover in the flue pipe.
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4.8 STACK TEMPERATURE INDICATION AND ALARM
A stack temperature indicator is recommended.

The measurement of the stack temperature should take place as close as possible to the coil outlet.
For light oil and heavy oil fired steam generators, a combination of stack temperature indicator and switch is
recommended.
The temperature switch gives alarm if exhaust gas temperature exceeds the normal maximum values, which
are registered during start-up.
Too high temperature indicates that soot-blowing or coil washing must be executed to assure further save
operating of the unit.
4.9 DRAFT REQUIREMENTS
Pressure at the steam generator stack outlet connection in operation should be between 0 and -6 mm water
column. (negative pressure = below atmospheric pressure)
In general, the max. draft of 6mm WC is exceeded when the stack is higher than 10 m, measured vertically
at the steam generator outlet connection.
In these cases , a draft regulator should be installed. see fig. 4.2.
The draft regulator should be installed as close as possible to the steam generator.
See fig. 4.2.
4.10 RAIN CAP
A rain cap may be installed, if allowed by local rules. See fig 4.3. . This cap should not restrict stack section.
If a rain cap is not installed because of local regulations, rain entering the stack must be drained
continuously. Contact between water and soot must be avoided as far as possible to avoid corrosion.
Horizontal flue pipes must run trough the main stack at least 50 mm to avoid flow back of rain or condensate
towards the steam generator.
4.11 STACK MUFFLER
In case a stack muffler is installed, the makers installation instructions must be respected.
4.12 STACK INSULATION
Stack should be insulated. Insulation must be able to resist a temperature of 500 degrees C and must comply
with the local codes. (+/- 50mm)
4.13 SHUT DOWN PERIODS, COLD AREAS
During shut down periods in cold areas, it may be necessary to close stack connection as a freezing
precaution, if this is allowed by local rules. In this case, interlocks with the steam generator are necessary so
that firing of the steam generator is only possible when the stack is fully open.
The chosen solution must be checked with the local regulations and rules.
4.14 STACK ADAPTER
If a stack adapter is supplied with the steam generator, the adapter must be mounted directly on the steam
generator with the inner cone pointed upwards. See fig. 4.1.
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4.15 CONDENSATION, GAS FIRED UNITS
For oil and gas fired units, condensation water in the stack cannot be avoided during cold start-up.
Therefore, the free standing stack must be drained continuously. To avoid water running towards the steam
generator, a water collector should be installed immediately above the steam generator. See fig. 4.1.
It must be checked with local regulations how these continuous drains must be connected with the general
draining system.
4.16 ECONOMISER
As an option, all steam generator E-models (except E-10/15 en E-20/26) can be equipped with an economiser
section.
It is good practice to incorporate this feature in the stack planning for the standard E-model, so that the
fitting of an economiser at a later date requires a minimum of modifications.
4.17 VENTING OF BOILER ROOM
LOCAL CODES MUST BE RESPECTED.
• If generator is installed in a closed room, ventilation openings must be provided.

• Two vent openings are required, one for fresh air supply, one for warm air outlet.
• The fresh air supply openings must have a free intake area at least twice the area of the exhaust stack.
• Warm air is carried off trough an opening near the ceiling of the boiler room.
• Cross flow of air ventilation in the boiler room is prefered.
• The free area of the outlet opening should be 25% of the exhaust gas stack areas.
• When several boilers are installed in the same room, ventilation openings must be increased in area
proportionally.
• Avoid freezing conditions in the boiler room in case of shutdown of the boiler(s)
END Chapter .4
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Fig. 4.1-Ways of connecting stack to a Clayton steam generator
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Fig. 4.2-Examples of stack arrangement
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Fig. 4.3-Rain caps ( check with local codes )
Generator A B C D E F G H I J
E-10/15 195 210 295 208 30 75 135 195 75 60
E-20/26 195 210 295 208 30 75 135 195 75 60
E-40/50 295 315 445 310 45 110 200 290 110 91
E/SE-60 360 385 545 385 55 135 245 355 135 110
SE-80 440 470 665 460 65 165 300 435 165 135
E/SE-100/125 440 470 665 460 65 165 300 435 165 135
E/SE-150/185 530 565 800 565 80 200 360 520 200 160
E/SE-154/204 530 565 800 565 80 200 360 520 200 160
E/SE-254 635 680 960 715 95 240 430 625 240 190
E/SE-304/354 635 680 960 715 95 240 430 625 240 190
E/SE-404/505/604 740 790 1120 810 110 280 505 730 280 225
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INSTALLATION MANUAL
CHAPTER 5 : PIPING
5.1 GENERAL
Furnish unions and flanges at all pipe connections close to the steam generator and other equipment.
Galvanised piping may not be used, except for cold water lines (temp. lower than 40 degr. C) and if local
regulations allow the use of it.
Use steel pipes for all steam, condensate and feedwater lines.
5.2 STEAM DISCHARGE VALVE
A steam discharge valve (customer furnished) should be installed at the steam generator steam outlet within
reach of the operator. USE A GATE OR GLOBE VALVE FOR THIS PURPOSE.
5.3 STEAM TRAP RETURN LINE
This line returns the excess water from the steam generator separator back to the hotwell (open system) or
back to the return receiver (semi-closed system).
This line must be installed in such a way that it is entirely below the connection of this line on the hotwell or
return receiver.
No check valve may be installed in this line neither for open nor for semi-closed system.
Line size: see OPEN SYSTEM or SEMI-CLOSED SYSTEM.
ATTENTION: LINE SIZE IS AT LEAST ONE SIZE LARGER THAN STEAM TRAP CONNECTION.
5.4 BLOWDOWN LINE
This line returns blowdown from the steam generator to the blowdown tank, before being discharged to the
sewer.
Line size: see OPEN SYSTEM or SEMI-CLOSED system.
5.5 BLOWDOWN TANK
See fig. 5.1.

A blowdown tank is installed to :
- evacuate flash steam from the blowdown water
- cool down the blowdown water before it enters the drain.
Local regulations vary appreciably on the use of and requirments for blowdown tanks. Check with your
local authority.
It is possible that a cooling for the blowdown tank drain must be installed to limit the temperature of the
water going to the sewer.
Blowdown tanks can be delivered by Clayton : see fig. 5.1.
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INSTALLATION MANUAL
5.6 BACK PRESSURE REGULATOR
The installation of a back pressure regulator is recommended.

At boiler start it assures quick pressure rise so that the steam trap will function at normal rate.
During operation it prevents sudden pressure drop in the unit due to sudden load increase.
The back pressure regulator must be fitted on the steam generator as shown in fig 5.2. Sizes : see fig. 5.3.
Install the back pressure regulator as close as possible to the steam generator steam outlet, respecting a
maximum horizontal distance of 1m.
The pipe between the steam discharge valve and the BPR should rise towards the BPR.
The pipe from the back pressure regulator to the steal header should have a slope downwards of at least
5mm/m. See fig. 5.2.A.
5.7 STEAM SAFETY VALVES
Pipe discharge of safety valves to a suitable vent.

Preferably use separate discharge lines, the same size as the safety valve outlet.
LOCAL CODES HAVE TO BE RESPECTED.
Provide safety valve discharge lines with a 12mm diameter drain.

Do not position safety valve(s) blow off in a direction that may cause injury to personnel or damage to
equipment.
The discharge lines must be well supported. Forces on the safety valve body, caused by piping, must be
avoided. See also fig. 5.4.
5.8 STEAMHEADERS
Steam pipe connections to or from headers must be made on top of the header.
See fig. 5.5.
Trap all steam headers to maintain dry steam.
Steamtraps on headers must be able to evacuate maximum condensation rate in the steam pipes during cold
start up of the installation.
Provide manual drain valves on all steam headers.
AVOID VACUUM CONDITIONS ON STEAMHEADERS BY INSTALLING VACUUM BREAKERS.
5.9 TEST LINE
A test line to atmosphere, one size smaller than steam generator steam outlet, must be installed downstream
of the back pressure regulator.
This line is used to blow off steam to atmosphere for testing purposes of the generator, so that generated
steam quantity is independent of the actual steam demand of the installation during testing.
If test line is longer than 15 m, including 2 m for each elbow in the line, use same line size as steam
generator steam outlet.
It may be necessary to install a noise muffler on the outlet of this line.
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INSTALLATION MANUAL
5.10 STEAM AND CONDENSATE LINES
Branches to steam users should always be connected at the top of the steam supply line.
Condensate of steam using equipment should have a slope of 3 to 5mm/m towards draining points, equipped
with steam traps.
Steam traps have to be installed on all lowest points of the steam piping.
Steam and condensate lines should be well supported and at the same time be allowed for thermal expansion.
In case expansion joints or flexible joints are used, carefully follow the makers installation instructions
5.11 PROTECTION, SHUTDOWN
All water-, steam- and condensate lines have to be protected against freezing conditions during shutdown
periods.
Therefore it must be made possible to drain the lines completely.
5.12 SOOTBLOW LINES
Provide the sootblowlines with a drain, as low as possible and before the sootblow valves.
5.13 BLOW DOWN TANK
The water from de steam generator’s manual and automatic blowdown is collected in the blowdown tank,
where it flashes and eventually can be cooled down to 40°C.
It is possible to provide additional cooling by connecting a cooling water line to the blowdown tank outlet
Temperature sensor has to be installed in blowdown tank below point K ( fig. 5.1 )
The installation of the blowdown tank is subject to local regulations and/or requirements
Technical specifications.
Part number. 135286 135287 135288 135301

E-
Model steam E-201/126/154/185
10/15/20/26 E-80/100/125 E-404/504/604
generator E-204/254/304/354
E-40/50/60
A ( mm ) 305 305 475 750

B ( mm ) 870 1255 1360 1710
C ( mm ) 456 646 684 915
D ( mm ) 558 939 957 1375
E ( mm ) 120 120 175 280
F diam. ( mm ) 15 15 15 15
G ( mm ) 197 197 273,5 425
H / inlet 1” 1” 11/4” 2”
NW80 NW80 NW100 NW150
I / vent
DIN2576-B DIN2576-B DIN2576-B DIN2635
J / clean out 2” 2” 2” 2”
K ( to sewer ) 11/2” 11/2” 2” 2”
Weight ( kg ) 35 50 85 370
END Chapter .5
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Fig.5.1 :Blowdown tank
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Fig. 5.2-Installation of Back Pressure Regulator
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Fig. 5.2a-Piping arrangement – Back Pressure Regulator
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Fig. 5.3-Back Pressure Regulator
Part number. 1 9 4 0 3 4 194035 194036 194037 194038 194039 194040 194041

E-254
Steam generator E-10 E-20 E-40/50 SE-80 E-125 E-185 E-404
E-304 E-604
type E-15 E-26 E-60 E-100 E-154 E-204 E-354 E-504
Max.steam-
370 570 910 1500 2280 3650 5700 8650 1270
Capacity ( kg/hr )
Regulating range 4,5 – 10bar
Flange DN ( mm ) 25 32 40 50 65 80 100 125 150
Kvs ( m³/hr ) 8 125 20 32 50 80 125 190 280
H ( mm ) 390 445 445 445 575 575 590 900 1000
H1 ( mm ) 115 130 135 150 165 175 185 460 590
L ( mm ) 160 180 200 230 290 310 350 400 480
D ( mm ) 170 170 170 170 170 170 170
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Fig. 5.4-Safety valve outlet connection
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Fig.5.5-Example steam line Fig. 5.6-Example return condensate line
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CHAPTER 6 : FUEL SYSTEMS
6.1 GAS FIRED STEAM GENERATORS
These generators are equipped with burners to burn natural gas, unless otherwise specified. Gas pressure
regulation is essential for main and pilot burner.
Regulated gas pressure at unit gas inlet must be as follows :
REGULATED GAS PRESSURE GAS CONSUMPTION

MODEL FLOW
(mbar) (normal m³/hr)
MODEL VALUE
E-10 20 ± 10% 0 13
E-15 20 ± 10% 0 21
E-20 20 ± 10% 0 25
E-26 20 ± 10% 0 33
E-40 20 ± 10% 25 50
E-50 20 ± 10% 31 62
E-60 20 ± 10% 38 76
SE-80 20 ± 10% 46 92
E-100 20 ± 10% 62 124
E-125 20 ± 10% 79 158
E-185 20 ± 10% 117 234
E-154 95 ± 10% 61 182
E-154* 80 ± 10% 61 182
E-204 130 ± 10% 63 249
E-204* 90 ± 10% 63 249
E-254 101 ± 10% 64 318
E-254* 90 ± 10% 64 318
E-304 130 ± 10% 75 376
E-304* 90 ± 10% 75 376
E-354 159 ± 10% 89 445
E-354* 90 ± 10% 89 445
E-404 200 ± 10% 100 503
E-404* 90 ± 10% 100 503
E-504 300 ± 10% 129 643
E-504* 100 ± 10% 129 643
E-604 350 ± 10% 148 739
Tabel 6.1. : Regulated gas pressure flow and gas consumption ( LHV : 31.666kj/nm³ )
* Generator with low gas pressure train
Above table is based on natural gas having a low heat value of 31500kJ/nm³.
Gas supply line must be of adequate size for intermittent service without sag in pressure.
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INSTALLATION MANUAL
Minimum pressure at burner start (sag) may be 50% of regulated pressure for all models.
Maximum pressure at burner shut-down (lock-up) may be 100% of regulated pressure for models E-10 up to
E-150, E-154 (step), E-185 (step), E-204(step).
For models E-154 up to E-604 the maximum pressure at burner shut-down is limited to 500mbar
The maximum gas supply pressure before gas pressure is regulated is limited to 200mbar for models E-10 up
to E-150, E-154 (step), E-185 (step), E-204 (step) and to 500 mbar for models E-154 (modulating) up to E-
604 (modulating).
If this value is exceeded, the pressure downstream of the gas pressure regulator must be limited by using a
safety cut-off valve.
LOCAL RULES MUST BE RESPECTED - CHECK WITH YOUR LOCAL AUTHORITY.
Vents from bleed valves and regulators must be piped to a non-hazardous area
CHECK WITH YOUR LOCAL AUTHORITY
The oil-fired steam generators models from E-154 up to E-604 for land application are equipped with a gas
pilot.
If the pilot gas is coming from an external source (vb.:****), the pressure must be
regulated to 200-400 mbar with a maximum safety cut-off at 500 mbar.
IN GENERAL
If gas supply pressure is higher than 500 m bar, gas pressure regulation should be done with 2 regulators.One
pressure reducing valve with automatic shut-off valve, set point of the shut-off valve at 500 mbar or lower
This set is than followed by the actual burner pressure regulator.
Both regulators can be supplied by Clayton, please contact factory
An intermediate pressure relief valve avoids acctiviation of safety shut-off valve during stand-still periods
- Install a gas shut-off valve and a gas filter upstream of the gas pressure regulator.
- Provide a gas pressure gauge (or measuring point) upstream of the gas pressure regulator.
- Respect a minimum distance of 2.5m between gas pressure regulator and gas inlet connection on the
steam generator.
- Install a gas flow meter for each steam generator.
- For typical gas equipment installation see fig. 6.1. and fig. 6.2.
- CHECK WITH YOUR LOCAL AUTHORITY FOR INSTALLATION OF GAS EQUIPMENT.
6.2 OIL FIRED STEAM GENERATORS
In the steam generators gamma, there are two different types to burn oil.
Steam generators suited for burning light oil and generators for burning heavy oil.
The light oil fired steam generators with fuel specifications as in table 6.2.will be discussed behind
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INSTALLATION MANUAL
PREFERED
LIMIT
RANGE
Gravity,degrees API at 15°C 30 - 48 26 min
Gravity, specific at 15°C 0.84 - 0.87 0.80 - 0.90
Flash point, Pensky-Martens, °C 71 - 82 54 min - 110 min
Viscosity, SSU at 100°F 35 - 45 45 max
Viscosity, kinetic, at 120°C 4 - 9.5 9.5 max
Pour point°C -17.8 -9.4 max
Sediment and water, % by volume none 0.10 max
Sulfur, % 0.5 0.8 max
Carbon residu 0.02 0.25 max
ASTM Distillation range
Initial boiling point, °C 177 - 190.5 204 max
90% recovery, °C 316 - 329 357 max
Endpoint, °C 357 - 385 390.5 max
HIGH HEAT LOW HEAT
VALUE VALUE
Caloric value 42.700 kj/kg 0,86 kg/l
Table 6.2. :Light fuel oil specifications : Clayton steam generators with standard burner equipment
Heavy oil fired steam generators are described in detail in the installation instructions for heavy oil.
Fuel storage and transfer arrangements are shown in fig. 6.3. and 6.3a. .
Local rules must be respected for the installation of the fuel storage tank
The following pipe sizes are suitable for a maximum effective suction line length of 15m : see fig. 6.3. -
without transfer pump.
MODEL LEIDINGDIAMETER
E-10/15 en E-20/26 1/2”
E-40 en E-50 1/4”
E-60, SE-80, E-100, E-125 en E-185 3/8”
E-154, E-204, E-254, E-304, E-354, E-404, E-504, E-604 1/2”
Tabel 6.3. : Pipe sizes for a maximumeffective fuel suction line length of 15m
When longer fuel lines are unevitable a transfer pump should be installed. See fig. 6.3.A.
For single or multiple installations the transferpump should have a capacity, at least twice the maximum fuel
consumption of the burner.
The maximum inlet pressure of the generator fuel pump is 0.7 bar for models E-10/15 and E-20/26 and 10
bar for all other models.
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INSTALLATION MANUAL
Atomizing air
Atomizing air is regulated for the oil fired models : E-105, E-126, E-154, E-204, E-254, E-304, E-354, E-
404, E-504, E-604.
Following quantities and minimum air supply pressures are required :
QUANTITY MIN. INLET

MODEL
(normal m3/uur) PRESSURE (bar)
E-105 t/m E-154 38 5 bar
E-204 t/m E-254 27 5 bar
E-304 t/m E-354 32 5 bar
E-404 t/m E-604 40 5 bar
Table 6.4. : Quantity and minimum supply pressure for atomizing air
Maximum supply pressure is 10 bar. Steam generators equipped with air-an atomizing burner have an air
pressure regulator on the unit.
Atomizing air must be filtered and free of water.
END Chapter .6
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Fig. 6.1-Typical gas pressure regulator installation
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Fig. 6.2-Gas pressure regulator installation
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Fig. 6.3 & Fig. 6.3a-Typical fuel tank installation ( light fuel oil )
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INSTALLATION MANUAL
CHAPTER 7 : ELECTRICAL REQUIREMENTS
The electrical installation must comply with the LOCAL CODES.

The Clayton steam generators are designed to be connected to ONE of following types of power supply :
- 3 x 380 Volt, 50 Hz
- 3 x 220 Volt, 50 Hz
- 3 x 415 Volt, 50 Hz
- 3 x 440 Volt, 60 Hz.
The voltage must be clearly specified while ordering.

Always check steam generator identification plate before connecting to the power supply.
Power consumption for the different types of steam generators and accessory equipment is shown on pages
22 and 23.
The electrical installation for boiler and accessories should comply with the PRINCIPAL WIRING
DIAGRAM your installation (PART 8 of your instructions). On this wiring diagram, the basic functions and
interlocks are shown.
A fused disconnect switch for the steam generator should be located close to personnel door and preferably
within view from the steam generator location.
The fused disconnect switch is no standard Clayton delivery.
FOLLOWING LOCAL RULES AN ACOUSTIC ALARM MUST BE INSTALLED.
The Clayton control box is provided with the needed contact
ELECTRIC POWER SPECIFICATIONS FOR STANDARD CLAYTON EQUIPMENT
STEAM GENERATOR
TYPE MOTOR (kW) TYPE MOTOR (kW)
E-10/15 1.5 E/SE-185 11
E-20/26 2.25 E/SE-204 13
E-40/50 3.9 E/SE-254 18.5
E/SE-60 4 E/SE-304 22.5
SE-80 7.5 E/SE-404 37
E/SE-100 7.5 E/SE-504 52
E/SE-125 7.5 E/SE-604 52
E/SE-154 9.5
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INSTALLATION MANUAL
BOOSTERPUMP
TYPE VOLTAGE
PART NR POWER SUPPLY KW (1)
STEAMGENERATOR (V)
E-10/E-60 200350 220/380/415-50hz 0.37
E-80/E-345 200348 220/380/415-50hz 0.37
E-404/E-604 200349 220/380/415-50hz 0.37
LEVEL SWITCH HORIZONTAL HOTWELL

TYPE STEAMGENERATOR PART NR MAX. SWITCH CAPACITY
E-10/E-60 201171 220V-20W
E-80/E-204 201477 220V-20W
E-254/604 200738 220V-20W
SOLENOID VALVE VERTICAL

SOLENOID VALVE HORIZONTAL HOTWELL
HOTWELL
HOTWEL PART
POWER (1) PART NR POWER (1)
L (L) NR
water solenoid
200-800 190244 220V/50HZ 190244 220V/50HZ
valve
steam solenoid
1350-6000 201501 220V/50HZ 190148 220V/50HZ
valve
CHEMICAL PUMP
TYPE
PART NR POWER
STEAMGENERATOR
E-10/E-204 0099844 220V/50-60HZ
E-304/E-604 0099845 220V/50-60HZ
HEAVY OIL PRE-HEATING UNITS

TYPE
PART NR TYPE POWER (1)
STEAMGENERATOR
E-105/E-354 0160476 STEAM/ELECTRIC 220V-9 KW
0160477 STEAM/ELECTRIC 380V-9 KW
E-404/E-604 0160478 STEAM/ELECTRIC 220V-9 KW
0160479 STEAM/ELECTRIC 380V-9 KW
(1) These values are used for sizing of conductors, fuses and main switch. The electric motor on the
steam generator is protected by an overload relay on the unit.
Indicated power is shaft power of the motor.
END Chapter .7
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INSTALLATION MANUAL
CHAPTER 8 : OPEN SYSTEM
8.1 INTRODUCTION
In an open system, the installation condensate is returned to the atmospheric tank, called hotwell. The
hotwell also serves as feedwater tank for the steamgenerator. Make-up water for the system is added to the
hotwell, where it is preheated and treated with chemicals.
Principal flow diagram: see fig. 8.1. and list of components fig 8.1a.
Detailed flow diagram: see fig. 8.2.en pipe sizes table 8.7 for horizontal hotwells and fig. 8.3.,
8.4.and pipe sizes 8.8.,8.9 for vertical hotwells.
Up to about 50% condensate recovery, this system warrants consideration; in case of higher condensate
recovery, a semi-closed system should be considered.
8.2 HOTWELL
A Clayton designed vertical or horizontal hotwell should be used for open systems to obtain a good
functioning system and to make a proper water treatment possible.
The vertical hotwells can be used for the smaller generator types (up to (S)E-100).
To determine the correct size for horizontal hotwells see pages 5,6,7 and graph 8.1., 8.2. and table 8.7.
8.3 CONNECTIONS AND ACCESSORIES FOR THE HOTWELL
Accessories and connections are shown on fig 8.5. (p2,p4) horizontal hotwells and fig. 8.6.,8.7. for vertical
hotwells
Each Clayton hotwell must be equipped with the following:

8.3.1.Vent line
This line is necessary to keep atmospheric pressure on the hotwell under all circumstances and to evacuate
gasses from the water (O2, CO2). Pressure build-up in this line should never exceed 0.4 bar. This is achieved
when the vent line size has the same size as the hotwell vent connection.
The hotwell standard vent connection is found in fig 8.5.a, 8.5.b the hotwell, which corresponds with the
application: see table 8.5.
The vent line should go straight upwards with a minimum of bends. Pockets in this line are not allowed.
Free outlet of this line may not be obstructed.
8.3.2.Level switch and water supply to hotwell
The level switch controls the solenoid valve in the make-up water line, in order to maintain proper level in
the hotwell. The solenoid valve in the make -up water line must be installed at least 0.5 m lower than the
water inlet connection on the hotwell to protect the solenoid valve against high temperature.
8.3.3.Thermostat and steam supply valve.
In order to achieve proper feed water for the steam generator(s), it is necessary to keep the water in the
hotwell at a temperature of 90-95°C. In this way, CO2 dissolved in the condensate and oxygen (O2) coming
from the make-up water will be removed by thermal degassing.
Also, chemical reaction between the water in the hotwell and added chemicals is accelerated at high
temperature.
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To maintain water temperature, steam is injected in the hotwell, controlled by a thermostatic valve for
horizontal hotwells and by an electrical valve for vertical hotwells. For this purpose, steam is taken
immediately after the steam generator steam outlet. The thermostatic valve should be installed as close as
possible to the hotwell and must be positioned above hotwell center. The steam line downstream of the
thermostatic valve enters the steam generator condensate line on the top as shown in fig. 8.5a and 8.5.b. A
check valve must be installed downstream of the thermostatic valve.
8.3.4. Level gauge
To check the water level in the hotwell.
8.3.5. Thermometer
To check feedwater temperature.
8.3.6. Insulation
After installation, hotwell should be insulated. (Thickness of insulation: +/-50mm). Resistant to 100 degr C.
8.3.7. Overflow
The hotwell must be equipped with a syphontype overflow line. This line must be kept inside the boiler
room to prevent freezing of the water in it. The syphon prevents flash-steam from entering the boiler room.
At the bottom of the siphon a rotary ball valve or plugged socket should be installed to enable cleaning of the
siphon.
8.3.8. Inducer-tubes
The hotwell must be equipped with Clayton-designed inducer-tubes. These are separate items which are
screwed or flanged to the hotwell see fig. 8.5.a,8.5.b. The injection holes of the inducer tubes should be
installed horizontal.
Use unions or flanges in the piping to allow for the inducer-tubes removal.
The horizontal hotwells 200 l, 350 l, 800 l, have two connections for fitting 2 inducer-tubes see fig. 8.5.a.:
- one for system condensate return
- one for steam generator steam trap return.
The horizontal hotwells 1350l, 2000l, 3000l, 4000l, have 3 connections for fitting a maximum of 3 inducer-
tubes: see fig. 8.5.b.:
- one for system condensate return.
- one for steam generator steam trap return.
- one for the steam trap return of a second steam generator.
The vertical hotwells have preassembled inducer tubes
System condensate and steam trap return from steam generator may not be joined in the pipe work and must
go to separate inducer-tubes in the hotwell.
The system and return condensate line must be provided with a check valve.
8.4 WATER SUPPLY TO THE SYSTEM
The water softener and chemical pump can be installed underneath the hotwell to obtain a compact
installation.
The inlet water pressure at the solenoid valve under flow conditions should be minimum 2bar, max 5 bar.
Water softener should be sized for maximum anticipated make-up water supply for the system. When the
steam generator is used 24HRS/24HRS, it is necessary to have a duplex or twin type water softener. If the
unit is not used continuously, and if a single body water softener is used, the water softener must be sized in
such a way that regeneration of the water softener can be done during shutdown periods of the steam
generator.
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INSTALLATION MANUAL
8.5 FEEDWATER SUPPLY TO GENERATOR
Feedwater line size = pump intake size on unit in following conditions:
- Feedwater line length max. 15 m

- max. 5 elbows (r=D - 90°)
- 1 ball valve and 1 strainer in the line
This corresponds with the line sizes as indicated on fig. 8.2. 8.3.,8.4. and 8.7., 8.8. ,8.9.
If these conditions are not met, the feedwater line must be increased in diameter. In this case, a maximum
equivalent length of 80 m may not be exceeded, using the following values:
Equivalent length =
actual pipe length

+ 2 m for each elbow (r=D - 90°)
+ 10 m for 1 strainer and 1 ball valve combination.
Insulation
The feedwater lines should be insulated with minimum 50mm Rockwool with aluminium.
8.6 HOTWELL POSITION
The minimum required vertical distance between centerline of the hotwell and the inlet of the Clayton pump
depends on the type of generator installed and is as follows:
MINIMUM REQUIRED DISTANCE

GENERATOR TYPE HOTWELL CENTER - PUMP CENTER
(standard legs assumed)
E-10/15 3m
E-20/26 3m
E-40/50,SE-40/50 3m
E-60,SE-60 3m
SE-80 4m
E-100/105,SE-100/105 4m
E-125/126,SE-125/126 5m
E-154,SE-154 5,5 m
E-185,SE-185 3,5 m
E-204,SE-204 5m
E-254,SE-254 5m
E-304,SE-304 5,5 m
E-354,SE-354 6m
E-404,SE-404 5m
E-504,SE-504 5,5 m
E-604 6m
Table 8.1. : Minimum vertical distance required between hotwell center and pump inlet
The hotwell must be installed so that the center is above top of steam generator heating coil
(including economizer if present or planned)
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8.7 BOOSTERPUMP
A booster pump is used to increase the pressure on the Clayton pump inlet in case the hotwell cannot be
mounted on the height as indicated in par. 8.6 and with vertical hotwell installation.
Following points have to be respected while determing the booster pump type and size:
1. Centrifugal type
2. Pump suitable for pumping water of 100°C with pH of 12.
3. Mechanical seal preferred.
4. Pump must have a low ‘‘NPSH-required’’ value, not exceeding 1.5m WC at max.
5. The booster pump should be sized to supply the steam generator pump with minimum head of 8 to
10 mCW. Min. capacity of the pump should be 50% higher than the steam generator max. steam
capacity.
6. The booster pump should be suitable for continuous operation.
7. Common practice in a normal boiler room installation would be to mount the pump on the floor
below the hotwell to allow as much suction head on the booster pump as possible, and to keep the
suction line as short as possible.
8. The line size from hotwell to booster pump must comply with NPSH required value.Line size from
booster pump to the generator can be the generator intake size.
9. When the generator feedwater comes from a deaerator, a booster pump should always be used. Mind
the higher temperature of the feedwater!
See also supplemental instructions for deaerator applications.
10. Pumps may be protected by a strainer permanently.
If a permanent strainer is deleted, the booster pump should be protected by a temporarily installed
screen in the suction line.
This screen is removed after cleaning of the piping during first start-up of the installation.
If a stand-by booster pump is installed, each pump must have its own intake strainer, non-return-
and-shut-off valves. This to ensure continuous operation of the steam generator plant.
11. A pressure gauge with shut-off valve should be installed on the outlet side of the booster pump.
12. From the booster pump outlet, a return line to the hotwell must be provided, equipped with a
regulating valve and a check valve. (10% of nominal flow)
8.8 PIPE SIZES
( see fig. 8.2., 8.3., 8.4. and table 8.7,8.8., 8.9 )

Indicated pipe sizes are given as a general basic reference. It may be necessary to adapt pipe sizes in
function of the local circumstances and rules.
Special attention has to be given for the sizing of the following lines:
8.8.1.Safety valve outlet lines
Pipe size should be at least equal to the safety valve outlet size on the steam generator. This is necessary to
avoid too high-pressure build up downstream of the safety valve which will reduce blow-off capacity.
For line sizes: see tables 8.7,8.8.8.9. - Indicated sizes are valid for steam generators having a design pressure
of 10 bar and up. Check with specific flow diagram and plan installation dimension for other application.
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INSTALLATION MANUAL
When the steam generator is equipped with two safety valves, it is recommended to install two separate
discharge lines.
IMPORTANT REMARKS:
For steam generators having a design pressure of 10 bar and up, the equivalent length of the safety valve
outlet line, being: actual length (m) + number of elbows (r=D) x 2 m, is limited to following values:
MODEL MAXIMAL EQUIVALENT LENGTH(m)

using size of 1 size larger
table 8.7.,8.8.,8.9.
length/diameter length/diameter
E-10/15 45 m - 1" 157 m - 1-1/4"
E-20/26 18 m - 1” 35 m - 1 1/4”
E-40 104 m - 1 1/2” 317 m - 2”
E-50 115m - 1 1/2” 351 m - 2”
E-60 46 m - 1 1/2” 141 m - 2”
SE-80 28 m - 1 1/2” 86 m - 2”
E100/SE100 17 m - 1 1/2” 51 m - 2”
E- 125 33 m - 2” 131 m - 2 1/2”
E-154/SE-154 23 m - 2” 91 m - 2 1/2”
E-185 15 m - 2” 60 m - 2 1/2”
E-204/SE-204 13m - 2” 47 m - 2 1/2”
E-254/SE-254 8 m - 2” 33 m - 2 1/2”
E-304/SE-304 6 m - 2” 21 m - 2 1/2”
E-354/SE-354 4 m - 2” 15 m - 2 1/2”
E-404/SE-404 12 m - 2 1/ 2” 36 m - 3 “
E-504/SE-504 12 m - 2 1/2” 23m - 3”
E-604 5 m - 2 1/2” 16 m - 3”
Table 8.2. : Maximal equivalent length
If the equivalent length is longer than the indicated value listed in the first column, the entire line size must
be increased by one pipe size respecting the new maximum equivalent length shown in the second column.
For the steam generators having a design pressure lower than 10 bar, we refer to the specific flow diagram
and supplemental instructions for the application.
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8.8.2.Separator trap line

a. Line size should be minimum the line size of table 8.7,8.8.,8.9.
Indicated line sizes are calculated for a return line with following characteristics:
- max. pipe length: 35 m

- max. 5 bends in the line
- 1 valve in the line
Which corresponds with an equivalent pipe length of 55m.

The equivalent length of the line is determined as:
Actual length of the line (m)

+ number of elbows (r=D, 90 °) x 2 m
+ number of valves in the line x 10 m
It is very important to keep the steam trap return line entirely beneath water level of the hotwell so that wet
shutdown of the steam generator is assured.
b. Because of the high pH value of the condensate, we strongly advise you not to install an inspection
cover. In consequence of this the cover will be very soon affected.
8.8.3.Steam generator blowdown line
Following steam generator blowdown valves are to be connected with the blowdown line:
- coil drain
- Separator drain
- automatic blowdown valve
Line size should be minimum the size indicated in tables 8.7.,8.9 giving following maximum equivalent
lengths:
The equivalent length is calculated as follows:
Equivalent length =
- pipe length (m)
- + 2 m for each elbow (r = D, 90°) or fitting in the line.
MAXIMAL ALLOWABLE
MODEL EQUIVALENT LENGTH.
(m)
using size of table 8.7a.,8.7b,8.9. 1 size larger
length/diameter length/diameter
E-10/15 134 m - 1” 300 m - 1 1/4”
E-20/26 35 m - 1” 59 m - 1 1/4”
E-40/50 100 m - 1 1/4” 304 m - 1 1/2”
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MAXIMAL ALLOWABLE
MODEL EQUIVALENT LENGTH.
(m)
E-60/SE60 57 m - 1 1/4” 175 m - 1 1/2”
SE-80 22 m - 1 1/2” 67 m - 2”
E-100/SE-100 22 m - 1 1/2” 67 m - 2”
E-125/SE-125 22 m - 1 1/2” 67 m - 2”
E-154/SE-154 11 m - 2” 41 m - 2 1/2”
E-185/SE-185 9 m - 1 1/2” 26 m - 2”
E-204/SE-204 11 m - 2” 41 m - 2 1/2”
E-254/SE-254 11 m - 2” 41 m - 2 1/2”
E-304/SE-304 6 m - 2” 21 m - 2 1/2”
E-354/SE-354 6 m - 2” 21 m - 2 1/2”
E-404/SE-404 6 m - 2” 13 m - 2 1/2”
E-504/SE-504 6 m - 2” 13 m - 2 1/2”
E-604/SE-604 4 m - 2” 15 m - 2 1/2”
Table 8.3. : Equivalent length - Blowdown line
8.8.4.Blowdown tank vent line

Pressure build-up in this line should be avoided.
This is achieved when the vent line size has the same size as the connection on the blowdown tank AND if
the equivalent length of the vent line is equal or inferior to 20 m, including 2 m for each elbow (r=d, 90°) or
fitting in the line.
8.8.5.Steam supply to installation
Normal velocity of steam in the supply line to the installation should be limited to ± 30 m/sec.
Long steam supply lines are subject to a detailed calculation to determine the pressure drop over the line.
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How to choose hotwell size
1. Horizontal hotwell
STEAM PRODUCTION(kg/h) Min. water content to fill up

GENERATOR TYPE
(1bar, 100°C supply water) steam generator (L)
E-10 160 50
E-15 258 50
E-20 313 100
E-26 407 100
E/SE-40 626 120
E/SE-50 782 120
E/SE-60 938 140
SE-80 1200 400
E/SE-100 1563 400
E/SE-125 1955 400
E/SE-185 2895 640
E/SE-154 2348 1110
E/SE-204 3130 1110
E/SE-254 3912 1110
E/SE-304 4695 1550
E/SE-354 5477 1550
E/SE-404 6259 2990
E/SE-504 7824 2990
E/SE-604 9388 3750
Table 8.5. : Horizontal hotwells
Instructions to follow while determining the size of the hotwell:
- The boiler must be completed filled up with treated water after boiler stop.
- For degassing, fresh water must remain in the hotwell for ca. 15 min.
1. Choose a steam generator out of table 8.5.

2. The type of steam generator corresponds with the amount off Boiler Horse Power.
3. At column 3 of table 8.5, you can find the required volume to fill the generator.
4. Find in graph 8.1, 8.2, depending on condensate recovery, the required volume of the hotwell.
5. The largest volume is the one used to choose correct hotwell.
6. In table 8.6, you can choose a hotwell with an equal or larger volume.
7. In case of a multiple boiler installation, you need to add the respective values.
Example
- 2 generators: 1 x E-304 and E-185

connected to one hotwell
25% steam condensate return
304+185 = 489 Boiler horse power
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- Choosing the hotwell column 3: E-304: 1550l

E-185: 640l
2190l
Graphic 8.2: 304 + 185 = 489 Boiler Horse power

For 489BHP you will find a volume between 2000 and 3000 liter.
Use a 3000 l hotwell.
Available hotwells:
1- Horizontal hotwells
Part number Total volume Trim & heater kit Inducertube

0135493 200 l 182398 Generator 135503
System 135503
0135494 350 l 182399 Generator 135504
System 135504
0136020 800 l 182400 Generator 135505
System 135505
0135922 1350 l 182401 Generator 135507
System 135507
0135839 2000 l 182401 Generator 135507
System 135507
0135840 3000 l 182401 Generator 135508
System 135508
0135945 4000 l 182401 Generator 135508
System 135508
0136588 6000 l 182401 Generator 135508
System 135508
Table 8.6. : Horizontal hotwells The real quantity is 50% of the indicated values
2-Vertical hotwells
GENERATOR TOTAL OPERATION PART NUMBER

TYPE VOLUME VOLUME
Minimum Maximum
E-10 182 136 144 160655
E-16 182 136 144 160655
E-20 182 136 144 160655
E-26 182 136 144 160655
E-40 421 322 341 160651
E-50 421 322 341 160651
E-60 421 322 341 160651
E-80 875 UB80164
E-100 875 UB80164
E-125 875 UB80164
Tabel 8.7. : Volume vertical Hotwells
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Tabel 8.8- Line sizes for single installation with horizontal hotwell
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Tabel 8.9- Line sizes for single installation with vertical hotwell(E-10/E-50)
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Tabel 8.10- Line sizes for single installation with V-- hotwell(E(SE)-60/E(SE)-100)
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Open system – basic diagram 1 single generator
LINE NR COMPONENT
hard water 1 A steam generator
soft water 2 B hotwell
feedwater 3 C watersoftener
steam 4 D chemical tank and pump
condensate generator 5 E back pressure regulator
vent 9
condensate installation 6
chemicals 7
automatic blowdown 8
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Symbols
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Fig.8.1a-Dimensions H Hotwell 200/350/800 L ( HE-9083-A )
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Fig.8.1b-Accessories H. Hotwell 200/350/800 L ( HE-9084 A )
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Fig.8.2a-Dimensions H. Hotwell 13500/2000/3000/4000/6000 L. ( HE-9085-A )
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Fig.8.2b-Accessories H. Hotwell 13500/2000/3000/4000/6000 L. ( HE-9086-A )
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Fig.8.3a-Dimensions H.Hotwell with Level Controll 200/350/800 L. ( HE-9049-A )
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Fig.8.3b-Accessories H. Hotwell with Level Controll 200/350/800 L ( HE-9050-A )
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Fig.8.4a-Dimensoins H. Hotwell with L.C. 13500/2000/3000/4000/6000 L ( HE-9051-A )
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Fig.8.4b-Accessories H. Hotwell with L.C.l 13500/2000/3000/4000/6000 L ( HE-9052-A )
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Fig.8.5a-Vertcal Hotwell ( E-10/15/20/26 ) D=320-single installation ( 0160655 )
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Fig.8.5b-Vertcal Hotwell ( E-10/15/20/26 ) D=320-single installation ( 0160655 )
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Fig.8.6a-Vertical Hotwell ( E-40/100 ) D=500-single installation ( 0160651 )
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Fig.8.6b-Vertical Hotwell ( E-40/100 ) D=500-single installation ( 0160651 )
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Fig.8.7a-Vertical Hotwell ( SE-80 E-100/125 ) D=800- single installation ( UB-80164 )
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Fig.8.7b-Vertical Hotwell ( SE-80 E-100/125 ) D=800- single installation ( UB-80164 )
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Fig.8.8 -Basic flow diagram EOG-10/15 V--Hotwell- single installation ( HE-6540 )
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Fig.8.9 a-Basic flow diagram –EOG-10/25 SEOG-40/50 V--Hotwell 1 gen.. ( HE-6529 )
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Fig.8.9 b-Basic flow diagram –EOG-10/25 SEOG-40/50 V--Hotwell 1 gen. ( HE-6529 )
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Fig.8.10-Basic Flow diagram EG-20/26 EO-20 V—Hotwell 1 gen. ( HE-6538 )
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Fig.8.11-Basic Flow diagram EOG-40 EG-50 V—Hotwell 1 gen. ( HE-6536 )
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Fig.8.12a-Basic Flow diagram EOG-60/100 V—Hotwell 1 gen. ( HE-6530 )
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Fig.8.12b-Basic Flow diagram (S)EOG-60/100 V—Hotwell 1 gen. ( HE-6530 )
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Fig.8.13a-Basic Flow diagram EOG-10/26 (S)EOG-40/50 H--Hotwell 1 gen. ( HE-6526 )
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Fig.8.13b-Basic Flow diagram EOG-10/26 (S)EOG-40/50 H--Hotwell 1 gen. ( HE-6526 )
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Fig.8.14a-Basic Flow diagram (S)EOG-60/185 H--Hotwell 1 gen. ( HE-6527 )
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Fig.8.14b-Basic Flow diagram (S)EOG-60/185 H--Hotwell 1 gen. ( HE-6527 )
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Fig.8.15a-Basic Flow diagram (S)EOG-154/604 H--Hotwell 1 gen. ( HE-6528 )
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Fig.8.15b-Basic Flow diagram (S)EOG-154/604 H--Hotwell 1 gen. ( HE-6528 )
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Fig.8.16a-Basic Flow diagram E-10/50 V--Hotwell 1 gen. blow down tank PM60 ( HE-6535 )
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Fig.8.16b-Basic Flow diagram E-10/50 V--Hotwell – 1 gen. Blow down tank PM60 ( HE-6535 )
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Graf.8.1 : Det. of hotwell volume in relation to condensate return and boiler capacity ( 0-1000 L )
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Graf.8.2 : Det. of hotwell volume in relation to condensate return and boiler capacity ( 0-6000 L )
END INSTALLATION MANUAL

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INSTALLATION MANUAL

CLAYTON INDUSTRIES CLAYTON OF BELGIUM N.V.

CLAYTON NEDERLAND B.V. CLAYTON DEUTSCHLAND GmbH

CLAYTON DE FRANCE S.A.R.L. CLAYTON THERMAL PRODUCTS LTD

FIG. 4.1-WAYS OF CONNECTING STACK TO A CLAYTON STEAM GENERATOR...............................17

8.3 CONNECTIONS AND ACCESSORIES FOR THE HOTWELL ...............................................................38

END Table of contents

Which installation instructions are valid for your application?

A. For Clayton equipment

- General information : CHAPTER 1

2. Following instructions may also be valid, depending on the application :

-Supplemental instructions for multiple boiler applications : CHAPTER 3

3. Installation check list

B. Other installation components : see specific instructions.

1.1 APPLICATION OF THE INSTALLATION MANUALS

CHAPTER 2 : POSTION OF GENERATOR AND ACCESSORIES

2.2 LOCAL RULES

2.3 FLOOR DRAIN

2.4 ACCESS TO THE STEAM GENERATOR

2.5 LEG MOUNTING

2.6 HEATING SECTION DIMENSIONS AND WEIGHT

STEAM HEATING ECONOMISE APPROX. APPROX.

(diam.D(mm) x H (diam. D (mm) (kg) (kg)

Table 2.1. : Dimensions and weight of heating section and economiser.

2.7 HOTWELLS AND CONDENSATE RECEIVERS

Fig.2.2-Free working area to be respected around steam generator

Fig. 2.3-Installation above ‘’ Drip tray ‘’

Fig. 2.4-Free area around receivers

Feedwatertreatment is entirely the responsibility of the user.

FOR WATER TREATMENT INSTRUCTIONS :

CHAPTER 4 : STACK AND VENTING ARRANGEMENTS

DRAFT REQUIREMENT FOR ALL E-MODELS : 0 TO -6MM WC AT

4.2 STACK ARRANGEMENTS, LOCAL RULES

4.3 REMOVABLE FLUE PIPE

4.4 FREE STANDING STACK

4.5 MOVEMENT AND FORCES

4.7 INSPECTION COVER

4.8 STACK TEMPERATURE INDICATION AND ALARM

A stack temperature indicator is recommended.

4.9 DRAFT REQUIREMENTS

4.10 RAIN CAP

4.11 STACK MUFFLER

4.12 STACK INSULATION

4.13 SHUT DOWN PERIODS, COLD AREAS

4.14 STACK ADAPTER

4.15 CONDENSATION, GAS FIRED UNITS

4.17 VENTING OF BOILER ROOM

LOCAL CODES MUST BE RESPECTED.

• If generator is installed in a closed room, ventilation openings must be provided.

Fig. 4.1-Ways of connecting stack to a Clayton steam generator

Fig. 4.2-Examples of stack arrangement

5.2 STEAM DISCHARGE VALVE

5.3 STEAM TRAP RETURN LINE

5.4 BLOWDOWN LINE

5.5 BLOWDOWN TANK

See fig. 5.1.

- evacuate flash steam from the blowdown water

- cool down the blowdown water before it enters the drain.

Blowdown tanks can be delivered by Clayton : see fig. 5.1.

5.6 BACK PRESSURE REGULATOR

The installation of a back pressure regulator is recommended.

5.7 STEAM SAFETY VALVES